Curtis Instruments MultiMode 1230 User manual

1230 Manual, p/n 37092
Rev. C: October 2007
© 2007 CURTIS INSTRUMENTS, INC.
DESIGN OF CURTIS 1200 SERIES
CONTROLLERS PROTECTED BY U.S.
PATENT NO. 4626750.
1230
MODEL
MultiMode™ AC INDUCTION
MOTOR CONTROLLER
CURTIS INSTRUMENTS, INC.
200 Kisco Avenue
Mt. Kisco, New York 10549 USA
Tel. [phone]
Fax [phone]
www.curtisinstruments.com

Curtis 1230 Manual, Rev. C iii
CONTENTS
1. OVERVIEW ..............................................................................1
2. INSTALLATION AND WIRING .............................................4
Mounting the Controller .....................................................4
Connections: Low Current ..................................................6
Connections: High Current ................................................7
Wiring: Standard Configuration A, no multiplexer .............8
Wiring: Standard Configuration B, with multiplexer ........10
Wiring: Standard Configuration C, with multiplexer
and a proportional valve on the hydraulic line .............12
Wiring: Throttles ..............................................................14
5kΩ–0 two-wire resistive throttle (“Type 1”) ...............15
Single-ended 0–5V, current source,
and 3-wire pot throttles (“Type 2”) .....................15
0–5kΩ two-wire resistive throttle (“Type 3”) ...............17
Wigwag 0–5V and 3-wire pot throttles (“Type 4”) ......17
Three-step switch throttle (“Type 5”) ..........................18
Wiring: Auxiliary Drivers ..................................................18
Wiring: Emergency Reverse ..............................................18
Wiring: Emergency Reverse Check ...................................19
Wiring: Spyglass Display ...................................................19
Wiring: Tiller Multiplexer .................................................20
Contactor, Switches, and Other Hardware .........................20
3. PROGRAMMABLE PARAMETERS ......................................23
Vehicle Parameters
Rate Parameters ..................................................................25
Acceleration Rate, Deceleration Rate,
Brake Rate, Fast Stop Rate, Accel Release Rate
Speed Parameters ...............................................................26
Minimum Speed, Maximum Speed,
Speed Limit Type
MultiMode Parameters .......................................................27
Mode Select Type, Coast Decel Rate,
Anti-Tiedown
Throttle Parameters ............................................................28
Throttle Type, Throttle Deadband,
Throttle Maximum, Throttle Map,
Pot Low Check
CONTENTS

iv Curtis 1230 Manual, Rev. C
CONTENTS
Sequencing Parameters .......................................................30
Interlock Normally Open, Sequencing Delay,
SRO, HPD, Main Contactor Interlock Type,
Main Contactor Open Delay,
Main Contactor Check
Brake Parameters ................................................................32
Brake Fault Check, Brake Delay,
Brake Hold Voltage, Brake Driver Type,
Anti-Rollback Time
Emergency Reverse Parameters ..........................................33
Wiring Check, Speed, Direction Interlock,
Time Limit, Accel Rate, Switch Normally Closed
Motor & Control Parameters
Motor Parameters .............................................................35
Min Motor Voltage, Nominal Motor Voltage,
Nominal Motor Frequency, Max Motor Speed,
Number of Motor Poles, Encoder Pulses
Per Revolution, Swap Encoder Direction,
Failsafe Delay
Control Parameters ...........................................................36
P Gain, I Gain, Accel Slip, Regen Slip, Slip Boost,
Pull-Out Slip, Accel Slip Voltage, Regen Slip Voltage,
Accel Comp, Regen Comp, Regen Voltage Offset
System Parameters
Battery Parameters .............................................................38
Full Battery Voltage, Empty Battery Voltage,
BDI Reset Battery Voltage, Battery Recharge Level,
Low Voltage Level
Hourmeter Parameters .......................................................39
Enable Total Service Hours,
Enable Drive Service Hours, Adjust Hours,
Set Total Hours, Set Drive Hours,
Total Service Hours, Drive Service Hours,
Total Disable Hours, Drive Disable Hours,
Drive Disable Speed, Service Total Expired,
Service Drive Expired

Curtis 1230 Manual, Rev. C v
Hydraulics Parameters ........................................................40
Lift PV Max, Lift PV Min,
Lift PV Accel Rate, Lift PV Decel Rate,
Lower PV Max, Lower PV Min,
Lower PV Accel Rate, Lower PV Decel Rate,
PV Dither, Pump Start Delay,
Pump BDI Lockout, Lift PV Hold Delay,
Load Hold Delay, Open Load Hold During Lift,
Hyd Throttle Type, Hyd Throttle Deadband,
Hyd Throttle Max, Hyd Throttle Map,
Max Pump Run Time
Other System Parameters ...................................................43
Power Save Delay, Mux Inputs Enabled,
Inhibit Input Type, Auxiliary Output Type,
Fault Code
Controller Cloning .....................................................................44
4. MONITOR MENU ................................................................45
5. INITIAL SETUP .....................................................................46
6. VEHICLE PERFORMANCE ADJUSTMENT ......................51
7. DIAGNOSTICS AND TROUBLESHOOTING ....................54
LED Diagnostics ................................................................54
Spyglass Diagnostics ...........................................................55
Programmer Diagnostics ....................................................55
Troubleshooting Chart .......................................................55
8. MAINTENANCE ...................................................................58
APPENDIX A Vehicle Design Considerations ............................A-1
APPENDIX B Programmer Operation and Menus ....................B-1
APPENDIX C Specifications ..................................................... C-1
CONTENTS

vi Curtis 1230 Manual, Rev. C
FIGURES
FIG. 1: Curtis 1230 AC motor controller ............................................. 1
FIG. 2: Mounting dimensions, Curtis 1230 controller ........................ 4
FIG. 3: Standard wiring configuration A,
for applications without tiller multiplexer ................................ 8
FIG. 4: Standard wiring configuration B,
for applications with tiller multiplexer ................................... 10
FIG. 5: Standard wiring configuration C,
for applications with tiller multiplexer and PV ..................... 12
FIG. 6: Wiring for 5kΩ–0 potentiometer (“Type 1”) ......................... 15
FIG. 7: Wiring for 0–5V voltage sources (“Type 2”) .......................... 15
FIG. 8: Wiring for current source (“Type 2”) ..................................... 16
FIG. 9: Wiring for 3-wire potentiometer (“Type 2”) .......................... 16
FIG. 10: Wiring for 0–5kΩ potentiometer (“Type 3”) ......................... 17
FIG. 11: Wiring for wigwag 3-wire potentiometer (“Type 4”) .............. 17
FIG. 12: Wiring guide and mounting dimensions,
Curtis 840 Spyglass display .................................................... 19
FIG. 13: Wiring guide and mounting dimensions,
Curtis 1312 Multiplexer ......................................................... 20
FIG. 14: Influence of various parameters on controller
output response to throttle demand ..................................... 29
FIG. 15: Overview of motor control .................................................. 34
FIG. 16: Motor control parameters and their effect
on operating characteristics .................................................. 34
FIG. 17: Hydraulic system, configuration B ......................................... 40
FIG. 18: Hydraulic system, configuration C ......................................... 40
FIG. B-1: Curtis 1311 programmer .....................................................B-1
TABLES
TABLE 1: Throttle wiper input (threshold values) ................................ 14
TABLE 2: Three-step switch throttle speeds .......................................... 18
TABLE 3: Status LED fault codes ........................................................ 54
TABLE 4: Status LED fault categories ................................................. 55
TABLE 5: Troubleshooting chart ........................................................... 56
TABLE C-1: Specifications, Curtis 1230 controller ................................ C-1
FIGURES / TABLES

1
Curtis 1230 Manual, Rev. C
1 — OVERVIEW
OVERVIEW
The Curtis 1230 motor controller is an AC induction motor speed controller
designed for use in a variety of material handling vehicles. Typical applications
include walkie/rider pallet trucks, low lifts, stackers, sweeper/scrubber machines,
and other small industrial vehicles. This high performance programmable con-
troller is simple to install, efficient, and cost effective.
1
Fig. 1 Curtis 1230
AC motor controller.
The 1230 controller offers smooth precise control of motor speed and
torque. When used with hydraulic systems, the 1230 turns the pump motor
on and off and also controls valves on the hydraulic line—thus controlling the
hydraulic path for Lift and Lower operations.
These controllers are fully programmable through Curtis’s optional 1311
handheld programmer or 1314 PC programming station. The programmer
provides diagnostic and test capability in addition to configuration flexibility.
The 1230 is also designed to work with the optional Curtis 840 Spyglass
data display and the optional Curtis 1312 tiller multiplexer.

2 Curtis 1230 Manual, Rev. C
1 — OVERVIEW
Like all Curtis motor controllers, the 1230 offers superior operator control of
motor speed. Features include:
✓ 60–200 amp AC induction motor controller
✓ MultiMode™ feature allows two distinct user-selectable operation
modes
✓ Programmability through the Curtis 1311 handheld programmer and
1314 PC programming station
✓ Complete diagnostics through the 1311 and 1314 programmers and
through the controller’s built-in Status LED
✓ Throttle input for single-ended or wigwag 5kΩ pots or 0–5V throttles
(both standard full stroke and restricted range)
✓ Active precharge of controller capacitor bank extends life of main
contactor tips
✓ Two hourmeters—total KSI-on hours and drive hours—and their associ-
ated maintenance timers are built into the controller, with EEPROM
storage (no battery)
✓ BDI calculations performed within controller
✓ Meets EEC fault detection requirements
✓ Fault detection circuitry on throttle inputs can be used to inhibit
operation if throttle signal goes out of range for any reason (applies both
to the traction throttle and, in applications that include a proportional
valve, to the hydraulic throttle as well)
✓ Stall protection
✓ Internal reverse polarity protection (no external diode required)
✓ Continuous diagnostics during operation, with microprocessor
power-on self-test
✓ All output drivers are short-circuit protected and provide built-in
coil spike protection
✓ Positive battery connections for all inputs
✓ Fully protected inputs
✓ Internal and external watchdog circuits ensure proper software operation
✓ High environmental protection rating (IP53)
✓ 3-wire serial interface for multifunction display

3
Curtis 1230 Manual, Rev. C
1 — OVERVIEW
Additional features on 1230-2X01 models (for use with multiplexer)
✓ 4-wire serial interface for all tiller functions
✓ Two auxiliary outputs, controlled by switches on the tiller multiplexer,
can be used for a lift relay, lowering valve, horn, etc.
✓ Internal main contactor for battery reverse polarity protection and ad-
ditional safety
✓ Variable PWM voltage for precise control during lift/lower operation,
in applications with a proportional valve
Curtis Model 840 Spyglass Display
✓ 3-wire serial interface
✓ Sequences between hourmeter, BDI, and error displays
✓ Alphanumeric, 8 character, 5 mm LCD display for hourmeter, BDI,
and fault messages
✓ Operating temperature range -10°C to 70°C; models with lower
temperature ratings available for freezer applications
Curtis Model 1312 Tiller Multiplexer
✓ 4-wire serial interface increases reliability
✓ Multiplexes up to 12 signals, analog or digital
✓ All signals sampled 50 times per second
✓ Signal integrity checked 150 times per second.
Familiarity with your Curtis controller will help you install and operate it prop-
erly. We encourage you to read this manual carefully. If you have questions,
please contact the Curtis office nearest you.

4 Curtis 1230 Manual, Rev. C
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
The 1230 controller can be oriented in any position, and meets the IP53 ratings
for environmental protection against dust and water. However, the location
should be carefully chosen to keep the controller clean and dry. If a clean,
dry mounting location cannot be found, a cover must be used to shield the
controller from water and contaminants.
When selecting the mounting position, be sure to also take into consid-
eration (1) that the built-in Status LED is visible only through the view port
in the label on top of the controller, and (2) that convenient access is needed
at the top of the controller to plug the programmer into its connector.
The outline and mounting hole dimensions for the 1230 controller are
shown in Figure 2. To ensure full rated power, the controller should be fastened
to a clean, flat metal surface with four 6 mm (1/4”) diameter bolts, using the
2
2 — INSTALLATION & WIRING: Controller
Fig. 2 Mounting
dimensions, Curtis 1230
controller.
Dimensions in millimeters (and inches)
MOTOR CONTROLLER
STATUS
AC
B+B-
UVW
M5,
6 plcs
10
(0.4)
80
(3.1)
148 (5.8)
164 (6.4)
8 (0.3)
Status LED
6.5 (0.25) dia.,
4 plcs
146
(5.7)
130
(5.1)
F+

5
Curtis 1230 Manual, Rev. C
2 — INSTALLATION & WIRING: Controller
Working on electrical systems is potentially dangerous. You should
protect yourself against uncontrolled operation, high current arcs, and
outgassing from lead acid batteries:
UNCONTROLLED OPERATION — Some conditions could cause the motor to
run out of control. Disconnect the motor or jack up the vehicle and get
the drive wheels off the ground before attempting any work on the motor
control circuitry. NOTE: If the wrong throttle input signal type is selected
with the 13XX programmer, the vehicle may suddenly begin to move.
HIGH CURRENT ARCS — Batteries can supply very high power, and arcs can
occur if they are short circuited. Always open the battery circuit before
working on the motor control circuit. Wear safety glasses, and use properly
insulated tools to prevent shorts.
LEAD ACID BATTERIES — Charging or discharging generates hydrogen gas,
which can build up in and around the batteries. Follow the battery
manufacturer’s safety recommendations. Wear safety glasses.
holes provided. Although not usually necessary, a thermal joint compound
can be used to improve heat conduction from the controller heatsink to the
mounting surface.
You will need to take steps during the design and development of your
end product to ensure that its EMC performance complies with applicable
regulations; suggestions are presented in Appendix A.
The 1230 controller contains ESD-sensitive components. Use appro-
priate precautions in connecting, disconnecting, and handling the controller.
See installation suggestions in Appendix A for protecting the controller from
ESD damage.
☞
CAUTION

6 Curtis 1230 Manual, Rev. C
2 — INSTALLATION & WIRING: Controller
123456789101112
13 14 15 16 17 18 19 20 21 22 23 24
4-pin 6-pin 24-pin
J3 J2 J1
J1
CONNECTIONS
Low Current Connections
Three low current connectors (J1, J2, J3) are built into the 1230 controller.
They are located in a row on the top of the controller:
The 24-pin connector (J1) provides the logic control connections for the
contactor drivers and switches that are wired directly to the vehicle. The mating
connector is a 24-pin Molex Mini-Fit Jr. connector part number 39-01-2245
using type 5556 terminals.
WITH MULTIPLEXER
J1 Pin 1 keyswitch input (KSI)
J1 Pin 2 interlock
J1 Pin 3 mode switch input—M1 (open), M2 (closed)
J1 Pin 4 inhibit input
J1 Pin 5 pot high output
J1 Pin 6 wiper/0–5V input for throttle
J1 Pin 7 pot low input
J1 Pin 8 [not used]
J1 Pin 9 feed-through ground
J1 Pin 10 speed limit input
J1 Pin 11 feed-through input 1
J1 Pin 12 feed-through input 2
J1 Pin 13 forward switch input
J1 Pin 14 reverse switch input
J1 Pin 15 emergency reverse input
J1 Pin 16 emergency reverse check output
J1 Pin 17 Status LED output
J1 Pin 18 Battery LED output
J1 Pin 19 display power output
J1 Pin 20 display ground reference output
J1 Pin 21 display data output
J1 Pin 22 main contactor driver output
J1 Pin 23 auxiliary output 1
J1 Pin 24 auxiliary output 2
J1 Pin 9 mux supply
J1 Pin 10 mux data
J1 Pin 11 mux clock
J1 Pin 12 mux ground
NO MULTIPLEXER

7
Curtis 1230 Manual, Rev. C
J2 Pin 1 encoder power output
J2 Pin 2 encoder A
J2 Pin 3 E-M brake coil return
J2 Pin 4 encoder B
J2 Pin 5 encoder ground reference output
J2 Pin 6 E-M brake driver output
21
43
J2
J3
J3 Pin 1 receive data (+5V)
J3 Pin 2 ground (B-)
J3 Pin 3 transmit data (+5V)
J3 Pin 4 +15V supply (100mA)
2 — INSTALLATION & WIRING: Controller
A 6-pin low power Molex connector (J2) is provided for the speed encoder and
electromagnetic brake connections. The mating connector is a Molex Mini-Fit
Jr. p/n 39-01-2065 using type 5556 terminals.
Note: In some applications using a tiller multiplexer, J2 Pins 3 and 6 are used
for a proportional valve instead of an electromagnetic brake.
A 4-pin low power connector (J3) is provided for the 13XX programmer. A
complete programmer kit, including the appropriate connecting cable, can be
ordered; see Curtis programmer manual for further information on the various
programmers available for programming Curtis controllers.
J3 can also be used for the Curtis Model 840 Spyglass display. Although
the display is typically wired directly into Pins 19, 20, and 21 of the 24-pin
connector (J1), it can alternatively be plugged into J3 and unplugged when the
programmer is used. Only Pins 2, 3, and 4 of J3 are needed for the display.
High Current Connections
Six round tin-plated brass studs are provided for the high current connections
to the battery (B+ and B-), the fuse (F+), and the three motor phases (U, V, W),
located as shown in Figure 2.
The studs are threaded to accept M5 bolts. This simplifies the assembly
and reduces the mounting hardware necessary for the power connections.
Appropriate screws, washers, and cable lugs should be used to provide secure
vibration-resistant connections on all power terminals.
The tightening torque applied to the bolts should not exceed 10 N·m (7.4
ft-lbs). Exceeding this limit could damage the studs’ internal threads, resulting
in loose connections.
321
654

8 Curtis 1230 Manual, Rev. C
2 — INSTALLATION & WIRING: Controller
Fig. 3 Standard wiring configuration A: Curtis 1230-2X02 controller.
WIRING: Standard Configuration A (no multiplexer)
Figure 3 shows the typical wiring configuration for applications where a tiller
multiplexer is not used; these applications typically include an external main
contactor.
For walkie applications the interlock switch is typically activated by the
tiller, and an emergency reverse switch on the tiller handle provides the emer-
gency reverse signal. For rider applications the interlock switch is typically a
seatswitch or a footswitch, and there is no emergency reverse.
F+
B-
U
V
W
Enc Supply
Enc A
Enc B
Enc Ground
Brake
Brake Return
Feed-thru 1
Feed-thru 2
Aux Ground
Main Contactor
B+
1230-2X02 CONTROLLER
Feed-thru 2
J1-12
Lower
Inhibit
J1-4
Inhibit
Emerg Rev Check
J1-16
Emergency Reverse
J1-15
Mode (M1/M2)
J1-3
Reverse
J1-14
Forward
J1-13
Forward
Interlock
J1-2
KSI
J1-1
Prog Supply
J3-4
Prog Receive
J3-1
Prog Transmit
J3-3
Prog Ground
J3-2
Pot High
J1-5
Speed Limit
J1-10
Throttle Wiper
J1-6
Pot Low
J1-7
Speed
Limit
PotThrottle
Pot
AC
MOTOR
Main
Contactor
SPEED
ENCODER
J2-1
J2-2
J2-4
J2-5
J2-6
J2-3
E-M Brake
J1-23
J1-24
J1-9
Keyswitch
BATTERY
Interlock
Reverse
Mode
Emerg. Reverse
Status LED
J1-17
Status LED
Battery LED
J1-18
Battery LED
Feed-thru 1
J1-11
Lift
Disp Supply
J1-19
Disp Data
J1-21
Disp Ground
J1-20
CURTIS
840
DISPLAY
(Spyglass)
CURTIS
1311/1314
PROGRAMMER
J1-22
Lowering Valve
Lift Relay
Power
Fuse
(mounted
on controller)
Control
Fuse

9
Curtis 1230 Manual, Rev. C
2 — INSTALLATION & WIRING: Controller
☞
CAUTION
13 14 15 16 17 18 19 20 21 22 23 24
123456789101112
LIFT
RELAY
(feed-thru)
DISPLAY
SUPPLY
DISPLAY
GROUND
FORWARD
SWITCH
24-pin detail (see Fig. 3):
BATTERY
LED
POT
LOW
SPEED
LIMIT
POT
INHIBIT
LOWERING
VALVE
(feed-thru)
EMERGENCY
REVERSE
EMERGENCY
REVERSE
CHECK
POT
HIGH
AUX
GROUND
DISPLAY
DATA
REVERSE
SWITCH
LOWER
SWITCH
(feed-thru)
INTERLOCK
MODE
SWITCH
(M1/M2)
KEYSWITCH
INPUT (KSI)
THROTTLE
WIPER
MAIN
CONTACTOR
LIFT
SWITCH
(feed-thru)
STATUS
LED
Power Wiring, Configuration A
Motor phase wiring is straightforward, with the motor’s U, V, W phases con-
nected directly to the controller’s U, V, W studs. CAUTION: The sequence of the
motor phase connections will affect the operation of the emergency reverse
feature. The forward and reverse switches and the U, V, W connections must
be configured so that the vehicle drives away from the operator when the
emergency reverse button is pressed.
The negative battery terminal is always connected directly to the B- stud.
The positive battery terminal is typically connected to the F+ stud via the ex-
ternal main contactor, as shown in Figure 3. If the main fuse in not mounted
on the controller, F+ is not used and the positive battery terminal is connected
to the B+ stud.
If a main contactor is not required, the positive battery terminal can be
connected directly to the B+ or F+ stud on the controller.
Standard Control Wiring, Configuration A
Wiring for the input switches and contactors is shown in Figure 3; the 24-pin
connector is shown in more detail below.
The main contactor coil must be wired directly to the controller as shown in
Figure 3. The controller can be programmed to check for welded or missing
contactor faults and uses the main contactor coil driver output to remove power
from the controller and motors in the event of various other faults. If the main
contactor coil is not wired to J1 Pin 22, the controller will not be able to
open the main contactor in serious fault conditions and the controller will
not be protected against reverse battery polarity.
Feed-throughs from J1 Pin 11 to Pin 23 and from J1 Pin 12 to Pin 24
are provided as a convenience, to simplify the wiring harness for lift/lower.

10 Curtis 1230 Manual, Rev. C
2 — INSTALLATION & WIRING: Controller
Fig. 4 Standard wiring configuration B: Curtis 1230-2X01 controller,
in applications with a 1312 tiller multiplexer (but without a proportional valve).
WIRING: Standard Configuration B (with multiplexer)
Figure 4 shows the typical wiring configuration for applications where a tiller
multiplexer is used. Most 1230 models designed for use with a multiplexer
include an internal main contactor (see specifications in Table C-1); for the
1230-2301 and -2401 models, which do not, the main contactor should be
wired as shown in Figure 3.
With configuration B, there is no control of the lift/lower speed; the lift
relay (at Pin 23) is a contactor that turns the pump motor on and off, and the
lower valve output (at Pin 24) opens and shuts the lowering valve.
F+
B-
U
V
W
Enc Supply
Enc A
Enc B
Enc Ground
Brake
Brake Return
Auxiliary Output 1
Auxiliary Output 2
B+
1230-2X01 CONTROLLER
Pot Low
J1-7
Emerg Rev Check
J1-16
Emergency Reverse
J1-15
Mode (M1/M2)
J1-3
Reverse
J1-14
Interlock
J1-2
Battery LED
Battery LED
Status LED
KSI
J1-1
Prog Supply
J3-4
Prog Receive
J3-1
Prog Transmit
J3-3
Prog Ground
J3-2
AC
MOTOR
SPEED
ENCODER
J2-1
J2-2
J2-4
J2-5
J2-6
J2-3
E-M Brake
J1-23
Keyswitch
BATTERY
Status LED
Interlock
Inhibit
J1-17
Pot High
J1-18
Throttle Wiper
J1-6
Disp Supply
J1-19
Disp Data
J1-21
Disp Ground
J1-20
CURTIS
840
DISPLAY
(Spyglass)
CURTIS
1311/1314
PROGRAMMER
J1-24
Lift Relay
Lowering Valve
Power
Fuse
(mounted
on controller)
Control
Fuse
Forward
J1-13
J1-5
J1-4
Mux Supply
J1-9
Mux Data
J1-10
Mux Clock
J1-11
Mux Ground
J1-12
5
6
8
J3-6
J3-3
J3-4
J3-2
Switch and throttle inputs can be connected
to either the controller or the multiplexer, or
to both as an “or” function.
Inhibit
Emergency Reverse
Mode (M1/M2)
Reverse
Lift
Lower
Forward
+5V
Ground
Throttle
Speed Limit
CURTIS
1312
TILLER
MULTIPLEXER
See page 20 for
multiplexer pinout.

11
Curtis 1230 Manual, Rev. C
2 — INSTALLATION & WIRING: Controller
☞
CAUTION
13 14 15 16 17 18 19 20 21 22 23 24
12345678910 11 12
LIFT
RELAY
(AUX OUTPUT 1)
DISPLAY
SUPPLY
DISPLAY
GROUND
FORWARD
SWITCH
24-pin detail (see Fig. 4):
BATTERY
LED
POT
LOW
MUX
DATA
INHIBIT
LOWERING
VALVE
(AUX OUTPUT 2)
EMERGENCY
REVERSE
EMERGENCY
REVERSE
CHECK
POT
HIGH
MUX
SUPPLY
DISPLAY
DATA
REVERSE
SWITCH
MUX
GROUND
INTERLOCK
MODE
SWITCH
(M1/M2)
KEYSWITCH
INPUT (KSI)
THROTTLE
WIPER
MAIN
CONTACTOR *
STATUS
LED
MUX
CLOCK
* Required for 1230-2301 and -2401 only.
Power Wiring, Configuration B
Motor phase wiring is straightforward, with the motor’s U, V, W phases con-
nected directly to the controller’s U, V, W studs. CAUTION: The sequence of the
motor phase connections will affect the operation of the emergency reverse
feature. The forward and reverse switches and the U, V, W connections must
be configured so that the vehicle drives away from the operator when the
emergency reverse button is pressed.
The negative battery terminal is always connected directly to the B- stud.
The positive battery terminal is typically connected to the F+ stud, as shown
in Figure 4. If the main fuse in not mounted on the controller, F+ is not used
and the positive battery terminal is connected to the B+ stud.
Standard Control Wiring, Configuration B
Wiring for the input switches and contactors is shown in Figure 4; the 24-pin
connector is shown in more detail below.
The controller can be programmed to check for welded or missing contactor
faults and uses the internal main contactor to remove power from the controller
and motor in the event of various faults, including reversed battery polarity.

12 Curtis 1230 Manual, Rev. C
2 — INSTALLATION & WIRING: Controller
Fig. 5 Standard wiring configuration C: Curtis 1230-2X01 controller, in applications
with a 1312 tiller multiplexer and a proportional valve on the hydraulic line.
WIRING: Standard Configuration C (with multiplexer & PV)
Figure 5 shows the typical wiring configuration for applications where a pro-
portional valve is used with the tiller multiplexer. Most 1230 models designed
for use with a multiplexer include an internal main contactor (see specifications
in Table C-1); for the 1230-2301 and -2401 models, which do not, the main
contactor should be wired as shown in Figure 3. If there is a load hold valve,
it needs to be controlled externally.
The proportional valve in configuration C is controlled by the hydraulic
throttle in the multiplexer, providing variable speed lift/lower operation.
F+
B-
U
V
W
Enc Supply
Enc A
Enc B
Enc Ground
PV
PV Return
Auxiliary Output 1
Auxiliary Output 2
B+
Load Hold Valve
1230-2X01 CONTROLLER
Pot Low
J1-7
Emerg Rev Check
J1-16
Emergency Reverse
J1-15
Mode (M1/M2)
J1-3
Reverse
J1-14
Interlock
J1-2
Battery LED
Battery LED
Status LED
KSI
J1-1
Prog Supply
J3-4
Prog Receive
J3-1
Prog Transmit
J3-3
Prog Ground
J3-2
AC
MOTOR
SPEED
ENCODER
J2-1
J2-2
J2-4
J2-5
J2-6
J2-3
Proportional
Valve
J1-23
Keyswitch
BATTERY
Status LED
Interlock
Inhibit
J1-17
Pot High
J1-18
Throttle Wiper
J1-6
Disp Supply
J1-19
Disp Data
J1-21
Disp Ground
J1-20
CURTIS
840
DISPLAY
(Spyglass)
CURTIS
1311/1314
PROGRAMMER
J1-24
Lift Relay
J1-22 Load Hold Valve
E-M Brake
Power
Fuse
(mounted
on controller)
Control
Fuse
Forward
J1-13
J1-5
J1-4
Mux Supply
J1-9
Mux Data
J1-10
Mux Clock
J1-11
Mux Ground
J1-12
5
6
8
J3-6
J3-3
J3-4
J3-2
Switch and throttle inputs can be connected
to either the controller or the multiplexer, or
to both as an “or” function.
Inhibit
Emergency Reverse
Mode (M1/M2)
Reverse
Lift
Lower
Forward
+5V
Ground
Throttle
Hydraulic Throttle
CURTIS
1312
TILLER
MULTIPLEXER
See page 20 for
multiplexer pinout.
Speed Limit

13
Curtis 1230 Manual, Rev. C
13 14 15 16 17 18 19 20 21 22 23 24
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LIFT
RELAY
(AUX OUTPUT 1)
DISPLAY
SUPPLY
DISPLAY
GROUND
FORWARD
SWITCH
24-pin detail (see Fig. 5):
BATTERY
LED
POT
LOW
MUX
DATA
INHIBIT
E-M
BRAKE
(AUX OUTPUT 2)
EMERGENCY
REVERSE
EMERGENCY
REVERSE
CHECK
POT
HIGH
MUX
SUPPL
Y
DISPLAY
DATA
REVERSE
SWITCH
MUX
GROUND
INTERLOCK
MODE
SWITCH
(M1/M2)
KEYSWITCH
INPUT (KSI)
THROTTLE
WIPER
LOAD
HOLD
VALVE *
STATUS
LED
MUX
CLOCK
*Main contactor output for 1230-2301 and -2401;
no Load Hold available for these models.
☞
CAUTION
2 — INSTALLATION & WIRING: Controller
Power Wiring, Configuration C
Motor phase wiring is straightforward, with the motor’s U, V, W phases con-
nected directly to the controller’s U, V, W studs. CAUTION: The sequence of the
motor phase connections will affect the operation of the emergency reverse
feature. The forward and reverse switches and the U, V, W connections must
be configured so that the vehicle drives away from the operator when the
emergency reverse button is pressed.
The negative battery terminal is always connected directly to the B- stud.
The positive battery terminal is typically connected to the F+ stud, as shown
in Figure 5. If the main fuse in not mounted on the controller, F+ is not used
and the positive battery terminal is connected to the B+ stud.
Standard Control Wiring, Configuration C
Wiring for the input switches and contactors is shown in Figure 5; the 24-pin
connector is shown in more detail below.
The controller can be programmed to check for welded or missing contactor
faults and uses the internal main contactor to remove power from the controller
and motor in the event of various faults, including reversed battery polarity.
The controller must be configured to control the proportional valve volt-
age by programming the Auxiliary Output Type parameter to 4, which assigns
the PWM capability of J2 Pin 6 to the PV and the digital on/off output J1
Pin 24 to the electromagnetic brake. As the brake is no longer connected to J2
Pin 6 the Brake Fault Check parameter is moot and brake fault checking is
disabled. The Brake Holding Voltage parameter is also moot, and the holding
voltage is set at 100%.
☞
CAUTION

14 Curtis 1230 Manual, Rev. C
2 — INSTALLATION & WIRING: Throttles
Table 1 THROTTLE WIPER INPUT THRESHOLD VALUES
MINIMUM THROTTLE THROTTLE MAXIMUM
THROTTLE THROTTLE DEADBAND MAX THROTTLE
TYPE PARAMETER FAULT (0% speed request) (100% modulation) FAULT
1 Wiper Voltage 5.00 V 3.80 V 0.20 V 0.06 V
Wiper Resistance 7.50 kΩ 5.50 kΩ 0 kΩ —
2 Wiper Voltage 0.06 V 0.20 V 5.00 V 5.30 V
Wiper Resistance — — — —
3 Wiper Voltage 0.06 V 0.20 V 3.80 V 5.00 V
Wiper Resistance — 0 kΩ 5.50 kΩ 7.50 kΩ
4 Wiper Voltage 0.50 V 2.50 V (Fwd) * 4.40 V (Fwd) 4.50 V
2.50 V (Rev) * 0.60 V (Rev)
Wiper Resistance — — — —
Notes: The upper and lower deadbands are valid for nominal 5kΩ potentiometers or 5V sources
with the default Throttle Deadband and Throttle Max parameter settings of 0% and 100%
respectively. These values will change with variations in the Throttle DB and Throttle Max
parameter settings—see Section 3, pages 28 and 29.
* With 0% Throttle Deadband, there is no neutral point on a Type 4 pot. It is recommended
that an 8% minimum deadband be used with Type 4 throttles.
WIRING: Throttles
Various throttles can be used with the 1230 controller. They are categorized as
one of five types in the programming menu of the 13XX programmer. Only
Types 2 and 4 can be used for the hydraulic throttle.
Type 1: two-wire 5kΩ–0 potentiometer throttles
Type 2: 0–5V, current source, and three-wire pot throttles—wired for
single-ended operation
Type 3: two-wire 0–5kΩ potentiometer throttles
Type 4: 0–5V and three-wire pot throttles—wired for wigwag operation
Type 5: three-step switch throttles
Table 1 summarizes the operating specifications for the first four throttle
types. For Type 5 throttles, see Table 2 on page 18. Note: For Type 2 and Type
4 throttles, the controller reads only voltage at the wiper input, even when
potentiometers are used.
For potentiometers, the 1230 provides complete throttle fault protection that
meets all applicable EEC regulations. For voltage throttles, the 1230 protects
against out-of-range wiper voltages (see Table 1), but does not detect wiring
faults; it is therefore the responsibility of the OEM to provide full throttle fault
protection in vehicles using voltage throttles.
Wiring for the most common throttles is described in the following text.
If the throttle you are planning to use is not covered, contact the Curtis office
nearest you.