Curtis instruments Multimode 1243 generation 2 User manual

MANUAL

DESIGN OF CURTIS PMC 1200 SERIES

CONTROLLERS PROTECTED BY U.S.

PATENT NO. 4626750.

CURTIS INSTRUMENTS, INC.

200 Kisco Avenue

Mount Kisco, NY 10509 USA

Tel: 914-666-2971

Fax: 914-666-2188

www.curtisinst.com

1243GEN2 Manual, p/n 37044

Rev. A: October 2002

1 2 4 3

M O D E L

MultiMode™

MOTOR CONTROLLER

Generation 2

Curtis 1243GEN2 Manual ii

CONTENTS

1. OVERVIEW ............................................................................. 1

2. INSTALLATION AND WIRING ........................................... 4

Mounting the Controller .................................................... 4

Connections: Low Current ................................................ 6

Connections: High Current ............................................... 6

Wiring: Controller ............................................................. 7

Wiring: Throttle ................................................................ 9

5kΩ–0, 2-wire potentiometer throttle (“Type 1”) ...... 10

Single-ended 0–5V, current source, 3-wire pot,

and electronic throttles (“Type 2”) ..................... 11

0–5kΩ, 2-wire potentiometer throttle (“Type 3”) ...... 13

Wigwag 0–5V and 3-wire pot throttles ...................... 14

Wiring: Fault Outputs ..................................................... 14

Wiring: Spyglass Display.................................................. 15

Wiring: Emergency Reverse ............................................. 16

Wiring: Emergency Reverse Check .................................. 16

Wiring: Auxiliary Driver .................................................. 16

Contactor, Switches, and Other Hardware........................ 17

3. PROGRAMMABLE PARAMETERS ..................................... 19

Battery Parameter ............................................................. 21

Battery Voltage ........................................................... 21

Acceleration Parameters .................................................... 21

Drive Current Limit, M1–M4 ................................... 21

Acceleration Rate, M1–M4 ........................................ 21

Quick Start ................................................................ 21

Current Ratio ............................................................. 22

Braking Parameters ........................................................... 23

Braking Current Limit, M1–M4 ................................ 23

Deceleration Rate, M1–M4 ....................................... 23

Throttle Deceleration Rate ......................................... 23

Restraint, M1–M4 ..................................................... 23

Braking Rate, M1–M4 ............................................... 24

Taper Rate .................................................................. 25

Variable Braking ......................................................... 25

Interlock Braking Parameters ............................................ 26

Interlock Braking Rate ............................................... 26

Max. Forward Regen .................................................. 26

Max. Reverse Regen ................................................... 26

CONTENTS

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Curtis 1243GEN2 Manual iii

Min. Forward Regen .................................................. 27

Min. Reverse Regen ................................................... 27

Max. Load Volts ......................................................... 27

Min. Load Volts ......................................................... 27

Electromagnetic Brake Parameters .................................... 28

Aux Type .................................................................... 28

EM Brake PWM ........................................................ 28

Aux Delay .................................................................. 28

Interlock Brake Delay ................................................ 28

Speed Parameters .............................................................. 31

Max. Forward Speed, M1–M4 ................................... 31

Max. Reverse Speed, M1–M4 .................................... 31

Creep Speed ............................................................... 31

Load Compensation ................................................... 31

Throttle Parameters .......................................................... 32

Throttle Type ............................................................. 32

Throttle Deadband .................................................... 32

Throttle Max ............................................................. 34

Throttle Map ............................................................. 36

Pot Low Fault............................................................. 38

Field Parameters................................................................ 38

Min. Field Current Limit ........................................... 38

Max. Field Current Limit ........................................... 38

Field Map Start .......................................................... 38

Field Map................................................................... 39

Field Check ................................................................ 40

Main Contactor Parameters .............................................. 40

Main Contactor Interlock .......................................... 40

Main Contactor Open Delay ..................................... 40

Main Contactor Diagnostics ...................................... 40

Sequencing Fault Parameters............................................. 41

Anti-Tiedown ............................................................. 41

High Pedal Disable (HPD) ........................................ 41

Static Return to Off (SRO) ........................................ 42

Sequencing Delay ....................................................... 42

Emergency Reverse Parameters ......................................... 43

Emergency Reverse Current Limit ............................. 43

Emergency Reverse Check.......................................... 43

Emergency Reverse Direction Interlock...................... 43

Motor Protection Parameters ............................................ 44

Warm Speed ............................................................... 44

Motor Warm Resistance ............................................. 44

Motor Hot Resistance ................................................ 44

Motor Resistance Compensation ................................ 44

CONTENTS

234567890

Curtis 1243GEN2 Manual iv

Hourmeter Parameters ...................................................... 45

Adjust Hours High .................................................... 45

Adjust Hours Middle ................................................. 45

Adjust Hours Low ...................................................... 45

Set Total Hours .......................................................... 45

Set Traction Hours ..................................................... 46

Total Service Hours .................................................... 46

Traction Service Hours ............................................... 46

Total Disable Hours ................................................... 46

Traction Disable Hours .............................................. 46

Traction Fault Speed .................................................. 47

Service Total ............................................................... 47

Service Traction .......................................................... 47

Hourmeter Type ......................................................... 48

Pump Meter ............................................................... 48

Battery Discharge Indicator (BDI) Parameters .................. 49

Full Voltage ................................................................ 49

Empty Voltage............................................................ 49

Reset Voltage .............................................................. 49

Battery Adjust ............................................................ 50

BDI Disable ............................................................... 50

BDI Limit Speed ........................................................ 50

Fault Code Parameters ...................................................... 51

Fault Code ................................................................. 51

BDI Lockout .............................................................. 51

Controller Cloning ........................................................... 52

4. INSTALLATION CHECKOUT ............................................ 53

5. VEHICLE PERFORMANCE ADJUSTMENT ..................... 55

Major Tuning ................................................................... 55

Tuning the active throttle range ................................. 55

Tuning the controller to the motor ............................ 58

Setting the unloaded vehicle top speed....................... 60

Equalizing loaded and unloaded vehicle speed ........... 61

Fine Tuning ...................................................................... 62

Response to reduced throttle ...................................... 62

Response to increased throttle .................................... 63

Smoothness of direction transitions ............................ 63

Ramp climbing .......................................................... 64

CONTENTS

234567890

Curtis 1243GEN2 Manual v

6. PROGRAMMER MENUS .................................................... 65

1243GEN2 Program Menu ................................................ 65

1243GEN2 Monitor Menu................................................. 69

1243GEN2 System Faults Menu......................................... 70

7. DIAGNOSTICS AND TROUBLESHOOTING .................. 71

Programmer Diagnostics ................................................... 71

Spyglass Diagnostics ......................................................... 71

Status LED Diagnostics .................................................... 74

Fault Output LED Diagnostics......................................... 75

8. CONTROLLER MAINTENANCE ...................................... 76

Cleaning ........................................................................... 76

Diagnostic History ........................................................... 76

APPENDIX A Electromagnetic Compatibility (EMC) ............... A-1

APPENDIX B 1311 Programmer Operation .............................. B-1

APPENDIX C Programmable Parameters Index ......................... C-1

APPENDIX D Speciﬁcations....................................................... D-1

CONTENTS

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Curtis 1243GEN2 Manual vi

FIGURES

FIG. 1: Curtis 1243GEN2 electronic motor controller........................... 1

FIG. 2: Mounting dimensions, Curtis 1243GEN2 controller ................. 4

FIG. 3: Basic wiring conﬁguration, Curtis 1243GEN2 controller .......... 7

FIG. 4: Wiring for 5kΩ–0 throttle (“Type 1”) ................................... 10

FIG. 5: Wiring for 20kΩpotentiometer used as

a wigwag-style throttle (“Type 1”).......................................... 10

FIG. 6: Wiring for 0–5V throttles (“Type 2”) .................................... 11

FIG. 7: Wiring for current source throttle (“Type 2”) ........................ 12

FIG. 8: Wiring for 3-wire potentiometer throttle (“Type 2”) ............. 12

FIG. 9: Wiring for Curtis ET-XXX electronic throttle (“Type 2”) ...... 13

FIG. 10: Wiring for 0–5kΩthrottle (“Type 3”) ................................... 14

FIG. 11: Wiring for fault outputs ........................................................ 15

FIG. 12: Wiring for Curtis Spyglass display ......................................... 15

FIG. 13: Ramp restraint maps for controller with the minimum

ﬁeld set at 3 amps, maximum ﬁeld at 18 amps, and

braking current limit at 300 amps ......................................... 24

FIG. 14: Electromagnetic brake parameters, in the context

of the four delay parameters ................................................... 29

FIG. 15: Effect of adjusting the throttle deadband parameter .............. 33

FIG. 16: Effect of adjusting the throttle max parameter ................. 34, 35

FIG. 17: Throttle maps for controller

with maximum speed set at 100%

and creep speed set at 0 ......................................................... 36

FIG. 18: Throttle maps for controller

with maximum speed set at 100%

and creep speed set at 10% .................................................... 37

FIGURES

Curtis 1243GEN2 Manual vii

TABLES

FIG. 19: Throttle maps for controller

with maximum speed set at 90%

and creep speed set at 10% .................................................... 37

FIG. 20: Field current relative to armature current,

with ﬁeld map parameter set at 50% and 20% ...................... 39

FIG. 21: Curtis 840 Spyglass, 3-LED and 6-LED models .................... 73

FIG. B-1 Curtis 1311 handheld programmer ..................................... B-1

TABLES

TABLE 1: Throttle wiper input (Pin 6) threshold values .......................... 9

TABLE 2: Mode selection....................................................................... 18

TABLE 3: Conﬁguration options: auxiliary driver .................................. 30

TABLE 4: Programmable throttle types .................................................. 32

TABLE 5: Standard battery voltages ....................................................... 49

TABLE 6: Fault categories ...................................................................... 50

TABLE 7: Troubleshooting chart ............................................................ 72

TABLE 8: Status LED fault codes .......................................................... 74

TABLE 9: Fault category codes ............................................................... 75

TABLE D-1: Speciﬁcations .................................................................... E-1

Curtis 1243GEN2 Manual 1

1 — OVERVIEW

OVERVIEW

Curtis 1243 Generation 2 MultiMode™controllers are separately excited

motor speed controllers designed for use in a variety of small industrial vehicles

and in material handling equipment. These programmable controllers are

simple to install, efﬁcient, and cost effective, while offering more features than

the original 1243.

1

Fig. 1 Curtis 1243GEN2

MultiMode™ electronic

motor controller.

The 1243GEN2 MultiMode™controller provides smooth precise control

of motor speed and torque. A full-bridge ﬁeld control stage is combined with a

half-bridge armature power stage to provide solid state motor reversing and full

regenerative braking without additional relays or contactors.

The controller’s rugged IP53 housing and packaging are built to with-

stand shock and vibration. State-of-the-art surface mount logic board fabrica-

tion makes the 1243GEN2 controller even more reliable than the original 1243.

The 1243GEN2 is fully programmable through the Curtis 13XX handheld

programmer. In addition to conﬁguration flexibility, the programmer provides

diagnostic and test capability.

Curtis 1243GEN2 Manual 2

1 — OVERVIEW

Like all Curtis motor controllers, the 1243GEN2 offers superior operator control

of the vehicle’s motor drive speed. Features include:

Interlock braking with load sensor to meet required braking distance

without unnecessary harsh braking at light loads

Maintenance monitor responds to preset vehicle operating hours and

drive hours as programmed by the OEM

Two hourmeters—total KSI-on hours and traction hours—and the

associated maintenance timers are built into the controller

BDI calculations performed within controller

Estimates motor temperature based on ﬁeld resistance and cuts back

maximum speed if the motor is overheated

Diagnostic checks for ﬁeld open and ﬁeld shorted faults

Supports PWM electromagnetic brake with maximum continuous

current of 2 amps

Supports Type 4 throttle

Active precharge of controller capacitor bank extends life of main

contactor

Compatibility with Curtis 1307/1311 handheld programmers for quick

and easy testing, diagnostics, and parameter adjustment

MultiMode™allows four user-selectable vehicle operating modes

Continuous armature current control, reducing arcing and brush wear

Complete diagnostics through the handheld programmer, the built-in

Status LED, and the optional 840 Spyglass display

Two fault outputs provide diagnostics to remotely mounted displays

Regenerative braking allows shorter stopping distances, increases battery

charge, and reduces motor heating

Automatic braking when throttle is reduced provides a compression

braking feel and enhances safety

Brake/Drive Interlock meets ISO stopping distance requirements

Ramp restraint feature provides automatic electronic braking

that restricts vehicle movement while in neutral

Meets EEC fault detect requirements

Linear cutback of motor drive current during overtemperature or

undervoltage

Curtis 1243GEN2 Manual 3

Linear cutback of regenerative braking current during overvoltage

High pedal disable (HPD) and static return to off (SRO) interlocks

prevent vehicle runaway at startup

Internal and external watchdog circuits ensure proper software operation

Fully protected inputs and short-circuit protected output drivers.

Curtis Model 840 Spyglass Display [optional]

3-wire serial interface

Sequences between hourmeter, BDI, and error displays

Single alphanumeric, non-backlit, 8 character, 5 mm LCD display for

hourmeter, BDI, and fault messages

Display updated by dedicated unidirectional serial port

Available in 52 mm round case, DIN case, and as a bare board, each

with an 8-pin Molex connector; cases feature front seal to IP65 and rear

seal to IP40; shock and vibration protection to SAE J1378

Operating temperature range -10°C to 70°C; models with lower

temperature ratings available for freezer applications

Familiarity with your Curtis controller will help you install and operate it

properly. We encourage you to read this manual carefully. If you have questions,

please contact the Curtis ofﬁce nearest you.

1 — OVERVIEW

Curtis 1243GEN2 Manual 4

INSTALLATION AND WIRING

MOUNTING THE CONTROLLER

The controller can be oriented in any position, but the location should be

carefully chosen to keep the controller as clean and dry as possible. 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 consideration (1) that access is

needed at the front of the controller to plug the programmer into its connector,

and (2) that the built-in Status LED is visible only through the view port in the

label on top of the controller.

The outline and mounting hole dimensions for the 1243GEN2 controller

are shown in Figure 2. To ensure full rated power, the controller should be

fastened to a clean, flat metal surface with three 6 mm (1/4") diameter screws,

using the holes provided.

2

2 — INSTALLATION & WIRING:

Controller

Fig. 2 Mounting

dimensions, Curtis

1243GEN2 controller.

Dimensions in millimeters (and inches)

C

L

S

EP

E

X

198 (7.78)

6.4 (0.25) dia., 3 plcs

68

(2.68)

114

(4.50)

173 (6.81)

17

(0.66)

7.9

(0.31)

99

(3.88)

4.8

(0.19)

7.9

(0.31)

STAT U S

Status LED

TRACTION CONTROLLER

TM

Curtis 1243GEN2 Manual 5

2 — INSTALLATION & WIRING:

Controller

The mounting surface must be at least a 300×300×3 mm (12"×12"×1/8")

aluminum plate, or its equivalent, and subjected to a minimum 3 mph airflow

to meet the speciﬁed time/current ratings. 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 1243GEN2 controller contains ESD-sensitive components. Use

appropriate precautions in connecting, disconnecting, and handling the con-

troller. See installation suggestions in Appendix A for protecting the controller

from ESD damage.

Working on electric vehicles is potentially dangerous. You should

protect yourself against runaways, high current arcs, and outgassing from

lead acid batteries:

RUNAWAYS —Some conditions could cause the vehicle 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.

HIGH CURRENT ARCS —Electric vehicle 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 circuitry. 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.

☞

C A U T I O N

Curtis 1243GEN2 Manual 6

CONNECTIONS

Low Current Connections

A 16-pin Molex low current connector in the controller provides the low current

logic control connections:

2 — INSTALLATION & WIRING:

Controller

The mating connector is a 16-pin Molex Mini-Fit Jr. connector p/n 39-01-2165

using type 5556 terminals.

A 4-pin low power connector is provided for the handheld programmer. A

complete 1311 programmer kit, including the appropriate connecting cable,

can be ordered from Curtis.

The 4-pin connector can also be used for the Spyglass display. The display

is unplugged when the programmer is used.

High Current Connections

Three tin-plated solid copper bus bars are provided for high current connections

to the battery (B+ and B-) and the motor armature (M-). Cables are fastened to

the bus bars by M8 bolts.The 1243GEN2 case provides the capture nuts required

Pin 1 load sensor input [optional]

Pin 2 Fault 1 output / pump input

Pin 3 Fault 2 output

Pin 4 main contactor driver output

Pin 5 throttle: 3-wire pot high

Pin 6 throttle: 0–5V; pot wiper

Pin 7 throttle: pot low

Pin 8 auxiliary driver output (typically

used for an electromagnetic brake)

Pin 9 Mode Select 2 input

Pin 10 emerg. reverse check output [optional]

Pin 11 reverse input

Pin 12 forward input

Pin 13 emergency reverse input

Pin 14 Mode Select 1 input

Pin 15 interlock input

Pin 16 keyswitch input (KSI)

87654321

16 15 14 13 12 11 10 9

Pin 1 receive data (+5V)

Pin 2 ground (B-)

Pin 3 transmit data (+5V)

Pin 4 +15V supply (100mA)

34

12

Curtis 1243GEN2 Manual 7

2 — INSTALLATION & WIRING:

Controller

for the M8 bolts. The maximum bolt insertion depth below the surface of the

bus bar is 1.3cm (1/2"). Boltshafts exceeding thislength maydamagethe controller.

The torque applied to the bolts should not exceed 16.3 N·m (12 ft-lbs).

Two 1/4" quick connect terminals (S1 and S2) are provided for the

connections to the motor ﬁeld winding.

WIRING: Standard Configuration

Figure 3 shows the typical wiring conﬁguration for most applications. For

walkie applications the interlock switch is typically activated by the tiller, and

an emergency reverse switch on the tiller handle provides the emergency reverse

signal.

For rider applications the interlock switch is typically a seat switch or a

foot switch, and there is no emergency reverse.

Fig. 3 Standard wiring conﬁguration, Curtis 1243GEN2 controller.

S1 S2

B- M- B+

INTERLOCK

5 kΩPOT

THROTTLE

(TYPICAL)

EMERGENCY

REVERSE

emergency reverse wiring check (optional)

FORWARD

MAIN

CONTACTOR

COIL

POLARITY

PROTECTION

DIODE

REVERSE

MODE

SELECT

1

MODE

SELECT

2

ELECTRO-

MAGNETIC

BRAKE

KEY

SWITCH

POWER

FUSE

A

MAIN

CONTACTOR

B+

B-

A2 A1

S2 S1

CONTROL

FUSE

1

9

8

16

Curtis 1243GEN2 Manual 8

2 — INSTALLATION & WIRING:

Controller

Standard Power Wiring

Motor armature wiring is straightforward, with the armature’s A1 connection

going to the controller’s B+ bus bar and the armature’s A2 connection going to

the controller’s M- bus bar.

The motor’s ﬁeld connections (S1 and S2) are less obvious. The direction

of vehicle travel with the forward direction selected will depend on how the

motor’s S1 and S2 connections are made to the controller’s two ﬁeld terminals

(S1 and S2) and how the motor shaft is connected to the drive wheels through

the vehicle’s drive train.

CAUTION:

The polarity of the S1 and S2 connections

will affect the operation of the emergency reverse feature. The forward and

reverse switches and the S1 and S2 connections must be conﬁgured so that the

vehicle drives away from the operator when the emergency reverse button is

pressed.

Standard Control Wiring

Wiring for the input switches and contactors is shown in Figure 3; the pins are

identiﬁed on page 6. In the standard wiring conﬁguration, the auxiliary driver

at Pin 8 is used to drive an electromagnetic brake.

The main contactor coil must be wired directly to the controller as shown

in Figure 3. The controller checks for welded or missing contactor faults and

uses the main contactor coil driver output to disconnect the battery from the

controller and motor when speciﬁc faults are present. If the main contactor coil

is not wired to Pin 4, the controller will not be able to open the main contactor

in serious fault conditions and the system will therefore not meet EEC safety

requirements.

☞

C A U T I O N

Curtis 1243GEN2 Manual 9

2 — INSTALLATION & WIRING:

Throttle

WIRING: Throttle

Wiring for various throttles is described below. They are categorized as Type 1,

2, 3, and 4 throttles in the program menu of the handheld programmer. Note:

In the text, throttles are identiﬁed by their nominal range and not by their actual

active range.

Appropriate throttles for use with the 1243GEN2 controller include two-

wire 5kΩ–0 throttles (“Type 1”); 0–5V throttles, current source throttles,

three-wire potentiometer throttles, and electronic throttles wired for single-

ended operation (all “Type 2”); two-wire 0–5kΩthrottles (“Type 3”), and

0–5V and three-wire potentiometer throttles wired for wigwag operation

(“Type 4”). The operating speciﬁcations for these throttle types are summarized

in Table 1. Refer to Section 3: Programmable Parameters, for information on

the effects of the Throttle Deadband and Throttle Max parameters on the

minimum and maximum throttle thresholds.

If the throttle you are planning to use is not covered, contact the Curtis

ofﬁce nearest you.

Table 1 THROTTLE WIPER INPUT THRESHOLD VALUES

MAXIMUM THROTTLE HPD THROTTLE MINIMUM

THROTTLE THROTTLE DEADBAND (25% throttle MAX THROTTLE

TYPE PARAMETER FAULT (0% speed request) active range) (100% modulation) FAULT

1(5kΩ–0) Wiper Voltage 5.00 V 3.80 V 2.70 V 0.20 V 0.06 V

Wiper Resistance 7.50 kΩ5.50 kΩ3.85 kΩ0 kΩ—

2(0–5V) Wiper Voltage 0.06 V 0.20 V 1.50 V 5.00 V 5.80 V

Wiper Resistance — — — — —

3(0–5kΩ) Wiper Voltage 0.06 V 0.20 V 1.30 V 3.80 V 5.00 V

Wiper Resistance — 0 kΩ1.65 kΩ5.50 kΩ7.50 kΩ

4(0–5V) Wiper Voltage 0.50 V 2.50 V (fwd) *3.10 V (fwd) 4.40 V (fwd) 4.50 V

2.50 V (rev) *1.90 V (rev) 0.60 V (rev)

Wiper Resistance — — — — —

Notes: The Throttle Deadband and Throttle Max thresholds 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 threshold values

will change with variations in the Throttle Deadband and Throttle Max param-

eter settings

.

The HPD thresholds are 25% of the active throttle range and therefore

dependent on the programmed Throttle Deadband and Throttle Max settings

(which define the active range).

The wiper voltage is measured with respect to B-.

The wiper resistance is measured from pot low to pot wiper. The potentiometer

must be disconnected from the controller when making this measurement.

*With a 0% Throttle Deadband setting, there is no neutral point on

a Type 4 throttle. A Throttle Deadband setting of at least 8% is

recommended for Type 4 throttles.

Curtis 1243GEN2 Manual 10

2 — INSTALLATION & WIRING:

Throttle

5kΩ–0 Throttle (“Type 1”)

The 5kΩ–0 throttle (called a “Type 1”throttle in the programming menu of the

13XX programmer) is a 2-wire resistive throttle that connects between the Pot

Wiper and Pot Low pins (Pins 6 and 7), as shown in Figure 4. It doesn’t matter

which wire goes on which pin. For Type 1 throttles, zero speed corresponds to

5 kΩmeasured between the two pins and full speed corresponds to 0 Ω. (Note:

This wiring is also shown in the standard wiring diagram, Figure 3.)

Fig. 4 Wiring for 5k

Ω

–0

throttle (“Type 1”).

In addition to accommodating the basic 5kΩ–0 throttle, the Type 1

throttle is the easiest with which to implement a wigwag-style throttle.

Using a 20kΩpotentiometer wired as shown in Figure 5, the pot wiper can

be set such that the controller has 5 kΩbetween Pins 6 and 7 when the

throttle is in the neutral position. The throttle mechanism can then be

designed such that rotating it either forward or back decreases the resistance

between Pins 6 and 7, which increases the controller output. The throttle

mechanism must provide signals to the controller’s forward and reverse

inputs independent of the throttle pot resistance. The controller will not

sense direction from the pot resistance.

Fig. 5 Wiring for 20k

Ω

potentiometer used as a

wigwag-style throttle

(“Type 1”).

20 kΩ

FASTERFASTER

Pot Wiper input (Pin 6)

Pot Low input (Pin 7)

Broken wire protection is provided by the controller sensing the current

flow from the wiper input through the potentiometer and into the Pot Low pin.

If the Pot Low input current falls below 0.65 mA or its voltage below 0.06 V, a

throttle fault is generated and the controller is disabled. Note: The Pot Low pin

(Pin 7) must not be tied to ground (B-).

5kΩ–0

Pot Low input (Pin 7)

Pot Wiper input (Pin 6)

FASTER

Curtis 1243GEN2 Manual 11

2 — INSTALLATION & WIRING:

Throttle

0–5V, Current Source, 3-Wire Potentiometer,

and Electronic Throttles (“Type 2”)

With these throttles (“Type 2”in the programming menu) the controller looks

for a voltage signal at the wiper input (Pin 6). Zero speed will correspond to 0 V

and full speed to 5 V (measurements made relative to B-). A voltage source,

current source, 3-wire potentiometer, or electronic throttle can be used with this

throttle type. The wiring for each is slightly different and each has varying levels

of throttle fault detection associated with it.

0–5V Throttle

Two ways of wiring the 0–5V throttle are shown in Figure 6. The active range

for this throttle is from 0.2 V (at 0% Throttle Deadband) to 5.0 V (at 100%

Throttle Max), measured relative to B-.

Fig. 6 Wiring for

0–5V throttles (“Type 2”).

Sensor-referenced 0–5V throttles must provide a Pot Low current greater

than 0.65 mA to prevent shutdown due to pot faults. It is recommended that

the maximum Pot Low current be limited to 55 mA to prevent damage to the

Pot Low circuitry.

Ground-referenced 0–5V throttles require setting the Pot Low Fault

parameter (see Section 3, page 38) to Off; otherwise the controller will register

a throttle fault and will shut down. For ground-referenced 0–5V throttles, the

controller will detect open breaks in the wiper input but cannot provide full

throttle fault protection. Also, the controller recognizes the voltage between the

wiper input and B- as the applied throttle voltage and not the voltage from the

voltage source relative to the Pot Low input.

For either throttle input, if the 0–5V throttle input (Pin 6) exceeds 5.5 V

relative to B-, the controller will register a fault and shut down.

+

-

B-

+

SENSOR GROUND

SENSOR OUTPUT (0–5V)

S E N S O R

Pot Low input (Pin 7)

0–5V input (Pin 6)

Pot Low Fault setting = OFF

☞

Sensor-referenced 0–5V source Ground-referenced 0–5V source

Curtis 1243GEN2 Manual 12

2 — INSTALLATION & WIRING:

Throttle

Current Sources As Throttles

A current source can also be used as a throttle input, wired as shown in Figure 7.

A resistor, Rthrottle, must be used to convert the current source value to a voltage.

The resistor should be sized to provide a 0–5V signal variation over the full

current range.

The Pot Low Fault parameter (see Section 3, page 38) must be set to Off;

otherwise the controller will register a throttle fault and will shut down. It is the

responsibility of the vehicle manufacturer to provide appropriate throttle fault

detection in applications using a current source as a throttle.

Fig. 8 Wiring for 3-wire

potentiometer throttle

(“Type 2”).

1kΩ–10kΩ

Pot Wiper input (Pin 6)

Pot Low input (Pin 7)

Pot High output (Pin 5)

FASTER

Fig. 7 Wiring for current

source throttle (“Type 2”).

3-Wire Potentiometer (1k

Ω

–10k

Ω

) Throttle

A 3-wire pot with a total resistance value anywhere between 1 kΩand 10 kΩcan

be used, wired as shown in Figure 8. The pot is used in its voltage divider mode,

with the voltage source and return being provided by the 1243GEN2 controller.

Pot High (Pin 5) provides a current limited 5V source to the pot, and Pot Low

(Pin 7) provides the return path. If a 3-wire pot is used and the Pot Low Fault

parameter (see Section 3, page 38) is set to On, the controller will provide full

throttle fault protection in accordance with EEC requirements. Note: the Pot

Low pin (Pin 7) must not be tied to ground (B-).

R

throttle

I

source

B-B-

0–5V input (Pin 6)

Pot Low Fault setting = OFF

☞

Curtis 1243GEN2 Manual 13

2 — INSTALLATION & WIRING:

Throttle

Curtis ET-XXX Electronic Throttle

The Curtis ET-XXX provides a 0–5V throttle and forward/reverse inputs for the

1243GEN2 controller. Wiring for the ET-XXX is shown in Figure 9. When an

electronic throttle is used, the Pot Low Fault parameter (see Section 3, page 38)

must be set to Off; otherwise the controller will register a throttle fault and will

shut down.

There is no fault detection built into the ET-XXX, and the controller will

detect only open wiper faults. It is the responsibility of the vehicle manufacturer

to provide any additional throttle fault detection necessary.

The ET-XXX can be integrated into a control head to provide wigwag-

style throttle control. Alternatively, a complete control head assembly is avail-

able from Curtis. This control head assembly—the CH series—combines the

ET-XXX throttle with a variety of standard control head switch functions for

use in walkie and lift truck applications.

0–5kΩThrottle (“Type 3”)

The 0–5kΩthrottle (“Type 3”in the programming menu) is a 2-wire resistive

throttle that connects between the Pot Wiper and Pot Low pins (Pins 6 and 7)

as shown in Figure 10. Zero speed corresponds to 0 Ωmeasured between the two

pins and full speed corresponds to 5 kΩ. This throttle type is not appropriate

for use in wigwag-style applications.

Broken wire protection is provided by the controller sensing the current

flow from the wiper input through the potentiometer and into the Pot Low pin.

If the Pot Low input current falls below 0.65 mA or its voltage below 0.06 V,

Fig. 9 Wiring for Curtis

ET-XXX electronic throttle

(“Type 2”).

GREEN

ORANGE

BLACK

BLACK/WHITE

WHITE

WHT/BRN

B+

KEYSWITCH

connector

WHT/GRN

Reverse input (Pin 11)

KSI (Pin 16)

0–5V input (Pin 6)

Forward input (Pin 12)

Pot Low Fault setting = OFF

☞

B-

Curtis Instruments MultiMode 1243 Generation 2 User manual

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