Curtis 1204M User manual

Manual
Models 1204M/05M/09M/21M
Electronic Motor Controllers
with Universal Logic Board
Read Instructions Carefully!
Specications are subject to change without notice.
© 2012 Curtis Instruments, Inc. ® Curtis is a registered trademark of Curtis Instruments, Inc.
© The design and appearance of the products depicted herein are the copyright of Curtis Instruments, Inc. 53121 Rev B 8/16
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com

Curtis 1204M/05M/09M/21M Manual iii
CONTENTS
1. OVERVIEW................................................................................... 1
2. INSTALLATION AND WIRING ................................................. 3
Mounting the 1204M/05M Controller..................................... 3
Mounting the 1209M/21M Controller..................................... 4
Connections: High Current ...................................................... 5
Connections: Low Current........................................................ 5
Controller Wiring Configuration, with active main driver ........ 7
Controller Wiring Configuration, with active reverse input ...... 8
KSI Wiring ............................................................................... 8
Forward/Reverse Wiring............................................................ 9
Throttle Wiring ...................................................................... 10
Wiring Configuration for Pump Applications......................... 14
Installation Checkout.............................................................. 15
3. PROGRAMMABLE PARAMETERS........................................... 17
Voltage Parameters .................................................................. 18
Current Parameters ................................................................. 19
Speed Parameters..................................................................... 20
Throttle Input Parameters....................................................... 21
Miscellaneous Parameters ........................................................ 23
Controller Cloning.................................................................. 24
4. MONITOR MENU..................................................................... 25
5. DIAGNOSTICS AND TROUBLESHOOTING ........................ 26
6. MAINTENANCE ........................................................................ 30
appendix aEMC & ESD Design Considerations
appendix bProgramming Devices
appendix cController Specifications
CONTENTS

iv Curtis 1204M/05M/09M/21M Manual
FIGURES
fig.1: Curtis 1204M and 1209M electronic motor controllers............1
fig.2: Mounting dimensions, Curtis 1204M/05M controllers ............3
fig.3: Mounting dimensions, Curtis 1209M/21M controllers.............4
fig.4: Standard wiring configuration, with active main driver .............7
fig.5: Standard wiring configuration, with active reverse input ..........8
fig.6: Wiring to inhibit plug braking .................................................9
fig.7: Wiring for mechanical reversing ..............................................10
fig.8: Wiring for Type 0 throttles .....................................................10
fig.9: Wiring for Type 1, 3, 4, and 5 throttles .................................11
fig.10: Wiring for Type 2 throttles ....................................................13
fig.11: Wiring configuration for pump applications ..........................14
fig.12: Effect of throttle adjustment parameters..................................22
TABLES
table 1: High current connections.....................................................5
table 2: Low current connections ......................................................5
table 3: J4 connector pinout .............................................................6
table 4: Status LED fault codes .......................................................26
table 5: Troubleshooting chart ........................................................28
FIGURES / TABLES

OVERVIEW
Curtis 1204M, 1205M, 1209M, and 1221M series motor controllers are the
form/fit/function replacements of the earlier 1204/1205/1209B/1221B con-
trollers, with the added functionality of being programmable—via a Curtis
handheld programmer or PC programming station. This means the controllers
can be tailored to the needs of specific applications. In addition to configuration
flexibility, use of the programmer offers diagnostic and test capability.
These controllers are the ideal solution for a variety of electric vehicle
applications, including industrial trucks, personnel carriers, material handing
vehicles, light on-road vehicles, golf cars, etc.
1
1 — OVERVIEW
Fig. 1 Curtis 1204M
and 1209M programmable
series motor controllers.
Except for their length, the
1204M and 1205M look
the same, as do the 1209M
and 1221M.
Like all Curtis controllers, the 1204M/05M/09M/21M models offer superior
operator control of motor drive performance. Features include:
3Universal logic board supports multiple throttle types and
high pedal disable (HPD) options.
3Environmental protection provided by rugged anodized
aluminum extruded housing.
3Simple mounting and wiring with push-on connectors
for control signals.
3Plated solid copper buses used for all power connections.
3Thermal protection and compensation circuit provides
constant current limit over operating range and during
under/over temperature cutback; no sudden loss of power
under any thermal conditions.
3Throttle fault protection circuitry disables controller
if throttle wires become open.
3HPD feature prevents controller operation if key is turned
on while throttle is applied.
More Features +
Curtis 1204M/1205M/1209M/1221M Manual 1

3Plug braking diode internal to controller.
3Undervoltage cutback function protects against low battery
voltage, including low voltage caused by external loads.
3Easily programmable through the Curtis handheld
programmer or PC programming station.
Familiarity with your Curtis 1204M/05M/09M/21M 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
2Curtis 1204M/1205M/1209M/1221M Manual

2 — INSTALLATION & WIRING
2
Fig. 2 Mounting
dimensions, Curtis 1204M
and 1205M motor
controllers.
Dimensions in millimeters.
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
The outline and mounting hole dimensions are shown for the 1204M and 1205M
controllers in Figure 2, and for the 1209M and 1221M controllers in Figure 3.
The controllers meet the IP54 requirements for environmental protection against
dust and water. Nevertheless, in order to prevent external corrosion and leakage
paths from developing, the mounting location should be carefully chosen to
keep the controller as clean and dry as possible.
It is recommended that the controller be fastened to a clean, flat metal
surface with four M6 bolts, using the holes provided. The mounting surface is
an integral part of the overall heatsinking of the controller, and affects its ability
to dissipate heat. Although not usually necessary, a thermal joint compound
can be used to improve heat conduction from the controller heatsink to the
mounting surface.
7.2 dia.
8.5 dia.
1204M:
22.2 × 19 × 3
1205M:
25 × 19 × 3
130.3
146
push-on terminal,
4 plcs
5.0
77
133.3
MODEL 1204M: 173
MODEL 1205M: 199
B+B-M-
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.
Curtis 1204M/1205M/1209M/1221M Manual 3

These controllers contain ESD-sensitive components. Use appropriate pre-
cautions in connecting, disconnecting, and handling the controller. See installation
suggestions in Appendix A for protecting the controller from ESD damage.
2 — INSTALLATION & WIRING
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.
HIGH CURRENT ARCS — Batteries can supply very high power, and arcing 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 man-
ufacturer’s safety recommendations. Wear safety glasses.
+
CAUTION
Fig. 3 Mounting
dimensions, Curtis 1209M
and 1221M motor
controllers.
push-on terminal,
4 plcs
B+B-M-
7.2 dia.
MODEL 1209M: 229
MODEL 1221M: 281
5.0
80
MODEL 1209M: 152.4
MODEL 1221M: 203
180
165
8.5 dia.
25
× 19 × 5
A2: 22.8 × 19 × 5
4Curtis 1204M/1205M/1209M/1221M Manual

2 — INSTALLATION & WIRING: Connections
High current connections
These controllers have four high-current busbars: B+, B-, A2, and M-. The
busbars are tin-plated solid copper.
Table 1 High Current Connections
B+ Battery+ and motor armature. (plug diode -)
B- B-.
A2 Motorarmatureandeld(plugdiode+).
M- Motoreld(controlleroutput).
Cables used for the battery and motor connections must be heavy enough to
carry the high current required. A minimum size of 25 mm2(#4 AWG) is
recommended.
Connections to the controller busbars should be made with lugs suitable
for the cable used, fastened by M8 bolts and nuts. When tightening the bolts,
two opposing wrenches should be used. Failure to use the double-wrench
technique could cause undue strain to be placed on the internal connections,
and could also result in cracked seals around the busbars.
Low current connections
These controllers have five low-current connections: four 6.35 mm push-on
terminals (J1, J2, J3, and J5), and one 4-pin connector (J4).
Table 2 Low Current Connections
J1 Keyswitch.
J2 Wire 1 of 2-wire throttle; Pot High of 3-wire or ITS throttle.
J3 Wire 2 of 2-wire throttle; Pot Wiper of 3-wire throttle;
Pot Low of ITS thottle; or electronic throttle input.
J4 4-pin connector: see Table 3.
J5 Reverse signal output / main contactor coil driver.
CONNECTIONS
The controller’s connectors are all conveniently located on one end:
For the control wiring, 0.75 mm2(#18 AWG) vinyl insulated stranded wire
is recommended.
A2
M–
B– B+
J1
J2
J3
J4
J5
Curtis 1204M/1205M/1209M/1221M Manual 5

The mating connector for J4 is a 4-pin Molex Mini-fit Jr. or equivalent. Either
an external Status LED or a Curtis programmer can be connected to J4. The
pinout is as follows.
2 — INSTALLATION & WIRING: Connections
Table 3 J4 Connector Pinout
PIN PROGRAMMER STATUS LED
J4-1 Data input from programmer (Rx). Status LED enable.
J4-2 Ground. Ground.
J4-3 Data output to programmer (Tx). Status LED output.
J4-4 +15 V. +15 V.
31
4
2
J4
Note: When J4 is used for a Status LED, a jumper must be added between
pins J4-1 and J4-4 as shown in the basic wiring diagram (Figure 3).
6Curtis 1204M/1205M/1209M/1221M Manual

Fig. 4 Basic wiring diagram, Curtis 1204M/05M/09M/21M with active main contactor.
2 — INSTALLATION & WIRING: Standard Wiring Diagrams
CONTROLLER WIRING: BASIC CONFIGURATIONS
Two basic wiring diagrams are shown; they are identical except for the wiring
at terminal J5. In the configuration in Figure 4, the main contactor driver is
active. In the configuration in Figure 5, the reverse input is active.
Wiring with active main contactor
For this option, set the Rev Input / Main Driver parameter = 2 (see
page 24), and wire the controller as shown in Figure 4.
J5 is used to drive the main contactor, which will open the battery
power in the event of a severe fault; this will help to meet safety regula-
tions. If you wish to limit reverse speed, you will need to add a speed
reduction resistor.
Wiring with active reverse input
For this option, set the Rev Input / Main Driver parameter = 1 (see
page 24), and wire the controller as shown in Figure 5.
J5 is used as the input when the reverse direction is selected. This
simplifies the wiring for limiting reverse speed; the speed in reverse is
limited by the setting of the Rev Speed parameter. However, with this
configuration the main contactor does not open the battery power in
the event of a severe fault.
STATUS
LED
MOTOR
FIELD
A2 A1
5kΩTHROTTLE
PRECHARGE RESISTOR
MOTOR
ARMATURE
FORWARD
REVERSE
MAIN
FR
MAIN
KEYSWITCH INTERLOCKS
POLARITY
PROTECTION
DIODE
CONTROL WIRING
FUSE
POWER WIRING
FUSE
S2S1
FR
FR
+
–
PEDAL
MICROSWITCH
Resistor Values
12V: 33Ω, 5W
24V: 100Ω, 10W
36–48V: 250Ω,10W
60–72V: 250Ω,20W
A2
M–
B– B+
J1
J2
J3
J4
J5
Curtis 1204M/1205M/1209M/1221M Manual 7

2 — INSTALLATION & WIRING: KSI Wiring
The throttle shown in the basic wiring diagrams is a 2-wire potentiometer.
Various types of throttles can be used; see Throttle Type parameter (page 21)
and throttle wiring (pages 10–13).
Coil suppression diodes should be used on the main and forward/reverse
contactors, as shown.
KSI Wiring
The keyswitch input (KSI) circuit includes input from the keyswitch and from
the various interlocks. The controller KSI is used to turn the controller on and
off. KSI is turned on by connecting it to battery B+. Any positive voltage greater
than about 16 volts will turn on the controller, but usually the full vehicle bat-
tery voltage is used. KSI draws up to 130 mA with the programmer connected,
and up to 70 mA without the programmer.
In its simplest form, KSI is operated by a keyswitch that turns the ve-
hicle off and prevents unauthorized use. The keyswitch should also turn off
the main contactor and the forward/reverse contactors. This will act as a safety
feature by removing power from the motor control system when the keyswitch
is turned off.
Fig. 5 Basic wiring diagram, Curtis 1204M/05M/09M/21M with active reverse input.
STATUS
LED
MOTOR
FIELD
A2 A1
5kΩTHROTTLE
MOTOR
ARMATURE
REVERSE
FORWARD
MAIN
RF
MAIN
KEYSWITCH INTERLOCKS
POLARITY
PROTECTION
DIODE
CONTROL WIRING
FUSE
POWER WIRING
FUSE
S2S1
FR
FR
+
–
PEDAL
MICROSWITCH
PRECHARGE RESISTOR
Resistor Values
12V: 33Ω, 5W
24V: 100Ω, 10W
36–48V: 250Ω,10W
60–72V: 250Ω,20W
A2
M–
B– B+
J1
J2
J3
J4
J5
8Curtis 1204M/1205M/1209M/1221M Manual

Interlocks (seat switches, battery charger interlocks, etc.) should be wired
in series so that they turn off the controller KSI and the contactors.
Forward/Reverse Wiring
With these controllers, it is essential that the field be reversed and that the
armature be connected directly to the controller’s B+ and A2 terminals,
because the plug diode inside is connected to these terminals; this is the
wiring shown in Figures 4 and 5. Some vehicles, especially those previously us-
ing older, resistor-type controllers, may reverse the motor armature rather than
the field winding. Be careful if you are replacing this type of controller.
Plug braking
Wired as shown in the basic wiring diagrams, the vehicle will plug brake if
the direction is changed with the vehicle moving and the throttle applied. The
forward/reverse switch should be in the positive feed to the contactor coils, so
that they can be turned off by the keyswitch and any interlocks. The coil of
one contactor or the other is energized to select the direction desired.
Freewheeling (wiring to inhibit plug braking)
If plug braking is not desired, the vehicle can be wired so that moving the
forward/reverse switch through neutral causes the vehicle to freewheel as long
as the throttle is applied. Plug braking can be reactivated during freewheeling
by releasing the throttle and reapplying it. The HPD option must be enabled
(programmed On) in order for this arrangement to work.
As shown in Figure 6, another set of contacts is added on the forward/reverse
switch. Therefore, a double-pole, double-throw (DPDT) center-off switch must
be used for this setup. A “hesitation switch” is recommended, to ensure the switch
is in neutral long enough to actuate HPD and inhibit plug braking.
Fig. 6 Control wiring
to inhibit plug braking, in
order to allow freewheeling.
+
–
J1
FORWARD
REVERSE
MAIN
KEYSWITCH INTERLOCKS
FUSE
POLARITY
PROTECTION
DIODE
F/R SWITCH
(DPDT, center off)
PEDAL
MICROSWITCH
2 — INSTALLATION & WIRING: Forward/Reverse Wiring
Curtis 1204M/1205M/1209M/1221M Manual 9

Wiring for mechanical reversing switch (golf car type)
As shown in Figure 7, this type of switch mechanically interchanges the two
motor field cables by rotating a movable contact bar. The configuration shown
is typical; many variations are in use.
Throttle Wiring
Ten throttle types can be used with these controllers:
Type 0 2-wire potentiometer, 0–5kΩ
Type 1 2-wire potentiometer, 5kΩ–0
Type 2 single-ended 0–5V input
Type 3 2-wire potentiometer, 4.6kΩ–0
Type 4 2-wire potentiometer, 5.5kΩ–0
Type 5 2-wire potentiometer, 1kΩ–0
Type 6 ITS input
Type 7 single-ended 6.3–10.6 V input
Type 8 single-ended 6–12 V input
Type 9 single-ended 3-wire potentiometer, 0–5kΩ
Throttle Type 0
Wiring for Type 0 throttles is simple: just connect the two wires to the J2 and J3
push-on terminals; it doesn’t matter which wire goes on which terminal. With
Type 0 throttles, resistance increases as the applied throttle is increased.
Fig. 7 Wiring for reversing
with a mechanical F/R
switch arm.
A2
M–
B– B+
+
–
MAIN
PRECHARGE RESISTOR
(250 �, 5 W)
FUSE
S2
S1
A2 A1
MOTOR ARMATURE
MOTOR FIELD
Mechanical potboxes and footpedals areType 0 throttles. It doesn’t matter which
wire goes on which terminal, and the wires can be extended as required.
Fig. 8 Wiring for Type 0
throttles. J1
J2
J3
2 — INSTALLATION & WIRING: Throttle Wiring
10 Curtis 1204M/1205M/1209M/1221M Manual

Some potboxes have a built-in microswitch, eliminating the need to install
a separate pedal-actuated microswitch. It is important that a pedal microswitch
be included in the circuit as shown in Figures 4 and 5 to allow the microcon-
troller a few milliseconds to boot up, run diagnostics and safety checks, and
then be ready in standby before receiving the throttle signal.
A potbox makes it easy to retain the vehicle’s original cable throttle pedal.
Curtis and various third-party vendors also offer self-contained footpedal units
that eliminate the need for fabricating and installing a pedal-potbox linkage.
Any potbox that can provide a nominal 0–5kΩoutput will work as a Type 0
throttle input.
If a potbox is used, it must be mounted so as to allow connection be-
tween the potbox lever arm and the vehicle accelerator linkage. Use of a second
return spring on the pedal, in addition to the potbox return spring, is required
to prevent an uncontrollable full-on throttle input (which could happen if
there was a single spring, and it broke). If the self-contained potbox spring is
insufficient to return the pedal by itself, two additional pedal return springs
must be used.
It is also required that the accelerator pedal hit a mechanical stop at its
full-on position just before (≈1 mm) the potbox lever hits its own full-on stop.
This mechanical stop will prevent the potbox lever arm from bending if undue
force is put on the pedal. Protection of the potbox from water and dirt will
help avoid problems of corrosion and electrical leakage.
After the potbox has been mounted, operation of the pot can be tested
by measuring the resistance between the two wires with an ohmmeter. With
the pedal not applied, the resistance should be less than 50 ohms. As the pedal
is applied, the resistance should rise smoothly until it reaches a value between
4500 and 5500 ohms. Values below 4500 ohms may cause a reduction in
efficiency and top speed; however, you still can get top speed by lowering the
Throttle Max setting. Values above 7500 ohms indicate a defective potbox, and
will cause controller shutdown.
Throttle Types 1, 3, 4, 5
Wiring for Type 1, 3, 4, and 5 throttles is the same as for Type 0 throttles;
again, it doesn’t matter which wire goes on which terminal. With these throttles,
resistance is in an inverse relationship to applied throttle; that is, resistance
decreases as applied throttle is increased.
2 — INSTALLATION & WIRING: Throttle Wiring
Fig. 9 Wiring for Type 1,
3, 4, and 5 throttles. J1
J2
J3
5k�–0 (Type 1)
4.6k�–0 (Type 3)
5.5k�–0 (Type 4)
1k�–0 (Type 5)
FASTER
Curtis 1204M/1205M/1209M/1221M Manual 11

2 — INSTALLATION & WIRING: Throttle Wiring
Throttle Type 2
With Type 2 throttles, the controller looks for a voltage signal at J3.
Zero throttle request corresponds to 0 V and full throttle request to 5 V. A
variety of devices can be used with this throttle input type, including voltage
sources, current sources, and electronic throttles. The wiring for each is slightly
different, as shown in Figure 10, and they have varying levels of throttle fault
protection.
When a voltage source is used as a throttle, it is the responsibility of the
OEM to provide appropriate throttle fault detection. For ground-referenced
0–5V throttles, the controller will detect open breaks in the wiper input but
cannot provide full throttle fault protection.
To use a current source as a throttle, a resistor must be added to the circuit
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. It is the responsibil-
ity of the OEM to provide appropriate throttle fault detection.
The Curtis ET-XXX electronic throttle contains no built-in fault detec-
tion, and the controller will detect only open wiper faults. It is the responsibil-
ity of the OEM to provide any additional throttle fault detection necessary.
For wiring other electronic throttles, consult the instructions that are provided
with the throttle.
There are many electronic footpedals on the market; for wiring, consult
the instructions that are provided with the footpedal.
Throttle Type 6
The ITS+ connects to J2, and ITS- connects to J3.
Throttle Types 7, 8
Wiring for these voltage input throttles is the same as for Type 2 throttles; the
throttle input goes to J3 and the ground return to B-.
Throttle Type 9
The Pot High input goes to J2, the Pot Wiper goes to J3, and the ground
return goes to B-.
When a 3-wire pot is used, the controller provides full fault protection.
12 Curtis 1204M/1205M/1209M/1221M Manual

2 — INSTALLATION & WIRING: Throttle Wiring
Fig. 10 Wiring for Type 2
throttles.
Curtis ET-XXX Electronic Throttle
Voltage Source
+
+
-
+
–
Current Source
Curtis 1204M/1205M/1209M/1221M Manual 13

Basic Wiring Conguration for Pump Applications
The 1204M-6302 controller has only three busbars; it is appropriate for use
with pump motors, wired as shown in Figure 11.
2 — INSTALLATION & WIRING: Throttle Wiring; Pump Applications
Fig. 11 Basic wiring diagram, Curtis 1204M-6302 motor controller—for pump applications.
STATUS
LED
MOTOR
FIELD
A2
5k�THROTTLE
PRECHARGE RESISTOR
(250 �, 5 W)
MOTOR
ARMATURE
MAIN
MAIN
KEYSWITCH INTERLOCKS
POLARITY
PROTECTION
DIODE
CONTROL WIRING
FUSE
POWER WIRING
FUSE
S1
+
–
ENABLE
A1
S2 M–
B– B+
J1
J2
J3
J4
J5
14 Curtis 1204M/1205M/1209M/1221M Manual

2 — INSTALLATION & WIRING: Installation Checkout
INSTALLATION CHECKOUT
Carefully complete the following checkout procedure before operating the
vehicle. If a step does not test correctly, refer to Section 5: Diagnostics and
Troubleshooting.
Put the vehicle up on blocks to get the drive wheels off
the ground before beginning these tests.
Don’t let anyone stand in front of or behind the vehicle
during the checkout.
Make sure the keyswitch is off and the vehicle is in
neutral before beginning.
Wear safety glasses and use well-insulated tools.
A. Connect the battery. Use a voltmeter to verify that the proper voltage and
polarity appears at the battery B+ and B- terminals.
B. Check the voltage at the controller B+ and B- busbars. If your system
has a precharge resistor in parallel with the main contactor, you should see
approximately 90% of the full battery voltage. If your system does not have
a resistor, temporarily connect one (100 to 200 ohms, 5 watts, or a 100 watt
light bulb). The voltage at the controller should rise to approximately 90% of
the full battery voltage.
C. If “A” and “B” do not check out, troubleshoot the wiring connections. Do
not turn on the keyswitch until the trouble is corrected and “A” and “B”
check out.
D. With the forward/reverse switch in neutral, turn on the keyswitch. If the
motor runs without the throttle being applied, turn the keyswitch off and
recheck the wiring. If the motor does not run without the throttle applied,
proceed with the checkout. Select a direction and slowly apply the throttle; the
motor should now respond.
E. Look to see which direction the wheels are turning. If the wheels are going
the wrong way, turn everything off and interchange the motor field connec-
tions.
F. If you have HPD, check it next. Turn off the keyswitch and direction
switch. Apply the throttle, turn the keyswitch on, and then select a direction.
The motor should not run. Release the throttle and re-apply it — the motor
should now run. If the motor runs before you release the throttle, recheck the
wiring.
+
CAUTION
Curtis 1204M/1205M/1209M/1221M Manual 15

2 — INSTALLATION & WIRING: Installation Checkout
G. Take the vehicle down off the blocks and drive it in a clear area. It should
have smooth acceleration and good top speed.
H. On vehicles that are intended to plug brake, test the plug braking by driv-
ing forward at moderate speed and shifting into reverse without letting up on
the throttle. The vehicle should smoothly brake to a stop and accelerate in
reverse.
I. On vehicles that are intended to have plug braking inhibited, verify that
the maneuver in “H” produces freewheel coasting.
16 Curtis 1204M/1205M/1209M/1221M Manual