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