Curtis 1298 User manual

1298
MODEL
INTEGRATED TRACTION
& HYDRAULIC SYSTEM
MOTOR CONTROLLER
OS 11 with VCL
© 2010 CURTIS INSTRUMENTS, INC.
CURTIS INSTRUMENTS, INC.
200 Kisco Avenue
Mt. Kisco, New York 10549 USA
Tel. [phone]
Fax [phone]
www.curtisinstruments.com
1298 Manual, p/n 38272
17 November 2010, Rev. B
» Software version OS 11.0 «

Curtis 1298 Manual, OS 11 iii
CONTENTS
1. OVERVIEW ..............................................................................1
2. INSTALLATION AND WIRING .............................................3
Mounting the Controller .....................................................3
High Current Connections and Wiring Guidelines ..............5
Low Current Connections and Wiring Guidelines ...............6
Controller Wiring: Basic Configuration ............................10
Switch Input Wiring ..........................................................11
Throttle Wiring .................................................................11
Input/Output Specifications ...............................................16
3. PROGRAMMABLE PARAMETERS .....................................21
Program Menu ..................................................................22
4a. MONITOR MENU ................................................................64
4b. CONTROLLER INFORMATION MENU ...........................74
5. INITIAL SETUP .....................................................................75
6. TUNING GUIDE ...................................................................81
7. VEHICLE CONTROL LANGUAGE .....................................85
8. DIAGNOSTICS AND TROUBLESHOOTING ..................112
9. MAINTENANCE .................................................................122
APPENDIX A Theory of Operation
APPENDIX B Vehicle Design Considerations
APPENDIX C Curtis WEEE / RoHS Statement
APPENDIX D Programming Devices
APPENDIX E Specifications, 1298 Controller
CONTENTS

iv Curtis 1298 Manual, OS 11
FIGURES
FIG. 1: Curtis 1298 controller .............................................................. 1
FIG. 2: Mounting dimensions, Curtis 1298 controller ........................ 3
FIG. 3: Basic wiring diagram .............................................................. 10
FIG. 4: Wiring for Type 1 throttles .................................................... 12
FIG. 5: Wiring for Type 2 throttles .................................................... 13
FIG. 6: Wiring for Type 3 throttles .................................................... 14
FIG. 7: Acceleration response rate diagram ......................................... 29
FIG. 8: Braking response rate diagram ................................................ 30
FIG. 9: Throttle mapping, torque control mode ................................ 34
FIG. 10: Effect of gear soften parameter, torque control mode ............ 34
FIG. 11: Effect of brake taper speed parameter, torque control mode ... 34
FIG. 12: Drive current limiting map .................................................... 37
FIG. 13: Regen current limiting map ................................................... 38
FIG. 14: Throttle adjustment ............................................................... 40
FIG. 15: Hydraulic system diagram ...................................................... 50
FIG. 16: Alternative hydraulic system ................................................... 50
FIG. 17: VCL motor command diagram, AC traction motor ............... 93
FIG. 18: VCL control mode processing ................................................ 96
FIG. 19: VCL hydraulics command diagram ........................................ 97
FIG. 20: VCL proportional driver processing ..................................... 100
FIG. A-1: IFO diagram .........................................................................A-2
FIG. A-2: Power section topology ..........................................................A-3
TABLES
TABLE 1: High current connections ....................................................... 5
TABLE 2: Low current connections ........................................................ 7
TABLE 3: Programmable parameter menus .......................................... 22
TABLE 4: Types of LED display ........................................................ 113
TABLE 5: Troubleshooting chart ......................................................... 114
TABLE E-1: Specifications, 1298 controller ............................................E-1
FIGURES / TABLES

Curtis 1298 Manual, OS 11 1
OVERVIEW
The Curtis 1298 motor controller combines AC traction motor control with
DC pump motor control. Advanced motor drive software provides smooth
control over full speed and torque, including regenerative braking and zero
speed control.
The 1298 is designed primarily for Class III material handling vehicles
needing solid state control of hydraulic pump motors. Generic software is
included for Walkie and Walkie-Stacker applications. Other applications can
be easily supported with alternative VCL programming.
1
1 — OVERVIEW
Fig. 1 Curtis 1298
integrated traction and
hydraulic system motor
controller.
Like all Curtis controllers, the 1298 offers superior operator control of motor
drive performance. Features include:
✓ High efficiency, field-oriented motor control algorithms
✓ Advanced Pulse Width Modulation technology for efficient use
of battery voltage, low motor harmonics, low torque ripple, and
minimized switching losses
✓ Extremely wide torque/speed range including full regeneration capability
✓ Smooth low speed control, including zero speed
✓ Special features and I/O for DC pump motor and hydraulic valve
control, allowing economical control of the entire vehicle system
✓ Software selectable options for variable-speed lift and lower or
single-speed lift and lower
More Features ☞

2 Curtis 1298 Manual, OS 11
✓ Adaptation of control algorithm to motor temperature variation so
optimal performance is maintained under widely varying conditions
✓ Real-time battery current, motor torque, and power estimates available
✓ Power limiting maps allow performance customization for reduced motor
heating and consistent performance over varying battery state-of-charge
✓ Powerful operating system allows parallel processing of vehicle control
tasks, motor control tasks, and user configurable programmable logic
✓ A wide range of I/O can be applied wherever needed, for maximum
distributed system control
✓ Internal battery-state-of-charge, hourmeter, and maintenance timers
✓ Easily programmable through the Curtis 1311 handheld programmer
and 1314 PC Programming Station
✓ CAN bus connection allows communication with other CAN bus
enabled system components such as the Curtis TH-1 tiller head;
protocol meets CANopen standards; other 11-bit identifier field
CAN protocols can be custom configured through VCL
✓ Field-programmable, with flash downloadable main operating code
✓ Thermal cutback, warning, and automatic shutdown provide protection
to traction motor and controller
✓ Rugged sealed housing and connectors meet IP65 environmental sealing
standards for use in harsh environments
✓ Insulated metal substrate power base provides superior heat transfer for
increased reliability
✓ Built-in Dual Drive software allows easy setup and control of typical
dual-drive vehicles, without VCL.
Note: If you have a dual-drive application, see the Dual Drive
Addendum to the 1298 manual, part number 38272-DD.
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.
Using the 1311 handheld programmer, you can set up the controller to per-
form all the basic operations. In this manual, we first show you how to wire
your system and adjust its performance characteristics without the use of VCL.
Then, in Section 7, we show you how to adjust the system using VCL (Vehicle
Control Language), an innovative software programming language developed
by Curtis. VCL interacts with a second, independent software realm resident
in a powerful logic controller embedded within the 1298 controller.
1 — OVERVIEW
☞
NOTE: The 1311
handheld programmer
has been superseded;
see Appendix D.

Curtis 1298 Manual, OS 11 3
2 — INSTALLATION & WIRING
2
Fig. 2 Mounting
dimensions, Curtis 1298
motor controller.
Dimensions in millimeters (and inches)
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
The outline and mounting hole dimensions for the 1298 controller are shown
in Figure 2. This controller meets the IP65 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 6mm (1/4") diameter bolts, using the holes provided. A thermal
joint compound can be used to improve heat conduction from the controller
heatsink to the mounting surface. Additional heatsinking or fan cooling may
be necessary to meet the desired continuous ratings.

4 Curtis 1298 Manual, OS 11
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 B.
The1234/36/38 controllers contain ESD-sensitive components. Use
appropriate precautions in connecting, disconnecting, and handling the con-
troller. See installation suggestions in Appendix B 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 TRACTION OPERATION — Some conditions could cause the
traction system to run out of control. Disconnect the traction motor or
jack up the vehicle and get the drive wheels off the ground before attempt-
ing any work on the traction motor control circuitry.
UNCONTROLLED HYDRAULIC OPERATION — Some conditions could cause the
hydraulic system to run out of control. Disconnect the pump motor or
make sure the hydraulic system has enough room to operate before at-
tempting any work on the pump 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

Curtis 1298 Manual, OS 11 5
2 — INSTALLATION & WIRING: High Current Connections
HIGH CURRENT CONNECTIONS
There are six high-current terminals, identified on the controller housing as
B+, B-, PUMP, U, V, and W.
Table 1 High Current Connections
TERMINAL FUNCTION
B+ Positive battery to controller.
B- Negative battery to controller.
PUMP Pump motor.
U Motor phase U.
V Motor phase V.
W Motor phase W.
Lug assembly
Six aluminum M6 terminals are provided. Lugs should be installed as follows,
using M6 bolts sized to provide proper engagement (see diagram):
• Place the lug on top of the aluminum terminal, followed by
a high-load safety washer with its convex side on top. The
washer should be a SCHNORR 416320, or equivalent.
• If two lugs are used on the same terminal, stack them so the
lug carrying the least current is on top.
• Tighten the assembly to 10.2 ±1.1 N·m (90 ±10 in-lbs).
High current wiring recommendations
Battery cables (B+, B-)
These two cables should be run close to each other between the controller
and the battery. Use high quality copper lugs and observe the recommended
torque ratings. For best noise immunity the cables should not run across the
center section of the controller. With multiple high current controllers, use a
star ground from the battery B- terminal.
Pump wiring (PUMP)
Cable lengths should be kept as short as possible. Use high quality copper lugs
and observe the recommended torque ratings. For best noise immunity the motor

6 Curtis 1298 Manual, OS 11
2 — INSTALLATION & WIRING: High C.000urrent Connections
cables should not run across the center section of the controller. Low current
signal wires should not be run next to the motor cables. When necessary they
should cross the motor cables at a right angle to minimize noise coupling.
Motor wiring (U, V, W)
The three phase wires should be close to the same length and bundled together
as they run between the controller and the motor. The cable lengths should be
kept as short as possible. Use high quality copper lugs and observe the recom-
mended torque ratings. For best noise immunity the motor cables should not
run across the center section of the controller. In applications that seek the
lowest possible emissions, a shield can be placed around the bundled motor
cables and connected to the B- terminal at the controller. Typical installations
will readily pass the emissions standards without a shield. Low current signal
wires should not be run next to the motor cables. When necessary they should
cross the motor cables at a right angle to minimize noise coupling.
LOW CURRENT CONNECTIONS
All low power connections are made through a single 35-pin AMPSEAL con-
nector. The mating plug housing is AMP p/n 776164-1 and the contact pins
are AMP p/n 770520-3. The connector will accept 20 to 16 AWG wire with
a 1.7 to 2.7mm diameter thin-wall insulation.
The 35 individual pins are characterized in Table 2.
Low current wiring recommendations
Motor encoder (Pins 31, 32)
All four encoder wires should be bundled together as they run between the
motor and controller logic connector. These can often be run with the rest of
the low current wiring harness. The encoder cables should not be run near
the motor cables. In applications where this is necessary, shielded cable should
be used with the ground shield connected to the I/O ground (pin 7) at only
the controller side. In extreme applications, common mode filters (e.g. ferrite
beads) could be used.
CAN bus (Pins 21, 23, 34, 35)
It is recommended that the CAN wires be run as a twisted pair. However,
many successful applications at 125 kBaud are run without twisting, simply
using two lines bundled in with the rest of the low current wiring. CAN wiring
should be kept away from the high current cables and cross it at right angles
when necessary.
All other low current wiring
The remaining low current wiring should be run according to standard practices.
Running low current wiring next to high current wiring should always be avoided.
J1

Curtis 1298 Manual, OS 11 7
2 — INSTALLATION & WIRING: Low Current Connections
* The related VCL columns are vital when writing VCL code (see Section 7).
VCL “functions” are used to access the various I/Os; VCL “references” are
predefined names for specific pins.
Table 2 Low Current Connections
RELATED VCL*
PIN NAME DESCRIPTION FUNCTIONS REFERENCES
1 KSI Keyswitch input. Setup_BDI Keyswitch_Voltage
Provides logic power for
the controller and power
for the coil drivers.
2 Prop. Driver Proportional driver. Automate_PWM Sw_13
This is a coil driver with Put_PWM PWM5
current control capability PD_Current
typically used for a PD_Output
proportional valve on a PD_Throttle
hydraulic manifold. VCL_PD_Throttle
Can also be used as a
digital input.
3 Driver 4 Generic driver #4. Automate_PWM Sw_12
Typically used for the Put_PWM PWM4
load hold valve. Can PWM4_Output
also be used as a digital
input. Has low frequency
PWM capabilities.
4 Driver 3 Generic driver #3; can Automate_PWM Sw_11
also be used as a digital Put_PWM PWM3
input. Has low frequency PWM3_Output
PWM capabilities. Typically
used for pump contactor.
5 Driver 2 Generic driver #2; can Automate_PWM Sw_10
also be used as a digital Put_PWM PWM2
input. Has low frequency PWM2_Output
PWM capabilities and a
slightly higher current
rating.Typically used for
electromagnetic brake.
6 Driver 1 Generic driver #1; can Automate_PWM Sw_9
also be used as a digital Put_PWM PWM1
input. Has low frequency Set_Interlock PWM1_Output
PWM capabilities. Clear_Interlock Interlock_State
Typically used for main Main_State
contactor.
7 I/O Ground Input and output ground
reference.
8 Switch 2 Can be used as generic Sw_2
Analog 2 switch input #2 or as Analog2_Input
generic analog input #2.
Typically used as the
motor temperature
analog input.
9 Switch 3 Generic switch input #3. Sw_3
Typically used as the
interlock switch.
10 Switch 4 Generic switch input #4. Sw_4

8 Curtis 1298 Manual, OS 11
11 Switch 5 Generic switch input #5. Sw_5
Typically used for the Lift
switch.
12 Switch 6 Generic switch input #6. Sw_6
Typically used for the
Lower switch.
13 Coil Return This is the coil return pin
for all the contactor coils.
14 Switch 16 Generic switch input #16. Sw_16
15 Throttle Pot High Pot high connection for
a 3-wire throttle pot.
16 Throttle Pot Wiper Pot wiper connection for Setup_Pot Throttle_Pot
the throttle pot. Setup_Pot_Faults Throttle_Pot_Output
17 Pot2 Wiper Pot wiper connection for Setup_Pot Brake_Pot
the hydraulic throttle pot. Setup_Pot_Faults Brake_Pot_Output
18 Pot Low Common pot low Pot_Low_Output
connection for the throttle
and brake pots.
19 Digital Out 6 An open collector digital Set_DigOut Sw_14
output. Can also be used Clear_DigOut DigOut6
as a digital input. Dig6_Output
20 Digital Out 7 An open collector digital Set_DigOut Sw_15
output. Can also be used Clear_DigOut DigOut7
as a digital input. Dig7_Output
21 CAN Term H High connection for the
CAN termination jumper.
22 Switch 7 Generic switch input #7. Sw_7
Typically used as the
Forward switch.
23 CANH CAN bus high. Setup_CAN
Setup_Mailbox
Send_Mailbox
etc.
24 Switch 1 Can be used as generic Sw_1
Analog 1 switch input #1 or as Analog1_Input
generic analog input #1.
Typically used for
emergency reverse switch
(if applicable).
25 +12V Out Unregulated low power Ext_Supply_Current
+12V output.
26 +5V Out Regulated low power 5_Volts_Output
+5V output. Ext_Supply_Current
2 — INSTALLATION & WIRING: Low Current Connections
Table 2 Low Current Connections, cont’d
RELATED VCL
PIN NAME DESCRIPTION FUNCTIONS REFERENCES

Curtis 1298 Manual, OS 11 9
2 — INSTALLATION & WIRING: Low Current Connections
Table 2 Low Current Connections, cont’d
RELATED VCL
PIN NAME DESCRIPTION FUNCTIONS REFERENCES
27 Pot2 High Pot high connection for
a 3-wire hydraulic throttle
pot.
28 Serial TX Serial transmit line for Setup_Serial
display or flash update.
29 Serial RX Serial receive line for Setup_Serial
flash update.
30 Analog Output Low power, low frequency Automate_PWM PWM6
0–10V analog output. Put_PWM Analog_Output
31 Encoder A Quadrature encoder Motor_RPM
input phase A. MotorspeedA
32 Encoder B Quadrature encoder Motor_RPM
input phase B. MotorspeedB
33 Switch 8 Generic switch input #8. Sw_8
Typically used as the
Reverse switch.
34 CAN Term L Low connection for the
CAN bus termination
jumper.
35 CANL CAN bus low. Setup_CAN
Setup_Mailbox
Send_Mailbox
etc.

10 Curtis 1298 Manual, OS 11
Fig. 3 Basic wiring diagram, Curtis 1298 motor controller.
2 — INSTALLATION & WIRING: Standard Wiring Diagram
CONTROLLER WIRING: BASIC CONFIGURATION
A basic wiring diagram is shown in Figure 3. The throttles are shown in the
diagram as 3-wire potentiometers; other types of throttle inputs are easily ac-
commodated, and are discussed in the following throttle wiring section.
The main contactor coil must be wired directly to the controller as shown
in Figure 3 to meet EEC safety requirements. The controller can be programmed
to check for welded or missing contactor faults and uses the main contactor

Curtis 1298 Manual, OS 11 11
2 — INSTALLATION & WIRING: Throttle Wiring
coil driver output to remove power from the controller and motor in the event
of various other faults. If the main contactor coil is not wired to Pin 6 of
the 35-pin connector as shown, 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.
Note that the basic wiring diagram is designed for generic applications
and may not fully meet the requirements of your system. These controllers have
very flexible I/O and wiring configurations; you may wish to contact your local
Curtis representative to discuss your particular application.
SWITCH INPUT WIRING
The following inputs are dedicated to specific functions when the parameter
settings are as shown:
Switch 1: Emergency Reverse input if the EMR Enable = On
and EMR Type = 0 (see page 59).
Switch 3: Interlock input if Interlock Type = 0 (see page 44).
Switch 5: Lift input if Lift Switch Only Enable = On or Off (see page 51).
Switch 6: Lower input if Lower Switch Only Enable = On or Off (see page 51).
Switch 7: Forward input if Throttle Type = 1–3 (see page 39).
Switch 8: Reverse input if Throttle Type = 1–3 (see page 39).
THROTTLE WIRING
Various throttles can be used with the 1298 controller. They are characterized
as one of five types in the programming menu of the 1311 programmer.
Type 1: 2-wire 5kΩ–0 potentiometers
Type 2: single-ended 0–5V throttles, current source throttles,
3-wire potentiometers, and electronic throttles
Type 3: 2-wire 0–5kΩ potentiometers
Type 4: wigwag 0–5V throttles and 3-wire potentiometers
Type 5: VCL input (VCL_Throttle or VCL_Hyd_Throttle)
The two throttle inputs (drive throttle and hydraulic throttle) are programmed
independently.
For potentiometers, the controller provides complete throttle fault
protection that meets all applicable EEC regulations. For voltage throttles, the
controller protects against out-of-range wiper values, 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.

12 Curtis 1298 Manual, OS 11
Throttle types 1–3 use the forward and reverse inputs (switches 7 and 8) in
addition to the throttle pot input to define the throttle command (see Figure 17,
page 93). Throttle types 4 and 5 do not use the forward and reverse inputs (or
the Lift and Lower inputs, switches 5 and 6).
Wiring for the most common throttles is described in the following text
and shown in the accompanying illustrations. If a throttle you are planning to
use is not covered, contact the Curtis office nearest you.
Throttle Type 1
For these 2-wire resistive potentiometers, shown in Figure 4, full throttle request
corresponds to 0 Ω measured between the pot wiper pin and the Pot Low pin.
2 — INSTALLATION & WIRING: Throttle Wiring
Fig. 4 Wiring for Type 1
throttles.
Broken wire protection is provided by the controller sensing the current flow
from the pot wiper input (pin 16 or 17) through the potentiometer and into
Pot Low (pin 18). If the Pot Low input current falls below 0.65 mA, a throttle
fault is generated and the throttle request is zeroed. Note: Pot Low (pin 18)
must not be tied to ground (B-).
Throttle Type 2
With these throttles, the controller looks for a voltage signal at the wiper input.
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, 3-wire pots, and electronic throttles. The wiring for each is
slightly different, as shown in Figure 5, 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.
When a 3-wire potentiometer is used, the controller provides full fault
protection in accordance with EEC requirements. The pot is used in its voltage
divider mode, with the controller providing the voltage source and return. Pot
High provides a current limited 5V source to the pot, and Pot Low provides

Curtis 1298 Manual, OS 11 13
2 — INSTALLATION & WIRING: Throttle Wiring
Fig. 5 Wiring for Type 2
throttles.
Curtis ET-XXX Electronic Throttle
Voltage Source
Current Source
3-wire Potentiometer
+
+
-

14 Curtis 1298 Manual, OS 11
the return path. This is the throttle shown in the basic wiring diagram (Figure 3)
for the drive throttle and for the hydraulic throttle.
The ET-XXX electronic throttle is typically used only as a drive throttle.
The ET-XXX contains no built-in fault detection, and the controller will detect
only open wiper faults. It is the responsibility of the OEM to provide any ad-
ditional throttle fault detection necessary.
Throttle Type 3
For these 2-wire resistive potentiometers, shown in Figure 6, full throttle request
corresponds to 5 kΩ measured between the pot wiper pin and the Pot Low pin.
2 — INSTALLATION & WIRING: Throttle Wiring
Broken wire protection is provided by the controller sensing the current flow
from the wiper input (pin 16 or 17) through the potentiometer and into Pot
Low (pin 18). If the Pot Low input current falls below 0.65 mA, a throttle
fault is generated and the throttle request is zeroed. Note: Pot Low (pin 18)
must not be tied to ground (B-).
Throttle Type 4
Type 4 throttles operate in wigwag style. No signals to the controller’s forward
and reverse inputs (or Lift and Lower inputs) are required; the direction is
determined by the wiper input value. Only 0–5V voltage sources and 3-wire
potentiometers can be used as Type 4 throttles. The controller interface for
Type 4 throttles is the same as for Type 2 throttles; see Figure 5. The neutral
point will be with the wiper at 2.5 V, measured between pot wiper input
(pin 16) and I/O ground return (pin 7). The controller will provide increas-
ing forward (Lift) speed as the wiper input value is increased, and increasing
reverse (Lower) speed as the wiper input value is decreased.
When a 3-wire pot is used, the controller provides full fault protection.
When a voltage throttle is used, the controller will detect open breaks in the
wiper input but cannot provide full throttle fault protection.
Throttle Type 5
Throttle Type 5 provides a different way of sending the throttle command to the
controller. This throttle type uses VCL to define the throttle signal that will be
“input” into the throttle signal chain; see Figures 16 and 18. This throttle type
can be used for either the drive throttle or the hydraulic throttle by using the
VCL variables VCL_Throttle and VCL_Hyd_Throttle. How the VCL program
is written will determine where the throttle signal originates from, making this
a very flexible throttle input method. VCL can be written to use the throttle
Fig. 6 Wiring for Type 3
throttles.

Curtis 1298 Manual, OS 11 15
2 — INSTALLATION & WIRING: Throttle Wiring
pot inputs, switch inputs, or CAN communication messages as the source of
the throttle signals. If you have questions regarding this throttle type, contact
the Curtis office nearest you.
Setting the Throttle Type to Type 5 also allows the throttle inputs to be
redefined by a VCL program for uses other than as throttle inputs. The variable
names that VCL can use to interface with these two inputs are Throttle_Pot_Out-
put (see page 94) for the drive throttle, and Brake_Pot_Output (see page 99)
for the hydraulic throttle.

16 Curtis 1298 Manual, OS 11
2 — INSTALLATION & WIRING: I/O Signal Specifications
INPUT/OUTPUT SIGNAL SPECIFICATIONS
The input/output signals wired to the 35-pin connector can be grouped by
type as follows; their electrical characteristics are discussed below.
— digital inputs
— high power outputs
— analog inputs
— analog output
— power supply outputs
— KSI and coil return inputs
— throttle and brake inputs
— communications port inputs/outputs
— encoder inputs.
Digital inputs
These control lines can be used as digital (on/off) inputs. Normal “on” connection
is direct to B+; “off” is direct to B-. Input will pull low (off) if no connection
is made. All digital inputs are protected against shorts to B+ or B-.
Nine of these lines (Switches 1–8, 16) are designed to pull current to keep
switch contacts clean and prevent leakage paths from causing false signals.
The remaining lines are digital inputs associated with driver outputs; note
that they have much higher input impedances. The two digital output lines can
also be read as inputs, and are therefore included in this group.
The lines at pins 24 and 8 can also be used as analog inputs, and are
included in that group as well.
DIGITAL INPUT SPECIFICATIONS
LOGIC INPUT VOLTAGE ESD
SIGNAL NAME PIN THRESHOLDS IMPEDANCE RANGE* TOLERANCE
Switch 1 24 Rising edge= 24V models: -10 V to ± 8 kV (air
Switch 2 8 4.4 V max about 7.1 kΩ (MaxV + 10 V) discharge)
Switch 3 9 Falling edge= 36-48V models:
Switch 4 10 1.5 V min about 11.0 kΩ
Switch 5 11 48-80V models:
Switch 6 12 about 26.0 kΩ
Switch 7 22
Switch 8 33
Switch 16 14
Digital Out 6 19 Rising edge= Below 10 V= - 0.5 V to
Digital Out 7 20 4.4 V max 300 kΩ (MaxV + 10 V)
Driver 1 6 Falling edge= Above 10 V=
Driver 2 5 1.5 V min 150 kΩ
Driver 3 4
Driver 4 3
Prop Driver 2
* “MaxV” in this and the following tables is the controller’s maximum voltage: 30 V for 24V models,
and 45 V for 24–36V models.