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Curtis PMC 1204 Series User manual

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MANUAL
© 1999 CURTIS INSTRUMENTS, INC.
DESIGN OF CURTIS PMC 1200 SERIES
CONTROLLERS PROTECTED BY U.S.
PATENT NO. 4626750.
1204X/1205X
and 1209/1221
MOTOR CONTROLLERS
1204X / 1205X / 1209 / 1221 Manual
p/n 98796, Rev. D: May 1999
CURTIS PMC
235 East Airway Boulevard
Livermore, California 94568 USA
Tel: 925-961-1088
Fax: 925-961-1099
www.curtisinst.com
1204X / 1205X / 1209 / 1221 Manual
p/n 98796, Rev. D: May 1999
© 1999 CURTIS INSTRUMENTS, INC.
This electronic version of the 1204X/1205X/1209/1221 manual is offered as a conve-
nience to our customers. You may download any or all of it.
Ifyouwouldlikeahardcopyofthepublishedmanual,pleaseorderitbypartnumberfrom
the Curtis office nearest you.
The electronic version of the manual is identical to the printed version published in May
1999 with the following exceptions:
Minor corrections were made to the dimensions shown in Figure 3.
Bookmarks have been added to the electronic version to speed the process of going
directly to a particular part of the document.
CURTIS INSTRUMENTS, INC.
200 KISCO AVENUE
MOUNT KISCO, NEW YORK 10549 USA
☎914-666-2971 FAX 914-666-2188
■CURTIS PMC
235 EAST AIRWAY BOULEVARD
LIVERMORE, CALIFORNIA 94550 USA
☎925-961-1088 FAX 925-961-1099
■
ADDITIONAL OFFICES
located in
Bulgaria, China, England, France, Germany,
India, Italy, Japan, Netherlands, Puerto Rico,
Russia, Sweden, and Switzerland
Curtis PMC 1204X/1205X/1209/1221 Manual iii
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CONTENTS
1. OVERVIEW ....................................................................... 1
2. HARDWARE INSTALLATION ....................................... 3
Controller .................................................................... 3
Throttle ........................................................................ 5
Other Hardware ........................................................... 8
Main contactor ..................................................... 9
Forward/reverse contactors .................................... 9
Forward/reverse switches ....................................... 9
Emergency reverse relay ...................................... 10
Bypass contactor ................................................. 10
Keyswitch and interlocks .....................................10
Polarity protection diode..................................... 10
Control wiring fuse ............................................. 10
Power wiring fuse................................................ 10
3. WIRING ........................................................................... 11
Connections: Low Current......................................... 11
Connections: High Current .......................................12
Wiring: Typical Installation ....................................... 12
KSI wiring .......................................................... 12
Forward/reverse wiring ........................................ 13
Plug braking ................................................ 14
Freewheeling ................................................ 14
Emergency reverse........................................ 15
Throttle pot wiring ............................................. 16
Standard potbox wiring ............................... 16
Pots for twist-grip throttles .......................... 16
Reduced speed operation ............................. 17
Electronic throttle wiring .................................... 18
Bypass wiring ...................................................... 19
CONTENTS
Curtis PMC 1204X/1205X/1209/1221 Manual iv
CONTENTS
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Wiring: Permanent Magnet Motors ........................... 19
Installation Checkout ................................................. 20
4. MAINTENANCE AND ADJUSTMENT .......................22
Controller .................................................................. 22
Potbox ........................................................................ 23
5. TROUBLESHOOTING AND BENCH TESTING ....... 25
Operational Notes ...................................................... 25
In-Vehicle Diagnostic Tests (Troubleshooting) .......... 26
Bench Testing ............................................................ 32
6. GLOSSARY: FEATURES AND FUNCTIONS .............. 36
APPENDIX AFunctional Description ................................ A-1
APPENDIX BPulse Width Modulation ............................. B-1
APPENDIX CElectrical Specifications................................ C-1
Curtis PMC 1204X/1205X/1209/1221 Manual v
FIGURES
FIG. 1: Curtis PMC 1205X full-feature
motor controller ......................................................... 1
FIG. 2: Mounting dimensions,
Curtis PMC 1204X/5X controllers ............................ 3
FIG. 3: Mounting dimensions,
Curtis PMC 1209/21 controllers................................ 3
FIG. 4: Mounting dimensions,
Curtis PMC potboxes PB-5, -6, -9, and -10 ............... 6
FIG. 5: Mounting dimensions, Curtis PMC footpedal ........... 6
FIG. 6: Mounting dimensions,
Curtis electronic throttle (ET series)........................... 7
FIG. 7: Typical installation,
1204X/1205X/1209/1221 controllers ........................ 8
FIG. 8: Basic wiring configuration,
1204X/1205X/1209/1221 controllers ...................... 13
FIG. 9: Control wiring for inhibiting plug braking,
in order to allow freewheeling .................................. 14
FIG. 10: Wiring for emergency reverse (enhanced
plug braking current)................................................ 15
FIG. 11: Standard throttle pot, 0–5kΩ................................... 16
FIG. 12: Bi-directional twist-grip throttle with
10 kΩcenter-tapped, 4-terminal pot ........................ 16
FIG. 13: Bi-directional twist-grip throttle with
a standard 20 kΩpot and a controller
with the optional 5kΩ–0 throttle input .................... 17
FIGURES
Curtis PMC 1204X/1205X/1209/1221 Manual vi
FIGURES/TABLES
FIG. 14: Reduced speed operation (with standard
(0–5kΩpot) ............................................................. 17
FIG. 15: Curtis electronic throttle (ET series)
with a controller having the optional
0–5V throttle input .................................................. 18
FIG. 16: Adjustment pots .......................................................23
FIG. 17: Guide to troubleshooting procedures ....................... 27
FIG. 18: Setup for bench testing ............................................. 33
FIG. A-1: Block diagram, Curtis PMC
1204X/1205X/1209/1221 controllers .................... A-1
FIG. B-1: Pulse width modulation.......................................... B-1
TABLES
TABLE C1: Electrical specifications, 1204X/1205X .................C-1
TABLE C2: Electrical specifications, 1209/1221 ......................C-2
Curtis PMC 1204X/1205X/1209/1221 Manual 1
OVERVIEW
OVERVIEW
Curtis PMC Model 1204X/1205X and 1209/1221 electronic motor speed
controllers are designed to provide smooth, silent, cost-effective control of motor
speed and torque on a wide variety of industrial electric vehicles.
Like all Curtis PMC 1200 series controllers, the 1204X/1205X and 1209/1221
models offer superior operator control of the vehicle’s motor drive speed. Key
features of these controllers include:
✓Infinitely variable drive and brake control
✓Power MOSFET design provides high efficiency (for reduced motor and
battery losses) and silent operation
✓High pedal disable (HPD) function monitors throttle status during turn-on
and prevents operation until throttle has been returned to neutral [optional
feature]
✓Thermal protection and compensation circuit provides both under-
temperature and overtemperature cutback, as well as steady current limit
throughout the entire operating range
✓Undervoltage cutback function protects against low battery voltage, includ-
ing low voltage caused by external loads
Fig. 1 Curtis PMC
1205X full-feature
electronic motor
controller.
Models 1204X, 1209,
and 1221 have
identical connections.
More Features ☞
1
Curtis PMC 1204X/1205X/1209/1221 Manual 2
OVERVIEW
Working on electric vehicles is potentially dangerous. You should protect
yourself against runaways, high current arcs, and outgassing from lead acid
batteries:
RUNAWAYS —Some fault conditions could cause the vehicle to run out of
control. Jack up the vehicle and get the drive wheels off the ground before
attempting these procedures or any other 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 circuit. Wear safety glasses, and use
properly insulated tools to prevent shorts.
LEAD ACID BATTERIES —Charging or discharging generates hydrogen gas,
which can build up in and around the batteries. Follow the battery
manufacturer’s safety recommendations. Wear safety glasses.
☞
CAUTION
✓Fault detection circuitry monitors battery, throttle connections, output
transistors, bypass contactor, etc., to prevent runaway conditions
✓Static return to off (SRO) function requires that forward or reverse selectors
be returned to neutral before output is allowed [optional feature]
✓Emergency reverse enhances plugging current when “belly-button”is acti-
vated on walkie-type applications [optional feature]
✓Delayed bypass (1A) output drives a bypass contactor [optional feature]
✓Forward, reverse, and bypass contactor driver outputs are internally pro-
tected against shorts in the contactor coils
✓Simple installation with no adjustments required
✓Tin-plated solid copper bus bars
✓Push-on connectors for control wiring
Familiarity with your Curtis PMC controller will help you to install and operate
it properly. We encourage you to read this manual carefully. If you have
questions, please contact the Curtis office nearest you.
Curtis PMC 1204X/1205X/1209/1221 Manual 3
HARDWARE INSTALLATION
HARDWARE INSTALLATION
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 deflect dirt
and water splash.
The controller should be fastened with four screws to a clean, flat metal
surface that provides an adequate heat sink. The mounting surface is an integral
part of the overall heatsinking of the controller, and affects its ability to dissipate
heat. The case outline and dimensions are shown in Figure 2 (1204X and1205X
controllers) and in Figure 3 (1209 and1221 controllers).
Fig. 2 Mounting
dimensions, Curtis PMC
1204X/5X controllers.
3.3
(0.13)
70 (2.8)
133 (5.25)
MODEL 1204X:
174 (6.85)
MODEL
1205X:
225 (8.85)
113 (4.45)
130 (5.13)
146 (5.75)
16.5 (0.65)
1204X:
19 (0.75)
1205X:
44 (1.75)
7 (0.28) dia.
8 (0.33) dia.
22
×
19
×
3
(0.85
×
0.75
×
0.125)
6 (0.25)
male push-on,
2 plcs
Dimensions in millimeters and (inches)
2
Curtis PMC 1204X/1205X/1209/1221 Manual 4
Fig. 3 Mounting
dimensions, Curtis PMC
1209/21 controllers.
HARDWARE INSTALLATION
6 (0.25)
male push-on,
2 plcs
7 (0.28) dia.
15 (0.60)
MODEL
1209:
231 (9.1)
MODEL
1221:
282 (11.1)
3.3
(0.13)
80 (3.15)
37 (1.45)
Dimensions in millimeters and (inches)
MODEL
1209:
152 (6.0)
MODEL
1221:
203 (8.0)
180 (7.1)
165 (6.5)
143 (5.6)
8.4 (0.33) dia.
25
×
19
×
5
(1.0
×
0.75
×
0.187)
Be sure to mount the controller so as to allow access to the adjustment
screws.
Although not usually necessary, a thermal joint compound can be used to
improve heat conduction from the case to the mounting surface.