Curtis Pmc 1204 series User manual

MANUAL

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

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

12345678901

234567890

12345678901

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

12345678901

234567890

12345678901

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

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 ☞

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

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.

(0.85

0.75

0.125)

6 (0.25)

male push-on,

2 plcs

Dimensions in millimeters and (inches)

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.

(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.

Curtis PMC 1204X/1205X/1209/1221 Manual 5

HARDWARE INSTALLATION

THROTTLE

0–5kΩInput

The standard controller throttle input is 0–5kΩ. Curtis PMC potboxes (PB-5,

-6, -9, -10) are designed to match this input. Some of these potboxes have a built-

in microswitch, eliminating the need to install a separate pedal-actuated

microswitch. Curtis PMC also offers a self-contained footpedal unit (FP-2) that

eliminates the need for fabricating and installing a pedal-potbox linkage. Mount-

ing dimensions for the potboxes and for the footpedal unit are shown in Figures

4 and 5.

Any potbox that provides a nominal 0–5kΩoutput (controller output

begins at ≈300 ohms, full output is ≈4400 ohms) will work with the standard

throttle input. For other types, contact your Curtis ofﬁce.

If a Curtis PMC potbox is used, it must be mounted so as to allow

connection between the potbox lever arm and the vehicle accelerator linkage.

The lever arm provides a series of holes so that the accelerator pedal “throw”can

be converted into the correct amount of potentiometer rotation. 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 [1/32"–1/16"]) 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. Values above 7000 ohms indicate a defective potbox, and will

cause controller shutdown.

5kΩ–0 Input

The 1204X/1205X/1209/1221 controllers are also available with 5kΩ–0 throttle

inputs. Using this throttle type, controller output begins at ≈4400 ohms with full

output at less than 300 ohms.

Curtis PMC 1204X/1205X/1209/1221 Manual 6

Fig. 4 Mounting

dimensions,

Curtis PMC potboxes

PB-5, -6, -9, and -10.

Fig. 5 Curtis PMC footpedal FP-2.

HARDWARE INSTALLATION

10 (0.38)

(1.25)

(0.25) 89 (3.5)

(2.37)

102 (4.0)

Dimensions in millimeters and (inches)

RIGHT-HAND OPERATION LEFT-HAND OPERATION

COM. N.O. N.C. N.C. N.O. COM.

WITH MICROSWITCH: PB-6

WITHOUT MICROSWITCH: PB-5 WITH MICROSWITCH: PB-9

WITHOUT MICROSWITCH: PB-10

42 (1.65)

52 (2.06)

Dimensions in millimeters and (inches)

≈

244 (9.6)

112 (4.4)

112

(4.4)

1.8 m

(6 ft)

WIRING:

BLACK

= throttle input

BLUE

= switch, common (Note:The green wire is not used with

WHITE

= throttle input

ORANGE

= switch, normally open 1204X/1205X/1209/1221 controllers)

BLK

GRN

(not used)

WHT

ORG

BLU

COM.N.O.

Curtis PMC 1204X/1205X/1209/1221 Manual 7

HARDWARE INSTALLATION

Fig. 6 Mounting

dimensions,

Curtis electronic throttle

(ET series).

Dimensions in millimeters and (inches)

99.00

(3.90)

44.00

(1.73)

69.00

(2.72)

24.00

(0.94)

VIS TC 3×12

6.00

(0.24

0.24)

24.00

(0.94)

∅ M5

22.00

(0.87)

22.00

(0.87)

116

44.00

(1.73)

0–5V Input

A 0–5V throttle input option is also available for the 1204X/1205X/1209/1221

controllers. The negative side of the 5V source should be referenced to B- and

must be capable of driving an input impedance of 5kΩ.

Curtis offers two bi-directional, wigwag electronic throttle assemblies de-

signed for use with the 0–5V input: the ET series and the CH series.

The ET-XXX throttle assembly provides a 0–5V output and forward/reverse

relay coil drivers. Dimensions for the ET-series electronic throttles are shown in

Figure 6. The CH-XXX is a complete control head assembly, consisting of an

ET-XXX throttle integrated into a molded steel and plastic assembly designed for

mounting directly to a tiller stem. For more information about ET and CH

products, contact your nearest Curtis ofﬁce.

Curtis PMC 1204X/1205X/1209/1221 Manual 8

HARDWARE INSTALLATION

Fig. 7 Typical installation, Curtis PMC 1204X/1205X/1209/1221 controllers.

CONTROL

WIRING

FUSE

POWER

WIRING

FUSE

POLARITY

PROTECTION

DIODE

KEYSWITCH POTBOX

FORWARD/REVERSE SWITCH

(SPDT, center off)

FORWARD/REVERSE

CHANGEOVER CONTACTOR

(Albright DC182 shown)

MAIN

CONTACTOR

(Albright

SW180

shown)

A1 A2

SERIES

MOTOR

BATTERY

B-

B+

PRECHARGE RESISTOR, such as Curtis PMC p/n MP-2

COIL SUPPRESSION DIODE, such as Curtis PMC p/n MP-1

(250Ω, 5W)

FWD REV

A2M-

B- B+

BYPASS CONTACTOR

(

Pedal microswitch not used with SRO controllers.)

(

See Figure 10 for emergency reverse.)

COM.

N.C.

Bypass cont. output

REV input

Emergency reverse **

FWD input

F/R cont. output

KSI

OTHER HARDWARE

The recommended hardware for a typical 1204X/1205X/1209/1221 controller

installation is shown in Figure 7.

Contactors should be mounted in a clean, dry location. If such a location is

unavailable, a cover should be used to deﬂect dirt and water splash.

The precharge resistor connected to the main contactor, and the coil

suppression diodes connected to the main contactor and to the forward/reverse

contactors, are somewhat delicate components. Care should be taken to prevent

damage to them during installation.

Curtis PMC 1204X/1205X/1209/1221 Manual 9

HARDWARE INSTALLATION

Main Contactor

Most applications use a main contactor in series with the battery positive (B+)

cable to disconnect all power when the system is turned off, as shown in Figure

7. A heavy-duty single-pole, single-throw (SPST) contactor with silver-alloy

contacts is recommended, such as an Albright SW80 or SW180 (available from

Curtis).

A coil suppression diode, such as a Curtis PMC p/n MP-1 (which is rated at

100 volts, 3 amps), should be used on the contactor coil.

The rapid charging of the controller’s internal ﬁlter capacitors causes a high

inrush current to ﬂow brieﬂy when the contactor closes. To extend contact life,

a precharge resistor, such as Curtis PMC’s p/n MP-2 (rated at 250Ω, 5W), is

recommended; the resistor precharges the capacitors and reduces the inrush

current through the contacts. If an inexpensive “can”type solenoid is used, the

resistor is mandatory to prevent contact welding. For applications above 48V, a

precharge resistor with a power rating greater than 5W is recommended.

Forward/Reverse Contactors

The forward/reverse contactor coils must match the vehicle’s battery voltage. The

maximum allowed coil current for each contactor is 1 amp. Use of a changeover

contactor set—such as the Albright DC88 or DC182 (available from Curtis)—

is recommended. Alternatively, two single-pole, double-throw (2×SPDT) con-

tactors may be used. Although inexpensive “can”type solenoids may be used,

their ratings are typically not sufﬁcient for long life.

A coil suppression diode, such as a Curtis PMC p/n MP-1 (which is rated at

100 volts, 3 amps) should be used on each of the forward/reverse contactor coils.

Forward/Reverse Switches

The forward/reverse contactor coils can be operated by any type of single-pole,

double-throw (SPDT) center-off switch capable of switching the coil current.

Toggle or rocker switches are generally used.

If your controller has the optional high pedal disable (HPD) feature and you

plan to wire it for freewheeling, the best switch to use is a double-pole, double-

throw (DPDT) “hesitation switch”—a toggle switch with a mechanism that

forces it to stop in the center (neutral) position before going into the opposite

direction. If a standard switch is moved quickly from one direction to the other,

it may not be in neutral long enough to actuate HPD, and the motor will plug

brake instead of freewheeling. The switch must be in neutral for several millisec-

onds to actuate HPD.

Bypass Contactor

A bypass contactor can be used with controllers that have the optional bypass

contactor output feature. The bypass option is available only on 12V and 24–36V

Curtis PMC 1204X/1205X/1209/1221 Manual 10

HARDWARE INSTALLATION

controllers. (NOTE: A bypass contactor should not be used with controllers that do

not have this feature, as the controller could be damaged when the system comes

out of bypass mode.)

The bypass contactor must be able to carry and to interrupt the maximum

motor current. A coil suppression diode should not be used on this contactor.

Refer to the controller speciﬁcations in Appendix C to determine the contact

current requirement for the bypass contactor. The maximum allowed coil

current for this contactor is 1 amp.

Emergency Reverse Relay

A small double-pole, double-throw relay must be installed to implement emer-

gency reverse. Its contact rating must be adequate to switch the current needed

by the forward/reverse contactor coils.

Keyswitch and Interlocks

The vehicle should have a master on/off switch to turn the system off when not

in use. A keyswitch is typically used for this purpose.

An interlock device is necessary for implementation of SRO. With the SRO

option, the vehicle cannot be started or operated without the designated SRO

interlock activated.

Various other safety and convenience interlocks may also be used to prevent

motor operation during certain conditions. For example, a battery charger

interlock can be used to prevent operation during charging. Similarly, a seat

switch can be used to turn the vehicle off when the operator gets up from the

driver’s seat. The contacts of these switches should be rated for the total coil

currents of all the contactors they operate.

Polarity Protection Diode

For polarity protection, a diode should be added to the control circuit. This diode

must be sized appropriately for the maximum total contactor coil currents.

Control Wiring Fuse

To protect the control circuitry from accidental shorts, a small fuse (typically 10

amps) connected in series with the B+ feed to the control circuitry wiring is

recommended.

Power Wiring Fuse

To protect the power wiring circuit, a fuse appropriate for the controller’s rated

current (see Appendix C) is recommended.

Curtis PMC 1204X/1205X/1209/1221 Manual 11

WIRING

CONNECTIONS: Low Current

Two 1/4" push-on terminals are provided for the throttle inputs. If your

controller has a voltage throttle input, there will be only one throttle terminal.

A 6-pin low power connector molded into the right side of the controller

face provides the low power logic control connections—KSI input, forward/

reverse contactor output, bypass contactor output (optional), emergency reverse

(optional), and forward and reverse inputs.

Several manufacturers make mating connectors that ﬁt this connector. The part

numbers listed are for the recommended 0.75 mm2(#18 AWG) vinyl insulated

stranded wire.

MFR PART NUMBER DESCRIPTION

AMP #640426-7 locking, insulation displacement terminals,

wires at right angle to connector

Methode #3300-107-218 locking, insulation displacement terminals

Molex #09-50-3071 locking, crimp terminals

Panduit #CE156F18-7 locking, insulation displacement terminals,

wires at right angle to connector

Throttle inputs 3

Keyswitch input (KSI)

F/R contactor output

Bypass contactor output

Emergency reverse input

Forward input

Reverse input

Curtis PMC 1204X/1205X/1209/1221 Manual 12

WIRING

M-

B- B+

Positive connection to battery

and to motor armature

Plug diode to motor armature

Negative connection to battery

Output to motor field

CONNECTIONS: High Current

Four tin-plated solid copper bus bars are provided for the high current connec-

tions to the battery and motor.

The cables used for the battery and motor connections must be heavy enough to

carry the high current required. Rubber insulated welding cable is convenient to

work with because of its flexibility.

Connections to the controller bus bars should be made with lugs suitable for

the cable used, fastened by M8 (5/16") 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 connec-

tions, and could also result in cracked seals around the bus bars.

WIRING: TYPICAL INSTALLATION

Curtis PMC 1204X/1205X/1209/1221 controllers are designed to satisfy the

requirements of material handling applications using series motors. Figure 8 is a

schematic diagram of the installation shown in Figure 7. Wired this way, the

vehicle will plug brake if the direction is changed with the vehicle moving and the

throttle applied. Reversing is accomplished via a forward/reverse changeover

contactor or two single-pole, double-throw (2×SPDT) contactors. Coil suppres-

sion diodes should be used on the main and forward/reverse contactors.

KSI Wiring

The keyswitch input (KSI) circuit includes inputs 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 8 volts will turn on the controller, but usually the full vehicle battery voltage

is used.

In its simplest form, KSI is operated by a keyswitch that turns the vehicle off

and prevents unauthorized use. The keyswitch should also turn off the main

Curtis PMC 1204X/1205X/1209/1221 Manual 13

WIRING

Fig. 8 Basic wiring conﬁguration, Curtis PMC 1204X/1205X/1209/1221 controllers.

A2M-

B- B+

–

FORWARD

REVERSE

MAIN

POTBOX

MAIN

KEYSWITCH INTERLOCKS

PEDAL

MICROSWITCH

CONTROL WIRING

FUSE

POLARITY

PROTECTION

DIODE

PRECHARGE RESISTOR

(250 Ω, 5 W)

POWER WIRING

FUSE

1A BYPASS

(*not used with SRO controllers)

(**See Figure 10 for

emergency reverse.)

Bypass cont. output

REV input

Emergency reverse **

FWD input

F/R cont. output

KSI

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 off.

Interlocks (seat switches, battery charger interlocks, etc.) should be wired in

series so that they turn off the controller KSI and the contactors. An SRO

interlock (a seat switch, for example) must be wired in order to implement the

optional SRO feature.

Forward/Reverse Wiring

The forward/reverse wiring schemes described here all assume the power wiring

shown by the heavy lines in Figure 8. Some vehicles, especially those previously

using older, resistor-type controllers, may reverse the motor armature rather than

the ﬁeld winding. Be careful if you are replacing this type of controller. When

using the Curtis PMC controller 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.

Curtis PMC 1204X/1205X/1209/1221 Manual 14

WIRING

Fig. 9 Control wiring for

inhibiting plug braking,

in order to allow

freewheeling.

A2M-

B- B+

FORWARD

REVERSE

MAIN

KEYSWITCH INTERLOCKS PEDAL

MICROSWITCH

FUSE

POLARITY

PROTECTION

DIODE F/R SWITCH

(DPDT, center off)

–

BYPASS

Bypass cont. output

REV input

Emergency reverse

(see Fig. 10)

FWD input

F/R cont. output

KSI

Plug Braking

The standard forward/reverse control wiring (as shown in Figure 8 by the thin

lines) provides plug braking. The forward/reverse switch should be in the positive

feed to the contactor coils, so that they can be turned off by the keyswitch,

interlocks, and pedal microswitch. The coil of one contactor or the other is

energized to select the direction desired. The contactor coils should have suppres-

sion diodes connected across them to improve switch contact life.

Freewheeling: Wiring to Inhibit Plug Braking

If a non-SRO controller has the HPD option, this feature can be used to inhibit

plug braking by brieﬂy turning off the controller’s KSI input when the forward/

reverse switch goes through neutral. As shown in Figure 9, 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.

Plug braking can be reactivated during freewheeling by releasing the throttle and

reapplying it.

NOTE: Contact factory for information on wiring SRO controllers for

freewheeling.

This manual suits for next models

Popular Controllers manuals by other brands

Mo-vis

Mo-vis coot Control R-net installation manual

SURAN

SURAN ENDA EHTC7425A manual

London Electronics

London Electronics INT2-AH manual

WOBIT

WOBIT SMC64 WP v2 manual

Sungrow

Sungrow BSC200 user manual

YASKAWA

YASKAWA U1000 iQpump Drive user manual

Eaton

Eaton ELC-PB Programming manual

Blue Sky Energy

Blue Sky Energy SOLAR BOOST 3024iL Installation and operation manual

Fancom

Fancom Aura 14 manual

Dometic

Dometic GoPower! GP-MPPT-85/20 user manual

Festo

Festo CPX-FEC Brief description

Siemens

Siemens SINUMERIK 808D Diagnostic manual

Toshiba

Toshiba Vm Series instruction manual

Honeywell

Honeywell PRO22IC installation manual

Sailor

Sailor N420 user manual

SYCLOPE

SYCLOPE INDIG'O Programming instructions

SMC Networks

SMC Networks AR20MK Series Operation manual

RTK

RTK REact 15E Series Installation and operating instructions

Curtis PMC 1204 Series User manual

Popular Controllers manuals by other brands