Kohler Curtis F Series User manual

Read Instructions Carefully!
Specications are subject to change without notice.
© 2022 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. 53240, Rev A April 2022
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
Manual
F Series Motor Controller
For Controllers: AC F4-A Model, AC F6-A Model
AC F2-A Model
» Software Device Profile: 4.5.0.0 «

Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
pg. ii
CHAPTERS
1: OVERVIEW ...................................................................................................................................... 1
HOW TO USE THIS MANUAL .......................................................................................................... 3
WHAT IS NEW IN FOS 4.4.0.0 ... HIGHLIGHTS ............................................................................... 4
GETTING THE MOST OUT OF YOUR CURTIS CONTROLLER ............................................................. 4
2: INSTALLATION AND WIRING ............................................................................................................ 5
PHYSICALLY MOUNTING THE CONTROLLER................................................................................... 5
PRECAUTIONS .............................................................................................................................. 7
HIGH CURRENT CONNECTIONS ..................................................................................................... 8
LOW CURRENT CONNECTIONS...................................................................................................... 9
ROTOR POSITION FEEDBACK................................................................................................. 12
CANBUS ................................................................................................................................ 12
ALL OTHER LOW POWER WIRING........................................................................................... 12
PROTECTED VOLTAGES.......................................................................................................... 12
CONTROLLER INPUTS AND OUTPUTS..................................................................................... 14
CONTROLLER WIRING DIAGRAM (EXAMPLES) ........................................................................ 16
LOW CURRENT CONNECTOR ELECTRICAL SPECIFICATIONS .................................................. 20
DIGITAL (SWITCH) INPUTS ..................................................................................................... 20
ANALOG INPUTS.................................................................................................................... 22
POTENTIOMETER INPUTS WITH DYNAMIC TESTING................................................................ 23
PWM AND DIGITAL DRIVERS .................................................................................................. 24
POWER SUPPLY OUTPUTS ..................................................................................................... 26
KEYSWITCH AND COIL SUPPLY .............................................................................................. 27
CAN PORTS........................................................................................................................... 27
MOTOR POSITION SENSOR INPUTS ....................................................................................... 28
SINE/COSINE SIGNAL TRACKING............................................................................................ 30
MOTOR TEMPERATURE INPUT ............................................................................................... 31
TABLE OF CONTENTS

Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 pg. iii
TABLE OF CONTENTS cont’d
3: APPLICATION-SPECIFIC FEATURES................................................................................................. 32
MOTOR SPEED CONSTRAINTS ..................................................................................................... 32
VOLTAGE LIMITS .......................................................................................................................... 33
OVER-VOLTAGE REGION......................................................................................................... 34
SEVERE OVER-VOLTAGE REGION............................................................................................ 34
UNDER-VOLTAGE REGION ...................................................................................................... 34
OUTPUT-DISABLED REGION................................................................................................... 35
BROWNOUT VOLTAGE ............................................................................................................ 35
KSI AND B+ INPUT................................................................................................................. 35
BATTERY DISCHARGE INDICATOR................................................................................................. 35
4: PROGRAMMABLE PARAMETERS .................................................................................................... 36
PROGRAMMABLE PARAMETERS .................................................................................................. 36
PROGRAMMING MENUS............................................................................................................... 36
PARAMETER CHANGE FAULTS [PCF]............................................................................................. 36
MONITOR VARIABLES WITHIN PARAMETER MENUS ...................................................................... 36
PROGRAMMING TOOLS................................................................................................................ 36
MENU CHART FORMAT ................................................................................................................ 37
TERMINOLOGY ............................................................................................................................ 37
SDO WRITE MESSAGE.................................................................................................................. 39
CONTROL MODE SELECT INDEX .................................................................................................. 41
SPEED MODE EXPRESS ......................................................................................................... 51
SPEED MODE ........................................................................................................................ 52
TORQUE MODE...................................................................................................................... 59
APPLICATION SETUP.............................................................................................................. 62
CONTROLLER SETUP............................................................................................................ 103
MOTOR SETUP ..................................................................................................................... 130

Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
pg. iv
TABLE OF CONTENTS cont’d
5: SYSTEM MONITOR MENU ............................................................................................................. 145
6: COMMISSIONING .......................................................................................................................... 156
INITIAL SETUP ............................................................................................................................ 156
TO BEGIN ............................................................................................................................. 157
CONTROL MODE SELECTION ................................................................................................ 158
PARAMETER SETTINGS – METHOD OVERVIEW...................................................................... 158
TRACTION MOTOR SETUP GUIDE.......................................................................................... 159
CONTROLLER SETUP GUIDE ................................................................................................. 161
TRACTION THROTTLE SETUP................................................................................................ 163
VOLTAGE THROTTLE ............................................................................................................. 166
AUTOMATED ACIM (MOTOR) CHARACTERIZATION PROCEDURE ................................................... 172
AC MOTOR SYSTEMS ................................................................................................................. 172
AUTOMATED PMAC (MOTOR) COMMISSIONING PROCEDURE....................................................... 179
AC MOTOR TUNING GUIDE .......................................................................................................... 183
SELECTING THE CONTROL MODE ......................................................................................... 183
0 − SPEED MODE EXPRESS TUNING..................................................................................... 183
1 − SPEED MODE TUNING .................................................................................................... 184
2 − TORQUE MODE TUNING.................................................................................................. 185
OTHER PARAMETER TUNING................................................................................................. 186
SETTING UP THE HYDRAULIC SYSTEM ........................................................................................ 187
HYDRAULIC LIFT AND LOWER COMMAND INPUTS....................................................................... 187
LIFT & LOWER SWITCH INPUTS ............................................................................................ 188
LIFT SWITCH INPUT, WITH A PROPORTIONAL LOWERING VALVE............................................. 190
7: DIAGNOSTICS AND TROUBLESHOOTING........................................................................................ 194
THE DIAGNOSTICS PROCESS ...................................................................................................... 194
TROUBLESHOOTING CHART INDEX.............................................................................................. 199
FAULT ACTIONS .......................................................................................................................... 203
TROUBLESHOOTING CHART........................................................................................................ 205

TABLE OF CONTENTS cont’d
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 pg. v
8: MAINTENANCE ............................................................................................................................. 239
CLEANING................................................................................................................................... 239
FAULT HISTORY........................................................................................................................... 239
APPENDIX A...................................................................................................................................... 240
CANOPEN PDO MAPPING OBJECT DESCRIPTION................................................................... 240
EXAMPLE FOR RPDO MAPPING WITH THE CIT PROGRAMMER............................................... 242
EXAMPLE FOR TPDO MAPPING WITH THE PROGRAMMER ..................................................... 244
EXAMPLE FOR RPDO MAPPING WITH SDO WRITES...................................................................... 245
APPENDIX B ..................................................................................................................................... 247
ELECTROMAGNETIC COMPATIBILITY (EMC) ................................................................................. 247
ELECTROSTATIC DISCHARGE (ESD) IMMUNITY ............................................................................ 248
DECOMMISSIONING AND RECYCLING THE CONTROLLER............................................................. 248
APPENDIX C ..................................................................................................................................... 249
EN 13849 COMPLIANCE ............................................................................................................. 249
APPENDIX D ..................................................................................................................................... 252
CURTIS INTEGRATED TOOLKITTM.................................................................................................. 252
CREATING A PROJECT WITH A NEW F-SERIES CONTROLLER................................................. 254
VEHICLE CAN PORT WIRING ........................................................................................................ 261
APPENDIX E...................................................................................................................................... 262
SPECIFICATIONS: CONTROLLER............................................................................................ 262

Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
pg. vi
TABLES
TABLE 1: HIGH POWER CONNECTIONS................................................................................................ 8
TABLE 2: THE AMPSEAL CONNECTOR COMPONENTS & PART NUMBERS............................................ 10
TABLE 3: THE AMPSEAL CONNECTOR COMPONENTS & PART NUMBERS............................................ 10
TABLE 4: THE AMPSEAL CONNECTION PROTECTED VOLTAGES – 23 PIN CONTROLLERS..................... 13
TABLE 5: AMPSEAL CONNECTIONS PROTECTED VOLTAGES – 35 PIN CONTROLLERS ........................ 13
TABLE 6: LOGIC AND LOW CURRENT CONNECTIONS-F2A .................................................................. 14
TABLE 7: LOGIC AND LOW-CURRENT CONNECTIONS-F4/6-A ............................................................ 15
TABLE 8: DIGITAL (SWITCH) INPUTS ELECTRICAL SPECIFICATIONS..................................................... 20
TABLE 9: ANALOG INPUTS ELECTRICAL SPECIFICATIONS ................................................................... 22
TABLE 10: POTENTIOMETER INPUT/CONFIGURATION ELECTRICAL SPECIFICATIONS ........................... 24
TABLE 11: DRIVER OUTPUTS ELECTRICAL SPECIFICATIONS................................................................ 25
TABLE 12: POWER-SUPPLY OUTPUTS ELECTRICAL SPECIFICATIONS .................................................. 26
TABLE 13: KEYSWITCH AND COIL SUPPLY ELECTRICAL SPECIFICATIONS............................................ 27
TABLE 14: CAN PORTS ELECTRICAL SPECIFICATIONS ........................................................................ 28
TABLE 15: DIGITAL/QUADRATURE ENCODER ELECTRICAL SPECIFICATIONS ........................................ 29
TABLE 16: SIN/COS SENSOR DEVICE ELECTRICAL SPECIFICATIONS ................................................... 30
TABLE 17: MOTOR TEMPERATURE SENSOR SPECIFICATIONS............................................................. 31
TABLE 18: PROGRAMMABLE PARAMETERS MENUS: CURTIS INTEGRATED TOOLKITTM/1313 HHP ........ 41
TABLE 19: SYSTEM MONITOR VARIABLES ........................................................................................ 145
TABLE 20: ACIM TEST TABLE ............................................................................................................ 174
TABLE 21: MOTOR CHARACTERIZATION AND PARAMETER MISMATCH ERROR TYPES........................ 175
TABLE 22: TROUBLESHOOTING CHART INDEX................................................................................... 199
TABLE 23: FAULT ACTIONS................................................................................................................ 203
TABLE 24: FAULT CODE TROUBLESHOOTING CHART ......................................................................... 205
TABLE E-1: SPECIFICATIONS: AC F6-A, F4-A AND F2-A CONTROLLERS ............................................. 262
TABLE OF CONTENTS cont’d

pg. vii
FIGURES
FIGURE 1: AC F2-A MOTOR CONTROLLER........................................................................................... 1
FIGURE 2: AC F4-A MOTOR CONTROLLER........................................................................................... 2
FIGURE 3: AC F6-A MOTOR CONTROLLER........................................................................................... 3
FIGURE 4: AC F2-A DIMENSIONS......................................................................................................... 5
FIGURE 5: AC F4-A DIMENSIONS......................................................................................................... 6
FIGURE 6: AC F6-A DIMENSIONS......................................................................................................... 7
FIGURE 7: BATTERY POWER AND MOTOR PHASE TERMINAL CONNECTIONS........................................ 8
FIGURE 8: 23-PIN AMPSEAL CONNECTOR ........................................................................................... 9
FIGURE 9: 35-PIN AMPSEAL CONNECTOR ........................................................................................... 9
FIGURE 10: 23-PIN AMPSEAL CONNECTION ASSIGNMENTS ............................................................... 11
FIGURE 11: 35-PIN AMPSEAL CONNECTION ASSIGNMENTS ............................................................... 11
FIGURE 12: AC F2-A BASIC WIRING DIAGRAM .................................................................................... 16
FIGURE 13: AC F4-A, F6-A BASIC WIRING DIAGRAM........................................................................... 17
FIGURE 14: AC F2-A CAN TILLER HEAD WIRING DIAGRAM .................................................................. 18
FIGURE 15: AC F4-A, F6-A ISOLATED CAN. TILLER HEAD WIRING DIAGRAM ....................................... 19
FIGURE 16: ACCELERATION RESPONSE RATE..................................................................................... 55
FIGURE 17: BRAKING RESPONSE RATE............................................................................................... 56
FIGURE 18: CREEP MODE THROTTLE — TORQUE MODE.................................................................... 61
FIGURE 19: GEAR SOFTEN — TORQUE MODE .................................................................................... 61
FIGURE 20: BRAKE TAPER SPEED — TORQUE MODE ......................................................................... 61
FIGURE 21: THROTTLE ADJUSTMENTS DIAGRAM .............................................................................. 64
FIGURE 22: THROTTLE SIGNAL PROCESSING ..................................................................................... 66
FIGURE 23: BRAKE SIGNAL PROCESSING ........................................................................................... 69
FIGURE 24: EMERGENCY REVERSE SUPERVISION FUNCTION.............................................................. 84
FIGURE 25: INTERLOCK BRAKE SUPERVISION SPEED LIMIT FOR POSITIVE INITIAL SPEED................... 86
TABLE OF CONTENTS cont’d
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022

pg. viii
TABLE OF CONTENTS cont’d
FIGURE 26: INTERLOCK BRAKE SUPERVISION SPEED LIMIT FOR NEGATIVE INITIAL SPEED ................. 87
FIGURE 27: INTERLOCK BRAKE SUPERVISION DISTANCE CHECK ........................................................ 87
FIGURE 28: HYDRAULIC SYSTEM DIAGRAM, WITH LOAD-HOLD AND
PROPORTIONAL LOWER VALVES ............................................................................... 89
FIGURE 29: HYDRAULIC SYSTEM DIAGRAM, WITH A FIXED (ON/OFF) LOAD-HOLD VALVE..................... 90
FIGURE 30: LIFT-INPUT SIGNAL CHAIN (PROCESSING) ....................................................................... 91
FIGURE 31: LIFT-LOWERING SIGNAL CHAIN (PROCESSING)................................................................. 91
FIGURE 32: INPUT 10 DIGITAL AND ANALOG SIGNAL CHAIN............................................................... 113
FIGURE 33: DRIVE CURRENT LIMITING MAP ...................................................................................... 128
FIGURE 34: REGEN CURRENT LIMITING MAP..................................................................................... 129
FIGURE 35: THROTTLE RELATED PARAMETERS – SETUP OPTIONS.................................................... 164
FIGURE 36: WIRING FOR 3-WIRE POTENTIOMETER THROTTLES ........................................................ 165
FIGURE 37: WIRING FOR 2-WIRE POTENTIOMETER THROTTLES ........................................................ 166
FIGURE 38: CURTIS FP-SCV-0022 HALL-EFFECT THROTTLE.............................................................. 167
FIGURE 39: WIRING FOR VOLTAGE TYPE THROTTLES ......................................................................... 168
FIGURE 40: THE PROPORTIONAL VALVE SIGNAL CHAIN...................................................................... 188
FIGURE 41: THE LOAD HOLD VALVE SIGNAL CHAIN ........................................................................... 188
FIGURE 42: CURTIS INTEGRATED TOOLKITTM PROGRAMMER PRESENT
AND FAULT HISTORY SEQUENCE EXAMPLE .............................................................. 195
FIGURE C-1 : SUPERVISORY SYSTEM IN THE CURTIS AC MOTOR CONTROLLER................................. 249
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022

1 — OVERVIEW pg. 1
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
1 — OVERVIEW
e Curtis F2-A and F4/6-A motor controllers provide accurate, dependable, and highly ecient control
of speed and torque of AC induction motors (ACIM) and permanent magnet AC motors (PMAC).
ese traction controllers are optimized for both class III pedestrian-operated (F2-A) and rider-
powered (F4/6-A) pallet trucks. They provide vehicle designers with the ability to fully define
and control the detailed dynamic performance of their vehicle’s drivetrain, and also provide
comprehensive vehicle management and CAN manager capabilities. ese models are also suitable
for traction or hydraulic pump control on other types of battery powered vehicles, based upon the
power requirements. e AC-F2-A is a 23-pin model. e AC F4/6-A is a 35-pin model oering a
higher-count I/O and a second CAN port.
Together with the Curtis model 3140/3141 CAN LCD display and the Curtis Integrated ToolkitTM,
these Curtis models are the ultimate Class III truck control system.
Easily enhance any application by using Curtis’s Vehicle Control Language (VCL). e setup and
diagnostic tasks use the new PC-based Curtis Integrated Toolkit™ program (CIT) or the CAN-based
Curtis 1313 handheld programmer (1313HHP).
Figure 1
AC F2-A Motor
Controller

1 — OVERVIEW
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 2
Figure 2
AC F4-A Motor
Controller

1 — OVERVIEW pg. 3
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
HOW TO USE THIS MANUAL
is manual combines the 23-pin F2-A and the 35-pin F4/6-A controllers.
e F-Series I/O operates the same way, the dierence lies in the input/output (I/O) count. e
35-pin controllers oer a second CAN port and more I/O (drivers, analog & switch inputs) as the
principle dierence.
is manual describes how to:
• Properly mount and wire the controller
• Understand the congurable inputs and outputs
• Apply specic features to match an application
• Access and change parameters
• View and use monitor variables
• Perform the initial setup
• Setup the PDO Mapping
• Diagnose and troubleshoot faults
• Select and use the available programming and diagnostic tools
3141 CAN Gauge
Figure 3
AC F6-A Motor
Controller

1 — OVERVIEW
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 4
WHAT IS NEW IN FOS 4.5.0.0 ... HIGHLIGHTS
1. Expanded the motor temperature sensor type to include the mapping of a custom sensor. See the
parameter Sensor Type (0x3688) = 0. When selected, the sensor map menu will open in CIT.
2. IM Motor Types updated to 558. PMAC Motor Types updated to 149.
3. Added the instructions for using Hall switch motor position sensor with PMAC motors in
Chapter 6.
4. Various FOS improvements. For example:
- Continued Parameter/Monitor variables help text updates.
- Fixes to main welded and motor open checks to correctly report motor open faults instead of
overcurrent.
- Fixed the monitor variable motor_control_active showing the wrong state. is variable can be
used to verify the controller is actively controlling torque to the motor and is typically useful
for manual control of an EM brake.
- Added the EM Brake Test menu (Chapter 4).
- Various faults, fault-actions updated, including for dual-drive applications.
For complete details on the FOS changes, consult the FOS 4.5 OEM Release Notes available from
the Curtis distributor or the regional Curtis sales-support oce.
GETTING THE MOST OUT OF YOUR CURTIS CONTROLLER
Thoroughly read and refer to this manual to apply and configure the controller. Understanding
the installation & wiring guidelines, the parameter settings, the VCL functions, the initial
setup & commissioning, and using the diagnostic and troubleshooting guide are critical to a
successful application.
This manual describes the typical usage of the controller. If the intended application is not
illustrated or discussed within this manual, contact the Curtis distributor or the regional Curtis
sales-support oce for additional technical support. e Curtis sales and support oce-contact
information is available from the Curtis Instruments website under the International tab.
https://www.curtisinstruments.com/international/

2 — INSTALLATION AND WIRING pg. 5
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
2 — INSTALLATION AND WIRING
PHYSICALLY MOUNTING THE CONTROLLER
Use the controller's outline and mounting-hole dimensions to determine the optimum mounting
location. Properly installed, the controller meets the IP65 requirements for environmental protection
against dust and water. Nevertheless, in order to prevent external corrosion and leakage paths from
developing, choose a mounting location to keep the controller as clean and dry as possible. Protect
all ends of the low-power (signal) harness from excessive moisture and water (e.g., any toggle switch,
sensor, and device connections on the vehicle).
Do not pressure wash the controller or its connectors and terminals.
Mount the controller to a at surface devoid of protrusions, ridges, or a curvature that can cause damage
or distortion to its heatsink (base plate). Secure the controller using evenly torqued bolts to the vehicle’s
mounting surface. Applying a thin layer of thermal joint compound improves heat conduction from
the controller heatsink to the vehicle’s mounting surface. Typically, when properly mounted to a larger
(smooth) metal surface, an additional heatsink or cooling fan is not necessary to meet the application’s
peak and continuous current ratings.
Apply a hot surface label to the controller compartment.
Figure 4
AC F2-A dimensions
Dimensions are in millimeters

2 — INSTALLATION AND WIRING
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 6
Figure 5
AC F4-A dimensions
5X M6X 1.0 - 6H 18 MIN
4X ø 7.0 169.0
180.0
5.5 5.5
129.0 140.0
STATUS LED
74.0 75.0
12.0
Dimensions are in millimeters
Working on electrical systems is potentially dangerous. Protect personnel and property
against uncontrolled operation, high current arcs, outgassing from lead-acid batteries, and
voltage shock hazards.
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 the
terminals 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.
SHOCK HAZARD — The vehicle design (OEMs) shall prevent user access to the battery/protect
controller terminals from a shock hazard, e.g., by mounting them in a compartment or behind a
panel that can only be opened with a tool or a key.
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 when servicing, charging and working around the battery.
LITHIUM ION BATTERIES — Follow the battery manufacturer’s “safety precautions for the Lithium
Ion battery pack.” Wear safety glasses when servicing, charging and working around the battery.
CAUTION

2 — INSTALLATION AND WIRING pg. 7
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
140.4
7.3
155
4X 7.00±0.13
200.6
212
5.5
5X M6X1.0 20.0
STATUS LED
Part Number: XXXXXXXX
MODEL: XXXXXXXXX
VOLTAGE: XXXXXXX CURRENT: XXXX
Serial Number: XXXXXXXXXXX
78
11.0
73.9
Figure 6
AC F6-A dimensions
PRECAUTIONS
Take the steps during the application’s design and development to ensure that the EMC performance
complies with applicable regulations; Appendix B presents some design considerations for
EMC mitigation.

2 — INSTALLATION AND WIRING
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 8
HIGH CURRENT CONNECTIONS
ere are ve high-current connections identied on the controller cover as B+, B–, U, V, and W.
Install the controller with a (main) contactor between the traction battery positive terminal and the
B+ terminal. is wiring circuit shall also be tted with a fuse (the fuse amperage rating to match
the application). Prevent user access to the terminals from a shock hazard, e.g., by mounting it in a
compartment or behind a panel that can only be opened with a tool or a key.
Terminal Function
B+ Positive Battery to Controller
B– Negative Battery to Controller
UMotor Phase U
VMotor Phase V
WMotor Phase W
Table 1 High Power Connections
e high power connections are aluminum M6 terminals. Terminate the battery and motor cables
with high quality (tin-plated) copper lugs to match the application. Ensure the M6 bolts are the
proper length to meet the minimum thread depth engagement. Do not bottom-out the bolts in any
terminal. Follow Figure 7 connection guidelines:
• Place the lug on top of the aluminum terminal, followed by a high-load safety washer with its
convex side on top. e washer should be a SCHNORR 416320, or equivalent.
• For terminal connections with more than one lug, stack them so the lug carrying the least
current is on top.
• Ensure the clamping bolt is within the minimum and maximum depth when assembled.
• Tighten the assembly to 10.2 ±1.1 Nm (90 ±10 in-lbs.).
When routing the battery cables between the battery and controller, run the positive and negative
battery cables close to each other, avoiding pinch-points and areas of possible cable abrasion.
Typically, the positive cable is red and the negative cable is black. e motor phase cables are oen
black, yet clearly labeled at both ends. Reference Appendix B, Vehicle Design Considerations for
EMC guidelines.
Figure 7
Battery Power
and Motor
Phase Terminal
Connections
M6 BOLT
HIGH LOAD
SAFETY WASHER
LUG
M6 TERMINAL
SECTION VIEW
HIGH POWER TERMINALS
EXPLODED VIEW
10 mm MIN
DEPTH
18 mm MAX
DEPTH

2 — INSTALLATION AND WIRING pg. 9
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
LOW CURRENT CONNECTIONS
All logic and low power connections are through a single 23 or 35-pin AMPSEAL connector (mold
in the cover) utilizing gold-plated pins. e matching AMPSEAL receptacle’s wire silos come sealed
by a membrane. Pierce the membrane by inserting the individual terminated wires. To maintain the
IP65 rating, use the proper wire gauge and insulation thickness. Seal any non-used wire positions
that have their silo-diaphragm pierced with the specic AMPSEAL sealing plug. Do not mix gold
and tin pin types.
• Figures 8 and 9 are the AMPSEAL receptacle (plug) housing. Note the molded-in silo numbering.
• Figures 10 and 11 illustrate the connection assignments (as the plug aligns with the controller).
• Tables 2 and 3 list the matching AMPSEAL vehicle-harness component part numbers.
Figure 9
35-Pin AMPSEAL
Connector
13
24
1
23
35
12
AMPSEAL 35 PIN Connector Harness-side view
8
1
15
16 23
9
Figure 8
23-Pin AMPSEAL
Connector

2 — INSTALLATION AND WIRING
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 10
Note: e silo numbers are molded on the top and sides of the AMPSEAL connector receptacle (plug).
Table 3 The AMPSEAL Connector Components & Part Numbers
Matching AMPSEAL 35-pin Component* Part Number
AMPSEAL receptacle housing (the black vehicle-harness plug) 776164-1
Plug’s gold-plated socket terminals (strip form p/n) 770520-3
Plug’s gold-plated socket terminals (loose piece p/n) 770854-3
Silo seal plug (for non-used pin positions with a pierced membrane) 770678-1
Plug’s tin-plated socket terminals (strip form p/n) 770520-1
Plug’s tin-plated socket terminals (loose piece p/n) 770854-1
Harness wire size (gauge) 0.5 – 1.25 mm2
(20 – 16 AWG)
Wire diameter (overall) [i.e., uses wire with thin-wall insulation] 1.7 – 2.7 mm
Hand Crimper for the wire-harness socket terminals 58440-1
*AMPSEAL components and tooling are available worldwide from multiple TE Connectivity electrical component distributors.
Reference the TE Connectivity Document: Application Specification 114-16016.
http://www.te.com/commerce/DocumentDelivery/DDEController
TE Connectivity website: http://www.te.com/usa-en/products/connectors/automotive-connectors/intersection/ampseal-connectors.html
Table 2 The AMPSEAL Connector Components & Part Numbers
Matching AMPSEAL 23-pin Component* Part Number
AMPSEAL receptacle housing (the black vehicle-harness plug) 770680-1
Plug’s gold-plated socket terminals (strip form p/n) 770520-3
Plug’s gold-plated socket terminals (loose piece p/n) 770854-3
Silo seal plug (for non-used pin positions with a pierced membrane) 770678-1
Harness wire size (gauge) 0.5 – 1.25 mm2
(20 – 16 AWG)
Wire diameter (overall) [i.e., uses wire with thin-wall insulation] 1.7 – 2.7 mm
Hand Crimper for the wire-harness socket terminals 58440-1

2 — INSTALLATION AND WIRING pg. 11
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
35 34 33 32 31 30 29 28 27 26 25 24
12 11 10 9 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13
CAN1 L
CAN 1
TERM L
CAN1 H
INPUT 8
INPUT 4
ENC 1B
INPUT 3
ENC 1A
DRIVER 8
CAN2 L
CAN2 H
INPUT 19
POT 19 SUPPLY
INPUT 31
+5V SUPPLY
INPUT 14
+12V SUPPLY
INPUT 9
KSI
DRIVER 1
INPUT 21
DRIVER 4
INPUT 24
DRIVER 3
INPUT 23
DRIVER 2
INPUT 22
DRIVER 5
INPUT 25
GND
INPUT 2
MOTOR TEMP
INPUT 5
INPUT 10
(PWM)
INPUT 11
ENC 1C
INPUT 12
ENC 2A
INPUT 7
CAN 1
TERM H
DRIVER 7
INPUT 27
DRIVER 6
INPUT 26
GND
INPUT 18
POT 18 WIPER
INPUT 1
POT 1 WIPER
INPUT 6
POT 6 SUPPLY
INPUT 13
ENC 2B
COIL
SUPPLY
ISOLATED GROUND
MODELS w/ Isolated CAN
NOT USED ON
MODELS w/ Isolated CAN
Figure 11
35-Pin AMPSEAL
Connection Assignments
The Input and Outputs (I/O) assignments in Figures 10 and 11 follow the basic wiring diagrams. The
orientation is looking at the controller, which is also the harness-side of the connector. When designing a
vehicle harness and its routing throughout a vehicle, follow these guidelines to avoid common control-signal
interference. Protect the wiring from abrasions due to vibrations, pinch, cut and pull-loose damage, which can
lead to an inoperative controller. Reference Appendix B, Vehicle Design Considerations for EMC guidelines.
15 9
SWITCH
14/+12V SWITCH
13
23 16 22 21 20 19 18 17
14 13 12 11 10
SWITCH
12 CAN
L
SWITCH
11 ENC
B
ENC
A
+5V
SWITCH
8
SWITCH
7
CAN
H
I/O
GND WIPER POT HI
MOTOR
TEMP
1
876 5 4 3 2
SWITCH
5DRIVER
1
DRIVER
4DRIVER
3
DRIVER
2DRIVER
5
COIL
RETURN KSI
Figure 10
23-Pin AMPSEAL
Connection Assignments

2 — INSTALLATION AND WIRING
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 12
Rotor Position feedback
e rotor-position sensor’s wiring (+5V, Feedback A, Feedback B, and Ground) should be bundled
together between the motor and controller. ese wires are oen run with the rest of the low current
wiring harness without interference issues, but the encoder wires should not be routed near the motor
cables. In applications where this is not possible or there is signal interference, twist the encoder
signal wires. In cases using a shielded cable (e.g., shielded 2-wire twisted-pair with drain-wire), only
ground the shield-drain wire at the controller ground. In cases where this is not possible, consider
a dierent controller.
CANbus
Use twisted-pair wires for the CANbus connections. Keep the CAN wiring away from the high
current cables and cross them at right angles when necessary. In extreme cases, use shielded cable
with the shield connected to the controller I/O ground and only on the controller side for the non-
isolated controller models.
e 35-pin AMPseal controllers allow the implementation of both 11-bit identiers (CANopen)
and 29-bit identiers (e.g., J1939), and/or dierent baud rates to support a high-speed CANbus for
safety or data logging.
An isolated CAN option uses a separate (isolated) CANbus ground reference, which is useful on
vehicles with CANbus systems operating at dierent battery voltages. It avoids common mode noise
issues. e isolated ground is provided for twisted pair shielding, and may not be needed. When
using shielded wiring, only connect the shield’s drain-wire to isolated ground. On controllers with
two CAN ports, the option always includes both CAN1 and CAN2 as isolated CAN.
All other low power wiring
Use standard vehicle-harness routing practices for the remaining connections. When designing the
vehicle’s wiring and routing, keep the inputs such as the throttle, temperature, and the motor feedback
signals separate from controller’s output lines such as the coil driver outputs. Avoid routing the low-
power wiring parallel to the high power (and high current) battery and motor cables.
Protected voltages
e low-power pins’ protected voltage ratings listed in Tables 4 and 5 are absolute and are not for normal
operation. To prevent damage to the controller, do not connect (i.e., short circuit) the Coil Supply to
battery negative. Further, do not connect (i.e., short circuit) the I/O Ground to battery positive.