Manual
Model 1244
MultiMode™ Electronic Motor Controller
Read Instructions Carefully!
Specications are subject to change without notice.
© 2013 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. 16958 Rev E 10/2013
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
CONTENTS
1. OVERVIEW ...........................................................................................1
2. INSTALLATION AND WIRING .........................................................4
Mounting the Controller ..................................................................4
Connections: Low Current ..............................................................6
Connections: High Current .............................................................7
Wiring: Controller ........................................................................... 8
Wiring: rottle.............................................................................10
5kΩ–0, 2-wire resistive throttle (“Type 1”) ..............................11
0–5V, current source, 3-wire pot, and electronic
single-ended throttles (“Type 2”) .....................................12
0–5kΩ, 2-wire resistive throttle (“Type 3”) ..............................15
0–5V and 3-wire pot wigwag-style throttles (“Type 4”) ............15
CAN-Nodes throttle (“Type 5”) ..............................................16
Wiring: Fault Outputs ...................................................................16
Wiring: Contactor Drivers ............................................................. 16
Wiring: Pedal Switch .....................................................................19
Wiring: Hour Meter ......................................................................19
Wiring: CAN Bus Interface ...........................................................19
Wiring: Emergency Reverse ........................................................... 19
Contactor, Switches, and Other Hardware ......................................21
CONTENTS
3. PROGRAMMABLE PARAMETERS ..................................................23
Acceleration Parameters ..................................................................26
Acceleration Rate, M1–M4 ......................................................26
Braking Rate, M1–M4 ............................................................26
Deceleration Rate ....................................................................26
Quick Start .............................................................................. 26
Taper Rate ............................................................................... 27
Speed Parameters ............................................................................27
Maximum Speed, M1–M4 ......................................................27
Creep Speed, M1–M4 ............................................................. 27
Regen Speed ............................................................................27
rottle Parameters ......................................................................... 28
Control Mode..........................................................................28
rottle Type ........................................................................... 29
rottle Deadband ..................................................................30
rottle Max ...........................................................................32
rottle Map, M1–M4 ............................................................ 34
rottle Braking Percent, M1–M4 ...........................................36
Current Limit Parameters ...............................................................36
Drive Current Limit, M1–M4 .................................................36
Braking Current Limit, M1–M4 ..............................................36
Minimum Field Current Limit ................................................ 36
Maximum Field Current Limit ................................................ 37
Restraint .................................................................................. 37
Emergency Reverse Current Limit ...........................................38
Current Ratio .......................................................................... 38
Curtis 1244 Manual, Rev. E
iii
CONTENTS
Field Control Parameters ................................................................38
Field Map Start ........................................................................ 38
Field Map ................................................................................ 39
Fault Parameters ..............................................................................41
High Pedal Disable (HPD) ...................................................... 41
HPD reshold ....................................................................... 42
Static Return to O (SRO) ...................................................... 42
Fault Code ............................................................................... 42
Output Driver Parameters ...............................................................43
Main Contactor Driver Interlock .............................................43
Main Contactor Dropout Delay ..............................................43
Main Coil Open Check ........................................................... 44
Main Contactor Weld Check ................................................... 44
Auxiliary Driver Dropout Delay ..............................................44
Auxiliary Coil Open Check .....................................................44
Reverse Signal Open Check .....................................................45
Electromagnetic Brake Delay ...................................................45
Electromagnetic Brake Open Check ........................................45
Contactor Holding Voltage ......................................................46
Contactor Pull-in Voltage ........................................................46
Other Parameters ............................................................................ 46
Battery Voltage ........................................................................46
Anti-Tiedown ..........................................................................47
Sequencing Delay .................................................................... 47
Pedal Interlock ......................................................................... 47
Emergency Reverse Enable .......................................................48
Emergency Reverse Check ....................................................... 48
Node Address ..........................................................................48
Precharge ................................................................................ 49
Load Compensation ................................................................ 49
4. OEMSPECIFIED, FACTORYSET PARAMETERS .........................50
MultiMode™ Enable ...................................................................... 50
Accessory Driver Enable ..................................................................50
CAN Bus Enable ............................................................................51
5. INSTALLATION CHECKOUT .........................................................52
6. VEHICLE PERFORMANCE ADJUSTMENT ..................................54
Major Tuning ..................................................................................54
Tuning the active throttle range ..............................................54
Tuning the controller to the motor .........................................57
Setting the unloaded vehicle top speed ....................................59
Equalizing loaded and unloaded vehicle speed ........................60
Fine Tuning ....................................................................................62
Response to increased throttle .................................................. 62
Response to reduced throttle .................................................... 63
Smoothness of direction transitions .........................................63
Ramp climbing ....................................................................... 65
Ramp restraint ........................................................................ 66
iv
Curtis 1244 Manual, Rev. E
7. PROGRAMMER MENUS .................................................................67
Paraneters Menu .............................................................................67
Monitor Menu ................................................................................ 70
Diagnostics Menu ........................................................................... 71
Other Menus .................................................................................. 71
8. DIAGNOSTICS AND TROUBLESHOOTING................................72
Programmer Diagnostics ................................................................. 72
LED Diagnostics ............................................................................ 74
Fault Output Drivers ...................................................................... 75
9. MAINTENANCE ................................................................................76
Cleaning ........................................................................................ 76
Diagnostic History .........................................................................76
appendix a Glossary of Features and Functions
appendix b Programming Devices
appendix c Specifications, 1244 Controller
CONTENTS
Curtis 1244 Manual, Rev. E
v
FIGURES / TABLES
. 1: Curtis 1244 electronic motor controller ...................................1
. 2: Mounting dimensions, Curtis 1244 controller ........................4
. 3: Standard wiring configuration ..................................................8
. 4: Wiring for 5kΩ–0 throttle (“Type 1”) .................................... 11
. 5: Wiring for wigwag throttle,
using the 5kΩ–0 throttle input (“Type 1”) ............................. 11
. 6: Wiring for 0–5V throttle (“Type 2”) ...................................... 12
. 7: Wiring for 3-wire potentiometer throttle (“Type 2”) .............. 13
. 8: Wiring for current source throttle (“Type 2”) ......................... 13
. 9: Wiring for Curtis ET-XXX electronic throttle (“Type 2”) ......14
. 10: Wiring for 0–5kΩ throttle (“Type 3”) ....................................15
. 11: Wiring for fault outputs .........................................................16
. 12: Wiring for main and auxiliary contactor coils when using
the interlock and dropout delay features .................................18
FIGURES
. 13: Wiring for emergency reverse
(applicable to walkie vehicles only) .........................................20
. 14: Eect of adjusting the neutral deadband parameter .........30, 31
. 15: Eect of adjusting the throttle max parameter .................32, 33
. 16: rottle maps for controller with maximum speed set
at 100% and creep speed set at 0 ...........................................34
. 17: rottle maps for controller with maximum speed set
at 80% and creep speed set at 10% .......................................35
. 18: Inuence of various parameters on controller output
response to throttle demand ..................................................35
. 19: Field current relative to armature current,
with field map parameter set at 50% and 20% ......................40
TABLES
1: Voltages at throttle wiper input ............................................ 10
2: Mode selection ..................................................................... 22
3: Programmable throttle types ................................................. 29
4: Fault categories .................................................................... 43
5: Troubleshooting chart .......................................................... 73
6: Status LED fault codes ........................................................ 74
7: Fault category codes ............................................................ 75
C-1: Specifications, 1244 controller ....................................... C-1
vi
Curtis 1244 Manual, Rev. E
1
Fig. 1 Curtis 1244
MultiMode™ electronic
motor controller.
1 — OVERVIEW
OVERVIEW
Curtis 1244 MultiMode™ controllers are separately excited motor speed controllers designed for use in a variety of material handling vehicles. ese programmable controllers are simple to install, efficient, and cost eective. Typical
applications include low lifts, stackers, fork lifts, reach trucks, personnel carriers,
counterbalance trucks, order pickers, boom trucks, and other industrial vehicles.
control of motor speed and torque. A four quadrant, full-bridge field winding
control stage is combined with a two quadrant, half-bridge armature power stage
to provide solid state motor reversing and regenerative braking power without
additional relays or contactors. e 1244 controller can also be specified to be
compatible with CAN Bus communication systems.
held programmer or PC programming station. Use of the programmer provides
diagnostic and test capability as well as configuration exibility.
Curtis 1244 Manual, Rev. E
e 1244 MultiMode™ controller oers smooth, silent, cost eective
ese controllers are fully programmable by means of the optional hand-
1
1 — OVERVIEW
Like all Curtis motor controllers, the 1244 oers superior operator control of
the vehicle’s motor drive speed. Features include:
✓ Full-bridge field and half-bridge armature power MOSFET design,
providing
•infinitelyvariableforward,reverse,drive,andbrakecontrol
• silenthighfrequencyoperation
• highefficiency
✓ Regenerative braking, providing longer operation on a single battery charge
and reducing motor brush wear and motor heating
✓ Programmability through the 1313 handheld programmer and 1314 PC
Programming Station
✓ Complete diagnostics through the programmer and the internal Status LED
✓ Two fault outputs provide diagnostics to remotely mounted displays
✓ Continuous armature current control, reducing arcing and brush wear
✓ Automatic braking when throttle is reduced from either direction; this
provides a compression braking feel and enhances safety by automatically
initiating braking in an operator hands o condition
✓ Deceleration Rate, Load Compensation, and Restraint features prevent
downhill runaway conditions; speed is controlled to within approximately
20% of level surface value
✓ MultiMode™ allows four user-selectable vehicle operating personalities
✓ Programmable to match individual separately excited motor characteristics
✓ Meets or exceeds EEC fault detect requirements
✓ Vehicle top speed is controlled and limited in each mode
✓ Linear temperature and undervoltage cutback on motor currents; no sudden
loss of power under any thermal conditions
✓ High pedal disable (HPD) and static return to o (SRO) interlocks prevent
vehicle runaway at startup
✓ Creep speed adjustable from 0% to 25% in each mode
✓ Continuous diagnostics during operation, with microprocessor power-on
self-test
✓ Internal and external watchdog circuits ensure proper software operation
✓ Programmable coil drivers provide adjustable contactor pull-in and holding
voltages
✓ Hour-meter enable output is active whenever the controller is providing
motor current
✓ Optional Electromagnetic Brake Driver provides automatic control of an
✓ Optional Reverse Signal Driver provides a low signal any time the vehicle
2
electromagnetic brake or other similar function
is driving or braking in reverse
Curtis 1244 Manual, Rev. E
1 — OVERVIEW
✓ Optional Auxiliary Driver provides a low signal to power an auxiliary
contactor or other similar function
✓ Driver outputs are short circuit protected and provide built-in coil spike
protection
✓ Controller is programmable to provide throttle control of motor speed,
applied motor voltage, or motor torque
✓ Can be configured for CAN Bus compatibility.
Familiarity with your Curtis controller will help you install and operate it
properly. We encourage you to read this manual carefully. If you have questions,
please contact the Curtis office nearest you.
Curtis 1244 Manual, Rev. E
3
2 — INSTALLATION & WIRING: Controller
MOUNTING THE CONTROLLER
2
e outline and mounting hole dimensions for the 1244 controller are shown
in Figure 2.
ratings for environmental protection against dust and water. However, the lo-
cation should be carefully chosen to keep the controller as clean and dry
as possible.When selecting the mounting position, be sure to also take into
consideration (1) that access is needed at the top of the controller to plug the
INSTALLATION AND WIRING
e controller can be oriented in any position, and meets the IP64/IP67
Fig. 2 Mounting
dimensions, Curtis
1244 controller.
7.1 (0.28) dia.,
178
(7.00)
159
(6.25)
9.5
(0.375)
4 plcs
M8 thread, 3 plcs
STATUS
LED
229 (9.00)
M6 thread, 2 plcs
210 (8.25)
(3.19)
Dimensions in millimeters (and inches)
4
81
12.7
(0.50)
Curtis 1244 Manual, Rev. E
2 — INSTALLATION & WIRING: Controller
programmer into its connector, and (2) that the built-in Status LED is visible
only through the view port in the label on top of the controller.
To ensure full rated power, the controller should be fastened to a clean,
at metal surface with four 6 mm (1/4") diameter screws, using the holes provided. Although not usually necessary, a thermal joint compound can be used to
improve heat conduction from the controller heatsink to the mounting surface.
CAUTION
☞
Working on electric vehicles is potentially dangerous. You should protect yourself against runaways, high current arcs, and outgassing from lead
acid batteries:
RUNAWAYS — Some conditions could cause the vehicle to run out of control.
Disconnect the motor or jack up the vehicle and get the drive wheels o
the ground before attempting any work on the motor control circuitry.
: If the wrong throttle type is selected with the programming device,
the vehicle may suddenly begin to move.
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.
Curtis 1244 Manual, Rev. E
5
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
2 — INSTALLATION & WIRING:
Controller
CONNECTIONS
Low Current Connections
ree low current connectors are built into the 1244 controller. ey are located
in a row on the top of the controller:
24-pin 6-pin 4-pin
e 24-pin connector provides the logic control connections. e mating
connector is a 24-pin Molex Mini-Fit Jr. connector part number 39-01-2245
using type 5556 terminals.
Pin 1 keyswitch input (KSI)
Pin 2 interlock input
Pin 3 Mode Select 1 input
Pin 4 Mode Select 2 input
Pin 5 Fault 1 output
Pin 6 Fault 2 output
Pin 7 emergency reverse input
Pin 8 pedal switch input
Pin 9 coil return input
Pin 10 forward input
Pin 11 reverse input
Pin 12 hour meter enable output
Pin 13 throttle: 3-wire pot high
Pin 14 throttle: pot low
Pin 15 throttle: 3-wire pot wiper or 0–5V
Pin 16 throttle: 2-wire 5kΩ–0 or 0–5kΩ input
Pin 17 main contactor driver output
Pin 18 auxiliary contactor driver output
Pin 19 reverse signal driver output
Pin 20 electromagnetic brake driver output
Pin 21 (not used)
Pin 22 emergency reverse check output
Pin 23 (not used)
Pin 24 (not used)
6
Curtis 1244 Manual, Rev. E
B- B+M-
456
123
2 — INSTALLATION & WIRING: Controller
A 6-pin low power Molex connector is provided for the CAN Bus interface.
However, the CAN Bus option must be specified for this interface to be active.
e mating connector is a Molex Mini-Fit Jr. p/n 39-01-2065 using type 5556
terminals.
Pin 1 +15V supply (limited)
Pin 2 ground return (B-)
Pin 3 CAN H I/O line
Pin 4 L termination
Pin 5 H termination
Pin 6 CAN L I/O line
e +15V supply should only be used with the CAN system or speed sensor
and not to power any other external systems.
e L and H terminations provide a 120Ω termination impedance for
the CAN H I/O and CAN L I/O inputs if necessary. Refer to the Curtis CAN
Protocol Document to determine the proper termination for a given application.
CABLE-FREE ZONES
F1
A 4-pin low power connector is provided for the handheld 1313 programmer
or 1314 PC programming station. A complete programmer kit, including the
appropriate connecting cable, can be ordered from Curtis.
If a programmer is already available but has an incompatible cable, the
1244 mating cable can be ordered as a separate part: Curtis p/n 16185.
High Current Connections
Five tin-plated solid aluminum bus bars are provided for the high current connections to the battery
and
F2). ese bus bars incorporate threaded mounting studs designed to accept
mounting bolts. e
(B+ and B-), the motor armature (M-), and the motor field (F1
B+, B-, and M- bus bars are threaded to accept M8 bolts to
a depth of 3/4". e F1 and F2 bus bars are threaded to accept M6
bolts to a depth of 5/8". is simplifies the assembly
STATUS
LED
and reduces the mounting hardware necessary for the
power connections. e tightening torque applied to
F2
the bolts should not exceed 16.3 N·m (12 ft-lbs) for
the M6 bolts or 20 N·m (15 ft-lbs) for the M8 bolts.
Exceeding these specifications could damage the bus
bars’ internal threads, resulting in loose connections.
CAUTION
☞
Power cables must not be routed over the indicated areas. Otherwise they
may interfere with the proper operation of sensitive electromagnetic components located underneath.
Curtis 1244 Manual, Rev. E
7
2 — INSTALLATION & WIRING: Controller
B- B+M-
F2F1
INTERLOCK
5 kΩ–0 THROTTLE
(TYPICAL)
FORWARD
MAIN
CONTACTOR
COIL
POLARITY
PROTECTION
DIODE
REVERSE
MODE SELECT 2
MODE SELECT 1
B+
B-
KEYSWITCH
POWER
FUSE
A
MAIN
CONTACTOR
A2 A1
F1 F2
CONTROL
FUSE
WIRING: Standard Conguration
Figure 3 shows the typical wiring configuration for most applications. e
interlock switch is typically a seat switch, tiller switch, or foot switch.
Standard Power Wiring
Motor armature winding is straightforward, with the armature’s A1 connection
going to the controller’s B+ bus bar and the armature’s A2 connection going
to the controller’s M- bus bar.
vious. e direction of vehicle travel with the forward direction selected will
depend on how the
terminals and how the motor shaft is connected to the drive wheels through
the vehicle’s drive train.
e motor’s field connections (
F1 and F2 connections are made to the controller’s two field
F1 and F2) to the controller are less ob-
Fig. 3 Standard wiring configuration, Curtis 1244 controller.
8
Curtis 1244 Manual, Rev. E
2 — INSTALLATION & WIRING: Controller
Standard Control Wiring
Wiring for the input switches and contactors is shown in Figure 3; the connector
is shown in more detail below.
24-pin detail (see Fig. 3):
EMERGENCY
REVERSE
CHECK
(factory option)
ELECTRO-
MAGNETIC
BRAKE
DRIVER
REVERSE
SIGNAL
DRIVER
AUX
CONTACTOR
DRIVER
MAIN
CONTACTOR
DRIVER
2-WIRE
POT
(5 kΩ)
POT
WIPER
POT
LOW
POT
HIGH
24 23 22 21 20 19 18 17 16 15 14 13
12 11 10 9 8 7 6 5 4 3 2 1
HOUR
METER
REVERSE
FORWARD
COIL
RETURN
PEDAL
SWITCH
EMERGENCY
REVERSE
(walkies only)
FAULT
2
FAULT
1
MODE
SELECT
2
MODE
SELECT
1
INTERLOCK
KEYSWITCH
INPUT (KSI)
e main contactor coil must be wired directly to the controller as shown in
Figure 3. e controller can be programmed to check for welded or missing
main contactor faults and uses the main contactor 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 17, 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.
Curtis 1244 Manual, Rev. E
9
2 — INSTALLATION & WIRING: Throttle
WIRING: Throttle
Various throttles can be used with the 1244 controller. ey are categorized
as one of five types in the programming menu of the handheld programmer.
Type 1: two-wire 5kΩ–0 throttles
Type 2: 0–5V throttles, current source throttles, three-wire potentiometer
throttles, and electronic throttles—wired for single-ended operation
Type 3: two-wire 0–5kΩ throttles
Type 4: 0–5V and three-wire potentiometer throttles—wired for wigwag-style operation
Type 5: CAN-Nodes throttles
e operating specifications for these throttle types are summarized in Table 1.
Table 1 THROTTLE WIPER INPUT: THRESHOLD VALUES
MINIMUM THROTTLE HPD THROTTLE MAXIMUM
THROTTLE THROTTLE DEADBAND (25% throttle MAX THROTTLE
TYPE PARAMETER FAULT (0% throttle) active range) (100% modulation) FAULT
1 Wiper Voltage 0.1 V 3.3 V 1.0 V 0.2 V 4.4 V
Wiper Resistance — 5.0 kΩ 3.8 kΩ 0 kΩ 7.5 kΩ
2 Wiper Voltage (none) 0.2 V 1.4 V 5.0 V 5.5 V
Wiper Resistance — — — — —
3 Wiper Voltage 0.1 V 0.2 V 1.0 V 3.3 V 4.4 V
Wiper Resistance — 0 kΩ 1.3 kΩ 5.0 kΩ 7.5 kΩ
4 Wiper Voltage 0.5 V 2.5 V (fwd)* 3.1 V (fwd) 4.4 V (fwd) 4.5 V
2.5 V (rev)* 1.9 V (rev) 0.6 V (rev)
Wiper Resistance 0.5 kΩ 2.5 kΩ (fwd)* 3.1 kΩ (fwd) 4.4 kΩ (fwd) 4.5 kΩ
2.5 kΩ (rev)* 1.9 kΩ (rev) 0.6 kΩ (rev)
5 Wiper Voltage N/A N/A N/A N/A N/A
Wiper Resistance N/A N/A N/A N/A N/A
Notes: The Upper and Lower Deadbands are valid for nominal 5kΩ potentiometers or 5V sources with the
default Throttle Deadband and Throttle Max parameter settings of 0% and 100% respectively. These
values will change with variations in the Throttle Deadband and Throttle Max parameter settings—see
Section 3, pages 30 and 32.
The HPD threshold is a percentage of the active throttle range, which is dependent on the pro-
grammed Throttle Deadband and Throttle Max settings. The default HPD Threshold is 25%; the
programmable range is 0–25%.
* With 0% Throttle Deadband, there is no neutral point on a Type 4 throttle. It is recommended that
an 8% minimum deadband be used with Type 4 throttles.
All throttle fault protection is accomplished by monitoring the wiper input.
is provides throttle fault protection that meets all EEC requirements. us,
no additional fault protection is required on any throttle type used with the
1244 controller.
10
Curtis 1244 Manual, Rev. E
2 — INSTALLATION & WIRING: Throttle
Pin 14
Pot Low
Wiring for various throttles is described below. : In the text, throttles
are identified by their nominal range and not by their actual operating range.
If the throttle you are planning to use is not covered, contact the Curtis
office nearest you.
5kΩ–0 Throttle (“Type 1”)
e 5kΩ–0 throttle (called a “Type 1” throttle in the programming menu of
the handheld programmer) is a 2-wire resistive throttle that connects between
the 2-Wire Pot and Pot Low pins (Pins 16 and 14), as shown in Figure 4. It
doesn’t matter which wire goes on which pin. For Type 1 throttles, zero speed
corresponds to a nominal 5 kΩ measured between the two pins and full speed
corresponds to 0Ω. (: is wiring is also shown in the standard wiring
diagram, Figure 3.)
Fig. 4 Wiring for 5k
Ω
–0
throttle (“Type 1”).
Fig. 5 Wiring for 20k
Ω
potentiometer used as part
of a wigwag-style throttle
(“Type 1”).
FASTER
14 1315161718192021222324
12 11 10 9 8 7 6 5 4 3 2 1
5kΩ–0
PIN KEY
Pin 16
Pin 14
2-Wire Pot
Pot Low
In addition to accommodating the basic 5kΩ–0 throttle, the Type 1 throttle
can also be used to implement a wigwag-style throttle. Using a 20kΩ pot wired
as shown in Figure 5, the pot wiper can be set such that the controller has 5 kΩ
between Pins 16 and 14 when the throttle is in the neutral position. e throttle
mechanism can then be designed such that rotating it either forward or back
decreases the resistance between Pins 16 and 14, which increases the controller
output. e throttle mechanism must provide signals to the controller’s forward
and reverse inputs independent of the throttle pot resistance. e controller
will not sense direction from the pot resistance with rottle Type 1. For true
FASTERFASTER
12 11 10 9 8 7 6 5 4 3 2 1
14 1315161718192021222324
Curtis 1244 Manual, Rev. E
20 kΩ
Pin 16
PIN KEY
2-Wire Pot
11
14 1315161718192021222324
12 11 10 9 8 7 6 5 4 3 2 1
14 1315161718192021222324
12 11 10 9 8 7 6 5 4 3 2 1
+
-
+
B-
Pin 15
0–5V Input
PIN KEY
Pin 15
Pin 14
0–5V Input
Pot Low
PIN KEY
SENSOR GROUND
SENSOR OUTPUT (0–5V)
SENSOR
2 — INSTALLATION & WIRING: Throttle
wigwag-style control—without the necessity of providing independent forward
and reverse input signals—see rottle Type 4.
controller’s 4.4 V upper fault limit will be exceeded and the controller output
will be disabled. is provides broken wire protection, and also serves as an
indication that the potentiometer’s nominal value has increased and the pot
needs to be replaced.
0–5V, 3-Wire Potentiometer, Current Source,
and Electronic Single-Ended Throttles (“Type 2”)
With these throttles (“Type 2” in the programming menu) the controller looks
for a voltage signal at the wiper input (Pin 15). Zero speed will correspond to
0V and full speed to 5 V. A 3-wire pot, voltage source, voltage sensor, or current
source can be used with this throttle type. e wiring for each is slightly dierent.
0–5V rottle
Two ways of wiring the 0–5V throttle are shown in Figure 6. e active range
for this throttle is from 0.2V (at 0% rottle Deadband) to 5.0 V (at 100%
rottle Max), measured relative to B-.
If the total resistance between Pins 14 and 16 is greater than 7.5 kΩ, the
Fig. 6 Wiring for
0–5V throttles (“Type 2”).
(a) Sensor-referenced
0–5V throttle
(b) Ground-referenced
0–5V throttle
12
Curtis 1244 Manual, Rev. E
Fig. 7 Wiring for 3-wire
14 1315161718192021222324
12 11 10 9 8 7 6 5 4 3 2 1
R
throttle
B-B-
source
Pin 15
0–5V Input
PIN KEY
I
potentiometer throttle
(“Type 2”).
2 — INSTALLATION & WIRING: Throttle
3-Wire Potentiometer (1kΩ–10kΩ) rottle
e 3-wire potentiometer is used in its voltage divider mode, with the voltage
source and return being provided by the 1244 controller. Pot High (Pin 13)
provides a current limited 5V source to the pot, and Pot Low (Pin 14) provides
the return path. e pot wiper is then connected to the Wiper Input (Pin15).
If a 3-wire pot is used in the application, the controller will provide full throttle
fault protection in accordance with EEC requirements. Potentiometers with total
resistance values between 1kΩ and 10kΩ can be used with rottle Type 2.
Wiring is shown in Figure 7.
Fig. 8 Wiring for current
source throttle (“Type 2”).
1kΩ–10kΩ
OFFON
12 11 10 9 8 7 6 5 4 3 2 1
Pin 15
Pin 14
Pin 13
14 1315161718192021222324
PIN KEY
Pot Wiper
Pot Low
Pot High
Current Sources As rottles
A current source can also be used as a throttle input, as shown in Figure 8. A
resistor, R
, must be used to convert the current source value to a voltage.
throttle
e resistor should be sized to provide a 0–5V signal variation over the full
current range.
Curtis 1244 Manual, Rev. E
13
2 — INSTALLATION & WIRING: Throttle
14 1315161718192021222324
12 11 10 9 8 7 6 5 4 3 2 1
GREEN
ORANGE
BLACK
BLACK/WHITE
WHITE
WHT/BRN
B+
KEYSWITCH
connector
WHT/
GRN
Pin 15
Pin 11
Pin 10
Pin 1
0–5V Input
Reverse
Forward
KSI Input
PIN KEY
B-
ET-XXX
B-
Curtis ET-XXX Electronic rottle
e Curtis ET-XXX provides a 0–5V throttle and forward/reverse inputs for
the 1244 controller. Wiring for the ET-XXX is shown in Figure 9.
Fig. 9 Wiring for Curtis
ET-XXX electronic throttle
(“Type 2”).
throttle control. Alternatively, a complete control head assembly is available
from Curtis. is control head assembly—the CH series—combines the ETXXX throttle with a variety of standard control head switch functions for use
in walkie and lift truck applications.
14
e ET-XXX can be integrated into a control head to provide wigwag-style
Curtis 1244 Manual, Rev. E
Fig. 10 Wiring
for 0–5k
Ω
throttle
(“Type 3”).
2 — INSTALLATION & WIRING: Throttle
0–5kΩ Throttle (“Type 3”)
e 0–5kΩ throttle (“Type 3” in the programming menu) is a 2-wire resistive
throttle that connects between the 2-Wire Pot and Pot Low pins (Pins 16 and 14)
as shown in Figure 10. Zero speed corresponds to 0Ω measured between the two
pins and full speed corresponds to 5 kΩ. is throttle type is not appropriate
for use in wigwag-style applications.
FASTER
14 1315161718192021222324
12 11 10 9 8 7 6 5 4 3 2 1
0–5kΩ
PIN KEY
Pin 16
Pin 14
2-Wire Pot
Pot Low
If the total resistance between Pins 14 and 16 is greater than 7.5 kΩ, the
controller’s 4.4 V upper fault limit will be exceeded and the controller output
will be disabled. is provides broken wire protection, and also serves as an
indication that the potentiometer’s nominal value has increased and the pot
needs to be replaced.
0–5V and 3-Wire Potentiometer Wigwag-Style Throttles (“Type 4”)
With these throttles (“Type 4” in the programming menu) the throttle can be
used in true wigwag style. Any potentiometer value between 1 kΩ and 10 kΩ
is supported. If a 5kΩ potentiometer is used, the neutral point will be with the
wiper at 2.5 kΩ (measured between the Pot Wiper and Pot Low pins [Pins 15
and 14]). e controller will provide increasing speed in the forward direction
as the wiper is moved toward Pot High, with maximum forward speed reached
at 4.5 kΩ. e controller will provide increasing speed in the reverse direction
as the wiper is moved toward Pot Low, with maximum reverse speed reached
at 0.5 kΩ.
A 0–5V voltage source can also be used as the wiper input (see Figure6).
However, the minimum and maximum wiper voltage must not exceed the 0.5V
and 4.5V fault limits.
With a Type 4 throttle, no direction signals to the controllers’ forward and
reverse inputs are required. Direction is determined by the wiper input value.
e throttle interface to the controller is similar to that for Type 2 throttles.
Curtis 1244 Manual, Rev. E
15
2 — INSTALLATION & WIRING: Fault Outputs and Contactor Drivers
CAN-Nodes Throttle (“Type 5”)
e “Type 5” throttle option is designed for use with CAN-based control
systems. No connections are required to the throttle input pins (Pins 13–16)
or direction pins (Pins 10 and 11), because all communications are handled
through the 6-pin CAN-Nodes interface connector. Details on how to combine
a given throttle with the CAN-Nodes system are provided in the Curtis CAN
Protocol Document. Fault detection for Type 5 throttles is handled by the
CAN CRC (Cyclic Redundancy Check) function, which is part of each node
in the CAN Bus architecture.
WIRING: Fault Outputs
e 1244 controller has two fault output drivers, at Pin 5 and Pin 6, which
can be used to provide diagnostic information either to a display panel on the
vehicle or to a remote location. ese outputs are rated at 10mA maximum
current at the nominal battery pack voltage. For information on programming
these outputs, see Section 3: Programmable Parameters.
Wiring for the Fault 1 and Fault 2 outputs is shown in Figure 11.
Fig. 11 Wiring for fault
outputs.
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12 11 10 9 8 7 6 5 4 3 2 1
+
Fault 1
Fault 2
-
B-
Pin 6
Pin 5
PIN KEY
Fault 2 Output
Fault 1 Output
WIRING: Contactor Drivers
e 1244 controller provides contactor coil drivers (at Pins 17–20) for the
main contactor, auxiliary contactor, reverse signal, and electromagnetic brake
functions. ese four outputs are low side drivers, designed to energize contactor
coils. e auxiliary, reverse signal, and electromagnetic brake drivers are optional
functions. ey are available only if the Accessory Driver option is specified—see
Section 4, page 50.
It is not necessary to specify the contactors’ coil voltage at the nominal
battery pack voltage as long as the Contactor Pull-In Voltage and Contactor
Holding Voltage parameters are programmed to accommodate the coils’ voltage rating. However, all coil voltage ratings should be the same, since only one
value of pull-in and holding voltage can be specified for all four of the drivers.
e driver outputs are rated at 2 amps and overcurrent protected at
3amps. e controller can be programmed to check for missing coil faults.
16
Curtis 1244 Manual, Rev. E
2 — INSTALLATION & WIRING: Contactor Drivers
ese checks can be disabled using a programmer—see Section 3, pages 44 and
45. A coil suppression diode is provided internally to protect the drivers from
inductive spikes generated at turn-o. To take advantage of the controller’s
internal coil suppression diode, Pin 9 must be wired such that the return path
to the contactor drivers cannot be opened by any switches or contactors.
e driver loads are not limited to contactor coils. Any load can be connected to a Pin 17–20 driver as long as it does not exceed the driver’s 2 amp
current rating.
For information on programming the various contactor-related parameters,
see Section 3: Programmable Parameters.
Main Contactor Driver
In the standard configuration, the main contactor driver (Pin 17) pulls low
when the keyswitch input is enabled; this wiring is shown in the standard wiring
diagram (Figure 3, page 8).
Alternatively, the main contactor driver can be programmed not to pull
low until the interlock input as well as the keyswitch input is enabled. To do
this, the Main Contactor Driver Interlock parameter must be set to “On.” If
the Main Contactor Driver Interlock parameter is On, the Main Contactor
Dropout Delay parameter can be set to allow the main contactor to remain
engaged for up to 40 seconds after the interlock signal has been disabled. If the
interlock and delay functions are used, the main contactor and the coil return
(Pin 9) must both be wired to KSI. is alternative wiring is shown in Figure 12.
Auxiliary Contactor Driver
Like the main contactor driver, the auxiliary contactor driver (Pin 18) pulls
low when the interlock input is enabled. e output will be pulse-width-modulated at the coil holding voltage along with the main, reverse signal, and
electromagnetic brake contactor drivers, if the Holding Voltage parameter is
set to less than 100%.
If desired, the Auxiliary Contactor Dropout Delay parameter can be set
to allow the auxiliary contactor to remain engaged for up to 40 seconds after
the interlock signal has been disabled. If the delay function is used, the auxiliary
contactor and the coil return (Pin 9) must both be wired to KSI rather than
the interlock input. is alternative wiring is shown in Figure 12.
Reverse Signal Driver
e reverse signal driver (Pin 19) pulls low when the vehicle is moving in the
reverse direction, either in drive or in braking mode. is driver is designed
to drive a reverse signal beeper or warning lamp that operates when one input
is pulled low. e output will be pulse-width-modulated at the coil holding
voltage along with the main, auxiliary, and electromagnetic brake contactor
drivers, if the holding voltage parameter is set to less than 100%.
Curtis 1244 Manual, Rev. E
17
2 — INSTALLATION & WIRING: Contactor Drivers
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12 11 10 9 8 7 6 5 4 3 2 1
Pin 20
Pin 19
Pin 18
Pin 17
Pin 9
Pin 2
Pin 1
Electromagnetic Brake
Reverse Signal
Auxiliary Contactor
Main Contactor
Coil Return
Interlock Input
KSI Input
PIN KEY
MAIN
CONTACTOR
COIL
KEYSWITCH
+
ELECTROMAGNETIC BRAKE
CONTACTOR
COIL
INTERLOCK
AUXILIARY
CONTACTOR
COIL
REVERSE SIGNAL
CONTACTOR
COIL
B-
Fig. 12 Wiring for main,
auxiliary, reverse signal,
and electromagnetic brake
contactor coils, using the
interlock and dropout delay
functions.
Electromagnetic Brake Driver
e electromagnetic brake driver (Pin 20) pulls low when the controller receives
a throttle request or detects that the vehicle is still in braking mode. If desired,
the Brake Delay parameter can be set to allow the brake to remain disengaged
for up to 5 seconds after braking to neutral has been completed. If the delay
function is used, the brake driver and the coil return (Pin 9) must both be
wired to KSI rather than the interlock input. is alternative wiring is shown
in Figure 12.
time begins when the throttle is returned to neutral and the PWM output decelerates to zero. e output will be pulse-width-modulated at the coil holding
voltage along with the main, auxiliary, and reverse signal contactor drivers, if
the holding voltage parameter is set to less than 100%.
18
If the rottle Braking parameter has been set to zero, the brake delay
Curtis 1244 Manual, Rev. E
2 — INSTALLATION & WIRING: Misc. Features
14 1315161718192021222324
12 11 10 9 8 7 6 5 4 3 2 1
Pin 22
Pin 7
Emergency Reverse Check
Emergency Reverse
PIN KEY
+
EMERGENCY
REVERSE
emergency reverse wiring check (optional)
B-
WIRING: Pedal Switch
When the Pedal Switch option is enabled, controller output is possible only when
the pedal input (Pin 8) is pulled to B+. is feature allows a switch connected to
the throttle mechanism to guarantee zero controller output when the operator
releases the throttle. is adds a safety feature to protect against throttle failures
that cause controller output when the throttle is in neutral.
Alternatively, the pedal input can be wired into the brake pedal circuit to
automatically force zero controller output when the brake pedal is depressed,
regardless of throttle request.
WIRING: Hour Meter
e hour meter output (Pin 12) pulls to B+ to enable an hour meter whenever
current is owing in the motor. is allows accurate accumulation of vehicle
operating hours. e output is current limited to 20 mA, and is compatible with
Curtis 700 and 800 series hour meters. For wiring, consult the documentation
supplied with the hour meter.
Fig. 13 Wiring for emer-
gency reverse (applicable to
walkie vehicles only).
WIRING: CAN Bus Interface
Refer to the Curtis CAN Protocol Document for information about the CAN
Bus interface.
WIRING: Emergency Reverse
If you are installing a 1244 controller in a walkie vehicle, the emergency reverse
switch should be wired to Pin 7, as shown in Figure 13.
Curtis 1244 Manual, Rev. E
gency reverse input is pulled to B+ by closing the emergency reverse switch.
After the emergency reverse switch is released, normal controller operation is
Emergency reverse is activated when the keyswitch is On and the emer-
19
2 — INSTALLATION & WIRING: Misc. Features
not resumed until neutral (no direction) is selected or until the interlock switch
CAUTION
☞
is cycled.
operation of the emergency reverse feature. e forward and reverse switches
and the
away from the operator when the emergency reverse button is pressed.
An optional wire connected directly to the emergency reverse switch
provides for broken wire protection when that feature is enabled by the OEM.
e emergency reverse check feature periodically pulses the emergency reverse
circuit to check for continuity in the wiring. If there is no continuity, controller
output is inhibited until the wiring fault is corrected. e emergency reverse
wiring check wire (see dotted line in Figure 13) should be connected to the
emergency reverse switch terminals and to Pin 22.
For information about the emergency reverse parameters, see Section 3:
Programmable Parameters.
CAUTION: e polarity of the F1 and F2 connections will aect the
F1 and F2 connections must be configured so that the vehicle drives
20
Curtis 1244 Manual, Rev. E
2 — INSTALLATION & WIRING: Switches, etc.
CONTACTOR, SWITCHES, and OTHER HARDWARE
Main Contactor
A main contactor is recommended for use with any 1244 controller. A main
contactor allows the controller and motor to be disconnected from the battery. is provides a significant safety feature in that the battery power can be
removed from the drive system if a controller or wiring fault results in battery
power being applied to the motor.
A single-pole, single-throw (SPST) contactor with silver-alloy contacts
is recommended for use as the main contactor. It is not necessary to specify
the coils at the nominal battery pack voltage as long as the Contactor Pull-In
Voltage and Contactor Holding Voltage are programmed to accommodate
the coil’s voltage rating—see Section 3, page 46. e contactor coil should be
specified with a continuous rating if the Holding Voltage parameter is to be
set at 100%. Intermittent duty coils can be specified if they are used with appropriate Holding Voltage values.
Keyswitch and Interlock Switch
e vehicle should have a master on/o switch to turn the system o when
not in use. e keyswitch input provides logic power for the controller. e
interlock switch provides a safety interlock to prevent operation when a mechanical brake is engaged or to ensure operator presence before the vehicle is
allowed to move. e keyswitch and interlock switch provide current to drive
the various contactor coils as well as the controller’s internal logic circuitry and
must be rated to carry these currents.
Forward, Reverse, Mode Select, and Pedal Switches
ese input switches can be any type of single-pole, single-throw (SPST) switch
capable of switching the battery voltage at 25 mA.
Reverse Polarity Protection Diode
For reverse polarity protection, a diode should be added to the control circuit.
is diode will prohibit main contactor operation and current ow if the battery
pack is accidentally wired with the B+ and B- terminals reversed. It should be
sized appropriately for the maximum contactor coil and fault diode currents
required from the control circuit. e reverse polarity protection diode should
be wired as shown in the standard wiring diagram (Figure 3, page 8).
Curtis 1244 Manual, Rev. E
21
2 — INSTALLATION & WIRING:
Switches, etc.
Circuitry Protection Devices
To protect the control circuitry from accidental shorts, a low current fuse (appropriate for the maximum current draw) should be connected in series with
the battery feed to the keyswitch. Additionally, a high current fuse should be
wired in series with the main contactor to protect the motor, controller, and
batteries from accidental shorts in the power system. e appropriate fuse for
each application should be selected with the help of a reputable fuse manufacturer or dealer. e standard wiring diagram (Figure 3, page 8) shows the
recommended location for each fuse.
Mode Select Switch Operation
e two mode select switches (Mode Select 1 and Mode Select 2) together
define the four operating modes. e switch combinations are shown in Table 2.
Wiring for the mode select switches is shown in the standard wiring diagram
(Figure 3, page 8).
Table 2 MODE SELECTION
MODE MODE
MultiMode™ 1 OPEN OPEN
MultiMode™ 2 CLOSED OPEN
MultiMode™ 3 OPEN CLOSED
MultiMode™ 4 CLOSED CLOSED
OPERATING MODE SELECT SELECT
SWITCH 1 SWITCH 2
22
Curtis 1244 Manual, Rev. E
3
3 — PROGRAMMABLE PARAMETERS
PROGRAMMABLE PARAMETERS
e 1244 controller has a number of parameters that can be programmed by
means of a 1313 handheld programmer or 1314 PC Programming Station.
ese programmable parameters allow the vehicle’s performance characteristics
to be customized to fit the needs of individual vehicles or vehicle operators.
Each controller is shipped with the parameter settings specified by the
OEM. For each programmable parameter, the specification process includes
designating whether it is to have User or OEM-only access rights. e OEM
specifies which—if any—parameters the user (dealer, distributor, etc.) will be
able to adjust. Accordingly, Curtis oers two versions of the programmers: for
example, the 1313-1109 is the User handheld programmer (which can adjust
only those parameters with User access rights) and the 1313-4409 is the OEM
programmer (which can adjust all the programmable parameters).
e MultiMode™ feature of these controllers allows operation in four
distinct modes. ese modes can be programmed to provide four dierent
sets of operating characteristics, which can be useful for operating in dierent
conditions—such as slow precise indoor maneuvering in one mode; faster,
long distance, outdoor travel in another mode; and application-specific special
conditions in the remaining two modes.
Eight parameters can be configured independently in the four modes:
— acceleration rate (M1–M4)
— braking rate (M1–M4)
— maximum speed (M1–M4)
— creep speed (M1–M4)
— throttle map (M1–M4)
— throttle braking percent (M1–M4)
— drive current limit (M1–M4)
— braking current limit (M1–M4).
Controllers can be factory-set to allow only one mode of operation if a
MultiMode™ system is not desirable for the application—see Section 4. It is
not necessary to have all eight MultiMode™ parameters on or o together; one
or any combination of these parameters can be specified as single-mode and
the others specified as MultiMode™.
Curtis 1244 Manual, Rev. E
23
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