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Contents : MANUAL 1209B/1221B 1221C/1231C MOTOR CONTROLLERS 1999 CURTIS INSTRUMENTS INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. CURTIS PMC 235 East Airway Boulevard Livermore California 94568 USA Tel: 925-961-1088 Fax: 925-961-1099 www.curtisinst.com 1209B/1221B/1221C/1231C Manual p/n 98827 Rev. D: August 1999 1209B / 1221B / 1221C / 1231C Manual p/n 98827 Rev. D: August 1999 1999 CURTIS INSTRUMENTS INC. This electronic version of the 1209B/1221B/1221C/1231C manual is offered as a convenience to our customers. You may download any or all of it. If you would like a hard copy of the published manual please order it by part number from the Curtis office nearest you. The electronic version of the manual is identical to the printed version published in August 1999. 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 s CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 USA 925-961-1088 FAX 925-961-1099 s ADDITIONAL OFFICES located in Bulgaria China England France Germany India Italy Japan Netherlands Puerto Rico Russia Sweden and Switzerland CONTENTS CONTENTS 1. 2. OVERVIEW ....................................................................... 1 HARDWARE INSTALLATION ....................................... 3 Controller .................................................................... 3 Throttle ........................................................................ 5 Other Hardware ........................................................... 8 Main contactor ................................................... 10 Forward/reverse contactors .................................. 11 Forward/reverse switches ..................................... 11 Keyswitch and interlocks ..................................... 11 Keyswitch relay ................................................... 11 Polarity protection diode ..................................... 12 Control wiring fuse ............................................. 12 Power wiring fuse ................................................ 12 WIRING ........................................................................... 13 Connections: Low Current ......................................... 13 Connections: High Current ....................................... 13 Wiring: Typical Installation ....................................... 14 KSI wiring .......................................................... 15 Forward/reverse wiring ........................................ 16 Plug braking ................................................ 16 Freewheeling ................................................ 16 Throttle wiring ................................................... 17 Standard potbox wiring ............................... 17 Pots for twist-grip throttles .......................... 18 Electronic throttle wiring ............................. 19 Reduced speed operation ............................. 20 Throttle ramp shaping ................................. 21 Installation Checkout ................................................. 22 3. 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 Curtis PMC 1209B/1221B/1221C/1231C Manual iii CONTENTS 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 4. MAINTENANCE AND ADJUSTMENT ....................... 24 Controller .................................................................. 24 Potbox ........................................................................ 25 TROUBLESHOOTING AND BENCH TESTING ....... 27 Operational Notes ...................................................... 27 In-Vehicle Diagnostic Tests (Troubleshooting) .......... 28 Bench Testing ............................................................ 34 GLOSSARY: FEATURES AND FUNCTIONS .............. 37 5. 6. APPENDIX A APPENDIX B APPENDIX C Functional Description ................................ A-1 Pulse Width Modulation ............................. B-1 Electrical Specifications ................................ C-1 Curtis PMC 1209B/1221B/1221C/1231C Manual iv FIGURES FIGURES FIG. 1: Curtis PMC 1209B full-feature motor controller ......................................................... 1 2: Mounting dimensions Curtis PMC 1209B/1221B/1221C controllers ........... 3 3: Mounting dimensions Curtis PMC 1231C controller ................................... 4 4: Mounting dimensions Curtis PMC potboxes PB-5 -6 -9 and -10 ............... 6 5: Mounting dimensions Curtis PMC footpedal ........... 6 6: Mounting dimensions Curtis electronic throttle (ET series) ........................... 7 7: Typical installation 1209B/1221B/1221C controllers ............................... 8 8: Typical installation 1231C controller ........................ 9 9: Basic wiring configuration 1209B/1221B/1221C controllers ............................. 14 FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. 10: Basic wiring configuration 1231C controller ........... 15 11: Control wiring for inhibiting plug braking in order to allow freewheeling .................................. 17 12: Standard throttle pot 0 5k ................................... 17 13: Bi-directional twist-grip throttle with a standard 20 k pot and a controller with the optional 5k 0 throttle input .................... 18 FIG. FIG. Curtis PMC 1209B/1221B/1221C/1231C Manual v

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