Page 1
Manual
Model 1253
Hydraulic Pump Motor Controller
Read Instructions Carefully!
Specications are subject to change without notice.
© 2015 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. 38329 Rev F 2/15
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
Page 2
Page 3
Blue Ox Rev. A, draft #1 [3 August 2007]
CONTENTS
CONTENTS
1. OVERVIEW ..............................................................................1
2. INSTALLATION AND WIRING ...........................................3
Mounting the Controller .....................................................3
Low Current Connections....................................................5
High Current Connections ..................................................6
Wiring: Standard Configuration..........................................7
Wiring: rottles ...............................................................11
Contactor, Switches, and Other Hardware .........................13
3. PROGRAMMABLE PARAMETERS .....................................15
Speed Parameters................................................................16
Maximum Speed, SS1–SS4 .........................................16
rottle Maximum Speed ............................................16
Minimum Speed ..........................................................16
Acceleration Rate .........................................................16
rottle Parameters ............................................................16
rottle Type ...............................................................16
rottle Deadband ......................................................17
rottle Maximum ......................................................18
rottle Map ...............................................................20
Final Speed Request Parameters .........................................22
SS Add Mode ..............................................................22
Final Add Mode ..........................................................23
SS High Speed On ......................................................24
Fault Parameters .................................................................25
Lift Lockout Type ........................................................25
Lift Lockout, SS1–SS4 ................................................25
Lift Lockout, rottle ..................................................25
rottle Fault Detection ..............................................26
Startup Lockout...........................................................26
Undervoltage Parameters ....................................................27
Low Voltage Cutback ..................................................27
Low Voltage Cutback Rate ..........................................27
Contactor Control Parameters ...........................................27
Pump Contactor Control ............................................27
Contactor Pull-in Voltage ............................................27
Contactor Holding Voltage..........................................27
SS4 Delay ....................................................................28
Interlock Delay ............................................................28
Precharge .....................................................................28
Precharge Delay ...........................................................28
Curtis 1253 Manual, Rev. F
iii
Page 4
CONTENTS
Current Limit Parameter ....................................................29
Main Current Limit (x10A) .........................................29
4. INSTALLATION CHECKOUT ............................................30
5. DIAGNOSTICS AND TROUBLESHOOTING ..................32
Programmer Diagnostics ....................................................32
LED Diagnostics ................................................................34
6. MAINTENANCE ...................................................................35
appendix a Vehicle Design Considerations
appendix b Programming Devices and Menus
appendix c Specifications, Curtis 1253 Controller
iv
Curtis 1253 Manual, Rev. F
Page 5
FIGURES
. 1: Curtis 1253 hydraulic system controller ................................... 1
. 2: Mounting dimensions, Curtis 1253 controller ........................ 3
. 3a: Standard wiring configuration,
using Curtis 803 gauge for lift lockout ..................................... 7
. 3b: Standard wiring configuration,
using Curtis 906 gauge for lift lockout ..................................... 8
. 3c: Standard wiring configuration,
using Curtis 841 “Superspy” for lift lockout............................. 9
. 3d: Standard wiring configuration,
using Curtis enGage™ IV for lift lockout ............................... 10
FIGURES
. 4: Wiring for 2-wire 5kΩ–0 potentiometer (“Type 0”) .............. 12
. 5: Wiring for 2-wire 0–5kΩ potentiometer (“Type 1”) .............. 12
. 6: Wiring for single-ended 0–5V input (“Type 2”) .................... 13
. 7: Wiring for single-ended 1–10kΩ 3-wire pot (“Type 3”) ........ 13
. 8: Eect of adjusting the throttle deadband parameter .............. 17
. 9: Eect of adjusting the throttle max parameter ....................... 19
. 10: rottle maps for controller
with maximum speed set at 100% ........................................ 20
. 11: rottle maps for controller
with maximum speed set at 80% .......................................... 21
. 12: Inuence of various parameters on controller
output response to throttle demand ...................................... 21
. 13: Speed conditioning ............................................................... 23
. 14: SS High Speed On speed conditioning ................................. 24
Blue Ox Rev. A, draft #1 [3 August 2007]
. 15: Bench test setup .................................................................... 31
Curtis 1253 Manual, Rev. F
v
Page 6
TABLES
TABLES
1: rottle wiper input (threshold values) ................................ 11
2: Programmable throttle input signal types ............................. 17
3: Programmable lift lockout signal types ............................... 25
4: Precharge function and fault detection................................. 28
5: Troubleshooting chart .......................................................... 33
6: Status LED fault codes ....................................................... 34
C-1: Specifications, 1253 controller .......................................... C-1
vi
Curtis 1253 Manual, Rev. F
Page 7
OVERVIEW
1 — OVERVIEW
1
Fig. 1 Curtis 1253
hydraulic pump motor
controller.
e Curtis 1253 provides a cost-eective solution for control of high power
DC series-wound hydraulic pump motors. Its system integration features are
designed primarily for Class I and Class II material handling vehicles. Typical
applications include the pump systems of material handling trucks (counterbalance trucks, reach trucks), aerial lift platforms (scissor lifts, articulating/
telescoping booms), and other industrial vehicles.
e 1253 accepts inputs from up to four Speed Select switches and also
from an analog throttle. Its internal microprocessor-based logic controller provides maximum exibility at minimum cost. Its performance characteristics can
be tailored through an array of programmable parameters.
e 1253 controller is fully programmable through a Curtis handheld
programmer or PC Programming Station. e programming device provides
diagnostic and test capability in addition to conguration exibility.
Like all Curtis motor controllers, the 1253 oers superior operator control of
motor speed and torque.
Blue Ox Review of wiring diagrams [24 July 2007]
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
Smooth and Quiet Control
✓ Programmable acceleration rates provide smooth application
✓ 15.6 kHz PWM frequency for near-silent operation.
of pump motor torque
1
Page 8
1 — OVERVIEW
Programmable Flexibility
✓ Easily programmable through a Curtis programming device
✓ Four Speed Select inputs (SS1–SS4) with individually programmable
top speeds
Programmable throttle input for precise speed control with a variety
✓
of signal sources
Programmable turn-o delay allows SS4 to be used for power steering
✓
✓ Adjustable minimum speed setting to ensure pump lubrication
and to maintain steering system pressure
SS High Speed On mode enhances speed stability (1253-4804 only).
✓
Robust Safety and Reliability
✓ Interlock feature disables the controller when operator is not present
✓ Programmable startup lockout prevents inadvertent operation
✓ Seamless integration with Curtis gauges (models 803, 841, 906, and
enGage™ IV) for lift lockout function
Lift lockout disables the controller at low battery state of charge
✓
✓ Redundant watchdog timer circuits ensure proper software operation
✓ External Status LED output for easy troubleshooting
✓ Short-circuit protection on main contactor driver
✓ Precharge control prevents pitting of contactor tips at startup
✓ ermal cutback provides protection to the controller
✓ Rugged housing meets IP54 environmental ratings
✓ Full-power operation over the -40°C – 80°C heatsink temperature
range.
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.
2
Curtis 1253 Manual, Rev. F
Page 9
2
2 — INSTALLATION & WIRING: Controller
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
e 1253 controller can be oriented in any position, and meets the IP54 ratings
for environmental protection against dust and water. However, the location
should be carefully chosen to keep the controller clean and dry. If a clean,
dry mounting location cannot be found, a cover must be used to shield the
controller from water and contaminants.
e controller’s outline and mounting hole dimensions are shown in
Figure 2. When selecting the mounting position, be sure to also take into
consideration that access is needed at the end of the controller to plug the
programmer into its connector.
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
7.2 (0.28) dia.
8.5 (0.33) dia.
25 ×19 × 3
(1.0 × 0.75 × 0.12
31.3 (1.23)
16 (0.63)
146.0 (5.75)
)
130.3 (5.12)
133.3 (5.25)
196 (7.72)
Blue Ox Review of wiring diagrams [24 July 2007]
Blue Ox Rev. A, draft #1 [3 August 2007]
Dimensions in millimeters and (inches)
Fig. 2 Mounting dimensions, Curtis 1253 controller.
Curtis 1253 Manual, Rev. F
5.0
(0.20)
77 (3.03)
3
Page 10
2 — INSTALLATION & WIRING: Controller
provided. Although not usually necessary, a thermal joint compound can be
used to improve heat conduction from the controller heatsink to the mounting
surface.
end product to ensure that its EMC performance complies with applicable
regulations; suggestions are presented in Appendix A.
You will need to take steps during the design and development of your
CAUTION
☞
Working on electrical systems is potentially dangerous. You should
protect yourself against uncontrolled operation, high current arcs, and
outgassing from lead acid batteries:
UNCONTROLLED OPERATION — Some conditions could cause the hydraulic
pump system to run out of control. Disconnect the motor or make sure
the pump system has enough room to operate before attempting any
work on the motor control circuitry. Note: If the wrong throttle input
signal type is selected with the programming device, the pump system
may suddenly begin to operate.
HIGH CURRENT ARCS — 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.
4
Curtis 1253 Manual, Rev. F
Page 11
2 — INSTALLATION & WIRING: Controller
LOW CURRENT CONNECTIONS
Two low current connectors are built into the 1253 controller. ey are located
on the end of the controller:
J1
17
12
6
13
24
J2
e 12-pin connector (J1) provides the logic control connections. e mating
connector is a 12-pin Molex Mini-Fit Jr. connector part number 39-01-2125
using type 5556 terminals.
1 2 3 4 5 6
7 8 9 10 11 12
J1
J2-1 Rx Data
J2-2 B-
J2-3 Tx Data
J2-4 +15V
21
43
J2
: e 1311 handheld programmer has
Blue Ox Review of wiring diagrams [24 July 2007]
Blue Ox Rev. A, draft #1 [3 August 2007]
been superseded; if you
are using a more recent
model, please refer to its
documentation.
J1-1 Keyswitch Input (KSI) input and return for main contactor coil
J1-2 Pot High +5V supply
J1-3 Pot Wiper pot wiper input (or 5V throttle input)
J1-4 Pot Low to ground through 511 ohm resistor
J1-5 Interlock input from operator-present switch, tied to B+
J1-6 Status LED LED driver low-side output
J1-7 SS1 Speed Select 1 input
J1-8 SS2 Speed Select 2 input
J1-9 SS3 Speed Select 3 input
J1-10 SS4 Speed Select 4 input
J1-11 Lift Lockout input to the inhibit lift feature
J1-12 Contactor main contactor coil driver low-side output
e 4-pin connector (J2) is for the programmer—either the 1311 handheld
programmer or the 1314 PC Programming Station. A complete programmer
kit with the appropriate connecting cable can be ordered:
Curtis p/n 168961101 for the User Programmer (model 1307M-1101)
Curtis p/n 168962101 for the OEM Programmer (model 1307M-2101).
If a handheld programmer is already available but has an incompatible cable,
the 1253 mating cable can be ordered as a separate part: Curtis
p/n 16185.
With a 1314 PC programming station, the 1309 interface box and cable connect
the computer to the controller:
p/n 117465704 1314-1101, 1314 PC Programming Station (User) CD-ROM
p/n 117465707 1314-4401, 1314 PC Programming Station (OEM) CD-ROM
p/n 16994001 1309 Interface Box
p/n 16185 Molex cable for 1309 Interface Box.
Curtis 1253 Manual, Rev. F
5
Page 12
2 — INSTALLATION & WIRING: Controller
HIGH CURRENT CONNECTIONS
ree tin-plated solid copper bus bars are provided for the high current connections to the battery
WIRING: Standard Conguration
(B+ and B‑) and the motor armature (M‑).
B- B+
M-
CAUTION
☞
Figure 3 shows the typical wiring configuration for most applications. e interlock switch is typically a seat switch, tiller switch, or foot switch. e throttle
shown is a 3-wire pot; other types of throttles can also be used.
Lift lockout can be provided through any of four Curtis gauges:
(a) Curtis 803
(b) Curtis 906
(c) Curtis 841 “Superspy”
(d) Curtis enGage™ I V.
As each of these gauges is wired somewhat dierently to provide lift lockout,
four individual wiring diagrams are included (Figs. 3a, 3b, 3c, 3d).
Power Wiring
Motor wiring is straightforward, with the field’s S1 connection going to the
controller’s
ler’s
M‑ bus bar.
Control Wiring
B+ bus bar and the armature’s A2 connection going to the control-
e main contactor coil should be wired directly to the controller as shown in
Figure 3. e controller uses the main contactor coil driver output to remove
power from the controller and pump motor in the event of various faults. If
the main contactor coil is not wired to Pin 12, the controller will not be
able to open the main contactor in serious fault conditions.
6
Curtis 1253 Manual, Rev. F
Page 13
1311 PROGRAMMER
J2-1
J2-2
J2-3
J2-4
J1-2
RxDATA
GROUND (B-)
TxDATA
+15V
POT HIGH
INTERLOCK
SS1
SS2
SS3
SS4
STATUS
J1-5
INTERLOCK
J1-7
J1-8
J1-9
J1-10
J1-6
2 — INSTALLATION & WIRING: Controller
SPEED SELECT SWITCHES
SS1 SS2 SS3 SS4
STATUS
THROTTLE
POT
J1-3
J1-4
POT WIPER
POT LOW
LIFT LOCKOUT
1253 CONTROLLER
KSI
CONTACTOR
B+
M-
B-
J1-1
J1-12
J1-11
KEYSWITCH
CONTACTOR
S1
803-8
803-5
M
A2
803-3
58
14
803-4
BATTERY
CURTIS 803
Lift lockout is activated when the 803’s internal
relay between pins 3 and 4 is opened at 80%
battery discharge.
LOCKOUT TYPE should be programmed to 1.
Fig. 3a Standard wiring configuration,
Curtis 1253 controller with Curtis 803 providing lift lockout.
Blue Ox Review of wiring diagrams [24 July 2007]
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
7
Page 14
1311 PROGRAMMER
J2-1
J2-2
J2-3
J2-4
J1-2
RxDATA
GROUND (B-)
TxDATA
+15V
POT HIGH
INTERLOCK
SS1
SS2
SS3
SS4
STATUS
J1-5
INTERLOCK
J1-7
J1-8
J1-9
J1-10
J1-6
2 — INSTALLATION & WIRING: Controller
SPEED SELECT SWITCHES
SS1 SS2 SS3 SS4
STATUS
THROTTLE
POT
J1-3
J1-4
POT WIPER
POT LOW
LIFT LOCKOUT
1253 CONTROLLER
KSI
CONTACTOR
B+
M-
B-
J1-1
J1-12
J1-11
KEYSWITCH
CONTACTOR
S1
906-1
M
1
A2
906-3
2
4
3
906-2
BATTERY
CURTIS 906
Lift lockout is activated when pin 3 of the 906
drops from 5 V to 0 V at 80% battery discharge.
LOCKOUT TYPE should be programmed to 0.
Fig. 3b Standard wiring configuration,
Curtis 1253 controller with Curtis 906 providing lift lockout.
8
Curtis 1253 Manual, Rev. F
Page 15
1311 PROGRAMMER
J2-1
J2-2
J2-3
J2-4
J1-2
RxDATA
GROUND (B-)
TxDATA
+15V
POT HIGH
INTERLOCK
SS1
SS2
SS3
SS4
STATUS
J1-5
INTERLOCK
J1-7
J1-8
J1-9
J1-10
J1-6
2 — INSTALLATION & WIRING: Controller
SPEED SELECT SWITCHES
SS1 SS2 SS3 SS4
STATUS
THROTTLE
POT
J1-3
J1-4
POT WIPER
POT LOW
LIFT LOCKOUT
1253 CONTROLLER
KSI
CONTACTOR
B+
M-
B-
J1-1
J1-12
J1-11
KEYSWITCH
CONTACTOR
S1
841-5
841-6
M
A2
841-3
58
14
841-4
BATTERY
CURTIS 841 “Superspy”
Lift lockout is activated when the 841’s internal
relay between pins 3 and 4 is opened at 80%
battery discharge.
LOCKOUT TYPE should be programmed to 1.
Fig. 3c Standard wiring configuration,
Curtis 1253 controller with Curtis 841 “Superspy” providing lift lockout.
Blue Ox Review of wiring diagrams [24 July 2007]
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
9
Page 16
1311 PROGRAMMER
J2-1
J2-2
J2-3
J2-4
J1-2
RxDATA
GROUND (B-)
TxDATA
+15V
POT HIGH
INTERLOCK
SS1
SS2
SS3
SS4
STATUS
J1-5
INTERLOCK
J1-7
J1-8
J1-9
J1-10
J1-6
2 — INSTALLATION & WIRING: Controller
SPEED SELECT SWITCHES
SS1 SS2 SS3 SS4
STATUS
THROTTLE
POT
J1-3
J1-4
POT WIPER
POT LOW
LIFT LOCKOUT
1253 CONTROLLER
KSI
CONTACTOR
B+
M-
B-
J1-1
J1-12
J1-11
KEYSWITCH
CONTACTOR
S1
enGage IV MOSFET Output
enGage IV J1-1
M
A2
11
1
20
10
J1
J2
enGage IV J1-2
BATTERY
CURTIS enGageTM IV
Lift lockout is activated when the enGageTM IV’s
MOSFET Output is pulled Low. The MOSFET Output
is at pin J1-14, -15, or -16, depending on the
gauge’s configuration.
LOCKOUT TYPE should be programmed to 0.
Fig. 3d Standard wiring configuration,
Curtis 1253 controller with Curtis enGage™ IV providing lift lockout.
10
Curtis 1253 Manual, Rev. F
Page 17
2 — INSTALLATION & WIRING: Throttles
WIRING: Throttles
Various throttles can be used with the 1253 controller. ey are categorized as
one of four types in the Program Menu.
Type 0: two-wire 0–5kΩ potentiometer throttles
Type 1: two-wire 5kΩ–0 potentiometer throttles
Type 2: single-ended 0–5V throttles
Type 3: single-ended three-wire 1kΩ–10kΩ pot throttles.
Table 1 summarizes the operating specifications for these four throttle types.
Table 1 WIPER INPUT: THROTTLE THRESHOLD VALUES
MINIMUM THROTTLE THROTTLE MAXIMUM
THROTTLE THROTTLE DEADBAND STARTUP MAX THROTTLE
TYPE PARAMETER FAULT (0% speed request) LOCKOUT (100% modulation) FAULT
0 Wiper Voltage — 0.6 V out of deadband 4.5 V 5.7 V
Wiper Resistance — 0 kΩ 5.0 kΩ 7.5 kΩ
1 Wiper Voltage — 4.5 V out of deadband 0.6 V 5.7 V
Wiper Resistance — 5.0 kΩ 0 kΩ 7.5 kΩ
2 Wiper Voltage — 0 V out of deadband 5.0 V 5.5 V
Wiper Resistance — — — —
3 Wiper Voltage 0.4 V 0.5 V out of deadband 5.0 V 5.5 V
Wiper Resistance — 0 kΩ 5.0 kΩ —
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 17 and 18.
The startup lockout threshold for all throttle types is set by the Throttle Deadband.
For potentiometers, the 1253 provides complete throttle fault protection that
meets all applicable EEC regulations. For voltage throttles, the 1253 protects
against out-of-range wiper voltages (see Table 1), but does not detect wiring
faults; it is therefore the responsibility of the OEM to provide full throttle fault
protection in vehicles using voltage throttles.
Wiring for the most common throttles is described below. If the throttle
you are planning to use is not covered, contact the Curtis office nearest you.
Note: In the text, throttles are identified by their nominal range (e.g.,
5kΩ–0 pot) and not by their actual operating range.
Blue Ox Review of wiring diagrams [24 July 2007]
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
11
Page 18
2 — INSTALLATION & WIRING: Throttles
5kΩ–0
0–5k
0–5kΩ Throttle (“Type 0”)
e 0–5kΩ throttle (“Type 0” in the Program Menu) is a 2-wire resistive throttle
that connects between the Pot Wiper and Pot Low pins, as shown in Figure 4.
Zero speed corresponds to 0Ω measured between the two pins and full speed
corresponds to 5 kΩ.
Fig. 4 Wiring for
0–5kΩ throttle (“Type 0”).
Fig. 5 Wiring for 5k
Ω
–0
throttle (“Type 1”).
Pot Wiper input (Pin J1-3)
FASTER
Pot Low input (Pin J1-4)
Ω
If the total resistance between the Pot Wiper and Pot Low pins is greater
than 7.5 kΩ, the controller’s upper fault limit will be exceeded (see Table 1) and
the throttle’s input value will be zeroed. is provides broken wire protection,
and also serves as an indication that the potentiometer’s resistance has increased
beyond the acceptable range and that the pot therefore needs to be replaced.
5kΩ–0 Throttle (“Type 1”)
e 5kΩ–0 throttle (“Type 1” in the Program Menu) is a 2-wire resistive throttle
that connects between the Pot Wiper and Pot Low pins, as shown in Figure 5.
Zero speed corresponds to a nominal 5kΩ measured between the two pins and
full speed corresponds to 0Ω.
Pot Wiper input (Pin J1-3)
FASTER
Pot Low input (Pin J1-4)
than 7.5 kΩ, the controller’s upper fault limit will be exceeded (see Table 1) and
the throttle’s input value will be zeroed. is provides broken wire protection,
and also serves as an indication that the potentiometer’s resistance has increased
beyond the acceptable range and that the pot therefore needs to be replaced.
12
If the total resistance between the Pot Wiper and Pot Low pins is greater
Curtis 1253 Manual, Rev. F
Page 19
2 — INSTALLATION & WIRING: Switches, etc.
B-
Single-Ended 0–5V Voltage Source (“Type 2”)
With this throttle (“Type 2” in the Program Menu) the controller looks for
a voltage signal at the Pot Wiper pin. Zero speed corresponds to 0 V and full
speed to 5 V.
Fig. 6 Wiring for
0–5V throttles (“Type 2”).
Fig. 7 Wiring for 3-wire
potentiometer throttle
(“Type 3”).
+
0–5V input (Pin J1-3)
-
e active range for this throttle is from 0 V (at 0% rottle Deadband) to
5.0 V (at 100% rottle Max), measured relative to B-. e signal is measured
at the Pot Wiper pin. It is the responsibility of the OEM to provide appropriate
throttle fault detection for 0–5V throttles.
Single-Ended 1kΩ–10kΩ 3-wire pot (“Type 3”)
e 3-wire potentiometer is used in its voltage divider mode, with the voltage
source and return being provided by the 1253 controller. Pot High provides a
current limited 5V source to the pot, and Pot Low provides the return path.
Wiring is shown in Figure 7 and is also shown in the standard wiring diagrams,
Figure 3.
Pot High output (Pin J1-2)
FASTER
Pot Wiper input (Pin J1-3)
Blue Ox Review of wiring diagrams [24 July 2007]
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
1kΩ–10kΩ
Pot Low input (Pin J1-4)
When a 3-wire pot is used, the controller provides full fault protection.
Potentiometers with total resistance values between 1 kΩ and 10 kΩ can be used.
CONTACTOR, SWITCHES, and OTHER HARDWARE
Main Contactor
A main contactor should be used with the 1253 controller. Otherwise, the
controller’s fault detection will not be able to fully protect the controller and
hydraulic system from damage in a fault condition. e main contactor allows
the controller and motor to be disconnected from the battery. is provides a
significant safety feature, because it means the battery power can be removed
13
Page 20
2 — INSTALLATION & WIRING: Switches, etc.
from the hydraulic system if a controller or wiring fault results in battery power
being applied to the motor inappropriately.
e 1253 provides a low-side contactor coil driver (at Pin J1-12) for the
main contactor. e driver output is rated at 1 amp and is short-circuit protected.
It is recommended that a coil suppression diode be included, as shown in the
wiring diagrams. is protects the contactor coil driver from inductive voltage
kickback spikes when the contactor is turned o.
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, which is typically implemented as a seatswitch or a
hand/foot activated deadman switch, provides a safety interlock to ensure that
an operator is present in order for the system to run.
e keyswitch and interlock switch provide current to drive the main
contactor coil as well as the controller’s internal logic circuitry, and must be
rated to carry these currents.
Speed Select 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 current required from the
control circuit. e reverse polarity protection diode should be wired as shown
in the standard wiring diagrams (Figure 3).
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 diagrams (Figure 3) show the recommended
location for each fuse.
14
Curtis 1253 Manual, Rev. F
Page 21
3 — PROGRAMMABLE PARAMETERS
PROGRAMMABLE PARAMETERS
3
: e 1311 handheld programmer has
been superseded; if you
are using a more recent
model, please refer to its
documentation.
e 1253’s programmable parameters allow the pump system’s performance
characteristics to be customized to fit the needs of individual applications or
system operators. Programming can be done with a 1311 handheld programmer or a 1314 PC Programming Station. e discontinued 1307 handheld
programmer is also fully compatible with the 1253 controller.
Curtis oers two versions of the 1311 programmer: the 1311-1101 is the
User programmer (which can adjust only those parameters with User access
rights) and the 1311-4401 is the OEM programmer (which can adjust all the
parameters with User or OEM access rights). Similarly, the 1314 PC Programming Station software is available in two versions: 1314-1101 and 1314-4401.
See Appendix B for more information about the programmers.
In the following descriptions, the 1253’s parameters are arranged in groups.
e parameter names are listed here in the abbreviated forms that appear on
the handheld programmer’s 14-character LCD screen. Not all of these parameters are available on all controllers; the parameters for any given controller are
dependent on its specifications.
For a list of the parameters in the order in which they appear in the Program Menu, see Appendix B.
Speed Parameters
SPEED (SS1–SS4)
THRTL MAX SPD
MINIMUM SPEED
ACCEL RATE
Throttle Parameters
THROTTLE TYPE
THRTL DEADBAND
THROTTLE MAX
THROTTLE MAP
Final Speed Request Parameters
SS ADD MODE
FINAL ADD MODE
SS HIGH SPEED ON
Fault Parameters
LOCKOUT TYPE
LIFT LOCK (SS1–SS4)
THRTL LIFTLOCK
THRTL FAULT
STARTUP LOCK
Undervoltage Parameters
LOVOLT CUTBACK
LOVOLT CB RATE
Contactor Driver Parameters
CONTACT CNTRL
CONT PULL IN
CONT HOLDING
SS4 DELAY
INTERLOCK DLY
PRECHARGE
PRECHARGE DLY
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
Current Limit Parameter
MAIN C/L(x10A)
15
Page 22
3 — PROGRAMMABLE PARAMETERS: Speed and Throttle Parameters
Speed Parameters
e 1253 controller can accept inputs from up to four individual speed select
switches (SS1–SS4) and from an analog throttle. e controller adjusts the pump
motor’s PWM output in response to these inputs, using the algorithm prescribed by
the programmed acceleration rate to reach the appropriate maximum speed.
e programmed Minimum Speed and Acceleration Rate are in eect regardless
of whether the speed request comes from a speed select switch or a throttle.
SS1–SS4 SPEED
e SS Maximum Speed parameter defines the maximum allowed armature
PWM output of the pump motor. It can be set independently for up to four
individual speed select switches (i.e.,
speed parameter is adjustable from 0% to 100% of the full output.
THRTL MAX SPEED
e rottle Maximum Speed parameter defines the maximum allowed armature
PWM output in response to throttle input. e maximum speed parameter is
adjustable from 0% to 100% of the controller’s full output.
SS1 SPEED, SS2 SPEED, etc.). e maximum
MINIMUM SPEED
e Minimum Speed parameter defines the minimum allowed armature PWM
output of the pump motor, and is adjustable from 0 to 50% of the full output.
e minimum speed feature ensures that adequate pressure is maintained for
the power steering system and for pump lubrication.
ACCEL RATE
e Acceleration Rate parameter defines the time it takes for the controller
to accelerate from 0% output to 100% output when a speed select switch is
closed or a full throttle request is made. e acceleration rate is adjustable from
0.2 to 3.0 seconds.
Throttle Parameters
Most applications use a throttle to provide variable speed control of a specic hydraulic operation (e.g., lift, reach, tilt, shift, rotate). A throttle gives the operator
more exibility and control over performance than is provided by switch inputs.
THROTTLE TYPE
e 1253 controller accepts a variety of throttle inputs, including 5kΩ–0 and
0–5kΩ two-wire rheostats, 3-wire pots, and 0–5V throttles. e standard throttle
input signal type options—Types “0” through “3” in the Program Menu—are
16
Curtis 1253 Manual, Rev. F
Page 23
3 — PROGRAMMABLE PARAMETERS: Throttle Parameters
Deadband
Deadband
Deadband
Deadband
Deadband
Deadband
Deadband
Deadband
Deadband
listed in Table 2. Wiring information and performance characteristics for each
type are presented in Section 2.
If no throttle is used in the application, the throttle fault parameter (see
page 25) should be programmed O; otherwise the controller will register a
throttle fault.
Table 2 PROGRAMMABLE THROTTLE INPUT SIGNAL TYPES
THROTTLE
TYPE DESCRIPTION
0 0–5kΩ, 2-wire rheostat
1 5kΩ–0, 2-wire rheostat
2 single-ended 0–5V input)
3 single-ended 3-wire potentiometer (1kΩ to 10kΩ range)
Fig. 8 Eect of adjusting
the throttle deadband
parameter (throttle types 0
and 1).
Blue Ox Rev. A, draft #1 [3 August 2007]
THRTL DEADBAND
e rottle Deadband parameter defines the pot wiper voltage range the
controller interprets as neutral. Increasing the throttle deadband setting increases
the neutral range. is parameter is especially useful with throttle assemblies
that do not reliably return to a well-defined neutral point, because it allows the
0
0
1.0V
(500Ω)
0.6V
(0Ω)
0
0.6V
(0Ω)
0.6V
(0Ω)
0.6V
(0Ω)
Throttle Type 0 (0–5k
1.8V
(1.5kΩ)
Throttle Type 1 (5k
Ω)
Ω–0)
3.3V
(3.5kΩ)
4.1V
(4.5kΩ)
4.5V
(5.0kΩ)
4.5V
(5.0kΩ)
4.5V
(5.0kΩ)
4.5V
(5.0kΩ)
5V
5V
5V
30%
30%
10%
10%
0%
0%
30%
10%
0%
Curtis 1253 Manual, Rev. F
17
Page 24
3 — PROGRAMMABLE PARAMETERS: Throttle Parameters
5V
0
4.5V
(5.0kΩ)
30% Deadband
10% Deadband
0% Deadband
4.1V
(4.5kΩ)
3.3V
(3.5kΩ)
0.6V
(0Ω)
0.6V
(0Ω)
0.6V
(0Ω)
100%
Deadband
0%
1.0V
(500Ω)
1.8V
(1.5kΩ)
4.5V
(5.0kΩ)
4.5V
(5.0kΩ)
4.5V
(5.0kΩ)
5V
0
30% Deadband
10% Deadband
0% Deadband
5V
0
30% Deadband
10% Deadband
0% Deadband
Throttle Type 1 (5k
Ω–0)
Throttle Type 0 (0–5k
Ω)
0.6V
(0Ω)
Fig. 8, cont’d Eect of
adjusting the throttle
deadband parameter
0
0
Throttle Types 2 and 3 (0–5V and 3-wire pot)
(throttle types 2 and 3).
0.5V
1.5V
5V
5V
30% Deadband
30% Deadband
10% Deadband
10% Deadband
0% Deadband
0% Deadband
KEY
Neutral
deadband to be defined wide enough to ensure that the controller goes into
neutral when the throttle mechanism is released.
Examples of deadband settings (30%, 10%, 0%) are shown in Figure 8
for throttle types 0 through 3, using a nominal 5kΩ–0 potentiometer (where
applicable).
e programmer displays the throttle deadband parameter as a percentage
of the nominal wiper voltage range and is adjustable from 4% to 90%, in 1%
increments. e default deadband setting is 10%. e nominal wiper voltage
range depends on the throttle type selected. See Table 1 (page 11) for the characteristics of your selected throttle type.
THROTTLE MAX
e rottle Max parameter sets the throttle wiper voltage required to produce
100% controller output. Decreasing the throttle max setting reduces the wiper
voltage and therefore the full stroke necessary to produce full controller output.
is feature allows reduced-range throttle assemblies to be accommodated.
Examples are shown in Figure 9 for throttle types 0 through 3, using a
nominal 5kΩ potentiometer (where applicable). ese examples illustrate the
eect of three dierent max output settings (100%, 90%, 60%) on the fullstroke wiper voltage required to attain 100% controller output.
Controller
Notes: Voltages shown are at the pot wiper relative to B-.
For Types 0 and 1, the deadband points are defined in
terms of the nominal 5kΩ pot resistance. Using a pot
e programmer displays throttle max as a percentage of the throttle’s
active voltage range. e nominal voltage range depends on the throttle type
selected. See Table 1 (page 11) for the characteristics of your selected throttle
type. e throttle max parameter can be adjusted from 100% to 10%, in 1%
increments.
18
Curtis 1253 Manual, Rev. F
Page 25
Fig. 9 Eect of adjusting
the throttle max parameter.
3 — PROGRAMMABLE PARAMETERS: Throttle Parameters
0
1.0V
(0.5kΩ)
1.0V
(0.5kΩ)
Throttle Type 0 (0–5k
1.8V
(1.5kΩ)
1.8V
(1.5kΩ)
2.9V
(3.0kΩ)
Ω)
4.1V
(4.5kΩ)
4.1V
(4.5kΩ)
4.5V
(5.0kΩ)
5V
100% Throttle Max
30% Deadband
90% Throttle Max
30% Deadband
90% Throttle Max
10% Deadband
60% Throttle Max
10% Deadband
0
Throttle Type 1 (5k
Ω–0)
5V
100% Throttle Max
30% Deadband
0.6V
(0Ω)
3.3V
(3.5kΩ)
90% Throttle Max
30% Deadband
1.0V
(0.5kΩ)
3.3V
(3.5kΩ)
90% Throttle Max
10% Deadband
1.0V
(0.5kΩ)
4.1V
(4.5kΩ)
60% Throttle Max
10% Deadband
2.2V
(3.0kΩ)
0
Throttle Types 2 and 3 (0–5V and 3-wire pot)
4.1V
(4.5kΩ)
5V
100% Throttle Max
30% Deadband
1.5V
90% Throttle Max
30% Deadband
1.5V
4.5V
90% Throttle Max
10% Deadband
0.5V
4.5V
60% Throttle Max
10% Deadband
0.5V
3.0V
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
KEY
Notes: Voltages shown are at the pot wiper relative to B-.
19
Page 26
3 — PROGRAMMABLE PARAMETERS: Throttle Parameters
THROTTLE INPUT (percent of active range)
THROTTLE MAP
e rottle Map parameter modifies the response to the throttle input. is
parameter determines the controller output for a given amount of applied
throttle. Setting the throttle map parameter at 50% provides a linear output
response to throttle position. Values below 50% reduce the controller output
at low throttle requests, providing enhanced slow speed control. Values above
50% give the function a faster, jumpier feel at low throttle requests.
e throttle map can be programmed in 5% increments between 20%
and 80%. e number refers to the controller output at half throttle, as a
percentage of the throttle’s full active range. e throttle’s active range is the
voltage or resistance between the 0% output point (throttle deadband) and the
100% output point (throttle max). For example, if maximum speed is set at
100%, a throttle map setting of 50% will give 50% output at half throttle. e
50% setting corresponds to a linear response. Six throttle map profiles (20, 30,
40, 50, 60, and 80%) are shown as examples in Figure 10, with the maximum
speed set at 100%.
Fig. 10 rottle maps for
controller with maximum
speed set at 100%.
100
90
80
70
60
50
40
30
20
10
CONTROLLER OUTPUT (PWM percent)
0
THROTTLE MAP
80%
60%
50%
40%
30%
20%
SPEED PARAMETER
100% Thrtl Max Speed
100908070605040302010 0
profiles with the max speed reduced from 100% to 80% are shown in Figure 11.
e throttle map is always a percentage of the controller’s output range. So, in
these examples, the throttle map is a percentage of the 0–80% output range; a
40% throttle map setting will give 32% output at half throttle (40% of 80% =
32%). Controller output will begin to increase as soon as the throttle is rotated
out of its normal neutral range (deadband). Controller output will continue to
increase, following the curve defined by the throttle map setting, as the throttle
input increases and will reach maximum output when the throttle input enters
the upper deadband (crosses the throttle max threshold).
20
Lowering the max speed limits the controller’s output range. rottle map
Curtis 1253 Manual, Rev. F
Page 27
Fig. 11 rottle maps for
THROTTLE INPUT (percent of active range)
THROTTLE INPUT (percent)
controller with maximum
speed set at 80%.
3 — PROGRAMMABLE PARAMETERS: Throttle Parameters
100
90
80
70
60
50
40
30
20
10
CONTROLLER OUTPUT (PWM percent)
0
100908070605040302010 0
THROTTLE MAP
80%
60%
50%
40%
30%
20%
SPEED PARAMETER
80% Thrtl Max Speed
e throttle map operates within the window established by the rottle
Max Speed, rottle Deadband, and rottle Max parameters, as shown below
in Figure 17. rottle Max Speed defines the controller’s output range, while
rottle Deadband and rottle Max define the throttle’s active range. ese
three parameters, together with the rottle Map parameter, determine the
controller’s output response to throttle demand.
Fig. 12 Inuence of various
parameters on controller
output response to throttle
demand.
Blue Ox Rev. A, draft #1 [3 August 2007]
100
90
80
70
60
50
40
30
20
10
CONTROLLER OUTPUT (PWM percent)
0
15% Throttle Deadband
80% Max Speed
HALF THROTTLE
40% Throttle Map
(32% output at
half throttle)
90% Throttle Max
100908070605040302010 0
THROTTLE
PARAMETERS
15% Deadband
90% Throttle Max
40% Throttle Map
SPEED PARAMETER
80% Thrtl Max Speed
Curtis 1253 Manual, Rev. F
21
Page 28
3 — PROGRAMMABLE PARAMETERS: Final Speed Request Parameters
Final Speed Request Parameters
e final speed request parameters define how the controller will handle multiple
requests—from more than one speed select switch or from a combination of speed
select switches and the throttle. It is this single nal calculated speed that is demanded
of the pump motor.
When multiple requests are received, the controller can add them (“Add Mode”)
or accept only the rst request (“First On Mode”), depending on how the Add Mode
parameters are set.
For 1253-4804 controllers, the controller will enter SS High Speed On mode
if the SS High Speed On parameter is set to On; otherwise, its speed request mode
is the same as above.
SS ADD MODE
e Speed Select Add Mode parameter enables Add Mode for speed select
switches SS1–SS4. Add Mode is enabled or disabled (programmed On or O)
for all four switches as a group.
When SS Add Mode is O, the controller responds to the first request it
receives and ignores—or “locks out”—any subsequent requests; this is called
“First On Mode.” If SS3 is the first speed select switch to be closed, the controller
accelerates to the programmed SS3 maximum output. If SS2 is then closed, the
controller output (and the pump speed) remain the same and the SS3 operation
is slowed because it must share the available hydraulic pressure with the SS2
operation. If two or more speed select switches are closed simultaneously, the
controller responds to the lowest-numbered switch (i.e., SS2 takes precedence
over SS3, etc.).
When SS Add Mode is On, the controller increases the pump speed in
order to maintain the level of work requested by each speed select switch input;
this is called “Add Mode,” because the individual requests are added together.
If SS3 is the first speed select switch to be closed, the controller accelerates to
the programmed SS3 maximum output. If SS2 is then closed, the controller
output (and the pump speed) increase so that each operation is performed at
the same level of eort as if it were operating alone. e controller sends the
pump the required amount of power (up to 100% of maximum output) to
provide enough hydraulic pressure to perform all the requested operations at
their individually-specified maximum speeds.
FINAL ADD MODE
Typically, some operations are controlled by speed select switches and others by
the throttle. e Final Add Mode parameter determines whether the controller
will respond to the first request it receives (either the SS request or the throttle
request) or whether it will add them. If Final Add Mode is programmed O,
the pump speed will be defined by the first request it receives (SS or throttle).
22
Curtis 1253 Manual, Rev. F
Page 29
3 — PROGRAMMABLE PARAMETERS: Final Speed Request Parameters
If Final Add Mode is programmed On, the controller will sum the two requests
(up to 100% output). e “final” speed request that is sent to the motor is, of
course, temporary—the final request is constantly recalculated in response to
changes in the inputs.
Speed conditioning is shown in detail in Figure 13.
The 1253 handles multiple speed requests according to how the Speed Select (SS) Add Mode
and Final Add Mode parameters are set.
The SS Add Mode parameter determines how SS switch requests are handled:
ON = multiple SS requests are summed.
OFF = first SS request locks out any additional ones.
The Final Add Mode parameter determines whether the final throttle request and final SS request
are summed (Final Add Mode ON) or lock each other out (Final Add Mode OFF).
Final Motor Speed Request
Throttle Conditioning
Throttle
Thrtl Max Spd
1
0 0.5 1
Throttle Map
Fig. 13 Speed conditioning diagram.
Min Speed
100%
Σ
OFF ON
Final
“First On”
Final SS Request
Final Throttle Request
100%
Final
Add Mode
On/Off
Σ
100%
ON
OFF
Σ
SS
Add Mode
On/Off
SS
“First On”
SS Switch Conditioning
SS1
SS2
SS3
SS4
SS1 Speed
SS2 Speed
SS3 Speed
SS4 Speed
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
23
Page 30
3 — PROGRAMMABLE PARAMETERS: Final Speed Request Parameters
SS HIGH SPEED ON (1253-4804 only)
In some applications using the 1253-4804 controller, it may be desirable to
have the pump speed dened by the highest request. When the SS High Speed
On parameter is programmed On, the controller will enter SS High Speed On
mode. In this mode, if the Final rottle request = 0, the pump speed will be
dened by the highest speed request among all the active speed select (SS) requests; otherwise, the pump speed will be dened by the Final rottle Request.
If SS High Speed On is programmed O, the pump speed will be dened
by Add Mode or First On Mode.
SS High Speed On speed conditioning is shown in detail in Figure 14.
The SS High Speed On parameter determines how multiple requests are handled:
ON = SS High Speed On mode.
OFF = Add mode or First On mode.
Final Motor Speed Request
Min Speed
Throttle Conditioning
Throttle
Thrtl Max Spd
1
0 0.5 1
Throttle Map
100%
Fig. 14 SS High Speed On speed conditioning diagram.
100%
Σ
Final Throttle
Request
=0
>0
Final SS Request
Final Throttle Request
100%
SS Switch Conditioning
MAX
SS1 Speed
SS2 Speed
SS3 Speed
SS4 Speed
24
Curtis 1253 Manual, Rev. F
Page 31
Fault Parameters
LOCKOUT TYPE
e Lift Lockout Type parameter denes how the controller will interpret the
lift lockout input signal at Pin J1-11. e lockout type options—Types “0”
through “3” in the Program Menu—are listed in Table 3.
LOCKOUT
TYPE DESCRIPTION APPLICATION
0 Low = enable lockout Curtis 906, Curtis enGage™ IV
High/Open = disable lockout
1 High/Open = enable lockout Curtis 803, Curtis 841 Superspy
Low = disable lockout
2 High = enable lockout —
Low/Open = disable lockout
3 Low/Open = enable lockout —
High = disable lockout
3 — PROGRAMMABLE PARAMETERS: Fault Parameters
Table 3 PROGRAMMABLE LIFT LOCKOUT SIGNAL TYPES
e lockout type should be programmed appropriately for the gauge you are
using to provide lift lockout. With the Curtis 906 and enGage
™ IV, set the
lockout type to 0. With the Curtis 803 and 841 “Superspy,” set the lockout
type to 1. e other two types are available for other system congurations.
LIFT LOCK (SS1–SS4)
e lift lockout feature is designed to prevent Lift operation during undervoltage
conditions. e SS Lift Lockout parameter can be programmed On or O
independently for each of the speed select switches. When programmed On, if
Pin J1-11 receives an enable lockout signal during a Lift operation, the Lift in
progress will be completed but further Lift requests will be ignored as long as
the lockout enable signal is present. If programmed O, the Lift will continue
to operate just as if Pin J1-11 were not receiving a lockout signal.
When SS4 is used for power steering, PWM output will be shut down
when lift lockout is activated. If you do not want low battery lockout of power
steering, SS4 lift lockout should be programmed O.
THRTL LIFTLOCK
Blue Ox Rev. A, draft #1 [3 August 2007]
e rottle Lift Lockout parameter can be programmed On or O, and works
just like SS lift lockout. When programmed On, if Pin J1-11 receives an enable
lockout signal during a Lift operation, the Lift in progress will be completed
but further Lift requests will be ignored as long as the lockout enable signal
is present. If programmed O, the Lift will continue to operate just as if Pin
J1-11 were not receiving a lockout signal.
Curtis 1253 Manual, Rev. F
25
Page 32
3 — PROGRAMMABLE PARAMETERS: Fault Parameters
THRTL FAULT
When the rottle Fault Detection parameter is programmed On, the 1253
issues a fault if there is a problem with the throttle or its wiring. is parameter
should be programmed O if there is no throttle in the system, to prevent a
throttle fault from being issued on a nonexistent throttle.
Regardless of how the throttle fault parameter is set, if there is no con-
nection to the throttle the throttle input is assumed to be zero.
If the throttle fault parameter is programmed O, the throttle input is
assumed to be zero even if a throttle is connected.
STARTUP LOCKOUT
e startup lockout feature prevents the pump motor from running if any of the
speed select inputs (SS1–SS4) is high or the throttle input is outside the neutral
deadband when the controller is turned on. e Startup Lockout parameter is
used to set the type of lockout. Two types of lockout are available: lockout on
KSI input alone or lockout on KSI plus interlock inputs. Startup lockout can
also be disabled.
No Startup Lockout (Type 0)
Startup lockout function is disabled.
KSI-type Startup Lockout (Type 1)
To start the pump motor, the controller must receive a KSI input before receiving
a speed select input or a throttle input outside the neutral deadband. Controller
operation will be disabled immediately if an inappropriate speed request is active
at the time KSI is enabled, and a sequence error fault will be declared. If the
inappropriate speed request is received before the interlock switch is closed but
after the KSI input has been enabled, the motor will accelerate to the requested
speed as soon as the interlock switch is closed. Normal operation is regained by
reducing any throttle request to within the neutral deadband and opening any
speed select switches that were already closed.
Interlock-type Startup Lockout (Type 2)
To start the pump motor, the controller must receive an interlock switch input
in addition to a KSI input before receiving a speed select input or a throttle
input outside the neutral deadband. Controller operation will be disabled immediately if an inappropriate speed request is active at the time the interlock
switch is closed, and a sequence error fault will be declared. Normal operation
is regained by reducing any throttle requests to within the neutral deadband
and opening any speed select switches that were already closed.
26
Curtis 1253 Manual, Rev. F
Page 33
3 — PROGRAMMABLE PARAMETERS: Undervoltage and Contactor Control Parameters
Undervoltage Parameters
LOVOLT CUTBACK
e Low Voltage Cutback parameter sets the undervoltage threshold. At this
threshold voltage, the output current starts to taper o. Output current is
reduced until reaching zero, at the rate established by the low voltage cutback
rate parameter (see below). Low voltage cutback can be set from 32–42 V
for 48V models and from 54–70 V for 80V models.
LOVOLT CB RATE
e Low Voltage Cutback Rate parameter determines how sharply the current
limit decreases when the battery voltage falls below the undervoltage threshold
(see above). e low voltage cutback rate can be set from 0 to 20, with cutback
response being more gradual at lower values and more abrupt at higher values.
A setting of 0 disables the cutback function entirely; this is not recommended,
as the cutback function protects the system from operating at voltages lower
than its electronics were designed for.
Contactor Control Parameters
Blue Ox Rev. A, draft #1 [3 August 2007]
CONTACT CNTRL
e Main Contactor Control parameter is programmed to correspond to the
way the contactor is wired. If the contactor is part of the 1253 circuit, this
parameter should be programmed On. If the contactor is controlled externally,
this parameter should be programmed O.
CONT PULL IN
e Main Contactor Pull-in Voltage parameter allows a high initial voltage
when the contactor driver rst turns on, to ensure contactor closure. After the
controller detects that the contactor is closed, this peak voltage will be applied
for 0.1 second to ensure a reliable close; the voltage will then drop to the programmed contactor holding voltage (see below).
For 48V models, the pull-in voltage can be set from 18–60 V. For 80V
models, the range is 30–100 V.
CONT HOLDING
e Contactor Holding Voltage parameter allows a reduced average voltage to
be applied to the contactor coil once it has closed. e holding voltage must
be set high enough to hold the contactor closed under all shock and vibration
conditions it will be subjected to.
For 48V models, the contactor holding voltage range is 12–60 V, with
48 V being the typical default setting. For 80V models, the range is 20–100 V,
with 80 V being the typical default setting.
Curtis 1253 Manual, Rev. F
27
Page 34
3 — PROGRAMMABLE PARAMETERS: Contactor Control Parameters
SS4 DELAY
e SS4 Delay parameter can be set to allow the SS4 output to continue for a
period of time after the SS4 switch is opened. e delay is useful for maintaining power to auxiliary functions, such as a steering pump motor, that may be
used for a short time after the operator has gotten up from the seat. e SS4
delay can be set from 0.0 to 60.0 seconds, with 0.0 corresponding to no delay.
INTERLOCK DLY
e Interlock Delay parameter can be set to allow the PWM output to continue
for a period of time (the interlock delay) after the interlock switch is opened. e
delay is useful for maintaining power to auxiliary functions, such as a steering
pump motor, that may be used for a short time after the operator has gotten
up from the seat. e interlock delay can be set from 0.0 to 60.0 seconds, with
0.0 corresponding to no delay.
PRECHARGE
e Precharge parameter enables or disables the precharge function. Precharge
provides a limited current charge of the controller’s internal capacitor bank before
the main contactor is closed. is decreases the arcing that would otherwise
occur when the contactor is closed with the capacitor bank discharged.
Precharging and the precharge fault detection depend on the setting of
both the precharge and the contactor control parameters, as shown in Table 4.
Table 4 PRECHARGE FUNCTION AND FAULT DETECTION
PRECHARGE CONTACT CNTRL PERFORMED DETECTION
ON ON YES YES
ON off YES YES
off ON no no
off off YES no
PARAMETER SETTING
PRECHARGE PRECHARGE FAULT
PRECHARGE DLY
e controller can be programmed to delay for a set time at powering on before
charging the capacitor bank. e Precharge Delay parameter denes the delay
time; it can be set from 0 to 1000 ms.
28
Curtis 1253 Manual, Rev. F
Page 35
Current Limit Parameter
MAIN C/L (x10A)
e Main Current Limit (x10A) parameter denes the maximum current the
controller will supply to the pump motor. e programmed value multiplied
by ten is the actual current limit. e programmable range for this parameter is
20–60, which means the actual range for the main current limit is 200–600 A.
3 — PROGRAMMABLE PARAMETERS: Current Limit Parameter
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
29
Page 36
4 — INSTALLATION CHECKOUT
4
INSTALLATION CHECKOUT
Carefully complete the following checkout procedure before operating the
hydraulic system. If you find a problem during the checkout, refer to the diagnostics and troubleshooting section (Section 5) for further information.
e installation checkout is typically conducted with the handheld programmer. Otherwise, if you have connected an external Status LED to Pin
J1-6, you can observe this LED for fault codes; the codes are listed in Section 5.
Before starting the procedure, check that the hydraulic hoses are secure,
and the system primed with oil.
CAUTION
☞
Drive the vehicle to a location that will provide enough
room for all the hydraulic functions to be tested; if indoors,
be sure the ceiling height is adequate.
Do not stand, or allow anyone else to stand, directly in front
of or beside the vehicle during the checkout.
Make sure the keyswitch is o, the throttles are in neutral,
and all the hydraulic system switches (Lift, Lower, Reach,
Tilt, Shift, Rotate, etc.) are open.
Wear safety glasses and use well-insulated tools.
1. If a programmer is available, connect it to the programmer connector.
2. Turn the keyswitch on. e controller should power up, the program-
mer should present an initial display, and the Status LED should begin
blinking a single ash.
If not, check for continuity in the keyswitch circuit and controller
ground.
3. If you are using a programmer, scroll to the Faults Menu. e display
If there is a problem, the LED will flash a fault code and the pro-
When the problem has been corrected, it may be necessary to cycle
4. If you are using a programmer, scroll to the Monitor Menu. Scroll down
30
should indicate “No Known Faults.” Close the interlock switch (if one
is used in your application). e Status LED should continue blinking
a single ash and the programmer should continue to indicate no faults.
grammer will display a fault message. If you are conducting the checkout
without a programmer, look up the LED fault code in Section 5.
the keyswitch in order to clear the fault.
to observe the status of the interlock and four speed select switches
Curtis 1253 Manual, Rev. F
Page 37
4 — INSTALLATION CHECKOUT
(SS1–SS4). Cycle each switch in turn, observing the programmer. e
programmer should display the correct status for each switch.
5. Use the throttle to operate the pump motor. It should accelerate smoothly.
6. Verify that Startup Lockout performs as desired.
7. Request multiple operations in various combinations, to conrm that
motor speed responds according to the settings you made for the SS Add
Mode and Final Add Mode parameters.
8. If you used a programmer, disconnect it when you have completed the
checkout procedure.
BENCH TESTING WITH THE 1311 PROGRAMMER
With the simple bench test setup shown in Figure 14, the controller parameters
can be verified or adjusted without the controller being wired into a vehicle.
e complete in-vehicle installation checkout, as described above in Steps
1–8, should still be conducted before the vehicle is operated.
Fig. 14 Bench test setup
for verifying and adjusting
the controller’s parameters.
B- B+
POWER
SUPPLY
KEYSWITCH
Pin
J1-1
1311
PROGRAMMER
Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F
1253 CONTROLLER
31
Page 38
5 — DIAGNOSTICS & TROUBLESHOOTING
DIAGNOSTICS AND TROUBLESHOOTING
e 1253 controller provides diagnostics information to assist technicians in
5
troubleshooting pump system problems. e diagnostics information can be
obtained by observing the appropriate display on the handheld programmer or
the fault codes issued by the optional Status LED. Refer to the troubleshooting
chart (Table 5) for suggestions covering a wide range of possible faults.
PROGRAMMER DIAGNOSTICS
e programmer presents complete diagnostic information in plain language.
Faults are displayed in the Faults Menu (see column 2 in the troubleshooting
chart), and the status of the controller inputs/outputs is displayed in the Monitor Menu.
occurred since the fault history file was last cleared. Checking (and clearing)
the fault history file is recommended each time the vehicle is brought in for
maintenance.
bleshooting an inoperative pump system: (1) visually inspect the vehicle for
obvious problems; (2) diagnose the problem, using the programmer; (3) test
the circuitry with the programmer; and (4) correct the problem. Repeat the last
three steps as necessary until the pump system is operational.
Accessing the Fault History Menu provides a list of the faults that have
e following 4-step process is recommended for diagnosing and trou-
Example: A vehicle that cannot perform the operation requested by
Speed Select 2 is brought in for repair.
1: Examine the vehicle and its wiring for any obvious problems,
such as broken wires or loose connections.
2: Connect the programmer, select the Faults Menu, and read
the displayed fault information. In this example, the display shows
“No Known Faults,” indicating that the controller has not detected
anything out of the norm.
3: Select the Monitor Menu, and observe the status of the SS2
input. In this example, the display shows that the switch does not
close when SS2 is selected, which means the problem is either in the
SS2 switch or the switch wiring.
4: Check or replace the SS2 switch and wiring and repeat the
test. If the programmer shows the SS2 switch closing and the system
now operates normally, the problem has been corrected.
32
Curtis 1253 Manual, Rev. F
Page 39
5 — DIAGNOSTICS & TROUBLESHOOTING
Table 5 TROUBLESHOOTING CHART
LED PROGRAMMER
CODE LCD DISPLAY EXPLANATION
1,1 EEPROM FAULT EEPROM fault. 1. EEPROM data lost or damaged.
POSSIBLE CAUSE
Note: Usually can be cleared by 2. EEPROM checksum error.
modifying any parameter value
in the Program Menu.
1,2 HW FAILSAFE Self-test or watchdog fault. 1. MOSFET shorted.
2. Controller defective.
1,3 MOTOR SHORTED Motor shorted. 1. Motor is shorted.
2,1 UNDERVOLTAGE CUTOFF Undervoltage cuto. 1. Battery voltage < LOVOLT CUTOFF setting.
2,2 LIFT LOCKOUT Lift operation locked out due 1. Controller received appropriate lift lock-
to undervoltage. out signal.
2. Inappropriate lift lockout signal:
SS LOCKOUT parameter not set correctly.
2,3 SEQUENCE ERROR Startup lockout. 1. Improper sequence of throttle or SS and
KSI or KSI plus interlock.
2. STARTUP LOCKOUT parameter not set
correctly.
3. Misadjusted throttle.
2,4 THROTTLE FAULT Wiper signal out of range 1. rottle input wire open or shorted.
(pot low fault). 2. rottle defective.
3. THROTTLE TYPE parameter not set correctly.
3,1 CONT DRVR OC Main contactor coil overcurrent. 1. Main contactor coil shorted.
2. Controller defective.
3,2 MAIN CONT WELDED Main contactor welded. 1. Main contactor stuck closed.
2. CONT CNTRL parameter not set correctly.
3. Main contactor driver shorted.
3,3 PRECHARGE FAULT Precharge fault. 1. Precharge circuit failure.
2. External short or leakage between B+
and B-.
3,4 MAIN CONT DNC Main contactor did not close. 1. Main contactor coil connection loose.
2. Main contactor did not close.
3. CONT CNTRL parameter not set correctly.
4,1 LOW BATTERY VOLTAGE Low battery voltage. 1. Battery voltage < undervoltage cutback
threshold.
2. Corroded battery terminal.
3. Loose battery or controller terminal.
4,2 OVERVOLTAGE Overvoltage. 1. Battery voltage > overvoltage shutdown
threshold.
2. Vehicle operating with charger attached.
4,3 THERMAL CUTBACK Over-/undertemperature 1. Temperature > 85°C or < -25°C.
cutback. 2. Excessive load on pump motor.
3. Improper mounting of controller
4. Operation in extreme environment.
5. ermistor failure.
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Curtis 1253 Manual, Rev. F
33
Page 40
5 — DIAGNOSTICS & TROUBLESHOOTING
LED DIAGNOSTICS
e 1253 controller has a Status LED output that can be used to drive an external LED. is Status LED displays fault codes when there is a problem with
the controller or with the inputs to the controller. During normal operation,
with no faults present, the Status LED ashes steadily on and o.
If the controller detects a fault, a 2-digit fault identification code is ashed
continuously until the fault is corrected. For example, code “3,2”—welded main
contactor—appears as:
( 3 , 2 ) ( 3 , 2 ) ( 3 , 2 )
e codes are listed in Table 6.
LED CODES EXPLANATION
LED o no power or defective controller
solid on controller or microprocessor fault
0,1 ■ ¤ controller operational; no known faults
¤¤¤ ¤¤ ¤¤¤ ¤¤ ¤¤¤ ¤¤
Table 6 STATUS LED FAULT CODES
1,1 ¤ ¤ EEPROM fault
1,2 ¤ ¤¤ hardware failsafe fault
1,3 ¤ ¤¤¤ motor shorted
1,4 ¤ ¤¤¤¤ [not used]
2,1 ¤¤ ¤ undervoltage
2,2 ¤¤ ¤¤ lift lockout
2,3 ¤¤ ¤¤¤ sequence error (startup lockout)
2,4 ¤¤ ¤¤¤¤ throttle fault
3,1 ¤¤¤ ¤ main contactor coil shorted
3,2 ¤¤¤ ¤¤ welded main contactor
3,3 ¤¤¤ ¤¤¤ precharge fault
3,4 ¤¤¤ ¤¤¤¤ main contactor missing or did not close
4,1 ¤¤¤¤ ¤ low battery voltage
4,2 ¤¤¤¤ ¤¤ overvoltage
4,3 ¤¤¤¤ ¤¤¤ thermal cutback, due to over/under temp
4,4 ¤¤¤¤ ¤¤¤¤ [not used]
Note: Only one fault is indicated at a time, and faults are not queued up. Refer
to the troubleshooting chart (Table 5) for suggestions about possible causes of
the various faults.
34
Curtis 1253 Manual, Rev. F
Page 41
6
CAUTION
☞
6 — MAINTENANCE
MAINTENANCE
ere are no user serviceable parts in the Curtis 1253 controller. No attempt
should be made to open, repair, or otherwise modify the controller. Doing
so may damage the controller and will void the warranty.
It is recommended that the controller be kept clean and dry that its fault
history file be checked and cleared periodically.
CLEANING
Periodically cleaning the controller exterior will help protect it against corrosion
and possible electrical control problems created by dirt, grime, and chemicals
that are part of the operating environment and that normally exist in battery
powered systems.
When working around any battery powered system, proper safety
precautions should be taken. ese include, but are not limited to: proper
training, wearing eye protection, and avoiding loose clothing and jewelry.
Use the following cleaning procedure for routine maintenance. Never use
a high pressure washer to clean the controller.
Blue Ox Rev. A, draft #1 [3 August 2007]
1. Remove power by disconnecting the battery.
2. Discharge the capacitors in the controller by connecting a load (such
as a contactor coil) across the controller’s B+ and B- terminals.
3. Remove any dirt or corrosion from the power and signal connector
areas. e controller should be wiped clean with a moist rag. Dry it
before reconnecting the battery.
4. Make sure the connections are tight.
FAULT HISTORY
e programmer can be used to access the controller’s fault history file. e
programmer will read out all the faults that the controller has experienced since
the last time the fault history file was cleared. e faults may be intermittent
faults, faults caused by loose wires, or faults caused by operator errors. Faults
such as contactor faults may be the result of loose wires; contactor wiring should
be carefully checked. Faults such as startup lockout or overtemperature may be
caused by operator habits or by overloading.
After a problem has been diagnosed and corrected, it is a good idea to clear
the diagnostic history file. is allows the controller to accumulate a new file
of faults. By checking the new fault history file at a later date, you can readily
determine whether the problem was indeed fixed.
Curtis 1253 Manual, Rev. F
35
Page 42
APPENDIX A: EMC & ESD DESIGN CONSIDERATIONS
REGARDING ELECTROMAGNETIC COMPATIBILITY (EMC)
ELECTROMAGNETIC COMPATIBILITY (EMC)
Electromagnetic compatibility (EMC) encompasses two areas: emissions and
immunity. Emissions are radio frequency (RF) energy generated by a product.
is energy has the potential to interfere with communications systems such
as radio, television, cellular phones, dispatching, aircraft, etc. Immunity is the
ability of a product to operate normally in the presence of RF energy.
EMC is ultimately a system design issue. Part of the EMC performance
is designed into or inherent in each component; another part is designed into
or inherent in end product characteristics such as shielding, wiring, and layout;
and, finally, a portion is a function of the interactions between all these parts.
e design techniques presented below can enhance EMC performance in
products that use Curtis motor controllers.
APPENDIX A
VEHICLE DESIGN CONSIDERATIONS
AND ELECTROSTATIC DISCHARGE (ESD)
Emissions
Signals with high frequency content can produce significant emissions if connected to a large enough radiating area (created by long wires spaced far apart).
Contactor drivers and the motor drive output from Curtis controllers can
contribute to RF emissions. Both types of output are pulse width modulated
square waves with fast rise and fall times that are rich in harmonics. (Note:
contactor drivers that are not modulated will not contribute to emissions.)
e impact of these switching waveforms can be minimized by making the
wires from the controller to the contactor or motor as short as possible and by
placing the wires near each other (bundle contactor wires with Coil Return;
bundle motor wires separately).
For applications requiring very low emissions, the solution may involve
enclosing the controller, interconnect wires, contactors, and motor together in
one shielded box. Emissions can also couple to battery supply leads and throttle
circuit wires outside the box, so ferrite beads near the controller may also be
required on these unshielded wires in some applications. It is best to keep the
noisy signals as far as possible from sensitive wires.
Immunity
Immunity to radiated electric fields can be improved either by reducing overall
circuit sensitivity or by keeping undesired signals away from this circuitry. e
controller circuitry itself cannot be made less sensitive, since it must accurately
detect and process low level signals from sensors such as the throttle potenti-ometer. us immunity is generally achieved by preventing the external RF
energy from coupling into sensitive circuitry. is RF energy can get into the
controller circuitry via conducted paths and radiated paths.
A-1
Curtis 1253 Manual, Rev. F
Page 43
APPENDIX A: EMC & ESD DESIGN CONSIDERATIONS
Conducted paths are created by the wires connected to the controller.
ese wires act as antennas and the amount of RF energy coupled into them
is generally proportional to their length. e RF voltages and currents induced
in each wire are applied to the controller pin to which the wire is connected.
Curtis controllers include bypass capacitors on the printed circuit board’s
throttle wires to reduce the impact of this RF energy on the internal circuitry.
In some applications, additional filtering in the form of ferrite beads may also
be required on various wires to achieve desired performance levels.
Radiated paths are created when the controller circuitry is immersed in
an external field. is coupling can be reduced by placing the controller as far
as possible from the noise source or by enclosing the controller in a metal box.
Some Curtis controllers are enclosed by a heatsink that also provides shielding
around the controller circuitry, while others are partially shielded or unshielded.
In some applications, the vehicle designer will need to mount the controller
within a shielded box on the end product. e box can be constructed of just
about any metal, although steel and aluminum are most commonly used.
Most coated plastics do not provide good shielding because the coatings
are not true metals, but rather a mixture of small metal particles in a non-conductive binder. ese relatively isolated particles may appear to be good based
on a dc resistance measurement but do not provide adequate electron mobility
to yield good shielding eectiveness. Electroless plating of plastic will yield a
true metal and can thus be eective as an RF shield, but it is usually more
expensive than the coatings.
A contiguous metal enclosure without any holes or seams, known as a
Faraday cage, provides the best shielding for the given material and frequency.
When a hole or holes are added, RF currents owing on the outside surface of
the shield must take a longer path to get around the hole than if the surface
was contiguous. As more “bending” is required of these currents, more energy
is coupled to the inside surface, and thus the shielding eectiveness is reduced.
e reduction in shielding is a function of the longest linear dimension of a
hole rather than the area. is concept is often applied where ventilation is
necessary, in which case many small holes are preferable to a few larger ones.
Applying this same concept to seams or joints between adjacent pieces or
segments of a shielded enclosure, it is important to minimize the open length
of these seams. Seam length is the distance between points where good ohmic
contact is made. is contact can be provided by solder, welds, or pressure
contact. If pressure contact is used, attention must be paid to the corrosion
characteristics of the shield material and any corrosion-resistant processes applied
to the base material. If the ohmic contact itself is not continuous, the shielding
eectiveness can be maximized by making the joints between adjacent pieces
overlapping rather than abutted.
e shielding eectiveness of an enclosure is further reduced when a wire
passes through a hole in the enclosure; RF energy on the wire from an external
field is re-radiated into the interior of the enclosure. is coupling mechanism
can be reduced by filtering the wire where it passes through the shield boundary.
Curtis 1253 Manual, Rev. F
A-2
Page 44
APPENDIX A: EMC & ESD DESIGN CONSIDERATIONS
Given the safety considerations involved in connecting electrical components
to the chassis or frame in battery powered vehicles, such filtering will usually
consist of a series inductor (or ferrite bead) rather than a shunt capacitor. If a
capacitor is used, it must have a voltage rating and leakage characteristics that
will allow the end product to meet applicable safety regulations.
e B+ (and B-, if applicable) wires that supply power to a control panel
should be bundled with the other control wires to the panel so that all these
wires are routed together. If the wires to the control panel are routed separately,
a larger loop area is formed. Larger loop areas produce more efficient antennas
which will result in decreased immunity performance.
Keep all low power I/O separate from the motor and battery leads. When
this is not possible, cross them at right angles.
ELECTROSTATIC DISCHARGE (ESD)
Curtis PMC motor controllers contain ESD-sensitive components, and it is
therefore necessary to protect them from ESD (electrostatic discharge) damage.
Most of these control lines have protection for moderate ESD events, but must
be protected from damage if higher levels exist in a particular application.
ESD immunity is achieved either by providing sufficient distance between conductors and the ESD source so that a discharge will not occur, or by
providing an intentional path for the discharge current such that the circuit
is isolated from the electric and magnetic fields produced by the discharge. In
general the guidelines presented above for increasing radiated immunity will
also provide increased ESD immunity.
It is usually easier to prevent the discharge from occurring than to divert
the current path. A fundamental technique for ESD prevention is to provide
adequately thick insulation between all metal conductors and the outside environment so that the voltage gradient does not exceed the threshold required for
a discharge to occur. If the current diversion approach is used, all exposed metal
components must be grounded. e shielded enclosure, if properly grounded,
can be used to divert the discharge current; it should be noted that the location
of holes and seams can have a significant impact on ESD suppression. If the
enclosure is not grounded, the path of the discharge current becomes more
complex and less predictable, especially if holes and seams are involved. Some
experimentation may be required to optimize the selection and placement of
holes, wires, and grounding paths. Careful attention must be paid to the control
panel design so that it can tolerate a static discharge.
MOV, transorbs, or other devices can be placed between B- and oending wires, plates, and touch points if ESD shock cannot be otherwise avoided.
A-3
Curtis 1253 Manual, Rev. F
Page 45
APPENDIX B: PROGRAMMING DEVICES & MENUS
APPENDIX B
PROGRAMMING DEVICES & MENUS
Curtis programmers provide programming, diagnostic, and test capabilities for
the 1253 controller. e power for operating the programmer is supplied by
the host controller via a 4-pin connector. When the programmer powers up,
it gathers information from the controller.
Two types of programming devices are available: the 1314 PC Programming Station and the 1313 handheld programmer. e Programming Station
has the advantage of a large, easily read screen; on the other hand, the handheld programmer (with its 45×60mm screen) has the advantage of being more
portable and hence convenient for making adjustments in the eld.
Both programmers are available in User, Service, Dealer, and OEM versions. Each programmer can perform the actions available at its own level and
the levels below that—a User-access programmer can operate at only the User
level, whereas an OEM programmer has full access.
PC PROGRAMMING STATION (1314)
e Programming Station is an MS-Windows 32-bit application that runs on
a standard Windows PC. Instructions for using the Programming Station are
included with the software.
HANDHELD PROGRAMMER (1313)
e 1313 handheld programmer is functionally equivalent to the PC Programming Station; operating instructions are provided in the 1313 manual. e
1313 programmer replaces the 1311, an earlier model with fewer functions.
PROGRAMMER FUNCTIONS
Programmer functions include:
Parameter adjustment — provides access to the individual programmable pa-
rameters.
Monitoring — presents real-time values during vehicle operation; these include
all inputs and outputs.
Diagnostics and troubleshooting — presents diagnostic information, and also a
means to clear the fault history file.
Programming — allows you to save/restore custom parameter settings les and
also to update the system software (not available on the 1311).
Favorites — allows you to create shortcuts to your frequently-used adjustable
parameters and monitor variables (not available on the 1311).
Curtis 1253 Manual, Rev. F
B-1
Page 46
APPENDIX B: PROGRAMMING DEVICES & MENUS
e Program Menu and Monitor Menu are presented here. For Faults, see
the Troubleshooting Chart in Section 5. e other programmer menus are
self-explanatory.
Program Menu
(not all items available on all controllers)
e 1253’s programmable parameters are listed here in the order in which they
are displayed by the programmer.
MAIN CL(x10A) Maximum current controller will supply to pump motor
SS1 SPEED Speed Select 1 maximum speed, as % PWM
SS2 SPEED Speed Select 2 maximum speed, as % PWM
SS3 SPEED Speed Select 3 maximum speed, as % PWM
SS4 SPEED Speed Select 4 maximum speed, as % PWM
THRTL MAX SPD rottle maximum speed, as % PWM
MINIMUM SPEED Minimum speed, as % PWM
ACCEL RATE Acceleration rate, in seconds
SS ADD MODE (SS switch) On: Add mode, O: First On mode
FINAL ADD MODE (Final SS + throttle) On: Add Mode, O: First On Mode
SS HIGH SPEED ON SS High Speed On enable: On= SS High Speed On mode,
O= Add mode or First On mode
THRTL FAULT rottle fault detection: On/O
THROTTLE TYPE rottle type, 0–3
THRTL DEADBAND Neutral deadband adjustment, as % of active range
THROTTLE MAX rottle input required for max output, as % of active range
THROTTLE MAP rottle map: 20–80%
SS1 LIFT LOCK Lift lockout of SS1: On/O
SS2 LIFT LOCK Lift lockout of SS2: On/O
SS3 LIFT LOCK Lift lockout of SS3: On/O
SS4 LIFT LOCK Lift lockout of SS4: On/O
THRTL LIFTLOCK Lift lockout of throttle: On/O
LOCKOUT TYPE Lockout type, 0–3
PRECHARGE Precharge enable: On/O
PRECHARGE DLY Precharge delay time: 0–1000 ms
STARTUP LOCK Startup lockout type, 0–2
CONTACT CNTRL Main contactor controlled internally: On/O
SS4 DELAY Delay between SS4 open and corresponding output shutdown, in seconds
INTERLOCK DLY Delay between interlock open and output shutdown, in seconds
LOVOLT CUTBACK Undervoltage cutback starting point, in volts
LOVOLT CB RATE Low voltage cutback rate, 0–20
CONT PULL IN Contactor pull-in voltage
CONT HOLDING Contactor holding voltage
1
2
3
4
3
B-2
Curtis 1253 Manual, Rev. F
Page 47
APPENDIX B: PROGRAMMING DEVICES & MENUS
Program Menu Notes
1
rottle types (see rottle Wiring in Section 2)
Type 0: 0–5kΩ, 2-wire pot
Type 1: 5kΩ–0, 2-wire pot
Type 2: single-ended 0–5V input
Type 3: single-ended 3-wire pot (1–10kΩ)
2
Lift lockout types (see Section 3: Programmable Parameters, page 25)
Type 0: Enable = low; Disable = high or open
Type 1: Enable = high or open; Disable = low
Type 2: Enable = high; Disable = low or open
Type 3: Enable = low or open; Disable = high
3
Precharge function and fault detection depend on the combined
setting of two parameters, Precharge and Contactor Control
(see Section 3: Programmable Parameters, pages 28, 27)
PRECHARGE CONTACT CNTRL Performed Detection
Parameter Setting
Precharge Precharge Fault
ON off YES YES
ON ON YES YES
off off YES no
off ON no no
4
Startup lockout types (see Section 3: Programmable Parameters, page 26)
Type 0: no startup lockout
Type 1: startup lockout unless KSI input is received before speed request
Type 2: startup lockout unless KSI and interlock inputs are both received
before speed request
Curtis 1253 Manual, Rev. F
B-3
Page 48
APPENDIX B: PROGRAMMER OPERATION & MENUS
Monitor Menu
Items are listed here in the order in which they appear in the Monitor Menu
displayed by the programmer.
HEATSINK TEMP Heatsink temperature, in °C.
CAP VOLTAGE Voltage at capacitor bank (controller B+ bus).
BATT VOLTAGE Voltage at KSI (pin J1-1).
MOTOR VOLTAGE Voltage across controller’s B+ and M- bus bars.
THROTTLE% rottle request, as % of full throttle.
MAIN CONT DRVR Main contactor output: on/o.
DUTY CYCLE % PWM duty cycle of motor drive section.
SS1 INPUT Speed Select switch 1: on/o.
SS2 INPUT Speed Select switch 2: on/o.
SS3 INPUT Speed Select switch 3: on/o.
SS4 INPUT Speed Select switch 4: on/o.
LIFTLOCK INPUT Lift lockout: on/o.
INTERLCK INPUT Interlock switch: on/o.
B-5
Curtis 1253 Manual, Rev. F
Page 49
APPENDIX C: SPECIFICATIONS
APPENDIX C
SPECIFICATIONS
Table C-1 SPECIFICATIONS: 1253 CONTROLLER
Nominal input voltage 48 V and 80 V
PWM operating frequency 15.6 kHz
Electrical isolation to heatsink 500 V ac (minimum)
KSI input voltage 28 V (minimum) for 48V model; 47 V (minimum) for 80V model
KSI input current (no contactors engaged) <60 mA without 1311 programmer; <130 mA with 1311 programmer
Logic input voltage see below
Logic input current <1 mA
Contactor driver output current 1 A (maximum)
Status LED output current 5 mA (maximum)
Operating ambient temperature range -40°C to 50°C (-40°F to 122°F)
Storage ambient temperature range -40°C to 85°C (-40°F to 185°F)
Heatsink overtemperature cutback linear cutback starts at 80°C (176°F); complete cutoff at 120°C (248°F)
Heatsink undertemperature cutback 50% current below -25°C (-13°F)
Package environmental rating IP54
Weight 2.6 kg (5.7 lb)
Dimensions (L×W×H) 196 × 146 × 77 mm (7.7" × 5.7" × 3.0")
NOMINAL ARMATURE KSI PROGRAMMABLE
BATTERY CURRENT INPUT UNDERVOLTAGE OVERVOLTAGE
MODEL VOLTAGE LIMIT VOLTAGE CUTBACK CUTOFF
NUMBER (volts) (amps) (volts) (volts) (volts)
1253-48XX 48 600 28–60 32–42 60
1253-80XX 80 600 47–102 54–70 102
Curtis 1253 Manual, Rev. F
C-1
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