HYDRAULIC PUMP MOTOR

1253
1253 Manual, p/n 38329 Rev. C: May 2008

CURTIS INSTRUMENTS, INC.

200 Kisco Avenue Mt. Kisco, New York 10549 USA Tel. 914.666.2971 Fax 914.666.2188 www.curtisinstruments.com

M O D E L

CONTROLLER
2008 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750.

CONTENTS

CONTENTS
1. OVERVIEW ..............................................................................1 2. INSTALLATION AND WIRING.............................................3 Mounting the Controller .....................................................3 Low Current Connections ...................................................5 High Current Connections ..................................................6 Wiring: Standard Conguration .........................................7 Wiring: Throttles ..............................................................11 Contactor, Switches, and Other Hardware .........................13 3. PROGRAMMABLE PARAMETERS ......................................15 Speed Parameters ...............................................................16 Maximum Speed, SS1SS4 .........................................16 Throttle Maximum Speed ...........................................16 Minimum Speed..........................................................16 Acceleration Rate .........................................................16 Throttle Parameters............................................................16 Throttle Type ..............................................................16 Throttle Deadband ......................................................17 Throttle Maximum .....................................................18 Throttle Map...............................................................20 Final Speed Request Parameters .........................................22 Add Mode ...................................................................22 Final Add Mode ..........................................................23 Fault Parameters .................................................................24 Lockout Type ..............................................................24 Lift Lockout, SS1SS4 ................................................24 Lift Lockout, Throttle .................................................24 Throttle Fault Detection .............................................25 Startup Lockout ..........................................................25 Undervoltage Parameters ....................................................26 Low Voltage Cutback ..................................................26 Low Voltage Cutback Rate ..........................................26 Contactor Control Parameters ...........................................26 Pump Contactor Control ............................................26 Contactor Pull-in Voltage ............................................26 Contactor Holding Voltage .........................................26 SS4 Delay ....................................................................27 Interlock Delay ............................................................27 Precharge .....................................................................27

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Rev. A, draft #1 [3 August 2007]

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CONTENTS

4. INSTALLATION CHECKOUT .............................................28 5. DIAGNOSTICS AND TROUBLESHOOTING....................30 Programmer Diagnostics ....................................................30 LED Diagnostics ................................................................32 6. MAINTENANCE ...................................................................33

APPENDIX A APPENDIX B APPENDIX C

Vehicle Design Considerations Programmer Operation and Menus Specications, Curtis 1253 Controller

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Curtis 1253 Manual, Rev. C

FIGURES

FIGURES
FIG. FIG. FIG.

1: 2:

Curtis 1253 hydraulic system controller ................................... 1 Mounting dimensions, Curtis 1253 controller ........................ 3 Standard wiring conguration, using Curtis 803 gauge for lift lockout ..................................... 7 Standard wiring conguration, using Curtis 906 gauge for lift lockout ..................................... 8 Standard wiring conguration, using Curtis 841 Superspy for lift lockout ............................ 9 Standard wiring conguration, using Curtis enGage IV for lift lockout ............................... 10 Wiring for 2-wire 5k0 potentiometer (Type 0) .............. 12 Wiring for 2-wire 05k potentiometer (Type 1) .............. 12 Wiring for single-ended 05V input (Type 2) .................... 13 Wiring for single-ended 110k 3-wire pot (Type 3) ........ 13 Effect of adjusting the throttle deadband parameter .............. 17 Effect of adjusting the throttle max parameter ....................... 19 Throttle maps for controller with maximum speed set at 100% ........................................ 20 Throttle maps for controller with maximum speed set at 80% .......................................... 21 Influence of various parameters on controller output response to throttle demand ...................................... 21 Speed conditioning ............................................................... 23 Bench test setup .................................................................... 29

3a:

FIG.

3b:

FIG.

3c:

FIG.

3d:

FIG. FIG. FIG. FIG. FIG. FIG. FIG.

4: 5: 6: 7: 8: 9:

Rev. A, draft #1 [3 August 2007]

10:

FIG.

11:

FIG.

12:

FIG. FIG.

13: 14:

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Curtis 1253 Manual, Rev. C

TABLES

TABLES

TABLE TABLE TABLE TABLE TABLE TABLE

1: Throttle wiper input (threshold values) ............................... 11 2: Programmable throttle input signal types............................. 17 3: Programmable lift lockout signal types ............................... 24 4: Precharge function and fault detection ................................ 27 5: Troubleshooting chart .......................................................... 31 6: Status LED fault codes ....................................................... 32

TABLE

C-1: Specications, 1253 controller .......................................... C-1

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1 OVERVIEW

1
Fig. 1 Curtis 1253

OVERVIEW
The Curtis 1253 provides a cost-effective 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. The 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. The 1253 controller is fully programmable through Curtiss 1311 handheld programmer or 1314 PC Programming Station. The programmer provides diagnostic and test capability in addition to conguration exibility.

hydraulic pump motor controller.

Review Rev. A,of draft wiring #1 [3 diagrams August[24 2007] July 2007]

Like all Curtis motor controllers, the 1253 offers superior operator control of motor speed and torque.
Smooth and Quiet Control

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Programmable acceleration rates provide smooth application of pump motor torque 15.6 kHz PWM frequency for near-silent operation.
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1 OVERVIEW

Programmable Flexibility

Easily programmable through the 1311 handheld programmer or 1314 PC Programming Station Four Speed Select inputs (SS1SS4) with individually programmable top speeds Programmable throttle input for precise speed control with a variety of signal sources Programmable turn-off delay allows SS4 to be used for power steering Adjustable minimum speed setting to ensure pump lubrication and to maintain steering system pressure.
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 Thermal cutback provides protection to the controller Rugged housing meets IP54 environmental ratings Full-power operation over the -40C 80C 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 ofce nearest you.

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2 INSTALLATION & WIRING: Controller

INSTALLATION AND WIRING

MOUNTING THE CONTROLLER The 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. The controllers 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

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Review Rev. A,of draft wiring #1 [3 diagrams August[24 2007] July 2007]

Fig. 2 Mounting dimensions, Curtis 1253 controller.

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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. You will need to take steps during the design and development of your end product to ensure that its EMC performance complies with applicable regulations; suggestions are presented in Appendix A.

C AU T I O N

Working on electrical systems is potentially dangerous. You should protect yourself against uncontrolled operation, high current arcs, and outgassing from lead acid batteries: 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 programmer, the pump system may suddenly begin to operate.
UNCONTROLLED OPERATION 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. Charging or discharging generates hydrogen gas, which can build up in and around the batteries. Follow the battery manufacturers safety recommendations. Wear safety glasses.

LEAD ACID BATTERIES

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2 INSTALLATION & WIRING: Controller

LOW CURRENT CONNECTIONS Two low current connectors are built into the 1253 controller. They are located on the end of the controller:

The 12-pin connector (J1) provides the logic control connections. The mating connector is a 12-pin Molex Mini-Fit Jr. connector part number 39-01-2125 using type 5556 terminals.

J1
J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7
Review Rev. A,of draft wiring #1 [3 diagrams August[24 2007] July 2007]

Keyswitch Input (KSI) Pot High Pot Wiper Pot Low Interlock Status LED SS1 SS2 SS3

input and return for main contactor coil +5V supply pot wiper input (or 5V throttle input) to ground through 511 ohm resistor input from operator-present switch, tied to B+ LED driver low-side output Speed Select 1 input Speed Select 2 input Speed Select 3 input Speed Select 4 input input to the inhibit lift feature main contactor coil driver low-side output

J1-8 J1-9

J1-10 SS4 J1-11 Lift Lockout J1-12 Contactor

J2-1 J2-2 J2-3 J2-4

Rx Data BTx Data +15V

J2

The 4-pin connector (J2) is for the programmereither 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).

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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 p/n p/n p/n 117465704 1314-1101, 1314 PC Programming Station (User) CD-ROM 117465707 1314-4401, 1314 PC Programming Station (OEM) CD-ROM 16994001 1309 Interface Box 16185 Molex cable for 1309 Interface Box.

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2INSTALLATION&WIRING: Controller

HIGH CURRENT CONNECTIONS Three tin-plated solid copper bus bars are provided for the high current connections to the battery (B+ and B-) and the motor armature (M-).

WIRING: Standard Conguration Figure 3 shows the typical wiring conguration for most applications. The interlock switch is typically a seat switch, tiller switch, or foot switch. The 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 IV. As each of these gauges is wired somewhat differently to provide lift lockout, four individual wiring diagrams are included (Figs. 3a, 3b, 3c, 3d).
Power Wiring

Motor wiring is straightforward, with the elds S1 connection going to the controllers B+ bus bar and the armatures A2 connection going to the controllers M- bus bar.
Control Wiring

C AU T I O N

The main contactor coil should be wired directly to the controller as shown in Figure 3. The 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.

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2 INSTALLATION & WIRING: Controller

Review Rev. A,of draft wiring #1 [3 diagrams August[24 2007] July 2007]

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Fig. 3a Standard wiring conguration,

Curtis 1253 controller with Curtis 803 providing lift lockout.

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2 INSTALLATION & WIRING: Controller

Fig. 3b Standard wiring conguration,

Curtis 1253 controller with Curtis 906 providing lift lockout.

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2 INSTALLATION & WIRING: Controller

Review Rev. A,of draft wiring #1 [3 diagrams August[24 2007] July 2007]

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Fig. 3c Standard wiring conguration,

Curtis 1253 controller with Curtis 841 Superspy providing lift lockout.

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2 INSTALLATION & WIRING: Controller

Fig. 3d Standard wiring conguration,

Curtis 1253 controller with Curtis enGage IV providing lift lockout.

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2 INSTALLATION & WIRING: Throttles

WIRING: Throttles Various throttles can be used with the 1253 controller. They are categorized as one of four types in the Program Menu. Type 0: Type 1: Type 2: Type 3: two-wire 05k potentiometer throttles two-wire 5k0 potentiometer throttles single-ended 05V throttles single-ended three-wire 1k10k pot throttles.

Table 1 summarizes the operating specications for these four throttle types.
Table 1 WIPER INPUT: THROTTLE THRESHOLD VALUES
THROTTLE TYPE MINIMUM THROTTLE FAULT THROTTLE DEADBAND STARTUP LOCKOUT THROTTLE MAX MAXIMUM THROTTLE FAULT

PARAMETER Wiper Voltage Wiper Resistance Wiper Voltage Wiper Resistance Wiper Voltage Wiper Resistance Wiper Voltage Wiper Resistance

(0% speed request)

(100% modulation)

0 1 2 3

0.4 V

0.6 V 0 k 4.5 V 5.0 k 0V 0.5 V 0 k

out of deadband out of deadband

4.5 V 5.0 k 0.6 V 0 k 5.0 V 5.0 V 5.0 k

5.7 V 7.5 k 5.7 V 7.5 k 5.5 V 5.5 V

out of deadband

out of deadband

Notes: The upper and lower deadbands are valid for nominal 5k 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 settingssee Section 3, pages 17 and 18.
Review Rev. A,of draft wiring #1 [3 diagrams August[24 2007] July 2007]

The startup lockout threshold for all throttle types is set by the Throttle Deadband.

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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 ofce nearest you. Note: In the text, throttles are identied by their nominal range (e.g., 5k0 pot) and not by their actual operating range.

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2 INSTALLATION & WIRING: Throttles

05k Throttle (Type 0)

The 05k 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 0 measured between the two pins and full speed corresponds to 5 k.
Fig. 4 Wiring for

05k throttle (Type 0).

FASTER

Pot Wiper input (Pin J1-3)

Pot Low input (Pin J1-4)

05k

If the total resistance between the Pot Wiper and Pot Low pins is greater than 7.5 k, the controllers upper fault limit will be exceeded (see Table 1) and the throttles input value will be zeroed. This provides broken wire protection, and also serves as an indication that the potentiometers resistance has increased beyond the acceptable range and that the pot therefore needs to be replaced.

5k0 Throttle (Type 1)

The 5k0 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 5k measured between the two pins and full speed corresponds to 0.
Fig. 5 Wiring for 5k0

throttle (Type 1).

Pot Wiper input (Pin J1-3)

FASTER

Pot Low input (Pin J1-4)

5k0

If the total resistance between the Pot Wiper and Pot Low pins is greater than 7.5 k, the controllers upper fault limit will be exceeded (see Table 1) and the throttles input value will be zeroed. This provides broken wire protection, and also serves as an indication that the potentiometers resistance has increased beyond the acceptable range and that the pot therefore needs to be replaced.

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2 INSTALLATION & WIRING: Switches, etc.

Single-Ended 05V 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 05V throttles (Type 2).

The active range for this throttle is from 0 V (at 0% Throttle Deadband) to 5.0 V (at 100% Throttle Max), measured relative to B-. The signal is measured at the Pot Wiper pin. It is the responsibility of the OEM to provide appropriate throttle fault detection for 05V throttles.

Single-Ended 1k10k 3-wire pot (Type 3)

The 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.
Fig. 7 Wiring for 3-wire potentiometer throttle (Type 3).
FASTER

+ B-

Review Rev. A,of draft wiring #1 [3 diagrams August[24 2007] July 2007]

When a 3-wire pot is used, the controller provides full fault protection. Potentiometers with total resistance values between 1 k and 10 k can be used.

CONTACTOR, SWITCHES, and OTHER HARDWARE

Main Contactor

A main contactor should be used with the 1253 controller. Otherwise, the controllers fault detection will not be able to fully protect the controller and hydraulic system from damage in a fault condition. The main contactor allows the controller and motor to be disconnected from the battery. This provides a signicant safety feature, because it means the battery power can be removed

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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. The 1253 provides a low-side contactor coil driver (at Pin J1-12) for the main contactor. The driver output is rated at 1 amp and is short-circuit protected. A built-in coil suppression diode is connected between the main contactor coil driver output and the keyswitch input. This protects the contactor coil driver from inductive voltage kickback spikes when the contactor is turned off.
Keyswitch and Interlock Switch

The vehicle should have a master on/off switch to turn the system off when not in use. The keyswitch input provides logic power for the controller. The 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. The keyswitch and interlock switch provide current to drive the main contactor coil as well as the controllers internal logic circuitry, and must be rated to carry these currents.
Speed Select Switches

These 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. This 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. The 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. The appropriate fuse for each application should be selected with the help of a reputable fuse manufacturer or dealer. The standard wiring diagrams (Figure 3) show the recommended location for each fuse.

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3 PROGRAMMABLE PARAMETERS

PROGRAMMABLE PARAMETERS
The 1253s programmable parameters allow the pump systems performance characteristics to be customized to t the needs of individual applications or system operators. Programming can be done with a 1311 handheld programmer or a 1314 PC Programming Station. The discontinued 1307 handheld programmer is also fully compatible with the 1253 controller. Curtis offers 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 1253s parameters are arranged in groups. The parameter names are listed here in the abbreviated forms that appear on the handheld programmers 14-character LCD screen. Not all of these parameters are available on all controllers; the parameters for any given controller are dependent on its specications. For a list of the parameters in the order in which they appear in the Program Menu, see Appendix B.

Speed Select Parameters

SPEED (SS1SS4) THRTL MAX SPD MINIMUM SPEED ACCEL RATE

Fault Parameters
LOCKOUT TYPE LIFT LOCK (SS1SS4) THRTL LIFTLOCK THRTL FAULT STARTUP LOCK

Throttle Parameters
Rev. A, draft #1 [3 August 2007]

THROTTLE TYPE THRTL DEADBAND THROTTLE MAX THROTTLE MAP

Undervoltage Parameters
LOVOLT CUTBACK LOVOLT CB RATE

Contactor Driver Parameters

CONTACT CNTRL CONT PULL IN CONT HOLDING SS4 DELAY INTERLOCK DLY PRECHARGE

Final Speed Request Parameters

ADD MODE FINAL ADD MODE

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3 PROGRAMMABLE PARAMETERS: Speed and Throttle Parameters

Speed Parameters The 1253 controller can accept inputs from up to four individual speed select switches (SS1SS4) and from an analog throttle. The controller adjusts the pump motors PWM output in response to these inputs, using the algorithm prescribed by the programmed acceleration rate to reach the appropriate maximum speed. The programmed Minimum Speed and Acceleration Rate are in effect regardless of whether the speed request comes from a speed select switch or a throttle. SS1SS4, SPEED The SS maximum speed parameter denes 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., SS1 SPEED, SS2 SPEED, etc.). The maximum speed parameter is adjustable from 0% to 100% of the full output. THRTL MAX SPEED The throttle maximum speed parameter denes the maximum allowed armature PWM output in response to throttle input. The maximum speed parameter is adjustable from 0% to 100% of the controllers full output. MINIMUM SPEED The minimum speed parameter denes the minimum allowed armature PWM output of the pump motor, and is adjustable from 0 to 50% of the full output. The minimum speed feature ensures that adequate pressure is maintained for the power steering system and for pump lubrication. ACCEL RATE The acceleration rate parameter denes 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. The 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 The 1253 controller accepts a variety of throttle inputs, including 5k0 and 05k two-wire rheostats, 3-wire pots, and 05V throttles. The standard throttle input signal type optionsTypes 0 through 3 in the Program Menuare 16
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3 PROGRAMMABLE PARAMETERS: Throttle Parameters

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 Off; otherwise the controller will register a throttle fault.
Table 2
THROTTLE TYPE

PROGRAMMABLE THROTTLE INPUT SIGNAL TYPES

DESCRIPTION

0 1 2 3

05k, 2-wire rheostat 5k0, 2-wire rheostat single-ended 05V input) single-ended 3-wire potentiometer (1k to 10k range)

THRTL DEADBAND The throttle deadband parameter denes the pot wiper voltage range the controller interprets as neutral. Increasing the throttle deadband setting increases the neutral range. This parameter is especially useful with throttle assemblies that do not reliably return to a well-dened neutral point, because it allows the
Fig. 8 Effect of adjusting

the throttle deadband parameter (throttle types 0 and 1).

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Rev. A, draft #1 [3 August 2007]

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3 PROGRAMMABLE PARAMETERS: Throttle Parameters

Fig. 8, contd Effect of

adjusting the throttle deadband parameter (throttle types 2 and 3).

deadband to be dened 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 5k0 potentiometer (where applicable). The 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. The default deadband setting is 10%. The 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 The throttle 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. This feature allows reduced-range throttle assemblies to be accommodated. Examples are shown in Figure 9 for throttle types 0 through 3, using a nominal 5k potentiometer (where applicable). These examples illustrate the effect of three different max output settings (100%, 90%, 60%) on the fullstroke wiper voltage required to attain 100% controller output. The programmer displays throttle max as a percentage of the throttles active voltage range. The nominal voltage range depends on the throttle type selected. See Table 1 (page 11) for the characteristics of your selected throttle type. The throttle max parameter can be adjusted from 100% to 10%, in 1% increments.

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3 PROGRAMMABLE PARAMETERS: Throttle Parameters

Fig. 9 Effect of adjusting

the throttle max parameter.

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3 PROGRAMMABLE PARAMETERS: Throttle Parameters

THROTTLE MAP The throttle map parameter modies the response to the throttle input. This 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. The throttle map can be programmed in 5% increments between 20% and 80%. The number refers to the controller output at half throttle, as a percentage of the throttles full active range. The throttles 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. The 50% setting corresponds to a linear response. Six throttle map proles (20, 30, 40, 50, 60, and 80%) are shown as examples in Figure 10, with the maximum speed set at 100%.
Fig. 10 Throttle maps for controller with maximum speed set at 100%.

Lowering the max speed limits the controllers output range. Throttle map proles with the max speed reduced from 100% to 80% are shown in Figure 11. The throttle map is always a percentage of the controllers output range. So, in these examples, the throttle map is a percentage of the 080% 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 dened 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).

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3 PROGRAMMABLE PARAMETERS: Throttle Parameters

Fig. 11 Throttle maps for

controller with maximum speed set at 80%.

The Throttle Map operates within the window established by the Throttle Max Speed, Throttle Deadband, and Throttle Max parameters, as shown below in Figure 17. Throttle Max Speed denes the controllers output range, while Throttle Deadband and Throttle Max dene the throttles active range. These three parameters, together with the Throttle Map, determine the controllers output response to throttle demand.
Fig. 12 Inuence of various

parameters on controller output response to throttle demand.

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3 PROGRAMMABLE PARAMETERS: Final Speed Request Parameters

Final Speed Request Parameters The nal speed request parameters dene how the controller will handle multiple requestsfrom 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 (rst-on mode), depending on how the Add Mode parameters are set. SS ADD MODE The speed select Add Mode parameter enables Add Mode for speed select switches SS1SS4. Add Mode is enabled or disabled (programmed On or Off ) for all four switches as a group. When SS Add Mode is Off, the controller responds to the rst request it receives and ignoresor locks outany subsequent requests; this is called First-On Mode. If SS3 is the rst 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 rst 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 effort as if it were operating alone. The 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-specied maximum speeds. FINAL ADD MODE Typically, some operations are controlled by speed select switches and others by the throttle. The Final Add Mode parameter determines whether the controller will respond to the rst request it receives (either the SS request or the throttle request) or whether it will add them. If Final Add Mode is programmed Off, the pump speed will be dened by the rst request it receives (SS or throttle).

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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). The nal speed request that is sent to the motor is, of course, temporarythe nal request is constantly recalculated in response to changes in the inputs. Speed conditioning is shown in detail in Figure 13.

Rev. A, draft #1 [3 August 2007]

0.5

Fig. 13 Speed conditioning diagram.

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3 PROGRAMMABLE PARAMETERS: Fault Parameters

Fault Parameters LOCKOUT TYPE The Lift lockout type parameter denes how the controller will interpret the lift lockout input signal at Pin J1-11. The lockout type optionsTypes 0 through 3 in the Program Menuare listed in Table 3.
Table 3
LOCKOUT TYPE

PROGRAMMABLE LIFT LOCKOUT SIGNAL TYPES

DESCRIPTION APPLICATION

0 1 2 3

Low = enable lockout High/Open = disable lockout High/Open = enable lockout Low = disable lockout High = enable lockout Low/Open = disable lockout Low/Open = enable lockout High = disable lockout

Curtis 906, Curtis enGage IV Curtis 803, Curtis 841 Superspy

The 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. The other two types are available for other system congurations. LIFT LOCK (SS1SS4) The Lift lockout feature is designed to prevent Lift operation during undervoltage conditions. The SS lift lockout parameter can be programmed On or Off 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 Off, 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 Off. THRTL LIFTLOCK The Throttle lift lockout parameter can be programmed On or Off, 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 Off, the Lift will continue to operate just as if Pin J1-11 were not receiving a lockout signal. 24
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3 PROGRAMMABLE PARAMETERS: Fault Parameters

THRTL FAULT When the throttle fault parameter is programmed On, the 1253 issues a fault if there is a problem with the throttle or its wiring. This parameter should be programmed Off 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 connection to the throttle the throttle input is assumed to be zero. If the throttle fault parameter is programmed Off, the throttle input is assumed to be zero even if a throttle is connected. STARTUP LOCKOUT The startup lockout feature prevents the pump motor from running if any of the speed select inputs (SS1SS4) is high or the throttle input is outside the neutral deadband when the controller is turned on. The 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)

Rev. A, draft #1 [3 August 2007]

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.

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3 PROGRAMMABLE PARAMETERS: Undervoltage and Contactor Control Parameters

Undervoltage Parameters LOVOLT CUTBACK The low voltage cutback parameter sets the undervoltage threshold. At this threshold voltage, the output current starts to taper off. 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 3242 V for 48V models and from 5470 V for 80V models. LOVOLT CB RATE The low voltage cutback rate parameter determines how sharply the current limit decreases when the battery voltage falls below the undervoltage threshold (see above). The 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 CONTACT CNTRL The 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 Off. CONT PULL IN The 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 1860 V. For 80V models, the range is 30100 V. CONT HOLDING The contactor holding voltage parameter allows a reduced average voltage to be applied to the contactor coil once it has closed. The 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 1260 V, with 48 V being the typical default setting. For 80V models, the range is 20100 V, with 80 V being the typical default setting. 26
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3 PROGRAMMABLE PARAMETERS: Contactor Control Parameters

SS4 DELAY The SS4 delay parameter can be set to allow the SS4 output to continue for a period of time after the SS4 switch is opened. The 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. The SS4 delay can be set from 0.0 to 60.0 seconds, with 0.0 corresponding to no delay. INTERLOCK DELAY The 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. The 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. The interlock delay can be set from 0.0 to 60.0 seconds, with 0.0 corresponding to no delay. PRECHARGE The precharge parameter enables or disables the precharge function. Precharge provides a limited current charge of the controllers internal capacitor bank before the main contactor is closed. This 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 PERFORMED PRECHARGE FAULT DETECTION

PARAMETER SETTING PRECHARGE CONTACT CNTRL

Rev. A, draft #1 [3 August 2007]

ON ON off off

ON off ON off

YES YES no YES

YES YES no no

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4 INSTALLATION CHECKOUT

4
C AU T I O N

INSTALLATION CHECKOUT
Carefully complete the following checkout procedure before operating the hydraulic system. If you nd a problem during the checkout, refer to the diagnostics and troubleshooting section (Section 5) for further information. The 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.

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 off, 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. 2.

If a programmer is available, connect it to the programmer connector. Turn the keyswitch on. The controller should power up, the programmer 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. If you are using a programmer, scroll to the Faults Menu. The display should indicate No Known Faults. Close the interlock switch (if one is used in your application). The Status LED should continue blinking a single ash and the programmer should continue to indicate no faults. If there is a problem, the LED will ash a fault code and the programmer will display a fault message. If you are conducting the checkout without a programmer, look up the LED fault code in Section 5. When the problem has been corrected, it may be necessary to cycle the keyswitch in order to clear the fault. If you are using a programmer, scroll to the Monitor Menu. Scroll down to observe the status of the interlock and four speed select switches

3.

4.

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4 INSTALLATION CHECKOUT

(SS1SS4). Cycle each switch in turn, observing the programmer. The programmer should display the correct status for each switch. 5. 6. 7. Use the throttle to operate the pump motor. It should accelerate smoothly. Verify that Startup Lockout performs as desired. 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. If you used a programmer, disconnect it when you have completed the checkout procedure.

8.

BENCH TESTING WITH THE 1311 PROGRAMMER With the simple bench test setup shown in Figure 14, the controller parameters can be veried or adjusted without the controller being wired into a vehicle. The complete in-vehicle installation checkout, as described above in Steps 18, should still be conducted before the vehicle is operated.
Fig. 14 Bench test setup

for verifying and adjusting the controllers parameters.

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29

5 DIAGNOSTICS & TROUBLESHOOTING

DIAGNOSTICS AND TROUBLESHOOTING

The 1253 controller provides diagnostics information to assist technicians in troubleshooting pump system problems. The 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 The 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. Accessing the Fault History Menu provides a list of the faults that have occurred since the fault history le was last cleared. Checking (and clearing) the fault history le is recommended each time the vehicle is brought in for maintenance. The following 4-step process is recommended for diagnosing and troubleshooting 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.
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.
STEP

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.
STEP

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.
STEP STEP 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.

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5 DIAGNOSTICS & TROUBLESHOOTING

Table 5 TROUBLESHOOTING CHART

LED CODE PROGRAMMER LCD DISPLAY EXPLANATION POSSIBLE CAUSE

1,1

EEPROM FAULT

EEPROM fault. Note: Usually can be cleared by modifying any parameter value in the Program Menu. Self-test or watchdog fault. Motor shorted. Undervoltage cutoff. Lift operation locked out due to undervoltage.

1. EEPROM data lost or damaged. 2. EEPROM checksum error.

1,2 1,3 2,1 2,2

HW FAILSAFE MOTOR SHORTED UNDERVOLTAGE CUTOFF LIFT LOCKOUT

1. MOSFET shorted. 2. Controller defective. 1. Motor is shorted. 1. Battery voltage < LOVOLT CUTOFF setting. 1. Controller received appropriate lift lockout signal. 2. Inappropriate lift lockout signal: SS LOCKOUT parameter not set correctly. 1. Improper sequence of throttle or SS and KSI or KSI plus interlock. 2. STARTUP LOCKOUT parameter not set correctly. 3. Misadjusted throttle. 1. Throttle input wire open or shorted. 2. Throttle defective. 3. THROTTLE TYPE parameter not set correctly. 1. Main contactor coil shorted. 2. Controller defective. 1. Main contactor stuck closed. 2. CONT CNTRL parameter not set correctly. 3. Main contactor driver shorted. 1. Precharge circuit failure. 2. External short or leakage between B+ and B-. 1. Main contactor coil connection loose. 2. Main contactor did not close. 3. CONT CNTRL parameter not set correctly. 1. Battery voltage < undervoltage cutback threshold. 2. Corroded battery terminal. 3. Loose battery or controller terminal. 1. Battery voltage > overvoltage shutdown threshold. 2. Vehicle operating with charger attached. 1. 2. 3. 4. 5. Temperature > 85C or < -25C. Excessive load on pump motor. Improper mounting of controller Operation in extreme environment. Thermistor failure.

2,3

SEQUENCE ERROR

Startup lockout.

2,4

THROTTLE FAULT

Wiper signal out of range (pot low fault). Main contactor coil overcurrent. Main contactor welded.

3,1 3,2

CONT DRVR OC MAIN CONT WELDED

3,3

PRECHARGE FAULT

Precharge fault.

3,4
Rev. A, draft #1 [3 August 2007]

MAIN CONT DNC

Main contactor did not close.

4,1

LOW BATTERY VOLTAGE

Low battery voltage.

4,2

OVERVOLTAGE

Overvoltage.

4,3

THERMAL CUTBACK

Over-/undertemperature cutback.

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5 DIAGNOSTICS & TROUBLESHOOTING

LED DIAGNOSTICS The 1253 controller has a Status LED output that can be used to drive an external LED. This 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 off. If the controller detects a fault, a 2-digit fault identication code is ashed continuously until the fault is corrected. For example, code 3,2welded main contactorappears as: (3,2) (3,2) (3,2)

The codes are listed in Table 6.

Table 6
LED CODES

STATUS LED FAULT CODES

EXPLANATION

LED off solid on 0,1 1,1 1,2 1,3 1,4 2,1 2,2 2,3 2,4 3,1 3,2 3,3 3,4 4,1 4,2 4,3 4,4

no power or defective controller controller or microprocessor fault controller operational; no known faults EEPROM fault hardware failsafe fault motor shorted [not used] undervoltage lift lockout sequence error (startup lockout) throttle fault main contactor coil shorted welded main contactor precharge fault main contactor missing or did not close low battery voltage overvoltage thermal cutback, due to over/under temp [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.

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6 MAINTENANCE

6
C AU T I O N

MAINTENANCE
There 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 le 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. These 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. 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 controllers B+ and B- terminals. 3. Remove any dirt or corrosion from the power and signal connector areas. The controller should be wiped clean with a moist rag. Dry it before reconnecting the battery. 4. Make sure the connections are tight.

Rev. A, draft #1 [3 August 2007]

FAULT HISTORY The programmer can be used to access the controllers fault history le. The programmer will read out all the faults that the controller has experienced since the last time the fault history le was cleared. The 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 le. This allows the controller to accumulate a new le of faults. By checking the new fault history le at a later date, you can readily determine whether the problem was indeed completely xed. The Fault History le and Clear Fault History are in the programmers Faults Menu; see Appendix B. 33

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APPENDIX A: EMC & ESD DESIGN CONSIDERATIONS

APPENDIX A
VEHICLE DESIGN CONSIDERATIONS REGARDING ELECTROMAGNETIC COMPATIBILITY (EMC) AND ELECTROSTATIC DISCHARGE (ESD)

ELECTROMAGNETIC COMPATIBILITY (EMC) Electromagnetic compatibility (EMC) encompasses two areas: emissions and immunity. Emissions are radio frequency (RF) energy generated by a product. This 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, nally, a portion is a function of the interactions between all these parts. The design techniques presented below can enhance EMC performance in products that use Curtis motor controllers. Decreasing Emissions Motor brush arcing can be a signicant source of RF emissions. These emissions may be reduced by installing bypass capacitors across the motor wires and/or between each motor wire and the motor frame. If the latter approach is used, the voltage rating and leakage characteristics of the capacitors must be adequate to meet any safety regulations regarding electrical connections between a battery operated circuit and the chassis. The bypass capacitor should be installed as close to the motor as possible, or even inside it, to provide the best performance. Alternatively a ferrite bead can be installed on the wires, as close as possible to the motor. In some instances, capacitors and ferrite beads may both be appropriate. Another option is to choose a motor with a brush material that will result in less arcing to the commutator. Brushes that have been run in for approximately 100 hours will typically generate lower emissions than new brushes because there is less arcing after they are properly seated. The motor drive output from Curtis controllers can also make a contribution to RF emissions. This output is a pulse width modulated square wave with rather fast rise and fall times that are rich in harmonics. The impact of these switching waveforms can be minimized by making the wires from the controller to the motor as short as possible. Ferrite beads installed on the drive wires can further reduce these emissions. For applications requiring very low emissions, the solution may involve enclosing the controller, interconnect wires, and motor together in one shielded box. The motor drive harmonics can couple to battery supply leads and throttle circuit wires, so ferrite beads may also be required on these other wires in some applications.

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A-1

APPENDIX A: EMC & ESD DESIGN CONSIDERATIONS

Increasing Immunity Immunity to radiated electric elds can be achieved either by reducing the overall circuit sensitivity or by keeping the undesired signals away from this circuitry. The controller circuitry itself cannot be made less sensitive, since it must accurately detect and process low level signals from the throttle potentiometer. Thus immunity is generally achieved by preventing the external RF energy from coupling into sensitive circuitry. This RF energy can get into the controller circuitry via conducted paths and via radiated paths. Conducted paths are created by the wires connected to the controller. These wires act as antennas and the amount of RF energy coupled into these wires is generally proportional to their length. The RF voltages and currents induced in each wire are applied to the controller pin to which the wire is connected. Curtis motor controllers include bypass capacitors on the printed circuit boards throttle wires to reduce the impact of this RF energy on the internal circuitry. In some applications, ferrite beads may also be required on the various wires to achieve desired performance levels. Radiated paths are created when the controller circuitry is immersed in an external eld. This coupling can be reduced by enclosing the controller in a metal box. Some Curtis motor controllers are enclosed by a heat sink that also provides shielding around the controller circuitry, while others are unshielded. In some applications, the vehicle designer will need to mount the controller within a shielded box on the end product. The box may 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. These 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 effectiveness. Electroless plating of plastic will yield a true metal and can thus be effective 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 effectiveness is reduced. The reduction in shielding is a function of the longest linear dimension of a hole rather than the area. This 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. This 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 A-2
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APPENDIX A: EMC & ESD DESIGN CONSIDERATIONS

to the base material. If the ohmic contact itself is not continuous, the shielding effectiveness can be maximized by making the joints between adjacent pieces overlapping rather than abutted. The shielding effectiveness of an enclosure is further reduced when a wire passes through a hole in the enclosure. RF energy on the wire from an external eld is re-radiated into the interior of the enclosure. This coupling mechanism can be reduced by ltering the wire at the point where it passes through the boundary of the shield. Given the safety considerations involved with connecting electrical components to the chassis or frame in battery powered vehicles, such ltering 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. The B+ (and B-, if applicable) wires that supply power to the throttle control panelsuch as for the keyswitchshould be bundled with the remaining throttle wires 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 efcient antennas which will result in decreased immunity performance. ELECTROSTATIC DISCHARGE (ESD) Curtis motor controllers contain ESD-sensitive components, and it is therefore necessary to protect them from ESD damage. Electrostatic discharge (ESD) immunity is achieved either by providing sufcient distance between conductors and the outside world 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 elds produced by the discharge. In general the guidelines presented above for increasing the 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. However, in some scooter applications isolation may not be appropriate; in these cases, connection to chassis ground may be required. If the current diversion approach is used, all exposed metal components must be grounded. The 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 signicant impact on the 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.
Curtis 1253 Manual, Rev. C

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A-3

APPENDIX B: PROGRAMMER OPERATION & MENUS

APPENDIX B
PROGRAMMERS
Curtis programmers provide programming, diagnostic, and test capabilities for the 1253 controller. The power for operating the programmer is supplied by the host controller via a 4-pin connector. Two programmers are available: the PC Programming Station (1314) and the handheld programmer (1311). The Programming Station has features not available on the handheld unit; on the other hand, the handheld programmer has the advantage of being more portable. Typically the Programming Station is used to set up the parameters initially and the handheld programmer is used to made adjustments in the eld. Two versions of each programmer are available: the User programmers can adjust only User-access parameters, whereas the OEM programmers can adjust all the parameters. HANDHELD PROGRAMMER (1311) The 1311 programmer is easy to use, with self-explanatory functions. After plugging in the programmer, wait a few seconds for it to boot up and gather
Fig. B-1 Curtis 1311

handheld programmer.

B-1

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APPENDIX B: PROGRAMMER OPERATION & MENUS

information from the controller. For experimenting with settings, the programmer can be left plugged in while the vehicle is driven. The bookmark keys can make parameter adjustment more convenient. To set a bookmark, press one of the three bookmark keys for more than two seconds. To jump to a bookmarked location, press the appropriate bookmark key quickly (for less than two seconds). The bookmark keys also have another function that makes programming easier. When setting the value of a parameter, you can use these keys to adjust the increments by which the value changeswith Bookmark Key 1, the value changes in 10-digit steps up or down; with Bookmark Key 2 pressed, the value changes in 100-digit steps; and with Bookmark Key 3, in 1000-digit stepswhich, for most parameters, takes you from the maximum to the minimum, or vice versa. PC PROGRAMMING STATION (1314) The Programming Station is an MS-Windows 32-bit application that runs on a standard Windows PC. It can do everything the handheld programmer can do, and more. Its additional capabilities include saving/restoring sets of parameters to/from disk and updating software. Instructions for using the Programming Station are included with the software. PROGRAMMER MENUS The programmers have six menus:
Program provides access to the individual programmable parameters. Monitor presents real-time values during vehicle operation; these include all
Rev. A, draft #1 [3 August 2007]

inputs and outputs.

Faults presents diagnostic information, and also a means to clear the fault history le. Functions provides access to the controller-cloning commands and to the reset command. Information displays data about the host controller: model and serial numbers, date of manufacture, hardware and software revisions, and itemization of other devices that may be associated with the controllers operation. Programmer Setup displays data about the programmer: model and serial

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numbers, and date of manufacture.

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B-2

APPENDIX B: PROGRAMMER OPERATION & MENUS

The Program Menu and Monitor Menu are presented here. For Faults, see the Troubleshooting Chart in Section 5. The other three menus are selfexplanatory. Program Menu
(not all items available on all controllers)

Parameters are listed here in the order in which they appear in the Program Menu displayed by the programmer.
SS1 SPEED SS2 SPEED SS3 SPEED SS4 SPEED THRTL MAX SPD MINIMUM SPEED ACCEL RATE SS ADD MODE FINAL ADD MODE THRTL FAULT THROTTLE TYPE THRTL DEADBAND THROTTLE MAX THROTTLE MAP SS1 LIFT LOCK SS2 LIFT LOCK SS3 LIFT LOCK SS4 LIFT LOCK THRTL LIFTLOCK LOCKOUT TYPE PRECHARGE STARTUP LOCK CONTACT CNTRL SS4 DELAY INTERLOCK DLY LOVOLT CUTBACK LOVOLT CB RATE CONT PULL IN CONT HOLDING

Speed Select 1 maximum speed, as % PWM Speed Select 2 maximum speed, as % PWM Speed Select 3 maximum speed, as % PWM Speed Select 4 maximum speed, as % PWM Throttle maximum speed, as % PWM Minimum speed, as % PWM Acceleration rate, in seconds (SS switch) On: Add Mode, Off: First-On Mode (Final SS & throttle) On: Add Mode, Off: First-On Mode Throttle fault detection: On/Off Throttle type, 03 1 Neutral deadband adjustment, as % of active range Throttle input required for max output, as % of active range Throttle map: 2080% Lift lockout of SS1: On/Off Lift lockout of SS2: On/Off Lift lockout of SS3: On/Off Lift lockout of SS4: On/Off Lift lockout of throttle: On/Off Lockout type, 03 2 Precharge enable: On/Off 3 Startup lockout type, 02 4 Main contactor controlled internally: On/Off 3
Delay between SS4 open and corresponding output shutdown, in seconds

Delay between interlock open and output shutdown, in seconds

Undervoltage cutback starting point, in volts Low voltage cutback rate, 020 Contactor pull-in voltage Contactor holding voltage

B-3

Curtis 1253 Manual, Rev. C

APPENDIX B: PROGRAMMER OPERATION & MENUS

Program Menu Notes

1

Throttle types (see Throttle Wiring in Section 2) Type 0: 05k, 2-wire pot Type 1: 5k0, 2-wire pot Type 2: single-ended 05V input Type 3: single-ended 3-wire pot (110k)

Lift lockout types (see Section 3: Programmable Parameters, page 24) Type 0: Enable = low; Type 2: Enable = high; Type 3: Enable = low or open; Disable = high or open Disable = low or open Disable = high Type 1: Enable = high or open; Disable = low

Precharge function and fault detection depend on the combined setting of two parameters, Precharge and Contactor Control (see Section 3: Programmable Parameters, pages 26, 27)
Parameter Setting PRECHARGE CONTACT CNTRL ON ON off off off ON off ON Precharge Performed YES YES YES no Precharge Fault Detection YES YES no no

4
Rev. A, draft #1 [3 August 2007]

Startup lockout types (see Section 3: Programmable Parameters, page 25) 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

Blue Ox

Curtis 1253 Manual, Rev. C

B-4

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 CAP VOLTAGE BATT VOLTAGE MOTOR VOLTAGE THROTTLE% MAIN CONT DRVR DUTY CYCLE % SS1 INPUT SS2 INPUT SS3 INPUT SS4 INPUT LIFTLOCK INPUT INTERLCK INPUT

Heatsink temperature, in C. Voltage at capacitor bank (controller B+ bus). Voltage at KSI (pin J1-1). Voltage across controllers B+ and M- bus bars. Throttle request, as % of full throttle. Main contactor output: on/off. PWM duty cycle of motor drive section. Speed Select switch 1: on/off. Speed Select switch 2: on/off. Speed Select switch 3: on/off. Speed Select switch 4: on/off. Lift lockout: on/off. Interlock switch: on/off.

B-5

Curtis 1253 Manual, Rev. C

APPENDIX C: SPECIFICATIONS

APPENDIX C
SPECIFICATIONS

Table C-1
Nominal input voltage PWM operating frequency Electrical isolation to heatsink

SPECIFICATIONS: 1253 CONTROLLER

48 V and 80 V 15.6 kHz 500 V ac (minimum) 28 V (minimum) for 48V model; 47 V (minimum) for 80V model <60 mA without 1311 programmer; <130 mA with 1311 programmer see below <1 mA 1 A (maximum) 5 mA (maximum) -40C to 50C (-40F to 122F) -40C to 85C (-40F to 185F) linear cutback starts at 80C (176F); complete cutoff at 120C (248F) 50% current below -25C (-13F) IP54 2.6 kg (5.7 lb) 196 146 77 mm (7.7" 5.7" 3.0")

KSI input voltage KSI input current (no contactors engaged) Logic input voltage Logic input current Contactor driver output current Status LED output current Operating ambient temperature range Storage ambient temperature range Heatsink overtemperature cutback Heatsink undertemperature cutback Package environmental rating Weight Dimensions (LWH)

Rev. A, draft #1 [3 August 2007]

MODEL NUMBER

NOMINAL BATTERY VOLTAGE (volts)

ARMATURE CURRENT LIMIT (amps)

KSI INPUT VOLTAGE (volts)

PROGRAMMABLE UNDERVOLTAGE CUTBACK (volts)

OVERVOLTAGE CUTOFF (volts)

1253-48XX 1253-80XX

48 80

600 600

2860 47102

3242 5470

60 102

Blue Ox

Curtis 1253 Manual, Rev. C

C-1