Curtis 1297 Manual Download

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MANUAL

DESIGN OF CURTIS PMC 1200 SERIES
CONTROLLERS PROTECTED BY U.S.
PATENT NO. 4626750.

1 2 9 7

MODEL

INTEGRATED TRACTION
& HYDRAULIC SYSTEM

C O N T R O L L E R

CURTIS PMC

235 East Airway Boulevard
Livermore, California 94550 USA
Tel: 925-961-1088
Fax: 925-961-1099
www.curtisinst.com

1297 Manual, p/n 36411

Rev. A: February 2001

Summary of Contents for 1297

Page 1: ...ERS PROTECTED BY U S PATENT NO 4626750 1 2 9 7 M O D E L INTEGRATED TRACTION HYDRAULIC SYSTEM C O N T R O L L E R CURTIS PMC 235 East Airway Boulevard Livermore California 94550 USA Tel 925 961 1088 F...

Page 2: ...KISCO NEW YORK 10549 U S A 914 666 2971 FAX 914 666 2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 U S A 925 961 1088 FAX 925 961 1099 ADDITIONAL OFFICES located in Bulgaria Chin...

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Page 4: ...mum 41 Field Map Start 41 Field Map 41 Field Check 42 Emergency Reverse Parameters 43 Emergency Reverse Current Limit 43 Emergency Reverse Check 43 Emergency Reverse Acceleration Rate 43 Emergency Rev...

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Page 7: ...glass display 19 FIG 12 Ramp restraint map for controller with Field Min set at 3 amps Field Max set at 18 amps and braking current limit set at 300 amps 28 FIG 13 Effect of adjusting the throttle dea...

Page 8: ...ndard 5k 3 wire throttle pot B 1 FIG B 2 Mounting dimensions Curtis PMC potboxes B 1 FIG B 3 Mounting dimensions Curtis PMC footpedal FP 2 B 2 FIG B 4 Mounting dimensions Curtis throttle WP 45 CP B 2...

Page 9: ...ost effective control of motor speed and torque The traction section includes a full bridge eld control and a half bridge armature control to provide full solid state regenerative braking The pump sec...

Page 10: ...s through the 13XX programmer and through the controller s built in Status LED Throttle inputs for single ended or wigwag 5k pots or 0 5V throttles both standard full stroke and restricted range one t...

Page 11: ...52 mm round case DIN case and as a bare board each with an 8 pin Molex connector cases feature front seal to IP65 and rear seal to IP40 shock and vibration protection to SAE J1378 Operating temperatur...

Page 12: ...port in the label on top of the controller and 2 that convenient access is needed at the top of the controller to plug the programmer into its connector The outline and mounting hole dimensions for th...

Page 13: ...operate before attempting any work on the pump motor control circuitry NOTE If the wrong hydraulic throttle input signal type is selected with the 13XX programmer the hydraulic system may suddenly beg...

Page 14: ...J1 Pin 12 forward switch input no multiplexer Lift limit switch input multiplexer J1 Pin 13 display data output J1 Pin 14 not used J1 Pin 15 display ground reference output J1 Pin 16 display power out...

Page 15: ...splay uses only three of J2 s six pins 1 2 and 5 A 4 pin low power connector J3 is provided for the 13XX programmer A complete programmer kit including the appropriate connecting cable can be ordered...

Page 16: ...rmature s A1 connection going to the controller s B bus bar and its A2 connection going to the controller s TRACTION M bus bar The traction motor s eld connections are Fig 3 Standard wiring configurat...

Page 17: ...iring for the input switches and contactors is shown in Figure 3 the connector is shown in more detail below The main contactor coil must be wired directly to the controller as shown in Figure 3 The c...

Page 18: ...n 3 J1 Pin 2 J1 Pin 1 J1 Pin 16 J1 Pin 13 J1 Pin 15 A A EMERG REV CHK J1 Pin 9 J1 Pin 6 EMERG REV KEYSWITCH TRACTION MOTOR PUMP MOTOR CONTROL FUSE A2 A1 A2 TRACTION MOTOR FIELD S1 FORWARD INTERLOCK LO...

Page 19: ...nection going to the B bus bar and its A2 connection going to the PUMP M bus bar Standard Control Wiring Wiring for the input switches and contactors is shown in Figure 4 the connector is shown in mor...

Page 20: ...V 3 80 V 5 00 V Wiper Resistance 0 k 1 65 k 5 50 k 7 50 k 4 Wiper Voltage 0 50 V 2 50 V Fwd Lift 3 10 V Fwd Lift 4 40 V Fwd Lift 4 50 V 2 50 V Rev Lower 1 90 V Rev Lower 0 60 V Rev Lower Wiper Resist...

Page 21: ...ent Source 3 Wire Pot and Electronic Throttles Type 2 With these throttles Type 2 in the programming menu the controller looks for a voltage signal at the wiper input Zero speed corresponds to 0V and...

Page 22: ...5V input Pin 4 Hyd 0 5V input Pin 21 0 5V input Pin 4 Traction Throttle Hydraulic Throttle Traction Throttle Hydraulic Throttle Also the controller recognizes the voltage between the wiper input and B...

Page 23: ...provides a current limited 5V source to the pot and Pot Low Pin 22 provides the return path Wiring is shown in Figure 8 and also in the standard wiring diagrams Figures 3 and 4 Potentiometers with tot...

Page 24: ...ault There is no fault detection built into the ET XXX and the controller will detect only open wiper faults It is the responsibility of the OEM to provide any additional throttle fault detection nece...

Page 25: ...orType 4 devices is similar to that forType 2 devices The neutral point will be with the wiper at 2 5 V measured between Pin 4 or 21 and B For the traction throttle the controller will provide increas...

Page 26: ...cy reverse switch is pressed After the emergency reverse switch is released normal controller operation is not resumed until neutral no direction is selected or until the interlock switch is cycled Th...

Page 27: ...12V 15V 16 1 4 6 receive data 13 5 3 7 N C 8 ground B 15 2 2 NOTE The Spyglass display can be connected to any of the 1297 s low current connectors J1 J2 or J3 not connected the vehicle will not oper...

Page 28: ...spikes The controller also performs a welded contactor check and a missing main contactor check each time the interlock switch is engaged Controller output is inhibited if these contactor checks are...

Page 29: ...oltage of the system and must not exceed the 2 amp rating of its driver The lowering valve solenoid coil should be rated at or below the nominal battery voltage and should be capable of opening the va...

Page 30: ...that identify this particular con guration e g 1297 2417 In addition to specifying parameter values the OEM can designate whether a parameter will have User or OEM only access rights Accordingly two v...

Page 31: ...Valve Parameters Lowering Valve Maximum Current Lowering Valve Minimum Current Lowering Valve Dither Lowering Valve Current Acceleration Lowering Valve Current Deceleration Load Hold Delay Lowering V...

Page 32: ...tance the time or distance required to achieve the requested speed is influenced by a variety of factors including initial speed vehicle load and terrain M1 M2 DRIVE C L The drive current limit parame...

Page 33: ...ratio is tuned as part of the vehicle performance adjustment process Section 5 NOTE Current ratio is only effective in drive it does not affect regenera tive braking BOOST ENABLE In situations where t...

Page 34: ...decel rate is adjustable from 0 1 to 10 0 seconds COAST DECEL Thecoast deceleration ratede nes how quickly the controller reduces it output to zero when the Pick switch is released This parameter allo...

Page 35: ...The interlock braking rate parameter de nes the time it takes the controller to increase from 0 braking output to 100 braking output when interlock braking is initiated The interlock braking rate is...

Page 36: ...ing parameter de nes how the controller will apply braking force when braking is requested If the variable braking parameter is pro grammed On the amount of braking current applied by the controller w...

Page 37: ...urations i e options 0 through 4 described in Table 2 E M BRAKE DLY The electromagnetic brake driver open delay parameter allows a delay after the interlock switch has been opened before the brake dri...

Page 38: ...s whenever the throttle is in neutral and the vehicle is not moving or after the emergency reverse switch closes and is then released During normal operation Brake Driver Option 3 controls braking as...

Page 39: ...never be set so high the vehicle is moving too fast when the throttle returns to small values just above the deadband NOTE The programmed creep speed is not displayed as the Throttle value in the pro...

Page 40: ...adjusts the applied motor voltage as a function of motor load current This results in more constant vehicle speeds over variations in driving surface ramps rough terrain etc without the vehicle opera...

Page 41: ...rottle The throttle type parameter can be programmed to 1 2 3 or 4 The standard throttle input signal type options are listed in Table 3 Table 3 PROGRAMMABLE THROTTLE TYPES Traction Throttle THROTTLE...

Page 42: ...useful with throttle assemblies that do not reliably return to a well de ned neutral point because it allows the deadband to be de ned wide enough to ensure that the controller goes into neutral when...

Page 43: ...wiper relative to B For throttle types 1 and 3 the deadband points are defined in terms of the nominal 5k pot resistance Using a pot of greater or lesser resistance will give different values for the...

Page 44: ...tle range The throttle max parameter can be adjusted from 100 to 60 the default setting is 90 The nominal throttle wiper range depends on the throttle type selected See Table 1 page 12 for the charact...

Page 45: ...at the pot wiper relative to B For throttle types 1 and 3 the deadband points are defined in terms of the nominal 5k pot resistance Using a pot of greater or lesser resistance will give different val...

Page 46: ...creep speed set at 0 and maximum speed set at 100 a throttle map setting of 50 will give 50 output at half throttle As noted above the 50 ramp shape is always a linear response A throttle map setting...

Page 47: ...sult in 45 output at half throttle TRACTION THROTTLE INPUT percent of active range 80 60 50 40 30 20 THROTTLE MAP 100 90 80 70 60 50 40 30 20 10 0 100 90 80 70 60 50 40 30 20 10 0 SPEED PARAMETERS 10...

Page 48: ...voltage throttle inputs are used It is recommended that the pot low check parameter be set to On in any application where a resistive throttle is used This will provide maximum throttle fault detecti...

Page 49: ...arts to increase it is adjustable from 25 amps up to the controller s full rated armature current value The full rated armature current depends on the controller model see speci cations in Table E 1 T...

Page 50: ...ith increasing armature current thus emulating a series wound motor Decreasing the eld map parameter reduces the eld current at a given armature current i e it weakens the eld As the eld current is re...

Page 51: ...shown in Figures 3 and 4 pages 8 and 10 EMR REV ACCEL Theemergency reverse acceleration rateparameter de nes the time it takes the controller to accelerate from 0 to 100 output in the opposite direct...

Page 52: ...ition to providing routine smooth starts HPD also protects against accidental sudden starts if problems in the throttle linkage e g bent parts broken return spring give a throttle input signal to the...

Page 53: ...rogrammer is used to make the selection Type 0 no SRO Type 1 SRO unless interlock input before a direction input Type 2 SRO unless KSI plus interlock input before a direction input Type 3 SRO unless K...

Page 54: ...ED When the Lift switch is closed the controller activates the load hold valve thus enabling the Lift function as shown in Figure 20 Themaximum pump speed parameter de nes the maximum allowed armature...

Page 55: ...throttle is reduced from full to none or when the Lift switch is opened The pump decel rate is adjustable from 0 1 to 3 0 seconds 3B PROGRAMMABLE HYDRAULIC PARAMETERS Pump Fig 20 Hydraulic system dia...

Page 56: ...rom 0 1 to 25 0 seconds PUMP BDI L O The pump BDI lockout feature prevents Lift operation when the battery state of charge is below 20 This parameter can be programmed On or Off When programmed On if...

Page 57: ...ent parameter sets the minimum current through the lowering valve Most proportional valves need a non zero closed current in order to start opening immediately when Lower is requested The LV minimum c...

Page 58: ...ase from 100 to 0 The LV current decel rate is programmable from 0 0 to 3 0 seconds LV CHECK The LV check parameter de nes whether the controller performs missing coil checks on the lowering valve sol...

Page 59: ...single ended or wigwag and the Curtis ET XXX electronic throttle The hydraulic throttle type parameter can be programmed to 2 or 4 The standard throttle input signal type options are listed in Table 4...

Page 60: ...stics of your selected throttle type Fig 21 Effect of adjusting the hydraulic throttle deadband parameter 3B PROGRAMMABLE HYDRAULIC PARAMETERS Hydraulic Throttle Throttle Type 2 0 5V single ended Thro...

Page 61: ...60 on the full stroke wiper voltage required to attain 100 controller output Fig 22 Effect of adjusting the hydraulic Throttle Max parameter 3B PROGRAMMABLE HYDRAULIC PARAMETERS Hydraulic Throttle Th...

Page 62: ...e 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 the maximum pump speed is set at 100 a throttle map sett...

Page 63: ...response to throttle demand for Lift operation 3B PROGRAMMABLE HYDRAULIC PARAMETERS Hydraulic Throttle Fig 24 Hydraulic throttle maps for Lift for controller with maximum speed set at 80 HYDRAULIC TH...

Page 64: ...plied VARIABLE LOWER The variable lower parameter enables throttle control of Lower speed if a proportional lowering valve is used When variable lower is programmed Off the proportional valve aperture...

Page 65: ...te the vehicle When this parameter is programmed On both the KSI input J1 Pin 1 and the interlock input J1 Pin 2 must be pulled high to B before the controller will engage the main contactor The conta...

Page 66: ...actor driver however is always protected from overcurrents short circuits and overheating MUX ENABLE The multiplexer enable parameter when programmed On enables the J2 connector and thus the multiplex...

Page 67: ...is being installed in a used vehicle however it may be desirable to transfer the existing hourmeter values to the new controller To do this the existing decimal hourmeter values must be converted to 8...

Page 68: ...reset high middle and low byte values to the pump hourmeter First adjust the byte values as desired for the pump hourmeter Then program the Apply Pump Hours parameter On which automatically loads the...

Page 69: ...d goes into effect DIS PUMP HRS The pump disable hours parameter is used to set the pump disable timer it can be adjusted between 0 and 250 hours in 1 hour increments If the pump disable timer expires...

Page 70: ...er expires the controller automatically sets the service traction parameter On The user must then program the service traction parameter Off to indicate the appropriate service has been performed SERV...

Page 71: ...ttery with no load Whenever this voltage is present for 6 seconds except during regenerative braking the BDI is reset to 100 The reset voltage value can be set from 0 90 to 3 00 VPC in 0 01 VPC increm...

Page 72: ...throttles are in neutral and all the switches are open Wear safety glasses and use well insulated tools 1 If a programmer is available connect it to the 4 pin connector J3 2 Turn the keyswitch on The...

Page 73: ...r should display the correct status for each switch If your application has a multiplexer cycle these switches on the multiplexer also 6 Take the vehicle down off the blocks and drive it in a clear ar...

Page 74: ...adjusted without the controller being wired into a vehicle The wiring can be expanded to conduct a complete functional test on the bench if you want to do this contact Curtis for further information T...

Page 75: ...ny changes in the motor the vehicle drive system or the controller will require that the system be tuned again to provide optimum performance The 1297 s MultiMode feature allows the vehicle to be con...

Page 76: ...forward switch is engaged and the controller recognizes the forward command STEP 6 Without moving the throttle scroll up to display the Throttle parameter and read the value shown This value should be...

Page 77: ...n full controller output at the maximum throttle position Select the Program Menu and decrease theThrottle Max setting Repeat this step until the Throttle value is 100 STEP 5 Now that the full throttl...

Page 78: ...is reduced Reductions in the eld current over the motor s typical operating temperature range can be 10 to 50 Since the maximum available eld current deter mines the maximum torque that can be produc...

Page 79: ...lower eld currents than speci ed will result in operation outside the motor s safe commu tation region and will cause arcing between the brushes and commutator signi cantly reducing motor and brush li...

Page 80: ...the desired top speed Increasing the Field Min value decreases the vehicle s top speed decreasing the Field Min value increases the vehicle s top speed CAUTION Do not decrease the Field Min below the...

Page 81: ...shed STEP 2 Once the vehicle s unloaded top speed has been set load the vehicle to its desired load capacity Leave the Field Min and Max Speed parameters at the settings determined during the unloaded...

Page 82: ...eding the motor s safe commutation region TRACTION FINE TUNING Four additional vehicle performance characteristics can be adjusted Response to reduced throttle Response to increased throttle Smoothnes...

Page 83: ...for the best overall response If the vehicle starts too slowly under all driving condi tions the Accel Rate should be reduced STEP 3 Increasing vehicle acceleration If acceleration feels good for slow...

Page 84: ...is reduced to 0 and the desired speed is still not attained the system is being limited by the motor s torque capability under these operating conditions CAUTION be careful when reducing the Field Ma...

Page 85: ...the Hydraulic Deadband and Throttle Max settings using the multi step procedures out lined for their traction throttle equivalents on pages 67 68 Step H 3 If a proportional valve is used and variable...

Page 86: ...is therefore not covered here see the programmer manual 1297 PROGRAM MENU not all items available on all controllers M1 DRIVE C L Mode 1 drive current limit in amps M2 DRIVE C L Mode 2 drive current l...

Page 87: ...3 4 or 4 8 BOOST ENABLE Boost current option enabled on off LOAD COMP Load compensation 0 to 25 SEQUENCING DLY Sequencing delay in seconds SRO Static return to off SRO type 3 HPD High pedal disable H...

Page 88: ...lve in LV maximum current ADJ HOURS HIGH Hourmeter preset high byte 0 151 ADJ HOURS MID Hourmeter preset middle byte 0 255 ADJ HOURS LOW Hourmeter preset low byte 0 255 SET TOTL HRS Apply preset value...

Page 89: ...interlock forward inputs received in that order 4 Main contactor control types see Section 3C page 57 On Interlock switch input required in addition to KSI to close contactor Off Contactor closes on...

Page 90: ...d duty cycle as ARM PWM Traction motor armature duty cycle as FORWARD INPUT Forward switch on off neutral switch for Type 4 throttle REVERSE INPUT Reverse switch on off MODE INPUT Mode switch on M2 of...

Page 91: ...D fault occurred HW FAILSAFE Hardware failsafe activated HYD INHIBIT Hydraulic throttle high at interlock HYD THROTTLE FAULT Hydraulic throttle fault LOW BATTERY VOLTAGE Battery voltage too low MAIN C...

Page 92: ...ded each time the vehicle is brought in for maintenance The following 4 step diagnostic and troubleshooting process is recom mended 1 visually inspect the vehicle for obvious problems 2 diagnose the p...

Page 93: ...Wrong throttle type selected 2 2 PUMP SENSOR pump motor current sensor error 1 Incorrect pump motor wiring 2 Controller defective 2 3 HPD HPD sequencing error 1 Improper sequence of KSI interlock and...

Page 94: ...maintenance monitor expired 4 2 OVERVOLTAGE battery voltage too high 1 Battery voltage overvoltage shutdown limit 2 Operation with charger attached LOW BATTERY VOLTAGE battery voltage too low 1 Batter...

Page 95: ...Table 6 Table 6 STATUS LED FAULT CODES LED CODES EXPLANATION LED off no power or defective controller solid on controller or microprocessor fault 0 1 controller operational no known faults 1 1 tractio...

Page 96: ...TING SPYGLASS DIAGNOSTICS The eight character LCD on the Spyglass displays a continuous sequence of hourmeter battery state of charge and fault messages Fault messages are displayed using the same cod...

Page 97: ...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 Removeanydirtorcorrosionfromthepower...

Page 98: ...assigned OEM access levels see Table D 1 On OEM speci ed models the OEM designates the access level for each parameter Restricting access rights to the OEM reduces the likelihood of important perform...

Page 99: ...eep speed until the throttle is rotated out of the throttle deadband typically 10 of throttle This feature helps to prevent rollback when starting uphill with low throttle see Section 3A page 31 Curre...

Page 100: ...decelera tion rates for the traction motor Emergency reverse Emergency reverse is activated when the emergency reverse switch is pressed After the emergency reverse switch is released normal controlle...

Page 101: ...active faults Fault recovery including recovery from disable Almost all faults require a cycling of the keyswitch or interlock switch to reset the controller and enable operation The only exceptions a...

Page 102: ...he controller is turned on when greater than 25 throttle is applied see Section 3A page 44 Hourmeters The 1297 has three built in hourmeters the total hourmeter measuring KSI on hours the traction mot...

Page 103: ...he throttle position see Section 3A page 32 Lowering valve The aperture of the hydraulic line s lowering valve determines the speed of Lower operation the lowering valve can be either a proportional v...

Page 104: ...is linearly decreased from full set current down to zero at 95 C NOTE Brakingcurrent limits are not reduced in overtemperature this ensures that full vehicle braking is available under all thermal co...

Page 105: ...orce and restrain the vehicle to the requested speed see Section 3 page 27 Reverse polarity protection The 1297 controller is protected against reverse polarity by an internal diode If the battery s B...

Page 106: ...ammable SRO feature prevents the vehicle from being started when in gear i e with a direction already selected see Section 3A page 45 Status LED A built in Status LED Light Emitting Diode is visible t...

Page 107: ...le and hydraulic throttle have separate throttle maximum parameters see Section 3A page 36 and Section 3B page 54 Throttle types The 1294 controller accepts a variety of throttle inputs The most commo...

Page 108: ...ft and Lower The variable Lift and variable Lower features allow the operator to use the throttle to control the speed of Lift and Lower operation see Section 3B page 56 Watchdog external internal The...

Page 109: ...millimeters and inches RIGHT HAND OPERATION LEFT HAND OPERATION COM N O N C N C N O COM WITH MICROSWITCH PB 6 WITHOUT MICROSWITCH PB 5 WITH MICROSWITCH PB 9 WITHOUT MICROSWITCH PB 10 42 1 65 52 2 06...

Page 110: ...8 Dimensions in millimeters and inches 55 2 2 ELEC SPECS ELECTRICAL TRAVEL 40 TOTAL RESISTANCE 5 k 10 8 0 3 1 2 3 Fig B 3 Mounting dimensions Curtis PMC footpedal FP 2 Dimensions in millimeters and in...

Page 111: ...SSARY B 3 APPENDIX B THROTTLES Fig B 5 Mounting dimensions Curtis electronic speed control device ET series Dimensions in millimeters and inches 99 3 90 44 1 73 69 2 72 24 0 94 VIS TC 3 12 6 6 0 24 0...

Page 112: ...citors 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 moto...

Page 113: ...ox 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...

Page 114: ...rtis PMC 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 suf cient...

Page 115: ...RRENT RATIO OEM 1 4 2 page 25 DECEL RATE M1 M2 OEM 0 1 10 0 3 0 seconds page 26 DRIVE C L M1 M2 OEM 50 RATED CURRENT 1 RC 1 amps page 24 E M BRAKE DLY OEM 0 0 30 0 3 0 seconds page 29 E M BRAKE TYPE O...

Page 116: ...BDI L O OEM OFF page 48 PUMP BDI WARN OEM OFF page 48 PUMP C L OEM 25 RATED CURRENT 3 RC 3 amps page 46 PUMP DECEL OEM 0 1 3 0 0 1 seconds page 47 PUMP LOCK C L OEM 25 RC 3 50 RC 3 amps page 48 PUMP...

Page 117: ...HRS OEM 0 250 10 hours page 61 TRAC FAULT SPD OEM 0 100 100 percent page 61 PUMP FAULT SPD OEM 0 100 100 percent page 61 SERVICE TOTL OEM OFF page 62 SERVICE TRAC OEM OFF page 62 SERVICE PUMP OEM OFF...

Page 118: ...1 SPECIFICATIONS 1297 CONTROLLER Nominal input voltage 24 V PWM operating frequency 16 kHz Electrical isolation to heatsink 500 V ac minimum KSI input voltage minimum 16 8 V KSI input current no cont...

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