MODEL MANUAL 12 9 7 INTEGRATED TRACTION & HYDRAULIC SYSTEM C O N T R O L L E R © 2001 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. CURTIS PMC 235 East Airway Boulevard Livermore, California 94550 USA Tel: 925-961-1088 Fax: 925-961-1099 www.curtisinst.com 1297 Manual, p/n 36411 Rev.
1297 Manual p/n 36411, Rev. A: February 2001 © 2001 CURTIS INSTRUMENTS, INC. CURTIS INSTRUMENTS, INC. 200 KISCO AVENUE MOUNT 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, China, England, France, Germany, India, Italy, Japan, Netherlands, Puerto Rico, Russia, Sweden, and Switzerland www.curtisinst.
CONTENTS CONTENTS 1. OVERVIEW ............................................................................. 1 2. INSTALLATION AND WIRING ........................................... 4 Mounting the Controller .................................................... 4 Connections: Low Current ................................................ 6 Connections: High Current ............................................... 7 Wiring: Standard Configuration, without multiplexer .......
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CONTENTS Pump BDI Lockout ................................................... 48 Pump BDI Lockout Warning ..................................... 48 Hydraulic Inhibit ....................................................... 48 Valve Control Parameters .................................................. 49 Lowering Valve Maximum Current ............................ 49 Lowering Valve Minimum Current ............................ 49 Lowering Valve Dither % ...........................................
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FIGURES FIGURES Curtis PMC 1297 Manual FIG. 1: Curtis PMC 1297 integrated traction and hydraulic system controller .................................. 1 FIG. 2: Mounting dimensions, Curtis PMC 1297 controller ............... 4 FIG. 3: Standard wiring configuration, for applications without tiller multiplexer ................................ 8 FIG. 4: Standard wiring configuration, for applications with tiller multiplexer ................................... 10 FIG.
TABLES FIG. 22: Effect of adjusting the hydraulic throttle max parameter ....... 53 FIG. 23: Hydraulic throttle maps for Lift, for controller with maximum speed set at 100% ......................................... 54 FIG. 24: Hydraulic throttle maps for Lift, for controller with maximum speed set at 80% ........................................... 55 FIG. 25: Influence of various parameters on controller output response to hydraulic throttle Lift demand ................. 55 FIG.
1 — OVERVIEW 1 OVERVIEW The Curtis PMC 1297 motor controller is an integrated controller that combines two motor controllers in one: it controls both a separately-excited traction motor and a series pump motor. Typical applications include walkie/rider pallet trucks, low lifts, stackers, small order-pickers, small reach trucks, and other small industrial vehicles. Fig. 1 Curtis PMC 1297 integrated traction and hydraulic system controller.
1 — OVERVIEW Like all Curtis PMC motor controllers, the 1297 offers superior operator control of motor speed.
1 — OVERVIEW ✓ Fully protected inputs ✓ Internal and external watchdog circuits ensure proper software operation ✓ High environmental protection rating (IP53) ✓ 3-wire serial interface for multifunction display—see below ✓ 4-wire serial interface for all tiller functions—see below Curtis Model 840 Spyglass Display Preliminary on Verso page is set with right edge at 7 and 7/8, 3-wire interface and the✓top (as onserial the Recto page) at 1/4.
2 — INSTALLATION & WIRING: Controller 2 INSTALLATION AND WIRING MOUNTING THE CONTROLLER The 1297 controller can be oriented in any position, and meets the IP53 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.
2 — INSTALLATION & WIRING: Controller 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 C. The 1297 controller contains ESD-sensitive components. Use appropriate precautions in connecting, disconnecting, and handling the controller. See installation suggestions in Appendix C for protecting the controller from ESD damage.
2 — INSTALLATION & WIRING: Controller CONNECTIONS Low Current Connections Three low current connectors (J1, J2, J3) are built into the 1297 controller. They are located in a row on the top of the controller: 24-pin J1 6-pin J2 4-pin J3 The 24-pin connector (J1) provides the logic control connections for the contactor drivers and switches that are wired directly to the vehicle.
2 — INSTALLATION & WIRING: Controller A 6-pin low power Molex connector (J2) is provided for the tiller multiplexer controls. The mating connector is a Molex Mini-Fit Jr. p/n 39-01-2065 using type 5556 terminals. The multiplexer uses four of J2’s six pins: 2, 3, 4, and 6.
2 — INSTALLATION & WIRING: Controller WIRING: Standard Configuration without multiplexer Figure 3 shows the typical wiring configuration for applications where a tiller multiplexer is not used. For walkie applications the interlock switch is typically activated by the tiller, and an emergency reverse switch on the tiller handle provides the emergency reverse signal. For rider applications the interlock switch is typically a seatswitch or a footswitch, and there is no emergency reverse.
2 — INSTALLATION & WIRING: Controller less obvious. The direction of vehicle travel with the forward direction selected will depend on how the motor’s field connections are made to the controller’s two field terminals and how the motor shaft is connected to the drive wheels through the vehicle’s drive train. CAUTION: The polarity of the F1 and F2 connections will affect the operation of the emergency reverse feature.
2 — INSTALLATION & WIRING: Controller WIRING: Standard Configuration with multiplexer Figure 4 shows the typical wiring configuration for applications where a tiller multiplexer is used. 5= 8= 6= DISPLAY J1 Pin 16 J1 Pin 17 LOAD HOLD VALVE J1 Pin 18 8 6 +15V ground data EMERG. REV. CHK J1 Pin 13 5 J1 Pin 15 MAIN CONTACTOR J1 Pin 9 J1 Pin 6 EMERG. REV. Preliminary on Verso page is set with right edge at 7 and 7/8, J1 Pin 24 HORN and the top (as on the Recto page) at 1/4.
2 — INSTALLATION & WIRING: Controller Power Wiring Traction motor armature wiring is straightforward, with the armature’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 field connections are less obvious.
2 — INSTALLATION & WIRING: Throttles WIRING: Throttles Various throttles can be used with the 1297 controller. They are categorized as one of four types in the programming menu of the 13XX programmer. Only Types 2 and 4 can be used for the hydraulic throttle.
2 — INSTALLATION & WIRING: Throttles 5kΩ–0 Throttle (“Type 1”) The 5kΩ–0 throttle (called a “Type 1” throttle in the programming menu of the 13XX programmer) is a 2-wire resistive throttle that connects between the pot wiper pin (Pin 4) and the Pot Low pin (Pin 22), as shown in Figure 5. For Type 1 devices, zero speed corresponds to a nominal 5kΩ measured between the pot wiper and Pot Low pins and full speed corresponds to 0Ω. Fig. 5 Wiring for 5kΩ–0 throttle (“Type 1”).
2 — INSTALLATION & WIRING: Throttles Fig. 6 Wiring for 0–5V throttles (“Type 2”). (a) Sensor-referenced 0–5V source Pot Low input (Pin 22) Hyd. 0–5V input (Pin 21) SENSOR + J1 Hydraulic Throttle 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 SENSOR OUTPUT (0–5V) + SENSOR GROUND Preliminary on Verso page is set with right edge at 7 and 7/8, SENSOR and the top (as on the Recto page) at 1/4.
2 — INSTALLATION & WIRING: Throttles Current Source Used As a Speed Control Device A current source can be used as a throttle input as shown in Figure 7. A resistor, R throttle, must be used to convert the current source value to a voltage. The resistor should be sized to provide a 0–5V signal variation over the full current range. It is the responsibility of the OEM to provide appropriate throttle fault detection for current sources used as throttles. Fig. 7 Wiring for current source throttle (“Type 2”).
2 — INSTALLATION & WIRING: Throttles Curtis ET-XXX Electronic Throttle The Curtis ET-XXX provides a 0–5V throttle input and also Forward/Reverse inputs (traction throttle) or Lift/Lower inputs (hydraulic throttle) for the 1297 controller. Wiring for the ET-XXX is shown in Figure 9. When an electronic throttle is used, the Pot Low Check parameter (see Section 3A, page 40) must be set to Off; otherwise the controller will register a throttle fault. Fig.
2 — INSTALLATION & WIRING: Throttles 0–5kΩ Throttle (“Type 3”) The 0–5kΩ throttle (“Type 3” in the programming menu) is a 2-wire resistive throttle that connects between the pot wiper pin (Pin 4) and the Pot Low pin, as shown in Figure 10. Zero speed corresponds to 0Ω measured between the two pins and full speed corresponds to 5 kΩ. Fig. 10 Wiring for 0–5kΩ throttle (“Type 3”).
2 — INSTALLATION & WIRING: Aux. Driver, Coast-and-Pick & Emerg. Reverse WIRING: Auxiliary Driver (REQUIRES MULTIPLEXER) The 1297 controller provides an auxiliary driver at Pin 8. This low side driver, designed to energize a contactor coil, can be used to perform a variety of functions—such as engaging a brush motor. The output is rated at 2 amps, is overcurrent protected, and the turn-off is voltage clamped. The recommended wiring for an auxiliary contactor coil is shown in Figure 4.
2 — INSTALLATION & WIRING: Emerg. Rev. Check & Spyglass not connected, the vehicle will not operate. If the option is not selected and the check wire is connected, no harm will occur—but continuity will not be checked. WIRING: Spyglass Display The Curtis 840 Spyglass features an 8-character LCD display that sequences between hourmeter, BDI, and fault messages. Three indicator LEDs—hourmeter, BDI, and service—are also located on the face of the gauge.
2 — INSTALLATION & WIRING: Switches, etc. CONTACTOR, SWITCHES, and OTHER HARDWARE Main Contactor A main contactor should be used with the 1297 controller. Otherwise, the controller’s fault detection will not be able to fully protect the controller, traction system, and hydraulic system from damage in a fault condition. The contactor allows the controller and both motors to be disconnected from the battery.
2 — INSTALLATION & WIRING: Switches, etc. wired in series with the main contactor to protect the motors, 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 (Figures 3 and 4) show the recommended location for each fuse.
3 — PROGRAMMABLE PARAMETERS 3 PROGRAMMABLE PARAMETERS The 1297 controller has nearly one hundred parameters that can be adjusted by means of a 13XX programmer. These programmable parameters allow various performance characteristics to be customized to fit the needs of individual applications or system operators. Each controller is either a generic model or an OEM-specific model. Generic controllers are shipped with the default parameter settings shown in Table D-1, and have model numbers ending “01” (e.g.
3 — PROGRAMMABLE PARAMETERS A: TRACTION B: HYDRAULICS C: SHARED (parameters related to the traction motor and drive system) (parameters related to the pump motor and hydraulics) (parameters related to both traction and hydraulics) Acceleration Parameters Pump Parameters Contactor and Sequencing Delay Parameters Drive Current Limit, M1–M2 Pump Current Limit Acceleration Rate, M1–M2 Pump Max Speed Sequencing Delay Current Ratio No Load Pump Current Limit Main Contactor Interlock Boost Enable
3A — PROGRAMMABLE TRACTION PARAMETERS: Acceleration A. TRACTION PARAMETERS The various traction parameters adjust the vehicle’s operating characteristics—its acceleration, braking, speed, and responsiveness. These parameters allow the vehicle to be tailored to a specific application, or to a specific operator’s preferences. The MultiMode™ feature of the 1297 controller allows operation in two distinct modes.
3A — PROGRAMMABLE TRACTION PARAMETERS: Braking CURRENT RATIO The current ratio parameter defines how much of the programmed drive current will be available to the traction motor at reduced throttle requests. The current ratio parameter can be set to 1, 2, 3, or 4.
3A — PROGRAMMABLE TRACTION PARAMETERS: Braking current. (The full rated braking current depends on the controller model; see specifications in Table E-1.) The braking current limit is tuned as part of the vehicle performance adjustment process (Section 5). M1–M2, BRAKE RATE The braking rate defines the time it takes the controller to increase from 0% braking output to 100% braking output when a new direction is selected. A larger value represents a longer time and consequently gentler braking.
3A — PROGRAMMABLE TRACTION PARAMETERS: Braking high can cause the vehicle to feel uncontrollable when the throttle is released, as it will continue to drive for a short period. The throttle decel rate is adjustable from 0.1 to 1.0 second, with a value of 0.3 or 0.4 working well for most vehicles. When the armature current goes negative (i.e., at the point when positive torque transitions to negative torque), the normal decel rate goes into effect.
3A — PROGRAMMABLE TRACTION PARAMETERS: Braking Fig. 12 Ramp restraint 25 20 Field Max = 18 A FIELD CURRENT (amps) map for controller with Field Min set at 3 amps, Field Max set at 18 amps, and braking current limit set at 300 amps. 15 t= s tr Re 10 n ai 35 A 5A int =2 = 15 A 0 int = 1 Restra A aint tr Res a str Re 5 Restraint = 3 A Field Min =3A 0 0 50 100 150 200 ARMATURE CURRENT (amps) 250 300 Brake C/L = 300 A slower the vehicle will creep down ramps.
3A — PROGRAMMABLE TRACTION PARAMETERS: Braking E-M BRAKE TYPE The electromagnetic brake type parameter configures the low side brake driver at J1 Pin 20. Driver output is rated at 2 amps and is monitored for overcurrent faults. An internal diode provides coil suppression through the KSI input (J1 Pin 1). The electromagnetic brake driver can be programmed to operate in any of the configurations (i.e., options 0 through 4) described in Table 2.
3A — PROGRAMMABLE TRACTION PARAMETERS: Braking Table 2 CONFIGURATION OPTIONS: ELECTROMAGNETIC BRAKE DRIVER (J1 Pin 20) OPTION DESCRIPTION OF OPERATION 0 Brake Driver disabled. 1 Electromagnetic brake used like a parking brake. The Brake Driver powers the brake coil when the interlock switch closes, and opens it immediately when the interlock switch opens. There is no delay, other than the specified Brake Delay, between the Brake Driver being turned off and the interlock switch opening.
3A — PROGRAMMABLE TRACTION PARAMETERS: Speed Speed Parameters M1–M2, MAX SPEED The maximum speed parameter defines the maximum controller voltage output at full throttle. The maximum speed parameter is adjustable from 0% to 100% of full output. The maximum speed is tuned as part of the vehicle performance adjustment process (Section 5). CREEP SPEED The creep speed parameter defines the initial controller output generated when a direction is first selected.
3A — PROGRAMMABLE TRACTION PARAMETERS: Speed If the interlock override feature is desired, you will probably want to configure M2 (mode switch closed) as the slow speed mode, and M1 (mode switch open) as the high speed mode. This is opposite of the typical setup. NOTE: The interlock override feature and the high speed latch parameters are mutually exclusive; you cannot have both. To initiate override, close the mode switch (M2) while the vehicle is stopped with the interlock switch open.
3A — PROGRAMMABLE TRACTION PARAMETERS: Throttle Throttle Parameters THROTTLE TYPE The 1297 controller accepts a variety of throttle inputs. Instructions are provided in Section 2 for wiring the most commonly used throttles: 5kΩ–0 and 0–5kΩ 2-wire rheostats, 3-wire pots (single-ended or wigwag), 0–5V throttles (single-ended or wigwag), current sources (single-ended or wigwag), and the Curtis ET-XXX electronic throttle. The throttle type parameter can be programmed to 1, 2, 3, or 4.
3A — PROGRAMMABLE TRACTION PARAMETERS: Throttle THROTTLE DB The throttle deadband parameter defines the throttle pot wiper voltage range that the controller interprets as neutral. Increasing the throttle deadband setting increases the neutral range.
3A — PROGRAMMABLE TRACTION PARAMETERS: Throttle Fig. 13, cont’d Effect of adjusting the throttle deadband parameter (throttle types 3 and 4). Throttle Type 3 (0–5kΩ) 0 5V 40% Deadband 3.3V (5.0kΩ) 1.4V (2.0kΩ) 10% Deadband 3.3V (5.0kΩ) 0.5V (450Ω) 0% Deadband 3.3V (5.0kΩ) 0.2V (0Ω) Throttle Type 4 (0–5V, wigwag) 0 5V 40% Deadband 0.5V 1.7V 3.3V 4.5V 10% Deadband 0.5V 2.3V 2.7V 4.5V 0% Deadband 2.5V 0.5V Notes: Voltages shown are at the pot wiper relative to B-.
3A — PROGRAMMABLE TRACTION PARAMETERS: Throttle THROTTLE MAX The throttle maximum parameter sets the wiper voltage or resistance required to produce 100% controller output. Decreasing the throttle max setting reduces the wiper voltage or resistance and therefore the full stroke necessary to produce full controller output. This feature allows reduced-range throttle assemblies to be accommodated.
3A — PROGRAMMABLE TRACTION PARAMETERS: Throttle Fig. 14, cont’d Effect of adjusting the throttle max parameter (throttle types 3 and 4). Throttle Type 3 (0–5kΩ) 0 5V 0.2V (0Ω) 100% Throttle Max 40% Deadband 1.4V (2.0kΩ) 3.3V (5.0kΩ) 90% Throttle Max 40% Deadband 1.4V (2.0kΩ) 3.0V (4.5kΩ) 90% Throttle Max 10% Deadband 3.0V (4.5kΩ) 0.5V (400Ω) 60% Throttle Max 10% Deadband 2.1V (3.0 kΩ) 0.5V (400Ω) Throttle Type 4 (0–5V, wigwag) 0 5V 100% Throttle Max 40% Deadband 0.5V 3.3V 1.7V 4.
3A — PROGRAMMABLE TRACTION PARAMETERS: Throttle THROTTLE MAP The throttle map parameter determines the static throttle map of the controller. This parameter modifies the vehicle’s response to the throttle input. 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 settings, providing enhanced slow speed maneuverability.
3A — PROGRAMMABLE TRACTION PARAMETERS: Throttle In Figure 16, the creep speed is increased to 10% and the maximum speed is left at 100%, resulting in a controller output range of 90%. With these speed settings, a 50% throttle map will result in 55% output (45% + 10%) at half throttle. Fig. 16 Throttle maps for 100 CONTROLLER OUTPUT (percent PWM) controller with maximum speed set at 100% and creep speed set at 10%.
3A — PROGRAMMABLE TRACTION PARAMETERS: Throttle 100 SPEED PARAMETERS 90 80% Max Speed 60 50 40 90% Throttle Max 70 HALF THROTTLE 80 15% Throttle Deadband CONTROLLER OUTPUT (percent PWM) Fig. 18 Influence of various parameters on controller output response to throttle demand.
3A — PROGRAMMABLE TRACTION PARAMETERS: Field Field Parameters FIELD MIN The minimum field current limit parameter defines the minimum allowed field winding current. The minimum field current limit setting determines the vehicle’s maximum speed. Field Min can be adjusted from 2 amps up to the programmed Field Max value. The Field Min parameter is tuned as part of the vehicle performance adjustment process (Section 5).
3A — PROGRAMMABLE TRACTION PARAMETERS: Field Fig. 19 Field current Max Field FIELD CURRENT relative to armature current, with field map parameter set at 50% and at 25%. Field Map (50%) Min Field 0 0 Field Map Start Field Map Midpoint Current Limit ARMATURE CURRENT FIELD CURRENT Max Field Field Map (25%) Min Field 0 0 Field Map Start Field Map Midpoint Current Limit ARMATURE CURRENT programmed drive current limit). This point is referred to as the Field Map Midpoint.
3A — PROGRAMMABLE TRACTION PARAMETERS: Emergency Reverse Emergency R everse Parameters EMR REV C/L The emergency reverse current limit parameter defines the maximum braking current provided through the motor when the optional emergency reverse function is engaged. The emergency reverse current limit is adjustable from 50 amps up to the controller’s full rated braking current. (The full rated braking current depends on the controller model; see specifications in Table E-1.
3A — PROGRAMMABLE TRACTION PARAMETERS: Other (Traction) the controller will return to normal operation from this point. If the emergency reverse direction interlock parameter is set to On, the operator can either open both direction switches or cycle the interlock switch to enable normal operation. With the parameter set to Off, the only way for the operator to resume normal operation is by cycling the interlock switch.
3A — PROGRAMMABLE TRACTION PARAMETERS: Other (Traction) at the time the interlock switch is closed. Normal controller operation is regained by reducing the throttle demand to less than 25%. KSI-type HPD (Type 2) To start the vehicle, the controller must receive a KSI input before receiving a throttle input greater than 25%. Controller operation will be disabled immediately if throttle demand is greater than 25% at the time KSI is enabled.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Pump B. HYDRAULIC PARAMETERS The various hydraulic parameters adjust the hydraulic system’s operating characteristics—its acceleration, speed, and responsiveness. These parameters allow the hydraulic system to be tailored to a specific application, or to a specific operator’s preferences. The 1297 controls the speed of the pump motor, and also the valves on the Lift cylinder’s hydraulic line. By so doing, it controls the hydraulic path for Lift and Lower operations.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Pump The 1297 controls: • the speed of the pump motor (which regulates how quickly the hydraulic fluid can push up the Lift cylinder), • the position of the load-hold valve (open/closed), and • the aperture of the proportional lowering valve (which regulates how quickly the hydraulic fluid can drain from the Lift cylinder).
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Lift Lockout Lift Lockout P arameters Lift operation can be prevented during overcurrent conditions or when the battery state-of-charge is below 20%. These are safety measures to protect the operator and the pump motor. In addition, both Lift and Lower can be prevented if more than 25% throttle is requested at the time the interlock switch is closed.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Valve Control Valve Control Parameters The 1297 controls the operation of the load-hold valve and the proportional lowering valve, as shown in Figure 21. By so doing, it controls the hydraulic path for Lift and Lower operations. Some hydraulic systems have a proportional lowering valve but no load-hold valve. Others have a simple open/closed lowering valve in place of a proportional valve. In these systems, variable lowering (i.e.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Valve Control LV DECEL The LV current deceleration rate parameter specifies how long it will take the lowering valve current to decrease from 100% to 0%. The LV current decel rate is programmable from 0.0 to 3.0 seconds. LV CHECK The LV check parameter defines whether the controller performs missing coil checks on the lowering valve solenoid coil.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Hydraulic Throttle Hydraulic Throttle Parameters Most applications use a throttle to provide variable speed control of Lift and Lower. A throttle gives the operator more flexibility and control over performance than is provided by the Lift and Lower switches alone.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Hydraulic Throttle The programmer displays the hydraulic throttle deadband parameter as a percentage of the nominal wiper voltage range and is adjustable from 0% to 40%. The default deadband setting is 10%. The nominal wiper voltage range depends on the throttle type selected. See Table 1 (page 12) for the characteristics of your selected throttle type. Fig. 21 Effect of adjusting the hydraulic throttle deadband parameter.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Hydraulic Throttle HYD THRTL MAX The hydraulic throttle maximum parameter sets the throttle wiper voltage required to produce 100% controller output. Decreasing the hydraulic 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 22 for throttle types 2 and 4.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Hydraulic Throttle The programmer displays hydraulic Throttle Max as a percentage of the throttle’s active voltage range. The nominal voltage range depends on the throttle type selected. See Table 1 (page 12) for the characteristics of your selected throttle type. The hydraulic Throttle Max parameter can be adjusted from 100% to 60%, in 1% increments. HYD THRTL MAP The hydraulic throttle map parameter modifies the response to a throttle input.
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Hydraulic Throttle Fig. 24 Hydraulic throttle 100 CONTROLLER OUTPUT (percent PWM) maps for Lift, for controller with maximum speed set at 80%. THROTTLE MAP 90 80% 60% 80 50% 40% 70 30% 60 20% 50 SPEED PARAMETER 40 80% Pump Max Speed 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 HYDRAULIC THROTTLE INPUT (percent of active range) to increase as soon as the throttle is rotated out of its normal neutral range (deadband).
3B — PROGRAMMABLE HYDRAULIC PARAMETERS: Hydraulic Throttle operation—with % LV current along the y axis instead of % PWM, and the speed ceiling being determined by the programmed LV Max Current rather than by the programmed Pump Max Speed. VARIABLE LIFT The variable lift parameter enables throttle control of Lift speed. When variable lift is programmed Off, the pump speed is determined by the maximum pump speed parameter.
3C — PROGRAMMABLE SHARED PARAMETERS: Sequencing Delay & Contactor C. SHARED PARAMETERS In addition to the traction parameters and hydraulic parameters, there are a number of parameters that affect both the traction and the hydraulic systems. These shared parameters include the sequencing delay, various contactor parameters, the enable for the multiplexer, and all the hourmeter and BDI parameters.
3C — PROGRAMMABLE SHARED PARAMETERS: Multiplexer commanded to so, and that it has not welded closed. These checks are not performed if the main contactor diagnostics parameter is set to Off. The main contactor driver, however, is always protected from overcurrents, short circuits, and overheating. Multiplexer Parameter MUX ENABLE The multiplexer enable parameter, when programmed On, enables the J2 connector—and thus the multiplexer—as shown in Figure 4, page 10.
3C — PROGRAMMABLE SHARED PARAMETERS: Hourmeters Hourmeter Parameters Three hourmeters are built into the 1297 controller, each with non-volatile memory: • a total hourmeter, that measures the total operating time (KSI on-time), • a traction hourmeter, that measures the traction motor on-time, and • a pump hourmeter, that measures the pump motor on-time. Each of these three hourmeters has a corresponding service timer and disable timer. Hourmeter information is viewable via the Spyglass display.
3C — PROGRAMMABLE SHARED PARAMETERS: Hourmeters SET TOTL HRS The set total hours parameter is used to apply the preset high, middle, and low byte values to the total (i.e., KSI on-time) hourmeter. First, adjust the byte values as desired for the total hourmeter. Then, program the Apply Total Hours parameter On, which automatically loads the preset values. Once they have been loaded, the apply hours parameter should be programmed Off.
3C — PROGRAMMABLE SHARED PARAMETERS: Hourmeters Hourmeter Disable Timer Setting DIS TOTL HRS The total disable hours parameter is used to set the total disable timer; it can be adjusted between 0 and 250 hours, in 1 hour increments. If the total disable timer expires, the traction fault speed and pump fault speed both go into effect. DIS TRAC HRS The traction disable hours parameter is used to set the traction disable timer; it can be adjusted between 0 and 250 hours, in 1 hour increments.
3C — PROGRAMMABLE SHARED PARAMETERS: Hourmeters Hourmeter Reset Service Times SERVICE TOTL When the total service timer expires, the controller automatically sets the service total parameter On. The user must then program the service total parameter Off to indicate the appropriate service has been performed. SERVICE TRAC When the traction service timer expires, the controller automatically sets the service traction parameter On.
3c — PROGRAMMABLE SHARED PARAMETERS: BDI Battery Discharge Indicator (BDI) Parameters The battery discharge indicator constantly calculates the battery state-of-charge whenever KSI is on. When KSI is turned off, the present battery state-of-charge is stored in non-volatile memory. BDI information is viewable via the Spyglass display and via the Test Menu of the 13XX programmer. Three parameters are used to adjust the display.
4 — INSTALLATION CHECKOUT 4 INSTALLATION CHECKOUT Carefully complete the following checkout procedure before operating the vehicle. If you find a problem during the checkout, refer to the diagnostics and troubleshooting section (Section 7) for further information. The installation checkout can be conducted with or without a 13XX programmer. The checkout procedure is easier with a programmer.
4 — INSTALLATION CHECKOUT Curtis PMC 1297 Manual 4. First, check out the traction system. With the interlock switch closed, select a direction and apply throttle. The motor should begin to turn in the selected direction. If it does not, first verify the wiring to the forward and reverse switches. If the wiring is correct, turn off the controller, disconnect the battery, and exchange the motor’s field connections (the F1 and F2 cables) on the controller. The motor should now turn in the proper direction.
4 — INSTALLATION CHECKOUT 12. Using the hydraulic throttle, operate the Lift and Lower. They should accelerate and decelerate smoothly. 13. Verify that the hydraulic inhibit feature performs as desired. 14. If you used a programmer, disconnect it when you have completed the checkout procedure. BENCH TESTING WITH A 13XX PROGRAMMER With the simple bench test setup shown in Figure 26, the controller parameters can be verified or adjusted without the controller being wired into a vehicle.
5 — VEHICLE PERFORMANCE ADJUSTMENT 5 VEHICLE PERFORMANCE ADJUSTMENT The 1297 controller is a very powerful vehicle control system. Its wide variety of adjustable parameters allow many aspects of vehicle performance to be optimized. This section provides explanations of what the major tuning parameters do and instructions on how to use these parameters to optimize the performance of your vehicle. Traction system tuning is described first, followed by hydraulic system tuning.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning range of the throttle mechanism to allow for throttle resistance variations over time and temperature as well as variations in the tolerance of potentiometer values between individual throttle mechanisms. ➀-A Tuning the Throttle Deadband 1. Jack the vehicle wheels up off the ground so that they spin freely. STEP 2. Plug the 13XX programmer into the controller, and turn on the keyswitch. If your application has an interlock switch, close it. STEP 3.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning ➀-B Tuning the Throttle Max STEP 1. Jack the vehicle wheels up off the ground so that they spin freely. STEP 2. Plug the 13XX programmer into the controller and turn on the keyswitch. If your application has an interlock switch, close it. STEP 3. When the programmer instructs you to select a menu, select the Test Menu. The Throttle % parameter should be visible in the initial display. You will need to reference the value displayed here. 4.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning ➁ Tuning the Controller to the Motor The 1297 controller has the flexibility to be tuned to nearly any separately excited motor from any manufacturer. Parameters in the 13XX programmer’s Program Menu allow full control of the motor’s maximum armature current during driving and braking and full control of the motor’s maximum and minimum field current as well as the field current relationship to the armature current.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning STEP 4. For the most consistent operation across temperature, set the Field Max to the maximum field current available at low battery voltage and with a hot motor. To determine this value, divide the low battery voltage (typically 70% of nominal) by the high temperature field winding resistance specification provided by the manufacturer. Set the Field Max to this value.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning ➂ Setting the Vehicle’s Unloaded Top Speed The controller and vehicle should be configured as follows before starting this procedure: • • • • • Max Speed = 100% Drive Current Limit as established in procedure ➁ Field Map = 50% Field Map Start = 50% of the specified drive current limit Field Min = motor manufacturer’s specified minimum (if available); otherwise, 5 amps • Load Comp = 0 Preliminary Verso should page isbe setunloaded with right edge at 7 and 7/
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning Min set at the value selected in Step 3, decrease the Max Speed parameter value until the desired vehicle top speed is set. STEP 5. For Walkie/Rider Applications: Typically, different top speeds are desired for walkie and rider operation. To tune a walkie/rider vehicle’s top speed, first tune it for rider operation by using the Field Min parameter.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning armature current displayed in the programmer’s Test Menu. (ii) Set the Field Map Start parameter to the observed armature current value. (iii) Load the vehicle and drive it on flat ground with full throttle applied. Further adjustments to the vehicle’s loaded speed can now be made by varying the Field Map parameter.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning STEP 2. The default Restraint setting (8 amps) should work well for most vehicles. If the vehicle exhibits excessive overspeed when driving down a ramp, increase the Restraint value. If the vehicle “speed hunts” while driving down a ramp or brakes too abruptly at low or released throttle, decrease the Restraint value. STEP 3.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Traction Tuning Ramp Climbing The vehicle’s response to increased gradients such as loading ramps can be tuned via the Field Map parameter. Decreasing the Field Map parameter allows faster vehicle speeds while climbing ramps, but it also has the effect of reducing the ability of the controller to generate torque in the vehicle’s mid-range speeds. 1.
5 — VEHICLE PERFORMANCE ADJUSTMENT: Hydraulic Tuning HYDRAULIC TUNING Tuning the hydraulic system is more straightforward than tuning the drive system, because the parameters are not so inter-related. Nonetheless, it is important that the effect of these programmable parameters be understood in order to take full advantage of the 1297 controller’s powerful features. Please refer to the descriptions of the applicable parameters in Section 3B if there is any question about what any of them do.
6 — PROGRAMMER MENUS: Program Menu 6 PROGRAMMER MENUS The universal 13XX Curtis PMC programmers allow you to program, test, and diagnose Curtis PMC programmable controllers. For further information about programmer operation, consult the programmer manual or call the Curtis office closest to you. There are five programmer menus: • Program Menu Test Menu Preliminary on•Verso page is set with right edge at 7 and 7/8, • Diagnostics Menu and the top (as on the Recto page) at 1/4.
6 — PROGRAMMER MENUS: Program Menu Program Menu, cont’d VARIABLE BRAKE Braking proportional to opposite-direction throttle: on/off TAPER RATE Threshold affecting end of regen during direction reversal: 1–20 INT OVERRIDE Special operation with interlock switch open: on/off H/S LATCH Momentary-type mode switch electrically “latchable” in M2: on/off Anti-tiedown: on/off THROTTLE TYPE Throttle input signal type 1 THROTTLE DB Neutral deadband, as % of throttle range THROTTLE MAX % of throttle movement a
6 — PROGRAMMER MENUS: Program Menu Program Menu, cont’d HYD THRTL MAX % of pump throttle movement at which 100% output occurs HYD THRTL MAP Throttle map, as % pump motor PWM at half pump throttle Enables variable Lift: on/off VARIABLE LOWER Enables variable Lower: on/off PUMP MAX SPEED Pump max. speed during Lift, as % armature PWM NO LOAD SPEED Pump max.
6 — PROGRAMMER MENUS: Program Menu Program Menu Notes 1 Traction throttle types (see Throttle Wiring in Section 2) Type 1: 5kΩ–0 Type 2: single-ended 0–5V throttles and 3-wire pots Type 3: 0–5kΩ Type 4: wigwag 0–5V throttles and 3-wire pots Preliminary on Verso page is set with right edge at 7 and 7/8, 2 HPD types (see Section 3A, page 44) Typetop 0: (as Noon HPD. and the the Recto page) at 1/4. Type 1: HPD unless KSI and interlock inputs received before throttle request.
6 — PROGRAMMER MENUS: Test Menu 1297 TEST MENU (not all items available on all controllers) Battery voltage across B+ and B-, in volts BDI % Battery state of charge, as % of full charge HEATSINK TEMP Heatsink temperature, in °C THROTTLE % Throttle reading, as % of full throttle FIELD CURRENT Traction motor field current, in amps ARM CURRENT Traction motor armature current, in amps FIELD PWM Traction motor field duty cycle, as % ARM PWM Traction motor armature duty cycle, as % Preliminary on Verso page is set
6 — PROGRAMMER MENUS: Diagnostics Menu 1297 DIAGNOSTICS AND DIAGNOSTIC HISTORY This is a list of the possible messages you may see displayed when the programmer is operating in either of the Diagnostics modes. The messages are listed here in alphabetical order for easy reference.
7 — DIAGNOSTICS & TROUBLESHOOTING 7 DIAGNOSTICS AND TROUBLESHOOTING The 1297 controller provides diagnostics information to assist technicians in troubleshooting pump system problems. The diagnostics information can be obtained by observing the appropriate display on a 13XX programmer, the fault codes issued by the Status LED, or the fault display on the Spyglass gauge. Refer to the troubleshooting chart (Table 5) for suggestions covering a wide range of possible faults.
7 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART LED CODE PROGRAMMER LCD DISPLAY EXPLANATION POSSIBLE CAUSE 1,1 DRIVE SENSOR traction motor current sensor error 1. Incorrect traction motor wiring. 2. Controller defective. 1,2 HW FAILSAFE self-test or watchdog fault 1. Controller defective. 1,3 DRIVE M- external short of traction motor Mto B-, or FET damage 1. Incorrect traction motor wiring. 2. Controller defective. 1,4 VALVE FAULT Lowering valve fault 1.
7 — DIAGNOSTICS & TROUBLESHOOTING Table 5 LED CODE 3,3 PROGRAMMER LCD DISPLAY TROUBLESHOOTING CHART, continued EXPLANATION POSSIBLE CAUSE FIELD SHORT traction motor field shorted 1. Field resistance too low. 2. Field winding shorted to B+ or B-. FIELD OPEN traction motor field open 1. Field winding or connection open. 3,4 MISSING CONTACTOR missing main contactor 1. Main contactor coil open. 2. Main contactor missing. 3. Wire to main contactor missing.
7 — DIAGNOSTICS & TROUBLESHOOTING LED DIAGNOSTICS A Status LED is built into the 1297 controller. It is visible through a window in the label on top of the controller. 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 flashes steadily on and off. If the controller detects a fault, a 2-digit fault identification code is flashed continuously until the fault is corrected.
7 — DIAGNOSTICS & TROUBLESHOOTING 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 codes that are flashed by the LED. For example, the LED flashes 3,2 for a welded main contactor: ¤¤¤ ¤¤ (3,2) ¤¤¤ ¤¤ (3,2) ¤¤¤ ¤¤ (3,2) and the corresponding Spyglass message is CODE 32.
8 — MAINTENANCE 8 MAINTENANCE There are no user serviceable parts in the Curtis PMC 1297 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 diagnostics history file be checked and cleared periodically.
APPENDIX A: GLOSSARY APPENDIX A GLOSSARY OF FEATURES AND FUNCTIONS Acceleration rate The acceleration rate is the time required for the controller to increase PWM output from zero to the maximum allowed.
APPENDIX A: GLOSSARY Bidirectional throttle A bidirectional (wigwag) throttle allows the operator to control vehicle speed and direction by rotating the throttle mechanism clockwise and counterclockwise. The Curtis ET-XXX is an example of this throttle type. Braking rate The braking rate is the time required for the controller to increase from 0% braking output to 100% braking output when a new direction is selected—see Section 3A, page 26.
APPENDIX A: GLOSSARY Current ratio The 1297 controller’s traction motor current limit increases linearly with increased throttle. The current ratio parameter allows adjustment of the amount of current available at low throttle requests in order to maximize startup torque while maintaining smooth vehicle starts—see Section 3A, page 25. Deceleration rate The deceleration rate is the time required for the controller to decrease PWM output from the maximum allowed to zero, in response to reduced throttle.
APPENDIX A: GLOSSARY Fault detection and response An internal microcontroller automatically maintains surveillance over the functioning of the controller. When a fault is detected, the appropriate fault code is signalled. If the fault is critical, the controller is disabled. More typically, the fault is a remediable condition and temporary. The faults covered by the 1297 controller’s automatic fault detection system are listed in Table 5—see Section 7, page 85.
APPENDIX A: GLOSSARY Field current values The maximum and minimum field current limit values have a powerful influence on the vehicle’s maximum speed and torque—see Section 3A, page 41. Tuning the maximum and minimum field current limits is described in detail in Section 5: Vehicle Performance Adjustment. Full bridge The 1297 controller uses a full bridge design for control of the traction motor’s field winding. This eliminates the need for external direction contactors.
APPENDIX A: GLOSSARY Cycling the interlock switch or the keyswitch clears most faults and re-enables operation. KSI KSI (Key Switch Input) provides power to the controller’s logic board, initializes the microprocessor, and starts diagnostics. In combination with the interlock switch input, KSI enables all logic functions.
APPENDIX A: GLOSSARY distance, outdoor travel. The following six parameters can be set independently in the two modes: — acceleration rate — braking current limit — braking rate — deceleration rate — drive current limit — maximum speed. The operator uses the mode switch to select Mode 1 (switch open) or Mode 2 (switch closed). Multiplexer (MUX) The Curtis PMC 1312 tiller multiplexer provides a 4-wire serial interface for all tiller functions.
APPENDIX A: GLOSSARY PWM Pulse width modulation (PWM), also called “chopping,” is a technique that switches battery voltage to the motor on and off very quickly, thereby controlling the speed of the motor. Curtis PMC 1200 series controllers use high frequency PWM—in this case, 16 kHz—which permits silent, efficient operation. Regenerative braking The 1297 controller uses regenerative braking to slow the vehicle to a stop and to reduce speed when traveling downhill.
APPENDIX A: GLOSSARY Smooth, stepless operation Like all Curtis PMC 1200 Series controllers, the 1297 allows superior operator control of the vehicle’s drive motor speed. The amount of current delivered to the motor is set by varying the “on” time (duty cycle) of the controller’s power MOSFET transistors. This technique—pulse width modulation (PWM)— permits silent, stepless operation.
APPENDIX A: GLOSSARY Throttle deadband (neutral deadband) The throttle deadband is the pot wiper voltage range that the controller interprets as neutral. The traction throttle amd hydraulic throttle have separate deadband parameters—see Section 3A, page 34, and Section 3B, page 51.
APPENDIX A: GLOSSARY battery voltage is pulled below the threshold by an external load. As soon as the voltage falls below the undervoltage threshold, the armature current is cut back linearly until it reaches zero at the cutoff point; normal controller operation resumes when the voltage rises above the threshold. During normal operation, the controller duty cycle will be reduced when the batteries discharge to below the undervoltage level.
APPENDIX APPENDIXA: B: GLOSSARY THROTTLES APPENDIX B MOUNTING DIMENSIONS FOR CURTIS THROTTLES Fig. B-1 Mounting dimensions, Curtis PMC standard 5kΩ, 3-wire potentiometer, p/n 98191. 14 (0.56) 20 (0.81) 28 (1.1) 6 (0.25) 35 (1.38) 35 (1.38) ELEC. SPECS: ELECTRICAL TRAVEL 40°± 3° TOTAL RESISTANCE (nominal) 5 kΩ HOPOFF RESISTANCE (max) 10 Ω Dimensions in millimeters and (inches) Fig. B-2 Mounting dimensions, Curtis PMC potboxes. 45° 42 (1.65) 10 (0.38) 60 (2.37) 32 (1.25) 52 (2.
APPENDIX APPENDIXA: B: GLOSSARY THROTTLES Fig. B-3 Mounting dimensions, Curtis PMC footpedal FP-2. 112 (4.4) 1.8 m (6 ft) ≈15 ° 244 (9.6) GRN ON BLK 112 (4.4) WHT N.O. WIRING: GREEN / BLACK / WHITE = throttle input BLUE = switch, common ORANGE = switch, normally COM. BLU open ORG Dimensions in millimeters and (inches) Fig. B-4 Mounting 45 (1.8) dimensions, Curtis potentiometer WP-45 CP. 55 (2.2) 8 (0.3) 1 45 (1.8) 30 (1.2) 40 ° 18 (0.7) 2 3 ELEC.
APPENDIX APPENDIXA: B: GLOSSARY THROTTLES Fig. B-5 Mounting 6 × 6 (0.24 × 0.24) dimensions, Curtis electronic speed control device (ET series). VIS TC 3×12 ∅ M5 99 (3.90) 24 (0.94) 44 (1.73) 24 (0.94) 69 (2.72) 116 ° 22 (0.87) 44 (1.73) 22 (0.
APPENDIX C: EMC & ESD DESIGN APPENDIX CONSIDERATIONS A: GLOSSARY APPENDIX C 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.
APPENDIX C: EMC & ESD DESIGN APPENDIX CONSIDERATIONS A: GLOSSARY Increasing Immunity Immunity to radiated electric fields 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.
APPENDIX C: EMC & ESD DESIGN APPENDIX CONSIDERATIONS A: GLOSSARY applied 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 field is re-radiated into the interior of the enclosure.
APPENDIX D: PROGRAMMABLE APPENDIX A: PARAMETERS GLOSSARY APPENDIX D PROGRAMMABLE PARAMETERS The 1297’s programmable parameters are listed below in alphabetical order (by display name), along with the default access levels, minimum and maximum allowable values, and default settings that are standard on generic models. Cross references to the main entry in the manual are also provided.
APPENDIX D: PROGRAMMABLE APPENDIX A: PARAMETERS GLOSSARY Table D-1, continued 1297 PARAMETER DEFAULT ACCESS MIN VALUE MAX VALUE DEFAULT SETTING 60 100 90 HYD THRTL MAX OEM HYD THRTL TYPE INT BRAKE C/L OEM OEM INT BRAKE DLY INT BRAKE RATE OEM OEM INT OVERRIDE LOAD COMP OEM OEM LOAD HOLD DLY LV ACCEL OEM OEM LV CHECK LV DECEL OEM OEM LV DITHER LV MAX C/L OEM OEM LV MIN C/L MAIN CONT DIAG OEM OEM MAIN CONT INT MAIN OPEN DLY OEM OEM 0 40 MAX SPEED, M1-M2 MUX ENABLE OEM OEM CREEP S
APPENDIX D: PROGRAMMABLE APPENDIX A: PARAMETERS GLOSSARY Table D-1, continued The 1297’s remaining parameters are listed below. For these lists, Program Menu order is used rather than alphabetical order.
APPENDIX APPENDIX E: SPECIFICATIONS A: GLOSSARY APPENDIX E SPECIFICATIONS Table E-1 SPECIFICATIONS: 1297 CONTROLLER Nominal input voltage PWM operating frequency Electrical isolation to heatsink 24 V 16 kHz 500 V ac (minimum) KSI input voltage (minimum) KSI input current (no contactors engaged) 16.8 V 80 mA without programmer; 120 mA with programmer Logic input voltage Logic input current >7.5 V High; <1 V Low 7.
