Curtis 1253 User manual

Manual
Model 1253
Hydraulic Pump Motor Controller
Read Instructions Carefully!
Specications are subject to change without notice.
© 2015 Curtis Instruments, Inc. ® Curtis is a registered trademark of Curtis Instruments, Inc.
© The design and appearance of the products depicted herein are the copyright of Curtis Instruments, Inc. 38329 Rev F 2/15
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com

Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F iii
CONTENTS
1. OVERVIEW..............................................................................1
2. INSTALLATION AND WIRING ...........................................3
Mounting the Controller .....................................................3
Low Current Connections....................................................5
High Current Connections ..................................................6
Wiring: Standard Configuration..........................................7
Wiring: rottles...............................................................11
Contactor, Switches, and Other Hardware.........................13
3. PROGRAMMABLE PARAMETERS.....................................15
Speed Parameters................................................................16
Maximum Speed, SS1–SS4 .........................................16
rottle Maximum Speed............................................16
Minimum Speed..........................................................16
Acceleration Rate.........................................................16
rottle Parameters ............................................................16
rottle Type...............................................................16
rottle Deadband ......................................................17
rottle Maximum......................................................18
rottle Map...............................................................20
Final Speed Request Parameters .........................................22
SS Add Mode ..............................................................22
Final Add Mode ..........................................................23
SS High Speed On ......................................................24
Fault Parameters.................................................................25
Lift Lockout Type........................................................25
Lift Lockout, SS1–SS4 ................................................25
Lift Lockout, rottle..................................................25
rottle Fault Detection..............................................26
Startup Lockout...........................................................26
Undervoltage Parameters....................................................27
Low Voltage Cutback ..................................................27
Low Voltage Cutback Rate ..........................................27
Contactor Control Parameters ...........................................27
Pump Contactor Control ............................................27
Contactor Pull-in Voltage ............................................27
Contactor Holding Voltage..........................................27
SS4 Delay....................................................................28
Interlock Delay............................................................28
Precharge.....................................................................28
Precharge Delay...........................................................28
CONTENTS

iv Curtis 1253 Manual, Rev. F
CONTENTS
Current Limit Parameter....................................................29
Main Current Limit (x10A).........................................29
4. INSTALLATION CHECKOUT............................................30
5. DIAGNOSTICS AND TROUBLESHOOTING..................32
Programmer Diagnostics ....................................................32
LED Diagnostics................................................................34
6. MAINTENANCE...................................................................35
appendix aVehicle Design Considerations
appendix bProgramming Devices and Menus
appendix cSpecifications, Curtis 1253 Controller

Blue Ox Rev. A, draft #1 [3 August 2007]
Curtis 1253 Manual, Rev. F v
FIGURES
. 1: Curtis 1253 hydraulic system controller................................... 1
. 2: Mounting dimensions, Curtis 1253 controller ........................ 3
. 3a: Standard wiring configuration,
using Curtis 803 gauge for lift lockout..................................... 7
. 3b: Standard wiring configuration,
using Curtis 906 gauge for lift lockout..................................... 8
. 3c: Standard wiring configuration,
using Curtis 841 “Superspy” for lift lockout............................. 9
. 3d: Standard wiring configuration,
using Curtis enGage™IV for lift lockout............................... 10
. 4: Wiring for 2-wire 5kΩ–0 potentiometer (“Type 0”) .............. 12
. 5: Wiring for 2-wire 0–5kΩpotentiometer (“Type 1”) .............. 12
. 6: Wiring for single-ended 0–5V input (“Type 2”) .................... 13
. 7: Wiring for single-ended 1–10kΩ3-wire pot (“Type 3”) ........ 13
. 8: Eect of adjusting the throttle deadband parameter .............. 17
. 9: Eect of adjusting the throttle max parameter ....................... 19
. 10: rottle maps for controller
with maximum speed set at 100% ........................................ 20
. 11: rottle maps for controller
with maximum speed set at 80% .......................................... 21
. 12: Inuence of various parameters on controller
output response to throttle demand ...................................... 21
. 13: Speed conditioning ............................................................... 23
. 14: SS High Speed On speed conditioning ................................. 24
. 15: Bench test setup .................................................................... 31
FIGURES

vi Curtis 1253 Manual, Rev. F
TABLES
TABLES
 1: rottle wiper input (threshold values)................................ 11
 2: Programmable throttle input signal types............................. 17
 3: Programmable lift lockout signal types ............................... 25
 4: Precharge function and fault detection................................. 28
 5: Troubleshooting chart.......................................................... 33
 6: Status LED fault codes ....................................................... 34
 C-1: Specifications, 1253 controller .......................................... C-1

Blue Ox Review of wiring diagrams [24 July 2007]
Curtis 1253 Manual, Rev. F 1
Blue Ox Rev. A, draft #1 [3 August 2007]
1 — OVERVIEW
OVERVIEW
e Curtis 1253 provides a cost-eective 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 (counter-
balance trucks, reach trucks), aerial lift platforms (scissor lifts, articulating/
telescoping booms), and other industrial vehicles.
e 1253 accepts inputs from up to four Speed Select switches and also
from an analog throttle. Its internal microprocessor-based logic controller pro-
vides maximum exibility at minimum cost. Its performance characteristics can
be tailored through an array of programmable parameters.
e 1253 controller is fully programmable through a Curtis handheld
programmer or PC Programming Station. e programming device provides
diagnostic and test capability in addition to conguration exibility.
1
Fig. 1 Curtis 1253
hydraulic pump motor
controller.
Like all Curtis motor controllers, the 1253 oers superior operator control of
motor speed and torque.
Smooth and Quiet Control
✓Programmable acceleration rates provide smooth application
of pump motor torque
✓15.6 kHz PWM frequency for near-silent operation.

2Curtis 1253 Manual, Rev. F
1 — OVERVIEW
Programmable Flexibility
✓Easily programmable through a Curtis programming device
✓Four Speed Select inputs (SS1–SS4) with individually programmable
top speeds
✓Programmable throttle input for precise speed control with a variety
of signal sources
✓Programmable turn-o delay allows SS4 to be used for power steering
✓Adjustable minimum speed setting to ensure pump lubrication
and to maintain steering system pressure
✓SS High Speed On mode enhances speed stability (1253-4804 only).
Robust Safety and Reliability
✓Interlock feature disables the controller when operator is not present
✓Programmable startup lockout prevents inadvertent operation
✓Seamless integration with Curtis gauges (models 803, 841, 906, and
enGage™IV) for lift lockout function
✓Lift lockout disables the controller at low battery state of charge
✓Redundant watchdog timer circuits ensure proper software operation
✓External Status LED output for easy troubleshooting
✓Short-circuit protection on main contactor driver
✓Precharge control prevents pitting of contactor tips at startup
✓ermal cutback provides protection to the controller
✓Rugged housing meets IP54 environmental ratings
✓Full-power operation over the -40°C – 80°C heatsink temperature
range.
Familiarity with your Curtis controller will help you install and operate it prop-
erly. We encourage you to read this manual carefully. If you have questions,
please contact the Curtis office nearest you.

Blue Ox Review of wiring diagrams [24 July 2007]
Curtis 1253 Manual, Rev. F 3
Blue Ox Rev. A, draft #1 [3 August 2007]
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
e 1253 controller can be oriented in any position, and meets the IP54 ratings
for environmental protection against dust and water. However, the location
should be carefully chosen to keep the controller clean and dry. If a clean,
dry mounting location cannot be found, a cover must be used to shield the
controller from water and contaminants.
e controller’s outline and mounting hole dimensions are shown in
Figure 2. When selecting the mounting position, be sure to also take into
consideration that access is needed at the end of the controller to plug the
programmer into its connector.
To ensure full rated power, the controller should be fastened to a clean,
at metal surface with four 6 mm (1/4") diameter screws, using the holes
2
2 — INSTALLATION & WIRING: Controller
Fig. 2 Mounting dimensions, Curtis 1253 controller.
7.2 (0.28) dia. 16 (0.63)
196 (7.72)
31.3 (1.23) 133.3 (5.25)
146.0 (5.75)
130.3 (5.12)
8.5 (0.33) dia.
25 ×19 × 3
(1.0 × 0.75 × 0.12)
5.0
(0.20)
77 (3.03)
Dimensions in millimeters and (inches)

4Curtis 1253 Manual, Rev. F
2 — INSTALLATION & WIRING: Controller
Working on electrical systems is potentially dangerous. You should
protect yourself against uncontrolled operation, high current arcs, and
outgassing from lead acid batteries:
UNCONTROLLED OPERATION — Some conditions could cause the hydraulic
pump system to run out of control. Disconnect the motor or make sure
the pump system has enough room to operate before attempting any
work on the motor control circuitry. Note: If the wrong throttle input
signal type is selected with the programming device, the pump system
may suddenly begin to operate.
HIGH CURRENT ARCS — Batteries can supply very high power, and arcs can
occur if they are short circuited. Always open the battery circuit before
working on the motor control circuit. Wear safety glasses, and use
properly insulated tools to prevent shorts.
LEAD ACID BATTERIES — Charging or discharging generates hydrogen gas,
which can build up in and around the batteries. Follow the battery man-
ufacturer’s safety recommendations. Wear safety glasses.
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.
☞
CAUTION