234/36/38 Manual M O D E L S 12 3 4 12 3 6 & 1238 AC INDUCTION MOTOR CONTROLLERS OS 11 with VCL © 2008 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. 1234/36/38 Manual, p/n 37022 4 August 2008 » Software version OS 11.0 « CURTIS INSTRUMENTS, INC. 200 Kisco Avenue Mt. Kisco, New York 10549 USA Tel. 914.666.2971 Fax 914.666.2188 www.curtisinstruments.
CONTENTS CONTENTS 1. OVERVIEW ..............................................................................1 2. INSTALLATION AND WIRING.............................................3 Mounting the Controller .....................................................3 High Current Connections and Wiring Guidelines..............6 Low Current Connections and Wiring Guidelines ...............8 Controller Wiring: Basic Configuration ............................12 Switch Input Wiring ...................................
FIGURES / TABLES FIGURES FIG. 1: FIG. 2a: FIG. 2b: FIG. 3: FIG. 4: FIG. 5: FIG. 6: FIG. 7: FIG. 8: FIG. 9: FIG. 10: FIG. 11: FIG. 12: FIG. 13: FIG. 14: FIG. 15: FIG. 16: FIG. Curtis 1234, 1236, and 1238 controllers ................................. 1 Mounting dimensions, Curtis 1234 controller ........................ 3 Mounting dimensions, Curtis 1236/38 controllers ................. 4 Basic wiring diagram .............................................................. 12 Wiring for Type 1 throttles ....
1 — OVERVIEW 1 OVERVIEW Curtis 1234, 1236, and 1238 AC induction motor controllers deliver smooth power unlike any previous vehicle control system. They provide unprecedented flexibility and power through inclusion of a field-programmable logic controller embedded in a state-of-the-art motor controller. The embedded logic controller runs a fully functional field-oriented AC motor control operating system (OS) that can be user-tailored via parameter modification; see Section 3.
1 — OVERVIEW ✓ Adaptation of control algorithm to motor temperature variation so optimal performance is maintained under widely varying conditions ✓ Real-time battery current, motor torque, and power estimates available ✓ Power limiting maps allow performance customization for reduced motor heating and consistent performance over varying battery state-of-charge ✓ Powerful operating system allows parallel processing of vehicle control tasks, motor control tasks, and user configurable programmable logic ✓ A w
2 — INSTALLATION & WIRING 2 INSTALLATION AND WIRING MOUNTING THE CONTROLLER The outline and mounting hole dimensions for the 1234 controller are shown in Figure 2a, and for the 1236 and 1238 controllers in Figure 2b. These controllers meet the IP65 requirements for environmental protection against dust and water. Nevertheless, in order to prevent external corrosion and leakage paths from developing, the mounting location should be carefully chosen to keep the controller as clean and dry as possible.
2 — INSTALLATION & WIRING heatsink to the mounting surface. Additional heatsinking or fan cooling may be necessary to meet the desired continuous ratings. 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 B. The1234/36/38 controllers contain ESD-sensitive components. Use appropriate precautions in connecting, disconnecting, and handling the controller.
2 — INSTALLATION & WIRING ☞ 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: UNCONTROLLED OPERATION — Some conditions could cause the motor to run out of control. Disconnect the motor or jack up the vehicle and get the drive wheels off the ground before attempting any work on the motor control circuitry.
2 — INSTALLATION & WIRING: High Current Connections HIGH CURRENT CONNECTIONS There are five high-current terminals, identified on the controller housing as B+, B-, U, V, and W. Table 1 TERMINAL High Current Connections FUNCTION B+ Positive battery to controller. B- Negative battery to controller. U Motor phase U. V Motor phase V. W Motor phase W. Lug assembly: 1234 models Five aluminum M6 terminals are provided.
2 — INSTALLATION & WIRING: High Current Connections Lug assembly: 1236 and 1238 models Five brass M8 terminals are provided. Lugs should be installed as follows, using M8 bolts sized to provide proper engagement (see diagram): • Place the lug on top of the brass terminal, followed by a high-load safety washer with its convex side on top. The washer should be a SCHNORR 700800, or equivalent. • If two lugs are used on the same terminal, stack them so the lug carrying the least current is on top.
2 — INSTALLATION & WIRING: Low Current Connections LOW CURRENT CONNECTIONS All low power connections are made through a single 35-pin AMPSEAL connector. The mating plug housing is AMP p/n 776164-1 and the contact pins are AMP p/n 770520-3. The connector will accept 20 to 16 AWG wire with a 1.7 to 2.7mm diameter thin-wall insulation. The 35 individual pins are characterized in Table 2.
2 — INSTALLATION & WIRING: Low Current Connections Table 2 PIN NAME Low Current Connections DESCRIPTION RELATED VCL* FUNCTIONS REFERENCES 1 KSI Keyswitch input. Provides logic power for the controller and power for the coil drivers. Setup_BDI Keyswitch_Voltage 2 Prop. Driver Proportional driver. This is a coil driver with current control capability typically used for a proportional valve on a hydraulic manifold. Can also be used as a digital input.
2 — INSTALLATION & WIRING: Low Current Connections Table 2 Low Current Connections, cont’d RELATED VCL PIN 10 NAME DESCRIPTION 12 Switch 6 Generic switch input #6. 13 Coil Return This is the coil return pin for all the contactor coils. 14 Switch 16 / DNC In the 1234, this is generic switch input #16. In the 1236 and 1238, Do Not Connect. 15 Throttle Pot High Pot high connection for a 3-wire throttle pot.
2 — INSTALLATION & WIRING: Low Current Connections Table 2 Low Current Connections, cont’d RELATED VCL PIN NAME DESCRIPTION FUNCTIONS REFERENCES 28 Serial TX Serial transmit line for display or flash update. Setup_Serial 29 Serial RX Serial receive line for flash update. Setup_Serial 30 Analog Output Low power, low frequency Automate_PWM 0–10V analog output. Put_PWM PWM6 Analog_Output 31 Encoder A Quadrature encoder input phase A.
2 — INSTALLATION & WIRING: Standard Wiring Diagram CONTROLLER WIRING: BASIC CONFIGURATION A basic wiring diagram is shown in Figure 3. Throttle and brake are shown in the diagram as 3-wire potentiometers; other types of throttle and brake inputs are easily accommodated, and are discussed in the following throttle wiring section. The main contactor coil must be wired directly to the controller as shown in Figure 3 to meet EEC safety requirements. The controller can be programmed Fig.
2 — INSTALLATION & WIRING: Throttle Wiring to check for welded or missing contactor faults and uses the main contactor coil driver output to remove power from the controller and motor in the event of various other faults. If the main contactor coil is not wired to Pin 6 of the 35-pin connector as shown, the controller will not be able to open the main contactor in serious fault conditions and the system will therefore not meet EEC safety requirements.
2 — INSTALLATION & WIRING: Throttle Wiring For potentiometers, the controller provides complete throttle fault protection that meets all applicable EEC regulations. For voltage throttles, the controller protects against out-of-range wiper values, 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.
2 — INSTALLATION & WIRING: Throttle Wiring Fig. 5 Wiring for Type 2 Voltage Source throttles.
2 — INSTALLATION & WIRING: Throttle Wiring When a 3-wire potentiometer is used, the controller provides full fault protection in accordance with EEC requirements. The pot is used in its voltage divider mode, with the controller providing the voltage source and return. Pot High provides a current limited 5V source to the pot, and Pot Low provides the return path. This is the throttle shown in the basic wiring diagram (Figure 3) for the drive throttle and for the brake throttle.
2 — INSTALLATION & WIRING: Throttle Wiring Throttle Type 5 Throttle Type 5 provides a different way of sending the throttle command to the controller. This throttle type uses VCL to define the throttle signal that will be “input” into the throttle signal chain (see Figure 14). This throttle type can be used for either the drive throttle or the brake throttle by using the VCL variables VCL_Throttle and VCL_Brake.
2 — INSTALLATION & WIRING: I/O Signal Specifications INPUT/OUTPUT SIGNAL SPECIFICATIONS The input/output signals wired to the 35-pin connector can be grouped by type as follows; their electrical characteristics are discussed below. — — — — — — — — — — digital inputs low power outputs high power outputs analog inputs analog output power supply outputs KSI and coil return inputs throttle and brake inputs communications port inputs/outputs encoder inputs.
2 — INSTALLATION & WIRING: I/O Signal Specifications Low power outputs Two control lines on the 1236/38 are available as low power digital outputs. These are open collector drivers that can only sink current, not source it, and are intended to drive LEDs or other low current loads connected to the +5V or +12V external power supplies; see power supply output group specs. Fault protection will turn off these outputs if output voltage exceeds about 15 V when the output is On (low output).
2 — INSTALLATION & WIRING: I/O Signal Specifications Analog inputs Two control lines can be used as analog inputs. Both inputs are protected against shorts to B+ or B-. Typically Analog 2 is used as the input for the motor temperature sensor. This input provides a constant current appropriate for a thermistor sensor. Some standard predefined motor temperature sensors are supported in software (see Sensor Type parameter, page 50).
2 — INSTALLATION & WIRING: I/O Signal Specifications KSI and coil return KSI input provides power for all low power control circuits, power capacitor precharge (before main contactor turn on), power supply outputs, and high power output drivers. Battery voltage is sensed on the input for the VCL battery discharge function.
2 — INSTALLATION & WIRING: I/O Signal Specifications Communications ports Separate CAN and serial ports provide complete communications and programming capability for all user available controller information. The Curtis 1311 handheld programmer plugs into a connector wired to pins 28 and 29, along with ground (pin 7) and the +12V power supply (pin 25); see wiring diagram, Figure 3. The Curtis Model 840 display can plug into the same 4-pin connector.
3 — PROGRAMMABLE PARAMETERS 3 PROGRAMMABLE PARAMETERS These controllers have a number of parameters that can be programmed using a Curtis 1311 handheld programmer or 1314 Programming Station. The programmable parameters allow the vehicle’s performance to be customized to fit the needs of specific applications. For programmer operation, see Appendix C. PROGRAMMING MENUS The programmable parameters are grouped into nested hierarchical menus, as shown in Table 3.
3 — PROGRAMMABLE PARAMETERS Table 3 Programmable Parameter Menus: 1311 Programmer CONTROL MODE SELECT ........... p. 27 0 - SPEED MODE EXPRESS ....... p. 28 —Max Speed —Kp —Ki —Accel Rate —Decel Rate —Brake Rate —Pump Enable 1 - SPEED MODE MENU —Speed Controller ............... p. 29 —Max Speed —Kp —Ki —Vel Feedforward ......... p. 29 —Kvff —Build Rate —Release Rate —Acc Feedforward ........ p. 30 —Kaff —Kbff —Build Rate —Release Rate —Response ..................... p.
3 — PROGRAMMABLE PARAMETERS Table 3 Programmable Parameter Menus: 1311 Programmer, cont’d EM BRAKE CONTROL MENU ........ p. 46 —Brake Type —Pull In Voltage —Holding Voltage —Battery Voltage Comp —Set EM Brake On Fault —Set Speed Threshold —Release Delay —Set Speed Settling Time —Torque Preload Delay —Torque Preload Enable —Torque Preload Cancel Delay DRIVERS MENU —Main Contactor ................ p.
3 — PROGRAMMABLE PARAMETERS Individual parameters are presented as follows in the menu charts: Parameter name as it appears in the programmer display Allowable range in the programmer’s units Description of the parameter’s function and, where applicable, suggestions for setting it ⇓ ⇓ ⇓ Max Speed Max_Speed_SpdM ⇑ Parameter name in VCL 100–8000 rpm 100–8000 Defines the maximum allowed motor rpm at full throttle. ⇑ Allowable range in VCL units Note: All bit variables have two VCL parameter names.
3 — PROGRAMMABLE PARAMETERS: Control Mode Select Parameter CONTROL MODE SELECT PARAMETER Control Mode Select Control_Mode_Select ALLOWABLE RANGE 0–2 0–2 DESCRIPTION This parameter determines which control method will be in effect when programming motor response: 0 = SPEED MODE EXPRESS 1 = SPEED MODE 2 = TORQUE MODE. Contact Curtis if you are interested in a custom control method. Note: Do not change this parameter while the controller is powering the motor.
3 — PROGRAMMABLE PARAMETERS: Speed Controller Parameters (SPEED MODE EXPRESS) 0 – SPEED MODE EXPRESS PARAMETER Max Speed Max_Speed_SpdMx ALLOWABLE RANGE SPEED MODE EXPRESS MENU DESCRIPTION 100–8000 rpm 100–8000 Defines the maximum requested motor rpm at full throttle. Partiallyapplied throttle is scaled proportionately; e.g., 40% applied throttle corresponds to a request for 40% of the set Max Speed Value. Note: The maximum motor rpm is subject to the constraints on page 27.
3 — PROGRAMMABLE PARAMETERS: Speed Controller & Velocity Feedforward Parameters (SPEED MODE) 1 – SPEED MODE PARAMETER Max Speed Max_Speed_SpdM ALLOWABLE RANGE 100–8000 rpm 100–8000 SPEED CONTROLLER MENU DESCRIPTION Defines the maximum requested motor rpm at full throttle. Partially-applied throttle is scaled proportionately; e.g., 40% applied throttle corresponds to a request for 40% of the set Max Speed Value. If Max_Speed_SpdM is set <100 rpm (through VCL or CAN), the throttle request is zeroed.
3 — PROGRAMMABLE PARAMETERS: Acceleration Feedforward Parameters (SPEED MODE) 1 – SPEED MODE PARAMETER ALLOWABLE RANGE ACCELERATION FEEDFORWARD MENU [OPTIONAL] DESCRIPTION Kaff Kaff_SpdM 0–500 A 0–5000 This acceleration feedforward term is designed to improve throttle responsiveness and speed controller performance at all speeds. It can be thought of as a “quick start” function which can enhance responsiveness at all speeds.
3 — PROGRAMMABLE PARAMETERS: Response Parameters (SPEED MODE) 1 – SPEED MODE PARAMETER ALLOWABLE RANGE RESPONSE MENU DESCRIPTION Full Accel Rate HS Full_Accel_Rate_HS_SpdM 0.1–30.0 sec 100–30000 Sets the rate (in seconds) at which the speed command increases when full throttle is applied at high vehicle speeds. Larger values represent slower response. Full Accel Rate LS Full_Accel_Rate_LS_SpdM 0.1–30.
3 — PROGRAMMABLE PARAMETERS: Fine Tuning Parameters (SPEED MODE) 1 – SPEED MODE ALLOWABLE RANGE PARAMETER Partial Decel Rate Partial_Decel_Rate_SpdM 0.1–30.0 sec. 100–30000 FINE TUNING MENU DESCRIPTION Sets the rate (in seconds) that is used to slow down the vehicle when the throttle is reduced without being released to neutral. Larger values represent slower response.
3 — PROGRAMMABLE PARAMETERS: Pump Enable Parameter (SPEED MODE) 1 – SPEED MODE PARAMETER ALLOWABLE RANGE Pump Enable On/Off AC_Pump_Enable_SpdM On/Off AC_Pump_Enable_SpdM_Bit0 [Bit 0] Curtis 1234/36/38 Manual, OS 11 PUMP ENABLE DESCRIPTION This parameter should be programmed On to operate a pump motor rather than a vehicle drive motor. Speed controller responsiveness and stability are enhanced, and the motor is allowed to turn only in the forward direction.
3 — PROGRAMMABLE PARAMETERS: Speed Limiter Parameters (TORQUE MODE) 2 – TORQUE MODE PARAMETER Max Speed Max_Speed_TrqM ALLOWABLE RANGE 500–8000 rpm 500–8000 SPEED LIMITER MENU DESCRIPTION Defines the maximum allowed motor rpm for torque control mode (independent of throttle position). In torque control mode, full throttle requests 100% of the available torque. Partially-applied throttle is scaled proportionately; e.g., 40% applied throttle corresponds to a request for 40% of the available torque.
3 — PROGRAMMABLE PARAMETERS: Response Parameters (TORQUE MODE) 2 – TORQUE MODE RESPONSE MENU PARAMETER ALLOWABLE RANGE Accel Rate Accel_Rate_TrqM 0.1–30.0 sec. 100–30000 Sets the rate (in seconds) at which the motor torque increases to full when full throttle is applied. Larger values represent slower response. Accel Release Rate Accel_Release_Rate_TrqM 0.1–2.0 sec. 100–2000 Determines how quickly deceleration will be initiated when the throttle is released while the vehicle is still accelerating.
3 — PROGRAMMABLE PARAMETERS: Fine Tuning Parameters (TORQUE MODE) 2 – TORQUE MODE PARAMETER ALLOWABLE RANGE FINE TUNING MENU DESCRIPTION Creep Torque Creep_Torque_TrqM 0–100 % 0–32767 Determines the amount of torque applied to the vehicle at a stop with no throttle input, to emulate the feel of an automatic transmission automobile; see Figure 8. WARNING! When interlock is engaged, creep torque allows vehicle propulsion if a direction is selected even though no throttle is applied.
3 — PROGRAMMABLE PARAMETERS: Fine Tuning Parameters (TORQUE CONTROL MODE) Fig. 8 Throttle mapping (torque control mode). Fig. 9 Effect of Gear Soften parameter (torque control mode). n TORQUE fte o rS = 0% 25 = 50 0% % % % = = 75 = 10 ea G TIME Fig. 10 Effect of Brake Taper Speed parameter (torque control mode).
3 — PROGRAMMABLE PARAMETERS: Restraint and Position Hold Parameters RESTRAINT MENU ALLOWABLE RANGE PARAMETER DESCRIPTION Restraint Forward Restraint_Forward 0–100 % 0–32767 Increases torque when on a steep hill in order to limit roll-forward speed. Setting this parameter too high may cause oscillations in the motor as it attempts to limit the roll-forward speed. Restraint Back Restraint_Back 0–100 % 0–32767 Increases torque when on a steep hill in order to limit roll-back speed.
3 — PROGRAMMABLE PARAMETERS: Current Limit Parameters POSITION HOLD MENU, cont’d ALLOWABLE RANGE PARAMETER DESCRIPTION Entry Rate Entry_Rate_Position_Hold 5–100 % 50–1000 When the vehicle transitions from forward speed to reverse speed or from reverse speed to forward speed (for example, when coming to a stop going up a steep ramp), Position Hold is automatically entered immediately at zero speed—regardless of this parameter.
3 — PROGRAMMABLE PARAMETERS: Power & Drive Limiting Map Parameters POWER LIMITING MAP MENU PARAMETER ALLOWABLE RANGE DESCRIPTION Nominal Speed PL_Nominal_Speed 100–4000 rpm 100–4000 Sets the base speed that will be used in the drive limiting map and regen limiting map. Delta Speed PL_Delta_Speed 50–1000 rpm 50–1000 Sets the width of the delta increment that will be used in the drive limiting map and regen limiting map.
3 — PROGRAMMABLE PARAMETERS: Regen Limiting Map Parameters REGEN LIMITING MAP MENU PARAMETER ALLOWABLE RANGE DESCRIPTION Nominal PL_Regen_Nominal 0–100 % 0–32767 Sets Plus Delta PL_Regen_Nominal_Plus_Delta 0–100 % 0–32767 Sets Plus 2xDelta PL_Regen_Nominal_Plus_2xDelta 0–100 % 0–32767 Sets Plus 4xDelta PL_Regen_Nominal_Plus_4xDelta 0–100 % 0–32767 Sets Plus 8xDelta PL_Regen_Nominal_Plus_8xDelta 0–100 % 0–32767 Sets These parameters define the percentage of regen current limit that will be
3 — PROGRAMMABLE PARAMETERS: Throttle Parameters THROTTLE MENU PARAMETER ALLOWABLE RANGE Throttle Type Throttle_Type 1–5 1–5 DESCRIPTION The 1234/36/38 controllers accept a variety of throttle inputs.
3 — PROGRAMMABLE PARAMETERS: Throttle Parameters THROTTLE MENU, cont’d PARAMETER ALLOWABLE RANGE Reverse Deadband Reverse_Deadband 0–5.00 V 0–32767 Reverse Map Reverse_Map 0–100 % 0–32767 Reverse Max Reverse_Max 0–5.00 V 0–32767 Reverse Offset Reverse_Offset 0–100 % 0–32767 DESCRIPTION The four Throttle Reverse parameters are the same as their Throttle Forward counterparts, and apply when the throttle direction is reversed. Fig. 13 Effect of throttle adjustment parameters.
3 — PROGRAMMABLE PARAMETERS: Throttle Parameters THROTTLE MENU, cont’d PARAMETER HPD/SRO Type HPD_SRO_Type OptionBits1 [Bit 4] ALLOWABLE RANGE 0–3 0–3 DESCRIPTION Determines whether the HPD/SRO feature will be active. One type of checks is available for material-handling vehicles, and two types for golf-style vehicles. If any of the HPD/SRO checks finds an input sequencing problem, an HPD/Sequencing Fault (flash code 47) is set. 0 HPD/SRO feature is disabled.
3 — PROGRAMMABLE PARAMETERS: Brake Parameters BRAKE MENU PARAMETER Brake Pedal Enable Brake_Pedal_Enable OptionBits1 [Bit 3] Brake Type Brake_Type ALLOWABLE RANGE On/Off On/Off 1–5 1–5 DESCRIPTION Determines whether the brake input and algorithm are enabled, making the brake throttle part of the motor control command. The 1234/36/38 controllers accept a variety of brake inputs.
3 — PROGRAMMABLE PARAMETERS: EM Brake Control Parameters EM BRAKE CONTROL MENU PARAMETER ALLOWABLE RANGE Brake Type EM_Brake_Type 0–2 0–2 DESCRIPTION The brake type parameter determines how the EM brake responds to the interlock input, throttle, and vehicle motor speed. 0 EM brake function disabled. The EM brake driver (PWM2) is released to general I/O use with VCL. 1 EM brake controlled by interlock.
3 — PROGRAMMABLE PARAMETERS: EM Brake Control Parameters EM BRAKE CONTROL MENU, cont’d PARAMETER Set Speed Threshold Set_Speed_Threshold ALLOWABLE RANGE 5–100 rpm 5–100 DESCRIPTION Determines the speed below which the EM brake will be commanded to set. Setting this speed too high may cause a jerky stop when the EM brake sets and stops the motor. Release Delay EM_Brake_Release_Delay 40–2000 msec 5–250 Estimated time for the EM brake to physically release after the pull-in voltage is applied.
3 — PROGRAMMABLE PARAMETERS: Main Contactor Parameters MAIN CONTACTOR MENU ALLOWABLE RANGE PARAMETER Main Enable Main_Enable OptionBits1 [Bit 0] DESCRIPTION On/Off On/Off When programmed On, the controller’s native software controls the main contactor when the interlock is enabled; when programmed Off, the contactor is controlled by VCL.
3 — PROGRAMMABLE PARAMETERS: Main Contactor Parameters MAIN CONTACTOR MENU, cont’d PARAMETER Main DNC Threshold Main_DNC_Threshold Precharge Enable Precharge_Enable OptionBits2 [Bit 6] ALLOWABLE RANGE DESCRIPTION 0–84.0 V 0–5376 When Checks Enable = On, this parameter is used as the threshold for detecting a Main Did Not Close fault. The Main DNC Threshold is the minimum voltage difference between the Keyswitch and Capacitor voltages.
3 — PROGRAMMABLE PARAMETERS: Proportional Driver Parameters PROPORTIONAL DRIVER MENU PARAMETER ALLOWABLE RANGE DESCRIPTION PD Enable PD_Enable OptionBits1 [Bit 6] On/Off On/Off Determines how the PWM of the proportional driver is controlled. When programmed On, it is controlled by the controller’s PD current control software. When programmed Off, it is controlled by the VCL function Put_PWM (PWM5, value); see Figure 16, page 97.
3 — PROGRAMMABLE PARAMETERS: Hydraulic Contactor Parameters HYDRAULIC CONTACTOR MENU PARAMETER Contactor Enable Hydraulic_Contactor_Enable OptionBits4 [Bit 1] ALLOWABLE RANGE DESCRIPTION On/Off On/Off When programmed On, VCL functions control Driver 3 as the hydraulic pump contactor. On: The VCL function Start_Pump() will close the pump contactor according to the defined pull-in and holding voltages. The VCL function Stop_Pump() will open the pump contactor.
3 — PROGRAMMABLE PARAMETERS: Fault Checking Parameters FAULT CHECKING MENU PARAMETER ALLOWABLE RANGE DESCRIPTION Driver1 Checks Enable Driver1_Checks_Enable OptionBits2 [Bit 1] On/Off On/Off C Driver2 Checks Enable Driver2_Checks_Enable OptionBits2 [Bit 2] On/Off On/Off S Driver3 Checks Enable Driver3_Checks_Enable OptionBits2 [Bit 3] On/Off On/Off S Driver4 Checks Enable Driver4_Checks_Enable OptionBits2 [Bit 4] On/Off On/Off S PD Checks Enable PD_Checks_Enable OptionBits2 [Bit 5] On/Off O
3 — PROGRAMMABLE PARAMETERS: Motor Parameters MOTOR MENU PARAMETER Typical Max Speed Typical_Max_Speed ALLOWABLE RANGE 500–8000 rpm 500–8000 DESCRIPTION Set this parameter to the typical maximum motor speed of the vehicle. This value does not need to be set precisely; an estimate will do. All of the vehicle response rates are normalized to Typical Max Speed. For example, suppose Typical_Max_Speed is fixed at 6000 rpm, and Full_Accel_Rate_LS_SpdM = 3.
3 — PROGRAMMABLE PARAMETERS: Motor Temperature Parameters MOTOR TEMPERATURE CONTROL MENU PARAMETER Sensor Enable MotorTemp_Sensor_Enable OptionBits3 [Bit 1] Sensor Type MotorTemp_Sensor_Type ALLOWABLE RANGE On/Off On/Off When programmed On, the motor temperature cutback and the motor temperature compensation features are enabled. This parameter can be used only if a temperature sensor has been properly configured.
3 — PROGRAMMABLE PARAMETERS: Battery Parameters BATTERY MENU PARAMETER Nominal Voltage Nominal_Voltage ALLOWABLE RANGE 24–84 V 1536–5376 DESCRIPTION Must be set to the vehicle’s nominal battery pack voltage. This parameter is used in determining the overvoltage and undervoltage protection thresholds for the electronic system. Overvoltage protection cuts back regen braking to prevent damage to batteries and other electrical system components due to overvoltage.
3 — PROGRAMMABLE PARAMETERS: Battery Parameters BATTERY MENU, cont’d PARAMETER User Undervoltage User_Undervoltage ALLOWABLE RANGE 50–80 % 128–204 DESCRIPTION The value of this parameter is a percentage of the Nominal Voltage setting. The User Undervoltage parameter can be used to adjust the undervoltage threshold, which is the voltage at which the controller will cut back drive current to prevent damage to the electrical system.
3 — PROGRAMMABLE PARAMETERS: Battery Parameters BATTERY MENU, cont’d ALLOWABLE RANGE PARAMETER DESCRIPTION Reset Volts Per Cell BDI_Reset_Volts_Per_Cell 0.90–3.00 V 900–3000 The reset voltage level is checked only once, when KSI is first turned on. Note that the BDI Reset Percent parameter also influences the algorithm that determines whether BDI Percentage is reset to 100%. Reset Volts Per Cell should always be set higher than Full Volts Per Cell.
3 — PROGRAMMABLE PARAMETERS: Vehicle Parameters VEHICLE MENU PARAMETER Metric Units Metric_Units OptionBits3 [Bit 5] ALLOWABLE RANGE DESCRIPTION On/Off On/Off When this parameter is programmed On, the distance variables (Vehicle Odometer, Braking Distance Captured, Distance Since Stop, Distance Fine, and the Capture Distance variables) will accumulate and display in metric units (km, meters, or decimeters).
3 — PROGRAMMABLE PARAMETERS: Emergency Reverse Parameters EMERGENCY REVERSE MENU PARAMETER EMR Enable EMR_Enable OptionBits1 [Bit 1] EMR Type EMR_Type ALLOWABLE RANGE On/Off On/Off 0–1 0–1 [SPEED MODE & SPEED MODE EXPRESS only] DESCRIPTION Determines whether the emergency reverse function is active. On = emergency reverse is enabled. Off = emergency reverse is disabled. Determines where the input comes from for emergency reverse. 0 = emergency reverse activated by switch 1 (pin 24).
3 — PROGRAMMABLE PARAMETERS: Interlock Braking Parameters INTERLOCK BRAKING MENU PARAMETER ALLOWABLE RANGE DESCRIPTION Enable Interlock_Brake_Enable OptionBits3 [Bit 7] On/Off On/Off Decel Rate HS Interlock_Brake_Decel_ Rate_HS 0.1–30.0 100–30000 Sets the rate (in seconds) that is used to slow down the vehicle when the interlock is released at high vehicle speeds. Larger values represent slower response. Decel Rate LS Interlock_Brake_Decel_ Rate_LS 0.1–30.
3 — PROGRAMMABLE PARAMETERS: CAN Interface Parameters CAN INTERFACE MENU PARAMETER ALLOWABLE RANGE DESCRIPTION CANopen Interlock CANopen_Interlock_Enable OptionBits3 [Bit 2] On/Off On/Off When programmed On, CAN NMT State must = 5 (operational state) in order for the interlock to be set; see Monitor » CAN Status menu, page 73. CAN Node ID CAN_Node_ID 0–127 0–127 Sets the Node ID of the CANopen Slave system. The Node ID is the first 7 bits of the 11-bit identifier (the COB ID).
3 — PROGRAMMABLE PARAMETERS: Field Weakening Control and Motor Type Parameters MOTOR CHARACTERIZATION TESTS MENU ALLOWABLE RANGE PARAMETER DESCRIPTION Contact your Curtis customer support engineer if you will be running the motor characterization tests yourself. See Initial Setup, step bl, page 79.
3 — PROGRAMMABLE PARAMETERS: Controiller Cloning CLONING (for copying parameter settings to multiple controllers) Once a controller has been programmed to the desired settings, these settings can be transferred as a group to other controllers, thus creating a family of “clone” controllers with identical settings. Cloning only works between controllers with the same model number and software version.
4a — MONITOR MENU 4a MONITOR MENU Through its Monitor menu, the 1311 programmer provides access to real-time data during vehicle operation. This information is helpful during diagnostics and troubleshooting, and also while adjusting programmable parameters. MONITOR MENU —Inputs ................. p. 64 —Outputs .............. p. 67 —Battery ............... p. 68 —Motor ................. p. 68 —Controller ........... p. 69 –Cutbacks ........ p. 70 –Motor Tuning .. p. 70 —Vehicle ............... p.
4a — MONITOR MENU Monitor Menu: INPUTS, cont’d VARIABLE Emer Rev EMR_State System_Flags1 [Bit 1] Curtis 1234/36/38 Manual, OS 11 DISPLAY RANGE On/Off On/Off DESCRIPTION Emergency reverse input on or off. The source of the emergency reverse input is determined by the EMR Type parameter: from Switch 1 (pin 24) if EMR Type = 0 from VCL function if EMR Type = 1. Analog 1 Analog1_Input 0–10.0 V 0–1023 Voltage at analog 1 (pin 24). Analog 2 Analog2_Input 0–10.0 V 0–1023 Voltage at analog 2 (pin 8).
4a — MONITOR MENU Monitor Menu: INPUTS, cont’d VARIABLE 66 DISPLAY RANGE DESCRIPTION Driver 3 Input Sw_11 Switches [Bit 10] On/Off On/Off Driver 3 input on or off (pin 4). Driver 4 Input Sw_12 Switches [Bit 11] On/Off On/Off Driver 4 input on or off (pin 3). PD Input Sw_13 Switches [Bit 12] On/Off On/Off Proportional driver on or off (pin 2). DigOut6 Input Sw_14 Switches [Bit 13] On/Off On/Off Digital Out 6 input on or off (pin 19).
4a — MONITOR MENU Monitor Menu: OUTPUTS VARIABLE DESCRIPTION Analog Out Analog_Output 0–10.0 V 0–32767 Digital Out 6 Dig6_Output On/Off On/Off Digital Out 6 output on or off (pin 19). Digital Out 7 Dig7_Output On/Off On/Off Digital Out 7 output on or off (pin 20). Driver 1 PWM PWM1_Output 0–100 % 0–32767 Driver 1 PWM output (pin 6). Driver 2 PWM PWM2_Output 0–100 % 0–32767 Driver 2 PWM output (pin 5). Driver 3 PWM PWM3_Output 0–100 % 0–32767 Driver 3 PWM output (pin 4).
4a — MONITOR MENU Monitor Menu: BATTERY VARIABLE DISPLAY RANGE BDI BDI_Percentage 0–100 % 0–100 Battery state of charge. Capacitor Voltage Capacitor_Voltage 0–105 V 0–6720 Voltage of controller’s internal capacitor bank at B+ terminal. Keyswitch Voltage Keyswitch_Voltage 0–105 V 0–10500 Voltage at KSI (pin 1). DESCRIPTION Monitor Menu: MOTOR VARIABLE Motor RPM Motor_RPM 68 DISPLAY RANGE -12000–12000 rpm -12000–12000 DESCRIPTION Motor speed in revolutions per minute.
4a — MONITOR MENU Monitor Menu: CONTROLLER VARIABLE DISPLAY RANGE Current (RMS) Current_RMS 0–1000 A 0–10000 RMS current of the controller, taking all three phases into account. Modulation Depth Modulation_Depth 0–100 % 0–1182 Percentage of available voltage being used. Frequency Frequency -300–300 Hz -18000–18000 Controller electrical frequency. Temperature Controller_Temperature -100–300 °C -1000–3000 Controller internal temperature.
4a — MONITOR MENU Monitor Menu: CUTBACKS VARIABLE Motor Temp Cutback MotorTempCutback DISPLAY RANGE DESCRIPTION 0–100 % 0–4096 Displays the current available as a result of the motor temperature cutback function. A value of 100% indicates no cutback in current. Controller Temp Cutback 0–100 % ControllerTempCutback 0–4096 Displays the current available as a result the controller temperature cutback function. A value of 100% indicates no cutback in current.
4a — MONITOR MENU ☞ Note: All vehicle calculations assume no tire slippage. Monitor Menu: VEHICLE VARIABLE DESCRIPTION Vehicle Speed Vehicle_Speed -327.7–327.7 -32768–32767 Vehicle Odometer Vehicle_Odometer 0–42949672.9 Vehicle distance traveled, in units of miles 0–4294967295 or km, depending on the setting of the Metric Units parameter (page 58). For accurate distance measurements, the Speed to RPM parameter must be set correctly (page 58).
4a — MONITOR MENU Monitor Menu: VEHICLE, cont’d VARIABLE Time to Dist 3 Time_to_Capture_Dist_3 DISPLAY RANGE DESCRIPTION 0–128 sec 0–32000 Time taken for the vehicle to travel from zero rpm to the programmed Capture Distance 3 (see Program » Vehicle menu) during its most recent such trip. For accurate distance measurements, the Speed to RPM parameter must be set correctly (page 58). Braking Distance Captured Braking_Distance_Captured 0–1000000.
4a — MONITOR MENU Monitor Menu: CAN STATUS DISPLAY RANGE VARIABLE DESCRIPTION CAN NMT State CAN_NMT_State 0–127 0–127 Controller CAN NMT state: 0=initialization, 4=stopped, 5=operational, 127=pre-operational. PDO1 MOSI Byte Map* 0 – 232 Mapping objects for PDO1 MOSI’s eight bytes. PDO1 MISO Byte Map* 0 – 232 Mapping objects for PDO1 MISO’s eight bytes. PDO2 MOSI Byte Map* 0 – 232 Mapping objects for PDO2 MOSI’s eight bytes.
4b — CONTROLLER INFO MENU 4b 74 CONTROLLER INFORMATION MENU This menu provides ID and version numbers for your controller hardware and software. CONTROLLER INFORMATION MENU VARIABLE DISPLAY RANGE Model Number Model_Number 0–4294967295 0–4294967295 Model number. For example, if you have a 1236 controller with the model number 1236-4501, the Model Number variable will have a value of 12364501. Serial Number Serial Number 0–4294967295 0–4294967295 Serial number.
5 — INITIAL SETUP 5 INITIAL SETUP The 1234/36/38 controllers can be used in a variety of vehicles, which differ widely in characteristics. Before driving the vehicle, it is imperative that these initial setup procedures be carefully followed to ensure that the controller is set up to be compatible with your application.
5 — INITIAL SETUP ☞ C AU T I O N the AC Motor Characterization Procedure is used, it can determine the encoder steps (but only for encoders with 32, 64, or 80 ppm). Setting the Encoder Steps parameter improperly may cause vehicle malfunction, including uncommanded drive. 2 Motor temperature sensor (see page 54) Set the Sensor Type parameter to the predefined type (1–5) that corresponds to your motor temperature sensor.
5 — INITIAL SETUP support engineer to resolve any issues about the interlock before continuing with the setup procedure. Once you have verified the interlock is off, you can set up the throttle input. The Throttle Type parameter must be set to match the type of throttle (1–5) and wiring that you are using, as described on pages 13–17. Adjust the Forward Deadband, Forward Max, Reverse Deadband and Reverse Max parameters to match the range of your throttle.
5 — INITIAL SETUP neutral. The displayed Mapped Brake should be = 100% through the range of motion that is considered max. Contact your Curtis customer support engineer to resolve any issues about the brake setup before continuing with the setup procedure. 9 Faults (see Section 8) Turn the KSI input Off and then On (to clear any parameter change faults) and use the 1311 to check for faults in the controller. All faults must be cleared before continuing with the setup procedure.
5 — INITIAL SETUP ☞ C AU T I O N the direction input. If the motor is turning in the correct direction but appears to be “fighting itself ” (struggling at full current while jerkily turning at very low speed), change the setting of the Swap Encoder Direction parameter. If the motor still does not respond properly you should contact your Curtis customer support engineer to resolve any issues about encoder direction or emergency reverse before continuing with the setup procedure.
6 — TUNING GUIDE 6 TUNING GUIDE Many aspects of vehicle performance can be optimized, using the wide variety of adjustable parameters available to the 1234/36/38 controllers. Once a vehicle/motor/controller combination has been tuned, the parameter values can be made standard for the system or vehicle model. Any changes in the motor, the vehicle drive system, or the controller will require that the system be tuned again to provide optimum performance.
6 — TUNING GUIDE Speed parameter you should not readjust it without adjusting all the rate parameters as well. d. Kp and Ki typically do not need to be changed as the default values will work well in most applications. If you want to adjust Kp (for looser or tighter following of the speed trajectory set by the accel, decel, and brake rates), follow the procedure in step “d” in the Speed Mode tuning section. e.
6 — TUNING GUIDE d. Kp typically does not need to be changed as the default value will work well in most applications. This parameter controls how tightly the actual motor speed will track the requested speed trajectory (speed trajectory is set by the accel, decel, and brake rates). If you want to adjust the Kp (for looser or tighter following of the speed trajectory), follow these guidelines. • Set the following parameters.
6 — TUNING GUIDE f. In the Speed Mode » Response menu, adjust the remaining three brake rate parameters as necessary while reversing the throttle input (i.e., full throttle forward to low throttle reverse, full throttle forward to full throttle reverse, full throttle reverse to low throttle forward, etc.). If a brake input is present in the application (Brake Pedal Enable = On) continue adjusting these three brake rates by applying different amounts of brake throttle (i.e.
7 — VCL 7 VEHICLE CONTROL LANGUAGE (VCL) Curtis 1234/36/38 AC induction controllers have a built-in programmable logic controller with application-specific functions. VCL (Vehicle Control Language) software provides a way to implement unique and complex vehicle control functions. VCL is a simple programming language that will feel very familiar to anyone who has worked with BASIC, Pascal, or C. Working with VCL requires the installation of the WinVCL program onto a PC.
7 — VCL The VCL functions described in the VCL Common Functions Manual are available on 1234/36/38 controllers. These controllers also have these additional functions: ENABLE_PRECHARGE()............ p. 103 DISABLE_PRECHARGE()........... p. 104 SET_DIGOUT()............................ p. 105 CLEAR_DIGOUT()....................... p. 105 ENABLE_EMER_REV()............... p. 106 DISABLE_EMER_REV().............. p. 106 SET_INTERLOCK() ..................... p. 107 CLEAR_INTERLOCK() ................ p.
7 — VCL are typically written to EEPROM through the 1311 programmer interface (i.e., when a 1311 user changes a parameter setting using the 1311). They can be used in the VCL code, but changing a P_User (or P_UserBit) value with VCL will only change the variable value in RAM and will not change the value in EEPROM. Thus, these variables are intended for creating and defining 1311 parameters only.
7 — VCL VCL RUNTIME RATES VCL is an interpreted language. Each line of VCL code is converted (compiled) into a set of codes and then flash loaded into the controller. The controller interprets these codes one line at a time while the system is powered up.
7 — VCL if (Sw_1 = ON) { ;put code here to run when switch 1 is On } if (Sw_16 = OFF) { ;put code here to run when switch 16 is Off } All switch inputs are automatically debounced by the VCL operating system. This prevents noisy contacts or contact bounce from causing erroneous events in your VCL code. The debounce time can be varied from 0 to 32 milliseconds in 4ms steps, using this function: Setup_Switches(5); 20 milliseconds If this line is not in the VCL code, the debounce time is set at 16 ms.
7 — VCL Set_DigOut(DigOut6) will set Digital Output 6 On (active). VCL can monitor the present value of a digital output driver: the bit variable Digx_Output (where “x” is the digital output channel number) is automatically filled with the present value of the driver output (On or Off ). It is important to note that all outputs are active Low. With 100% PWM or an output of “On,” the FET or transistor will be pulling hard to ground. A DVM on the output will measure near 0 volts.
7 — VCL To set up the brake pot input for use in VCL, use the Brake_Pot constant in place of the Thottle_Pot constant in the Setup_Pot function. Setup_Pot(BRAKE_POT,TWO_WIRE) will set up the brake pot input for wiring using two connections (pins 17, 18). The 0–100% position of the potentiometer is represented by a value from 0–32767 in VCL.
7 — VCL AnalogOut uses the same Put_PWM() and Automate_PWM() used by these other drivers. The scaling is 0–10V = 0–32767. Put_PWM(PWM6,6553) will generate 2.0 volts at the analog output. VCL can monitor this output using the variable Analog_Output. INTERFACING THE THROTTLE AND BRAKE COMMANDS VCL can interface and modify the throttle and brake signals at several points, from the potentiometer to the final motor controller command.
Fig. 14 Motor command diagram.
7 — VCL This allows the VCL to either multiply (Throttle_Multiplier > 128) or divide (Throttle_Multiplier < 128) the nominal throttle value. Typically the default multiplier is set to 128, thus having no net effect. Both Throttle_Multiplier and Throttle_Offset can be positive or negative. The output of the multiplying and summing nodes is a VCL variable called Mapped_Throttle, which is displayed in the 1311 Monitor » Inputs menu.
7 — VCL Brake Processing Brake processing is optional as it can be turned Off (by setting Brake_Pedal_Enable = Off, see page 45). If turned On, brake processing can be done with or without VCL. Any non-zero brake command will then override the throttle signal and the motor controller will brake to a stop as determined by the parameters Brake Current Limit (page 39) and Brake Taper Speed (page 36). The lower part of Figure 14 shows the brake signal processing section.
7 — VCL The following brake processing variables are accessible by VCL: VCL VARIABLE ACCESS DESCRIPTION Pot2_Raw Read Only Voltage measurement at pin 17 Brake_Pot_Output Read Only Brake pot input value after being scaled for the proper wiring OS_Brake Read Only Brake pot value after mapping, to be used in VCL when VCL Brake Enable = On and Brake Type = 1–3 VCL_Brake Read/Write VCL-accessible brake command Mapped_Brake Read Only Brake pot value after mapping Brake_Command Read Only Comma
Fig. 15 Control Mode processing.
7 — VCL Fig. 16 Proportional driver processing. function. Note that Mapped_Throttle is inverted; lowering its value (making it more negative) increases the PD_Throttle value. The Dither function adds and subtracts from the current command to the PD based on PD_Dither_Percent, at a rate set by PD_Dither_Period. The dithered current command is compared to the present PD_Current and the error is fed into a PI controller.
7 — VCL USING THE FAULT HANDLER IN VCL The operating system of the controller detects various faults and takes appropriate fault actions to protect the controller. These faults have fault codes that are flashed on the controller status LEDs, and fault text is displayed in the 1311 System Faults and Fault History menus. These operating system faults are covered in Section 8.
7 — VCL Status5 * Bit0 * Bit1 * Bit2 * Bit3 * Bit4 * Bit5 * Bit6 * Bit7 = = = = = = = = External Supply Out of Range (Code 69) Motor Temp Sensor Fault (Code 29) VCL Run Time Error (Code 68) +5V Supply Failure (Code 25) OS General (Code 71) PDO Timeout (Code 72) Encoder Fault (Code 36) Stall Detected (Code 73) Status6 * Bit0 * Bit1 * Bit2 * Bit3 * Bit4 * Bit5 * Bit6 * Bit7 = = = = = = = = Not Used Not Used Emer Rev HPD (Code 47) Not Used Motor Type Fault (Code 89) Not Used Motor Characterization Fault
7 — VCL The operating system also provides the capability to create OEM-defined custom faults using VCL. Just as with system faults, the VCL fault codes are flashed on the controller Status LEDs and fault text is displayed on the 1311 System Faults and Fault History menus. Optionally, the VCL can assign fault actions to occur automatically when the associated fault is set. Sixteen VCL faults are available, stored in the VCL variables UserFault1 and UserFault2.
7 — VCL To add automatic fault actions to the VCL faults, the VCL programmer must define the desired fault actions by using the sixteen VCL variables: User_Fault_Action_01 through User_Fault_Action_16. Each of the UserFault bits has a corresponding User_Fault_Action_xx variable (where “xx” is the number of the VCL fault bit). When a VCL fault bit is set, the actions defined in the corresponding User_Fault_Action_xx variable will be automatically executed by the operating system.
7 — VCL addition to flashing the code 52 on the controller status LEDs. An additional VCL line was added (Put_Spy_Text (“BDI Low”)) to show how additional actions beyond those provided in the User_Fault_Action_xx can be programmed using VCL. In this example the Put_Spy_Text(“BDI Low”) will result in the message “BDI Low” appearing on the model 840 display (presumably as a message to the vehicle operator). This example will still not result in any display on the 1311 System Faults and Fault History menus.
7 — VCL VCL FUNCTIONS SPECIFIC TO 1234/36/38 AC CONTROLLERS Function descriptions are provided here for the functions that are unique to these controllers. They are presented in the same format that is used in the VCL Common Functions Manual for the common functions. ENABLE_PRECHARGE() This function is designed to precharge the capacitor bank before engaging a main contactor thereby preventing current surges and to protect controller internal components and main contactor tips.
7 — VCL DISABLE_PRECHARGE() This function is designed to abort the precharge function and clear any precharge fault. This function aborts the request for precharge of the capacitor bank from KSI. The resultant state of the precharge variable (Precharge_State) will be set to = 3 (for precharge aborted). The precharge states are: 0 1 2 3 4 5 – – – – – – Precharge Precharge Precharge Precharge Precharge Precharge has not yet been done. is in progress. has passed.
7 — VCL SET_DIGOUT() This function turns on the selected digital output. The digital outputs are active low (On = driver on and pulled to ground, Off = open circuit at the pin). The low power digital output is protected from excessive current (current over 15 mA); a fault will occur when this current has been exceeded, and the driver will be shut off (open). Running the function again will reactivate the driver, and will attempt to clear the fault.
7 — VCL ENABLE_EMER_REV() This function is used to engage emergency reverse using VCL. The 1311 EMR Type must be set to = 1 in order for the Enable_Emer_Rev() function to operate. If the system emergency reverse state is enabled (EMR_State bit variable = On), the emergency reverse function will operate according to the Emergency Reverse parameter settings; see page 59. To view the current emergency reverse state, see the 1311 menu Monitor » Inputs: Emer Rev.
7 — VCL SET_INTERLOCK() This function is used to engage the system interlock using VCL. The 1311 Interlock Type parameter must be set to = 1 in order for the Set_Interlock() function to operate. If the system interlock is set (Interlock_State bit variable = On), the throttle input signal is allowed to pass along the throttle chain; see Figure 14.
7 — VCL SETUP_POT_FAULTS() This function sets the upper and lower wiper fault voltages for a given pot input and sets the replacement wiper voltage value that will be used if there is a fault. The valid range for the function parameters is 0–6.25 V (0–400 counts). If this function is not run, the default thresholds depend on the 1311 Throttle Type (or Brake Type) parameter setting; see table below.
7 — VCL START_PUMP() This function is used to turn on the pump lift contactor. If the 1311 parameter Drivers » Hydraulic Contactor » Contactor Enable = On (VCL HydraulicContactorEnable bit variable = On), the VCL function Start_Pump() will turn on the pump lift contactor (Driver 3). When HydraulicContactorEnable = On and neither Start_Pump() nor Stop_ Pump() has been called, the pump lift contactor is Off. Syntax Start_Pump() Parameters None. Returns 0 – Pump start function not enabled.
8 — DIAGNOSTICS & TROUBLESHOOTING 8 DIAGNOSTICS AND TROUBLESHOOTING These controllers detect a wide variety of faults or error conditions. Faults can be detected by the operating system or by the VCL code. This section describes the faults detected by the operating system. Faults detected by VCL code (faults 51–67 in Table 5) cannot be defined here as they will vary from application to application. Refer to the appropriate OEM documentation for information on these faults.
8 — DIAGNOSTICS & TROUBLESHOOTING Summary of LED display formats The two LEDs have four different display modes, indicating the type of information they are providing. Table 4 TYPES OF LED DISPLAY DISPLAY STATUS Neither LED illuminated Controller is not powered on; or vehicle has dead battery; or severe damage. Yellow LED flashing Controller is operating normally. Yellow and red LEDs both on solid Controller is in Flash program mode. Red LED on solid Watchdog failure or no software loaded.
8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART CODE PROGRAMMER LCD DISPLAY EFFECT OF FAULT POSSIBLE CAUSE SET/CLEAR CONDITIONS 12 Controller Overcurrent ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump. 1. External short of phase U,V, or W motor connections. 2. Motor parameters are mis-tuned. 3. Controller defective. Set: Phase current exceeded the current measurement limit. Clear: Cycle KSI.
8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued CODE PROGRAMMER LCD DISPLAY EFFECT OF FAULT POSSIBLE CAUSE SET/CLEAR CONDITIONS 18 Severe Overvoltage ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump. 1. See Monitor menu » Battery: Capacitor Voltage. 2. Battery menu parameters are misadjusted. 3. Battery resistance too high for given regen current. 4. Battery disconnected while regen braking.
8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued CODE PROGRAMMER LCD DISPLAY EFFECT OF FAULT POSSIBLE CAUSE SET/CLEAR CONDITIONS 27 Digital Out 7 Overcurrent Digital Output 7 driver will not turn on. 1. External load impedance on Digital Output 7 driver (pin 20) is too low. Set: Digital Output 7 (pin 20) current exceeded 15 mA. Clear: Remedy the overcurrent cause and use the VCL function Set_DigOut() to turn the driver on again.
8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued CODE PROGRAMMER LCD DISPLAY EFFECT OF FAULT POSSIBLE CAUSE SET/CLEAR CONDITIONS 35 PD Open/Short ShutdownPD. 1. Open or short on driver load. 2. Dirty connector pins. 3. Bad crimps or faulty wiring. Set: Proportional driver (pin 2) is either open or shorted. Clear: Correct open or short, and cycle driver. 36 Encoder Fault ShutdownEMBrake. 1. Motor encoder failure. 2. Bad crimps or faulty wiring. 3.
8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued CODE PROGRAMMER LCD DISPLAY EFFECT OF FAULT POSSIBLE CAUSE SET/CLEAR CONDITIONS 44 Pot2 Wiper Low FullBrake. 1. See Monitor menu » Inputs: Pot2 Raw. 2. Pot2 wiper voltage too low. Set: Pot2 wiper (pin 17) voltage is lower than the low fault threshold (can be changed with the VCL function Setup_Pot_Faults()). Clear: Bring Pot2 wiper voltage above the fault threshold. 45 Pot Low Overcurrent ShutdownThrottle; FullBrake. 1.
8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued CODE PROGRAMMER LCD DISPLAY POSSIBLE CAUSE EFFECT OF FAULT SET/CLEAR CONDITIONS 68 VCL Run Time Error ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake; ShutdownPump. 1. VCL code encountered a runtime VCL error. 2. See Monitor menu » Controller: VCL Error Module and VCL Error.
8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued CODE PROGRAMMER LCD DISPLAY EFFECT OF FAULT POSSIBLE CAUSE SET/CLEAR CONDITIONS 87 Motor Characterization Fault ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump. 1. Motor characterization failed during Set: Motor characterization failed during characterization process. See Monitor the motor characterization process. menu » Controller: Motor Clear: Correct fault; cycle KSI.
8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued CODE PROGRAMMER LCD DISPLAY EFFECT OF FAULT POSSIBLE CAUSE SET/CLEAR CONDITIONS 94 Emer Rev Timeout ShutdownEMBrake; ShutdownThrottle. 1. Emergency Reverse was activated and concluded because the EMR Timeout timer has expired. 2. The emergency reverse input is stuck On. Set: Emergency Reverse was activated and ran until the EMR Timeout timer expired. Clear: Turn the emergency reverse input Off.
9 — MAINTENANCE 9 MAINTENANCE There are no user serviceable parts in Curtis 1234/36/38 controllers. 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 and connections be kept clean and dry and that the controller’s fault history file be checked and cleared periodically.
APPENDIX A: THEORY OF OPERATION APPENDIX A THEORY OF OPERATION Curtis 1234/36/38 controllers convert DC battery power to 3-phase AC power by precisely controlling the induction drive for high bandwidth, high efficiency, and low ripple torque generation. To realize this level of precise torque control of induction motor drives in electric vehicles, Curtis engineers carefully evaluated and incorporated the latest technology in microprocessors, power electronics, and motor control.
APPENDIX A: THEORY OF OPERATION to provide better control. The mathematical model of an induction motor is complex. Using a series of reference frame transformations, vector control simplifies the model to enable precise control of torque and flux, similar to a SepEx motor controller. Figure A-1 shows a typical diagram of indirect rotor flux orientation.
APPENDIX A: THEORY OF OPERATION Fig. A-2 Power section topology. Heavy busbars connect the IMS modules to the external motor connection studs. A bank of power capacitors keeps DC bus levels stable during high frequency MOSFET switching and also reduces EMI on the external B+ and B- cables. Motor currents and motor speed and direction are the primary feedback signals used in the motor control algorithms.
APPENDIX B: EMC & ESD DESIGN CONSIDERATIONS APPENDIX B 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.
APPENDIX B: EMC & ESD DESIGN CONSIDERATIONS Conducted paths are created by the wires connected to the controller. These wires act as antennas and the amount of RF energy coupled into them 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 controllers include bypass capacitors on the printed circuit board’s throttle wires to reduce the impact of this RF energy on the internal circuitry.
APPENDIX B: EMC & ESD DESIGN CONSIDERATIONS Given the safety considerations involved in connecting electrical components to the chassis or frame in battery powered vehicles, such filtering will usually consist of a series inductor (or ferrite bead) rather than a shunt capacitor. If a capacitor is used, it must have a voltage rating and leakage characteristics that will allow the end product to meet applicable safety regulations.
APPENDIX C: PROGRAMMER OPERATION APPENDIX C PROGRAMMERS Curtis programmers provide programming, diagnostic, and test capabilities for 1234/36/38 controllers. 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).
APPENDIX C: PROGRAMMER OPERATION 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).
APPENDIX D: SPECIFICATIONS APPENDIX D SPECIFICATIONS Table D-1 SPECIFICATIONS: 1234/36/38 CONTROLLERS Nominal input voltage PWM operating frequency Maximum encoder frequency Maximum controller output frequency Electrical isolation to heatsink 24V, 24 –36 V, 36–48 V, 48–80 V 10 kHz 10 kHz 300 Hz 500 V ac (minimum) Storage ambient temperature range Operating ambient temp. range Internal heatsink operating temp.
