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Curtis 1243

GEN

2 Manual

55

5 — VEHICLE PERFORMANCE ADJUSTMENT

VEHICLE PERFORMANCE ADJUSTMENT

The 1243

GEN

2 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. Once a vehicle/motor/controller combination has
been tuned, the parameter values can be made standard for that 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.

The tuning procedures should be conducted in the sequence given,

because successive steps build upon the ones before. The tuning procedures
instruct personnel how to adjust various programmable parameters to accom-
plish speci

fi

c performance goals. It is important that the effect of these pro-

grammable parameters be understood in order to take full advantage of the
controller

’

s features. Please refer to the descriptions of the applicable parameters

in Section 3 if there is any question about what any of them do.

The 1243

GEN

2

’

s MultiMode

™

feature allows the vehicle to be con

fi

gured

to provide four distinct operating modes. Typically Mode 1 is con

fi

gured for

slow precise indoor maneuvering, Mode 4 for faster, long distance, outdoor
travel, and Modes 2 and 3 for application-speci

fi

c special conditions. Some of

the tuning procedures may need to be repeated four times, once for each mode.

MAJOR TUNING

Four major performance characteristics are usually tuned on a new vehicle:

1

Tuning the Throttle

’

s Active Range

2

Tuning the Controller to the Motor

3

Setting the Vehicle

’

s Unloaded Top Speed

4

Equalization of Loaded/Unloaded Vehicle Speed.

These four characteristics should be tuned in the order listed.

1

Tuning the Throttle’s Active Range

Before attempting to optimize any speci

fi

c vehicle performance characteristics,

it is important to ensure that the controller output is operating over its full range.
The procedures that follow will establish Throttle Deadband and Throttle Max
parameter values that correspond to the absolute full range of your particular
throttle mechanism. It is advisable to allow some buffer around the absolute full
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.

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Summary of Contents for MultiMode 1243 Generation 2

Page 1: ... CONTROLLERS PROTECTED BY U S PATENT NO 4626750 CURTIS INSTRUMENTS INC 200 Kisco Avenue Mount Kisco NY 10509 USA Tel 914 666 2971 Fax 914 666 2188 www curtisinst com 1243GEN2 Manual p n 37044 Rev A October 2002 1 2 4 3 M O D E L MultiMode MOTOR CONTROLLER Generation 2 ...

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Page 6: ... electronic throttle Type 2 13 FIG 10 Wiring for 0 5kΩ throttle Type 3 14 FIG 11 Wiring for fault outputs 15 FIG 12 Wiring for Curtis Spyglass display 15 FIG 13 Ramp restraint maps for controller with the minimum field set at 3 amps maximum field at 18 amps and braking current limit at 300 amps 24 FIG 14 Electromagnetic brake parameters in the context of the four delay parameters 29 FIG 15 Effect ...

Page 7: ...yglass 3 LED and 6 LED models 73 FIG B 1 Curtis 1311 handheld programmer B 1 TABLES TABLE 1 Throttle wiper input Pin 6 threshold values 9 TABLE 2 Mode selection 18 TABLE 3 Configuration options auxiliary driver 30 TABLE 4 Programmable throttle types 32 TABLE 5 Standard battery voltages 49 TABLE 6 Fault categories 50 TABLE 7 Troubleshooting chart 72 TABLE 8 Status LED fault codes 74 TABLE 9 Fault c...

Page 8: ...roller provides smooth precise control of motor speed and torque A full bridge field control stage is combined with a half bridge armature power stage to provide solid state motor reversing and full regenerative braking without additional relays or contactors The controller s rugged IP53 housing and packaging are built to with stand shock and vibration State of the art surface mount logic board fa...

Page 9: ...pe 4 throttle Active precharge of controller capacitor bank extends life of main contactor Compatibility with Curtis 1307 1311 handheld programmers for quick and easy testing diagnostics and parameter adjustment MultiMode allows four user selectable vehicle operating modes Continuous armature current control reducing arcing and brush wear Complete diagnostics through the handheld programmer the bu...

Page 10: ...numeric non backlit 8 character 5 mm LCD display for hourmeter BDI and fault messages Display updated by dedicated unidirectional serial port Available in 52 mm round case DIN case and as a bare board each with an 8 pin Molex connector cases feature front seal to IP65 and rear seal to IP40 shock and vibration protection to SAE J1378 Operating temperature range 10 C to 70 C models with lower temper...

Page 11: ...r to plug the programmer into its connector and 2 that the built in Status LED is visible only through the view port in the label on top of the controller The outline and mounting hole dimensions for the 1243GEN2 controller are shown in Figure 2 To ensure full rated power the controller should be fastened to a clean flat metal surface with three 6 mm 1 4 diameter screws using the holes provided 2 ...

Page 12: ... installation suggestions in Appendix A for protecting the controller from ESD damage Working on electric vehicles is potentially dangerous You should protect yourself against runaways high current arcs and outgassing from lead acid batteries RUNAWAYS Some conditions could cause the vehicle to run out of control Disconnect the motor or jack up the vehicle and get the drive wheels off the ground be...

Page 13: ...d copper bus bars are provided for high current connections to the battery B and B and the motor armature M Cables are fastened to the bus bars by M8 bolts The 1243GEN2 case provides the capture nuts required Pin 1 load sensor input optional Pin 2 Fault 1 output pump input Pin 3 Fault 2 output Pin 4 main contactor driver output Pin 5 throttle 3 wire pot high Pin 6 throttle 0 5V pot wiper Pin 7 thr...

Page 14: ...pplications 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 seat switch or a foot switch and there is no emergency reverse Fig 3 Standard wiring configuration Curtis 1243GEN2 controller S1 S2 B M B INTERLOCK 5kΩ POT ...

Page 15: ... forward and reverse switches and the S1 and S2 connections must be configured so that the vehicle drives away from the operator when the emergency reverse button is pressed Standard Control Wiring Wiring for the input switches and contactors is shown in Figure 3 the pins are identified on page 6 In the standard wiring configuration the auxiliary driver at Pin 8 is used to drive an electromagnetic...

Page 16: ...5 throttle MAX THROTTLE TYPE PARAMETER FAULT 0 speed request active range 100 modulation FAULT 1 5kΩ 0 Wiper Voltage 5 00 V 3 80 V 2 70 V 0 20 V 0 06 V Wiper Resistance 7 50 kΩ 5 50 kΩ 3 85 kΩ 0 kΩ 2 0 5V Wiper Voltage 0 06 V 0 20 V 1 50 V 5 00 V 5 80 V Wiper Resistance 3 0 5kΩ Wiper Voltage 0 06 V 0 20 V 1 30 V 3 80 V 5 00 V Wiper Resistance 0 kΩ 1 65 kΩ 5 50 kΩ 7 50 kΩ 4 0 5V Wiper Voltage 0 50 ...

Page 17: ...controller has 5 kΩ between Pins 6 and 7 when the throttle is in the neutral position The throttle mechanism can then be designed such that rotating it either forward or back decreases the resistance between Pins 6 and 7 which increases the controller output The throttle mechanism must provide signals to the controller s forward and reverse inputs independent of the throttle pot resistance The con...

Page 18: ...s must provide a Pot Low current greater than 0 65 mA to prevent shutdown due to pot faults It is recommended that the maximum Pot Low current be limited to 55 mA to prevent damage to the Pot Low circuitry Ground referenced 0 5V throttles require setting the Pot Low Fault parameter see Section 3 page 38 to Off otherwise the controller will register a throttle fault and will shut down For ground re...

Page 19: ...or 3 wire potentiometer throttle Type 2 1kΩ 10kΩ Pot Wiper input Pin 6 Pot Low input Pin 7 Pot High output Pin 5 FASTER Fig 7 Wiring for current source throttle Type 2 3 Wire Potentiometer 1kΩ 10kΩ Throttle A 3 wire pot with a total resistance value anywhere between 1 kΩ and 10 kΩ can be used wired as shown in Figure 8 The pot is used in its voltage divider mode with the voltage source and return ...

Page 20: ... This control head assembly the CH series combines the ET XXX throttle with a variety of standard control head switch functions for use in walkie and lift truck applications 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 and Pot Low pins Pins 6 and 7 as shown in Figure 10 Zero speed corresponds to 0 Ω measu...

Page 21: ...on for Type 4 traction throttles Any potentiometer value between 1 kΩ and 10 kΩ is sup ported When a voltage throttle is used it is the responsibility of the OEM to provide appropriate throttle fault detection Note If your Type 4 throttle has an internal neutral switch this internal neutral switch should be wired to the forward switch input Pin 12 The controller will behave as though no throttle i...

Page 22: ...e model either three or six indicator LEDs are also located on the face of the gauge See Section 7 Diagnostics and Troubleshooting for more information on the Spyglass displays The mating 8 pin connector is Molex 39 01 2085 with 39 00 0039 18 24 AWG pins Fig 12 Wiring guide and mounting dimensions for Curtis Spyglass 6 LED model shown dimensions and wiring are identical for the 3 LED model SPYGLAS...

Page 23: ...output is inhibited until the wiring fault is corrected The emergency reverse check wire is connected to Pin 10 as shown by the dotted line in the standard wiring diagram Figure 3 If the option is selected and the check wire is 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 Auxili...

Page 24: ... keyswitch input This protects the main contactor coil driver from failure due to inductive voltage kickback spikes when the contactor is turned off Keyswitch and Interlock Switch The vehicle should have a master on off switch to turn the system off when not in use The keyswitch input provides logic power for the controller The interlock switch which is typically implemented as a tiller switch dea...

Page 25: ...gram Figure 3 shows the recommended location for each fuse Mode Select Switch Operation The two mode select switches Mode Select 1 and Mode Select 2 together define the four operating modes The switch combinations are shown in Table 2 Table 2 MODE SELECTION MODE MODE OPERATING MODE SELECT SELECT SWITCH 1 SWITCH 2 MultiMode 1 OPEN OPEN MultiMode 2 CLOSED OPEN MultiMode 3 OPEN CLOSED MultiMode 4 CLO...

Page 26: ...des These modes can be programmed to provide four different sets of operating characteristics which can be useful for operating in different conditions such as slow precise indoor maneuvering in Mode 1 faster long distance outdoor travel in Mode 4 and application specific special conditions in Modes 2 and 3 Eight parameters can be configured independently in each of the four modes acceleration rat...

Page 27: ...cing Fault Parameters p 41 Anti Tiedown High Pedal Disable HPD Static Return to Off SRO Sequencing Delay Emergency Reverse Parameters p 43 Emerg Reverse Current Limit Emerg Reverse Check Emerg Reverse Direction Interlock Motor Protection Parameters p 44 Warm Speed Motor Warm Resistance Motor Hot Resistance Motor Resistance Compensation Hourmeter Parameters p 45 Adjust Hours High Adjust Hours Middl...

Page 28: ...e current limit is adjustable from 50 amps up to the controller s full rated armature current The full rated current depends on the controller model see specifications in Table D 1 The drive current limit is tuned as part of the vehicle performance adjust ment process Section 5 M1 M4 ACCEL RATE The acceleration rate defines the time it takes the controller to accelerate from 0 drive output to 100 ...

Page 29: ...e settings correspond to the following ratios SETTING RATIO 1 1 1 2 2 1 3 4 1 4 8 1 For example with the current ratio set at 1 with 20 throttle requested 20 of the battery voltage and 20 of the drive current will be allowed to flow in the motor assuming a 50 throttle map setting If the current ratio is set at 2 under these same conditions 40 of the current will be available if it is set at 3 80 T...

Page 30: ...for the opposite direction The decel rate is adjustable from 0 1 to 10 0 seconds The decel rate is tuned as part of the vehicle performance adjustment process Section 5 THROTTLE DECEL The throttle deceleration rate parameter adjusts the rate at which the vehicle transitions to braking when throttle is first reduced If the throttle decel rate is set low deceleration is initiated abruptly The transi...

Page 31: ...justable from the programmed minimum field Field Min up to the controller s full rated field current As shown in Figure 13 it is limited by the programmed maximum field Field Max Setting the restraint parameter to a high value will cause strong braking in an effort to bring the vehicle speed down to the requested speed Extremely high values may cause the vehicle speed to oscillate hunt while in ra...

Page 32: ...versal braking is requested If the variable braking parameter is programmed On the amount of braking current applied by the controller will be a function of the throttle s position when braking is requested With variable braking the operator can use the throttle to control the amount of braking force applied to a moving vehicle Increasing throttle in the direction opposite to the vehicle s motion ...

Page 33: ... The interlock braking rate defines the time it takes the controller to increase from 0 to 100 braking output as determined by the max regen current setpoints when interlock braking is initiated The interlock braking rate is adjustable from 0 1 to 3 0 seconds MAX FWD REGEN The maximum forward regen parameter defines the maximum regenerative current at maximum load while traveling in the forward di...

Page 34: ... REGEN applicable only with optional load sensor The minimum reverse regen parameter defines the maximum regenerative current at minimum load while traveling in the reverse direction The Min Rev Regen current is adjustable from 25 amps up to the controller s full rated current The reverse regen current increases linearly from Min Rev Regen to Max Rev Regen as the load sensor input varies from Min ...

Page 35: ...pull in at 100 PWM full current up to 3 amps for 500 ms and then pull back to 62 5 PWM 2 amps max at a frequency of about 250 Hz and continue at this level until released If programmed Off the auxiliary driver output will remain steadily at 100 PWM AUX DELAY The auxiliary driver delay parameter allows a delay before the electromagnetic brake is engaged Pin 8 driver opened after the vehicle reaches...

Page 36: ...n of Intk Brake Delay The neutral state is reached when during normal operation the throttle is in neutral both direction switches are open and the motor speed is approximately zero Aux Delay 0 0 30 0 s EM brake engages for Aux Types 2 3 and 4 INTERLOCK SWITCH OPENS VEHICLE REACHES NEUTRAL STATE Sequencing Delay 0 0 3 0 s HPD fault HPD Type 1 SRO fault Main Open Delay 0 0 40 0 s Main contactor ope...

Page 37: ...s the programmed Aux Delay has expired The Aux Delay timer starts when motor speed nears zero 3 Electromagnetic brake functions as in Type 2 except during Emerg Rev Emerg Rev a If both direction switches are open when the emergency reverse switch is released same as Type 2 b If a direction switch is closed when the emergency reverse switch is released the Aux Delay timer starts when the emergency ...

Page 38: ...d is adjustable from 0 to 25 of the controller output it cannot be set higher than the lowest programmed M1 M4 maximum forward speed The specified creep speed is not displayed as the throttle percent in the programmer s Test Menu when a direction is selected and zero throttle is applied only the 0 throttle command is displayed LOAD COMP The load compensation parameter actively adjusts the applied ...

Page 39: ...urce or current source driving external resistor 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 This parameter is especially useful with throttle assemblies that do not reliably return to a well defined neutral point because it allows the deadband...

Page 40: ...o B For throttle types 1 and 3 the deadband points are defined in terms of the nominal 5kΩ pot resistance Using a pot of greater or lesser resistance will give different values for the deadband points Throttle Max parameter set at 100 3 3V 5 0kΩ 5V 0 0 2V 40 Deadband 10 Deadband 0 Deadband 0 7V 2 1V 5V 0 3 3V 5 0kΩ 40 Deadband 10 Deadband 0 Deadband 3 0V 4 5kΩ 2 1V 3 0kΩ 0 2V 0Ω 3 3V 5 0kΩ 3 3V 5 ...

Page 41: ...ttle range The active throttle range is not affected by the throttle deadband setting The throttle max parameter can be adjusted from 100 to 60 the default setting is 90 The nominal throttle wiper range depends of the throttle type selected See Table 1 page 9 for the characteristics of your selected throttle type The throttle max parameter is tuned as part of the vehicle performance adjustment pro...

Page 42: ...ottle Max 10 Deadband Notes Voltages shown are at the pot wiper relative to B For throttle types 1 and 3 the deadband points are defined in terms of the nominal 5kΩ pot resistance Using a pot of greater or lesser resistance will give different values for the deadband points KEY 100 Neutral Deadband Controller Output 0 1 4V 2 0kΩ 0 5V 400Ω 3 0V 4 5kΩ 0 5V 100 Throttle Max 40 Deadband 90 Throttle Ma...

Page 43: ... resistance between the 0 modulation point the throttle deadband threshold and the 100 modulation point the throttle max threshold With creep speed set at 0 and maximum speed set 100 a 50 throttle map setting will give 50 output at half throttle A throttle map setting of 80 will give 80 output at half throttle Six throttle map profiles 20 30 40 50 60 and 80 are shown in Figure 17 in all these exam...

Page 44: ...Speed 3 PROGRAMMABLE PARAMETERS Throttle Parameters Fig 18 Throttle maps for controller with maximum speed set at 100 and creep speed set at 10 Reducing the max speed setting clips off the top of the throttle map Figure 19 shows throttle map curves with the same 10 creep speed setting and the maximum speed setting dropped to 90 The curves in this example are exactly as in Figure 18 except the PWM ...

Page 45: ...rent limit parameter defines the maximum allowed field current The maximum field current limit setting determines the vehicle s maximum torque and the maximum power that the field winding will have to dissipate Field Max can be adjusted from the programmed Field Min value up to the controller s full rated field current The full rated field current depends on the controller model see specifications...

Page 46: ...or Fig 20 Field current relative to armature current with field map parameter set at 50 and 20 ARMATURE CURRENT FIELD CURRENT Field Map Start Field Map Midpoint 100 Drive C L 0 0 Field Min Field Max Field Map 50 ARMATURE CURRENT FIELD CURRENT Field Map Start Field Map Midpoint 100 Drive C L 0 0 Field Min Field Max Field Map 20 Decreasing the field map parameter reduces the field current at a given...

Page 47: ... time after the interlock switch is opened The delay is useful for preventing unnecessary cycling of the contactor and for maintaining power to auxiliary functions such as a steering pump motor that may be used for a short time after the interlock switch has opened The main contactor open delay is programmable from 0 to 40 seconds After the interlock switch is opened the programmed sequencing dela...

Page 48: ...r simply a KSI input HPD Type 2 before receiving a throttle input greater than 25 if the inputs are not received in the proper sequence the controller will inhibit output to the motor An HPD fault can be cleared by reducing the throttle demand to less than 25 HPD fault detection can be turned off by setting the HPD Type to 0 To meet EEC requirements HPD must be programmed to Type 1 or Type 2 Note ...

Page 49: ... types of SRO are available along with a no SRO option SRO Type 0 No SRO fault detection SRO Type 1 KSI and Interlock before direction input To drive the vehicle the controller must receive both a KSI input and an interlock input before receiving an input from either direction switch The order in which the KSI and interlock inputs are received does not matter only that they are both received befor...

Page 50: ...ncy reverse feature is being used in the application If emergency reverse is not being used this parameter should be set to Off When enabled programmed On the emergency reverse check tests for continuity from the emergency reverse check output Pin 10 to the emergency reverse input Pin 13 Therefore the emergency reverse wiring should be connected as closely as possible to the controller side of the...

Page 51: ...nce is at or above the Motor Warm Resistance setpoint The warm speed is adjustable from 0 to 100 of drive output MOT WRM x10 mΩ The motor warm resistance parameter defines the field resistance setpoint at which a motor warm fault will occur and the maximum speed will be controlled by the Warm Speed setting Note The parameter value is in ten milliohm units If you want to program the Motor Warm Resi...

Page 52: ...cle these presets do not need to be adjusted If the controller is being installed in a used vehicle however it may be desirable to transfer the existing hourmeter values to the new controller To do this the existing hourmeter values must be entered as follows Each meter records time to 999999 9 hours 114 years and will roll over to 000000 0 if this is exceeded The adjust high adjust middle and adj...

Page 53: ... overall maintenance reminder SRVC TRAC HRS The traction service hours parameter is used to set the timer for the next scheduled traction motor maintenance The service interval can be up to 5 000 hours The traction service timer is adjustable between 0 0 and 50 0 in 0 5 increments with 25 0 being equivalent to 2 500 hours 25 0 100 Setting the parameter to 0 means that the timer will never expire i...

Page 54: ... must then be pro grammed Off to indicate the appropriate service has been performed If a vehicle is brought in for service before a service warning is issued you can check the accumulated total service hours Plug in the 1311 programmer and go to the Monitor menu Multiply the Tot Srvc X25 value by 25 and add the Tot Srvc value this is how many total hours have elapsed since the total service timer...

Page 55: ...r is displayed PUMP METER The pump meter parameter when programmed On configures the Fault Output 1 line at Pin 2 to function as an input to measure the hours a pump is running The pump is considered to be running when Pin 2 is at the battery voltage When the pump meter parameter is programmed On the traction hourmeter serves as a combination traction pump hourmeter and all the above TRAC hourmete...

Page 56: ...tery voltages rather than VPC values see Table 5 FULL VOLTS The full voltage parameter sets the battery voltage that will be considered 100 state of charge When a loaded battery drops below this voltage it begins to lose charge The full voltage value can be set from the programmed Empty Volts value up to the programmed Reset Volts value in 0 01 VPC increments After adjusting Full Volts KSI must be...

Page 57: ... speed to the BDI Limit Speed when the battery state of charge is 0 BDI LIMIT SPEED The BDI limit speed parameter sets the vehicle s maximum allowed speed when the BDI disable parameter is programmed On and the battery state of charge is 0 The BDI limit speed is adjustable from 0 to 100 of drive output If the BDI disable parameter is programmed Off the BDI limit speed will not be in effect Table 5...

Page 58: ...ault outputs defines one of four fault categories Table 6 lists the possible faults included in each category Note Alternatively Pin 2 can be used as a pump meter input and Pin 3 can be used to interface an external auxiliary enable circuit see fault output wiring page 14 Table 6 FAULT CATEGORIES FAULT FAULT 1 FAULT 2 CATEGORY OUTPUT OUTPUT POSSIBLE EXISTING FAULTS 0 HIGH HIGH no faults present 1 ...

Page 59: ... only works between controllers with the same model number and software version To perform cloning plug the 1311 programmer into the controller that has the desired settings Scroll down to the Functions menu Settings is the only function included here Select Get settings from controller to copy the settings into the programmer then select to save the settings or to abort them Plug the programmer i...

Page 60: ... the programmer connector 2 Turnthekeyswitchon Theprogrammershouldpowerupwithaninitial display and the controller s Status LED should begin steadily blinking a single flash If neither happens check for continuity in the keyswitch circuit and controller ground 3 Select the System Faults menu The display should indicate No Known Faults Close the interlock switch To do this on a walkie pull the tille...

Page 61: ... forward reverse interlock emergencyreverse andmodeswitches Cycle eachswitchinturn observingtheprogrammer Theprogrammershould display the correct status for each switch 6 Verify that all options such as high pedal disable HPD static return to off SRO and anti tiedown are as desired 7 Onwalkies verifythattheemergencyreversefeatureisworkingcorrectly i e press the emergency reverse button and confirm...

Page 62: ...is any question about what any of them do The 1243GEN2 s MultiMode feature allows the vehicle to be configured to provide four distinct operating modes Typically Mode 1 is configured for slow precise indoor maneuvering Mode 4 for faster long distance outdoor travel and Modes 2 and 3 for application specific special conditions Some of the tuning procedures may need to be repeated four times once fo...

Page 63: ...ep 7 If it is greater than zero the Throttle Deadband parameter must be increased go to the Program menu and the procedure repeated from Step 5 until the Throttle is zero at the forward direction engagement point Setting a second bookmark at the Throttle Deadband parameter will allow you to toggle back and forth easily between the parameter and the Throttle field STEP 7 While observing the Throttl...

Page 64: ...he Throttle Max parameter value and repeat this step until the value is 100 Setting a second bookmark at the Throttle Max parameter will allow you to toggle back and forth easily between the parameter and the Throttle field STEP 5 Now that the full throttle position results in a 100 value for Throttle slowly reduce throttle until the Throttle value drops below 100 and note the throttle position Th...

Page 65: ...range can be 10 to 50 Since the maximum available field current determines the maximum torque that can be produced by the motor the vehicle s performance under load and up inclines will change as the motor heats up The change in performance can be limited by tuning the motor when it is hot rather than cold Therefore it is recommended that the following procedure be performed with a hot motor STEP ...

Page 66: ...side the motor s safe commu tation region and will cause arcing between the brushes and commutator significantly reducing motor and brush life The Field Min parameter value can be increased from the manufacturer s specified value to limit the vehicle s top speed Setting the vehicle top speed will be addressed in tuning procedure 3 If the controller is tuned such that the system is operating outsid...

Page 67: ...red top speed Increasing the Field Min value decreases the vehicle s top speed decreasing the Field Min value increases the vehicle s top speed CAUTION Do not decrease the Field Min parameter value below the motor manufacturer s recommended minimum field current value and do not increase it above 10 amps STEP 3 If the Field Min parameter value is increased to 10 amps and the vehicle s top speed ha...

Page 68: ...city Leave the Field Min and Speed Max parameters at the settings determined during the unloaded test STEP 3A If the intent is to minimize the difference between the loaded and unloaded vehicle speeds then i Drive the fully loaded vehicle on flat ground with full throttle applied When the vehicle reaches maximum speed observe the armature current displayed in the programmer s Monitor Menu ii Set t...

Page 69: ... exceeding the motor s safe commutation region FINE TUNING Four additional vehicle performance characteristics can be adjusted 5 Response to Reduced Throttle 6 Response to Increased Throttle 7 Smoothness of Direction Transitions 8 Ramp Climbing These characteristics are related to the feel of the vehicle and will be different for various applications The fine tuning adjustments are especially noti...

Page 70: ... overall response If the vehicle starts too slowly under all driving con ditions the Accel Rate should be reduced STEP 3 Increasing vehicle acceleration If acceleration feels good for slow or moderate throttle transitions but the vehicle initially starts too slowly set the Current Ratio parameter to 2 or higher If the vehicle does not accelerate as quickly as desired when the throttle is transitio...

Page 71: ...red vehicle speed may not be attainable The system will find a compromise point at which sufficient motor torque is generated to climb the ramp at an acceptable speed If the Field Map parameter value is reduced to 0 and the desired speed is still not attained the system is being limited by the motor s torque capability under these operating conditions CAUTION be careful when reducing the Field Map...

Page 72: ...ACCEL RATE Mode 1 acceleration rate in seconds M2 ACCEL RATE Mode 2 acceleration rate in seconds M3 ACCEL RATE Mode 3 acceleration rate in seconds M4 ACCEL RATE Mode 4 acceleration rate in seconds M1 DECEL RATE Mode 1 deceleration rate in seconds M2 DECEL RATE Mode 2 deceleration rate in seconds M3 DECEL RATE Mode 3 deceleration rate in seconds M4 DECEL RATE Mode 4 deceleration rate in seconds THR...

Page 73: ...estraint braking in amps LOAD COMP Load compensation 0 to 25 drive output HPD High pedal disable HPD type 2 SRO Static return to off SRO type 3 SEQUENCING DLY Sequencing delay in seconds MAIN CONT INTR Main contactor uses interlock input On or Off MAIN OPEN DLY Main contactor open delay On or Off CONT DIAG Contactor diagnostics On or Off AUX TYPE Auxiliary driver type 4 AUX DELAY Auxiliary driver ...

Page 74: ...ce exceeds setpoint as MOT WRM x10 mΩ Field resistance setpoint for Warm Speed in 10 milliohm units MOT HOT x10 mΩ Field resistance at which no drive output in 10 milliohm units MOTOR Ω COMP Enable cutback cutoff response to motor overtemp On or Off MAX REV REGEN Max intk braking regen current fr rev max load in amps MAX FWD REGEN Max intk braking regen current fr fwd max load in amps MIN REV REGE...

Page 75: ...are received before a throttle request 25 Type 2 HPD fault unless KSI input is received before a throttle request 25 3 SRO types for detail see Section 3 Programmable Parameters page 42 Type 0 no SRO Type 1 SRO fault unless KSI interlock inputs are received before a direction is selected Type 2 SRO fault unless KSI interlock inputs in that order are received before a direction is selected Type 3 S...

Page 76: ...vice hours multiple of 25 TOT SRVC Total service hours in hours TRAC SRVC X25 Total traction hours multiple of 25 TRAC SRVC Total traction hours in hours FORWARD INPUT Forward switch on off neutral switch for Type 4 throttle REVERSE INPUT Reverse switch on off MODE INPUT A Mode Select 1 switch on off MODE INPUT B Mode Select 2 switch on off INTERLOCK Interlock switch on off EMR REV INPUT Emergency...

Page 77: ...TED M shorted to B MAIN CONT WELDED Welded main contactor MISSING CONTACTOR Missing contactor MOTOR HOT Field winding resistance at disable setpoint MOTOR WARM Field winding resistance at cutback setpoint NO KNOWN FAULTS No known faults OVERVOLTAGE Battery voltage too high SRO Static return to off SRO activated SRVC TOTAL Total service timer expired SRVC TRAC Traction service timer expired THERMAL...

Page 78: ...have occurred since the fault history file was last cleared Checking and clearing the fault history file is recommended each time the vehicle is brought in for maintenance For information on 1311 programmer operation see Appendix B If you are using the older 1307 programmer refer to existing documentation SPYGLASS DIAGNOSTICS The eight character LCD on the Spyglass displays a continuous sequence o...

Page 79: ... 2 2 EMR REV WIRING 1 1 Emergency reverse wire or check wire Re apply emergency reverse open or cycle interlock 2 3 HPD 3 1 Improper sequence of KSI interlock Follow proper sequence and throttle inputs adjust throttle if necessary 2 Misadjusted throttle pot adjust programmable 3 Sequencing delay too short parameters if necessary 3 Wrong HPD or throttle type selected 5 Misadjusted throttle pot SRVC...

Page 80: ...manently MOTOR HOT 3 1 Field resistance motor hot setpoint When resistance setpoint MOTOR WARM 3 1 Field resistance motor warm setpoint When resistance setpoint Fig 21 Curtis 840 Spyglass 3 LED and 6 LED models Fault LED red BDI LED yellow Hourmeter LED green 8 character LCD display Fault LED red BDI 0 100 LEDs yellow 8 character LCD display 0 1 green red 3 LED Spyglass The hourmeter LED lights wh...

Page 81: ...wer or defective controller solid on controller or microprocessor fault 0 1 controller operational no faults 1 1 current sensor error 1 2 hardware failsafe fault 1 3 M fault or motor output short 1 4 static return to off SRO 2 1 throttle wiper high 2 2 emergency reverse circuit check fault 2 3 high pedal disable HPD or expired timer 2 4 throttle wiper low 3 1 contactor driver overcurrent or field ...

Page 82: ...heir normal state high In Fault Category format the two fault outputs together define one of four fault categories as listed in Table 9 When a fault occurs the Fault 1 and Fault 2 lines Pins 2 and 3 go to the state indicating the category of the particular fault LOW HIGH HIGH LOW or LOW LOW When the fault is cleared the fault outputs return to their normal state i e HIGH HIGH Table 9 FAULT CATEGOR...

Page 83: ... contactor coil or a horn across the controller s B and B terminals 3 Remove any dirt or corrosion from the connector areas The controller should be wiped clean with a moist rag Dry it before reconnectingthebattery Thecontrollershouldnotbesubjected to pressured water flow from either a standard hose or a power washer 4 Make sure the connections are tight but do not overtighten them See Section 2 p...

Page 84: ...ge characteristics of the capacitors must be adequate to meet any safety regulations regarding electrical connections between a battery operated circuit and the chassis The bypass capacitor should be installed as close to the motor as possible or even inside it to provide the best performance Alternatively a ferrite bead can be installed on the wires as close as possible to the motor In some insta...

Page 85: ...ntroller within a shielded box on the end product The box may be constructed of just about any metal although steel and aluminum are most commonly used Most coated plastics do not provide good shielding because the coatings are not true metals but rather a mixture of small metal particles in a non conductive binder These relatively isolated particles may appear to be good based on a dc resistance ...

Page 86: ...ce ELECTROSTATIC DISCHARGE ESD Curtis motor controllers contain ESD sensitive components and it is therefore necessary to protect them from ESD damage Electrostatic discharge ESD immunity is achieved either by providing sufficient distance between conduc tors and the outside world so that a discharge will not occur or by providing an intentional path for the discharge current such that the circuit...

Page 87: ...play and for modifying parameters and three keys that can be used as bookmarks The 1311 programmer is easy to use with self explanatory functions After plugging in the programmer wait a few seconds for it to boot up and gather information from the controller For experimenting with settings the programmer can be left plugged in while the vehicle is driven APPENDIX B 1311 PROGRAMMER Parameter Modifi...

Page 88: ...is way you can easily toggle between the readout and the parameter 1311 PROGRAMMER MENUS There are six main menus which in turn lead to nested submenus Program provides access to the individual programmable parameters see page 65 Monitor presents real time values during vehicle operation see page 69 Faults presents diagnostic information on active system faults see page 70 and also provides access...

Page 89: ...ECK page 43 EMR REV C L page 43 FAULT CODE page 51 FIELD CHECK page 40 FIELD MAP page 39 FIELD MAX page 38 FIELD MIN page 38 FLD MAP START page 38 FULL VOLTS page 49 HOURMETER TYPE page 48 HPD page 41 INT BRAKE DLY page 28 INT BRAKE RATE page 26 LOAD COMP page 31 MAIN CONT INTR page 40 MAIN OPEN DLY page 40 MAX FWD REGEN page 26 MAX FWD SPD M1 M4 page 31 MAX LOAD VOLTS page 27 MAX REV REGEN page 2...

Page 90: ...erating frequency 16 kHz Electrical isolation to heatsink 500 V ac minimum KSI input voltage minimum 16 8 V KSI input current no contactors engaged 78 mA without programmer 120 mA with 1311 programmer 110 mA with 1307 Logic input voltage 7 5 V High 1 V Low Logic input current 15 mA Operating ambient temperature range 40 C to 50 C 40 F to 122 F Heatsink overtemperature cutback 85 C 185 F Heatsink u...

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