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Curtis 1232E, Manual

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Curtis 1232E Manual Download Page 4

 2 — WIRING

Curtis 1232E/34E/36E/38E/39E & 1232SE/34SE/36SE/38SE Manual, os 31 – May 2017  

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pg. 2

2 — WIRING

One of the two controllers is designated the master and the other the slave. The master controller operates 

the left motor and the slave operates the right motor. The throttle and brake inputs go to the master. The 

steering pot input goes to the Pot2 input on the slave controller.  
A single main contactor is used, and is controlled by the master. The KSI, CAN H, and CAN L pins of the 

two controllers are connected together. B+ from the main contactor and the keyswitch are supplied to 

each controller through separate pairs of fuses to enable operation to continue if one side fails. See Figure 

2a, below, for an overview of the common wiring between the two controllers, and Figures 2b and 2c for 

the detail in each controller. 

Figure 2a 

Wiring between the master and slave Dual Drive traction controllers.

SWITCH 2 /

ANALOG 2

J1-8

I/O GROUND

J1-7

POT2 HIGH

J1-27

POT2 WIPER

J1-17

POT LOW

J1-18

STEERING

PO

T

RIGHT

AC

MOTOR

J1-5

J1-13

KSI

COIL RETURN

BRAKE

J1-1

KSI

POSITION

FEEDBACK

DEVICE

J1-26
J1-31
J1-32
J1-7

J1-23

J1-35

J1-21

J1-34

Short for 120

Ω

CAN bus termination

B+

V

+5V

FEEDBACK B

CAN TERM L

CAN L

U

W

FEEDBACK A

I/O GROUND

CAN TERM H

CAN H

RIGHT MOTOR

TEMP

SENSOR

SLAVE CONTROLLER

1232E/34E/36E/38E/39E

1232SE/34SE/36SE/38SE

B-

DRIVER 2

SWITCH 8

J1-33

REVERSE

SWITCH 7

J1-22

FORWARD

SWITCH 3

J1-9

INTERLOCK

SWITCH 2 /

ANALOG 2

J1-8

I/O GROUND

J1-7

THROTTLE

POT HIGH

J1-15

THROTTLE

POT WIPER

J1-16

POT2 HIGH

J1-27

POT2 WIPER

J1-17

POT LOW

J1-18

TH

RO

TTLE P

OT

BRAKE P

OT

LEFT

AC

MOTOR

MAIN

J1-5

J1-6

J1-13

DRIVER 2

DRIVER 1

KSI

COIL RETURN

MAIN

BRAKE

J1-1

KSI

J1-26
J1-31
J1-32
J1-7

J1-23

J1-35

J1-21

J1-34

Short for 120

ΩΩ

CAN bus termination

BATTERY

(24–80V)

KEYSWITCH

B+

V

+5V

FEEDBACK B

CAN TERM L

CAN L

U

W

FEEDBACK A

I/O GROUND

CAN TERM H

B-

CAN H

LEFT MOTOR

TEMP

SENSOR

EMERGENCY

ST

OP

MASTER CONTROLLER

1232E/34E/36E/38E/39E

1232SE/34SE/36SE/38SE

POSITION

FEEDBACK

DEVICE

Note: See the 1239E manual for typical wiring for the external high-voltage  

battery precharge circuit and for the 12V KSI and switch/driver I/O.

Summary of Contents for 1232E

Page 1: ...ce 2016 Curtis Instruments Inc Curtis is a registered trademark of Curtis Instruments Inc The design and appearance of the products depicted herein are the copyright of Curtis Instruments Inc 53097 DD Supplement os31 May 2017 Curtis Instruments Inc 200 Kisco Avenue Mt Kisco NY 10549 www curtisinstruments com Software Version OS 31 0 DUAL DRIVE OPERATION ...

Page 2: ...1 Various Dual Drive vehicle configurations 1 Figure 2a Wiring between the master and slave Dual Drive traction controllers 2 Figure 2b Basic wiring diagram for master controller Dual Drive operation 3 Figure 2c Basic wiring diagram for slave controller Dual Drive operation 4 Figure 3 Typical 3 wheel Dual Drive vehicle geometry 10 Figure 4 Typical articulated steering Dual Drive vehicle geometry 1...

Page 3: ...and acceleration while turning Current is automatically balanced between the two traction motors when driving straight and a limited operating strategy LOS allows limp home in case of a steer angle sensor or single motor or controller failure Figure 1 shows three typical Dual Drive vehicle configurations Dual Drive uses different speed maps for the two traction motors one for the inner wheels and ...

Page 4: ...7 POT2 WIPER J1 17 POT LOW J1 18 STEERING POT RIGHT AC MOTOR J1 5 J1 13 KSI COIL RETURN BRAKE J1 1 KSI POSITION FEEDBACK DEVICE J1 26 J1 31 J1 32 J1 7 J1 23 J1 35 J1 21 J1 34 Short for 120 Ω CAN bus termination B V 5V FEEDBACK B CAN TERM L CAN L U W FEEDBACK A I O GROUND CAN TERM H CAN H RIGHT MOTOR TEMP SENSOR SLAVE CONTROLLER 1232E 34E 36E 38E 39E 1232SE 34SE 36SE 38SE B DRIVER 2 SWITCH 8 J1 33 ...

Page 5: ...R 4 DRIVER 3 DRIVER 2 DRIVER 1 KSI COIL RETURN MAIN BRAKE J1 1 KSI POSITION FEEDBACK DEVICE J1 26 J1 31 J1 32 J1 7 J1 23 J1 35 J1 21 J1 34 Connect jumper for 120Ω CAN bus termination J1 25 J1 28 J1 29 J1 7 SERIAL PORT 4 pin Molex 4 3 1 2 CURTIS MODEL 840 DISPLAY 8 6 5 BATTERY 24 96V KEYSWITCH B V 5V POSITION FEEDBACK B CAN TERM L CAN L 12V RX I O GROUND U W POSITION FEEDBACK A I O GROUND CAN TERM ...

Page 6: ... 2 B V 5V POSITION FEEDBACK B CAN TERM L CAN L 12V RX I O GROUND U W POSITION FEEDBACK A I O GROUND CAN TERM H CAN H TX RIGHT MOTOR TEMP SENSOR to J1 23 on master controller to J1 35 on master controller to KSI J1 1 on master controller to B on master controller SLAVE CONTROLLER 1232E 34E 36E 38E 39E 1232SE 34SE 36SE 38SE SWITCH 16 SWITCH 8 SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3 SWITCH 1 ANA...

Page 7: ...eer Angle Max Turn Accel Rate Critical Angle Max Turn Speed Inner Wheel Speed Steer Type Steer Pot Min Steer Pot Zero Steer Pot Max VCL Steer Enable SLAVE MENU p 8 Turn Accel Rate Critical Angle Steer Fault Min Steer Fault Max TURN FEEDFORWARD MENU p 8 Turn Accel Rate Turn Kvff Turn ff Build Rate Turn ff Release Rate PARAMETER CHANGE FAULTS Parameters marked PCF in the menu charts will set a Param...

Page 8: ...arameter Off in the master controller and On in the slave controller CAN Node ID Other Dual_CAN_Node_ID_Other 0x330F 0x00 1 127 1 127 The master and slave controllers must have different CAN Node IDs and each must know the CAN Node ID of the other controller so they can talk to each other Set this parameter to the slave controller s CAN Node ID in the master controller and set it to the master con...

Page 9: ...alue to the programmed Max Turn Speed see Figure 6 Inner Wheel Speed Dual_Inner_Wheel_Speed 0x38A9 0x00 100 0 0 0 32767 0 Set this parameter to the Inner wheel speed as a percentage of outer wheel speed when the steer angle is 90 degrees Use the equation on page 9 to determine the appropriate percentage Steer Type PCF Dual_Steer_Type 0x38AB 0x00 1 5 1 5 Set this parameter to the appropriate type f...

Page 10: ...t voltage goes below this threshold a Dual Severe Fault 75 will be issued Steer Fault Max Dual_Steer_Fault_Max 0x38B0 0x00 0 00 5 50 V 0 28864 Sets the minimum threshold for the Dual Drive steering pot input If the steering pot voltage goes below this threshold a Dual Severe Fault 75 will be issued DUAL DRIVE TURN FEEDFORWARD MENU PARAMETER ALLOWABLE RANGE DESCRIPTION Turn Accel Rate Dual_Turn_Acc...

Page 11: ...ront right and back left are perpendicular to each other 3 WHEEL APPLICATIONS The Critical Angle and Inner Wheel Speed can be determined empirically or calculated using the following equations where W wheelbase T track of the driven wheels and A distance between the steered axle and the pivot point see Figures 3 and 4 For vehicles without a steered axle use A 0 Any units can be used feet meters et...

Page 12: ...HEEL SPEED Curtis 1232E 34E 36E 38E 39E 1232SE 34SE 36SE 38SE Manual os 31 May 2017 Return to TOC pg 10 Figure 3 Typical 3 wheel Dual Drive vehicle geometry W T T W A Figure 4 Typical articulated steering Dual Drive vehicle geometry W T T W A ...

Page 13: ...ed to outer wheel speed assuming a 90 maximum steering angle 100 Inner Wheel Speed 0 100 10 90 C r i t i c a l A n g l e STEERING ANGLE speed of inner wheel speed of outer wheel Speed of inner wheel Speed of outer wheel Figure 6 Inner wheel and outer wheel speed maps assuming full throttle Max Turn Speed 0 10 90 C r i t i c a l A n g l e 100 100 STEERING ANGLE S t e e r i n g A n g l e M a x Inner...

Page 14: ...e slave a Set the master controller s CAN Node ID in the CAN Interface menu to the master controller s unique ID b Adjust the settings of the parameters in the Dual Drive menu Set Dual Motor Enable On Set Dual Motor Slave Off Set CAN Node ID Other the slave controller s CAN Node ID Set LOS Max Speed to the desired value c Adjust the settings of all the parameters in the Dual Drive Master menu d Se...

Page 15: ...els still jacked up apply interlock and throttle and verify that the wheels turn at the proper speed and direction as the steer angle changes If either wheel turns in the wrong direction or appears to be fighting itself struggling at full current while jerkily turning at very low speed try changing the setting of the Swap Encoder Direction or Swap Two Phases parameters Refer to setup procedures in...

Page 16: ... the throttle processing in a non dual drive controller because here the master controller is processing the throttle variables The Dual_Slave_Throttle_ From_Master Fig 7b point B and Dual_Slave_Brake_From_Master Fig 7b point C arrive from the master as shown The Throttle Pot input on the slave is not used for throttle and may be programmed in VCL for other uses VCL is not required to implement th...

Page 17: ...and Throttle TMap 1 1 128 1 Brake_Command Brake Type Brake Type Processing Brake OS Brake Brake Command Brake Mapping VCL_Brake Brake Type 5 or VCL_Brake_ Enable On 100 0 FullBrake Brake Max Brake Offset Brake Map Brake Deadband 0 Brake Pedal Enable On Control Mode Select 0 1 2 Mapped Throttle Mapped Brake ShutdownThrottle or ThrottleInvalid or Main Cont Not Closed or Interlock_State Off Steer Ang...

Page 18: ...pe 4 and Forward Off and Reverse On and TMap 0 Throttle Type 4 and Forward On and Reverse Off and TMap 0 U Phase W Phase V Phase Controller Torque Command Control Mode Select 0 or 1 and Pump_ Enable_ SpdM On and Mapped_ Throttle 0 Throttle_Command Throttle TMap 1 1 128 1 Control Mode Select 0 1 2 Mapped Throttle ShutdownThrottle or ThrottleInvalid or Main Cont Not Closed or Interlock_State Off Ste...

Page 19: ...ize inputs and outputs between master and slave Byte 6 Not used A Byte 7 Steer_Pot_Raw high byte 0x38BB 0x00 Voltage from steer pot for master to use in calculating steer angle A Byte 8 Steer_Pot_Raw low byte 0x38BB 0x00 The contents of Flags_Slave and Flags_Master are as follows Bit1 Dual_Motor_Interlock_Bit Used to synchronize the interlock between master and slave Bit2 Request_Dual_Motor_Interl...

Page 20: ...L parameter name Dual_LOS_Max_Speed see page 6 Then if the Throttle Command see the Monitor Inputs menu in the controller s manual and 1313 1314 results in the motor speed request exceeding the LOS Max Speed the motor rpm will be clamped to the LOS Max Speed subject to normal slewing constraints If the steer angle input is invalid both controllers will use the Dual Drive s LOS Max Speed and assume...

Page 21: ...lt On Bit3 ShutdownThrottle Set the Throttle_Command 0 Bit4 ShutdownInterlock Set the Interlock_State Off Bit5 ShutdownDriverl Shut down Driver1 Bit6 ShutdownDriver2 Shut down Driver2 Bit7 ShutdownDriver3 Shut down Driver3 Bit8 ShutdownDriver4 Shut down Driver4 Bit9 ShutdownPD Shut down Proportional Driver Bit10 FullBrake Set the Brake_Command 100 Bit11 reserved N A for 1232 1238E SE and 1239E con...

Page 22: ... SevereDual LOSDual TrimDisable 1 See Monitor menu Controller Temperature 2 Controller is operating in an extreme environment Set Heatsink temperature below 40 C Clear Bring heatsink temperature above 40 C and cycle interlock or KSI 16 Controller Severe Overtemp ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Other controller Same effects as this controller 1 See Mon...

Page 23: ...ed recharging Controller is performance limited at this voltage 2 Battery parameters are misadjusted 3 Non controller system drain on battery 4 Battery resistance too high 5 Battery disconnected while driving 6 See Monitor menu Battery Capacitor Voltage 7 Blown B fuse or main contactor did not close Set Capacitor bank voltage dropped below the Undervoltage limit with the FET bridge enabled Clear B...

Page 24: ...en or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring Set Driver 1 pin 6 is either open or shorted This fault can be set only when Main Enable Off Clear Correct open or short and cycle driver 31 Main Open Short ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Other controller Same effects as this controller 1 Open or short on driver load 2 Di...

Page 25: ...ed or open 3 An alternate voltage path such as an external precharge resistor is providing a current to the capacitor bank B connection terminal Set Just prior to the main contactor closing the capacitor bank voltage B connection terminal was loaded for a short time and the voltage did not discharge Clear Cycle KSI 39 Main Contactor Did Not Close ShutdownMotor ShutdownMainContactor ShutdownEMBrake...

Page 26: ...roller Set Controller operating system tried to write to EEPROM memory and failed Clear Download the correct software OS and matching parameter default settings into the controller and cycle KSI 47 HPD Sequencing Fault ShutdownThrottle Other controller Same effects as this controller 1 KSI interlock direction and throttle inputs applied in incorrect sequence 2 Faulty wiring crimps or switches at K...

Page 27: ...mbined current used by the 5V supply pin 26 and 12V supply pin 25 is either greater than the upper current threshold or lower than the lower current threshold The two thresholds are defined by the External Supply Max and External Supply Min parameter settings Clear Bring the external supply current within range 71 OS General ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle Shutd...

Page 28: ...nContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake TrimDisable SevereDual ShutdownSteer LOSDual Other controller Same effects as this controller 1 The Supervisor has detected a mismatch in redundant readings 2 Internal damage to Supervisor microprocessor 3 Switch inputs allowed to be within upper and lo...

Page 29: ...manually 2 motor temp sensor fault 3 motor temp hot cutback fault 4 controller overtemp cutback fault 5 controller undertemp cutback fault 6 undervoltage cutback fault 7 severe overvoltage fault 8 encoder signal not seen or one or both channels missing 9 motor parameters out of characterization range 20 sin cos sensor not found 21 phasing not detected 22 sin cos sensor characterization failure 23 ...

Page 30: ...ment has been sensed Clear 1 Activate the Throttle EM Brake type 2 2 Activate the Interlock EM Brake type 1 94 EMR Rev Timeout ShutdownEMBrake ShutdownThrottle Other controller Same effects as this controller 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 T...

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