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Manual

Model

1268

Electronic Motor Controller

Read Instructions Carefully!

Speciﬁcations are subject to change without notice.
© 2012 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.

37873 Rev D 3/12

Curtis Instruments, Inc.

200 Kisco Avenue

Mt. Kisco, NY 10549

www.curtisinstruments.com

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Summary of Contents for 1268

Page 1: ...ge without notice 2012 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 Instrumen...

Page 2: ......

Page 3: ...ate M1 M2 Reverse Field Brake Field Brake Speed Field Brake Max Field Brake Rate Speed Parameters 19 Max Forward Speed M1 M2 Max Reverse Speed RPM To Speed Tacho Poles Throttle Parameters 20 Throttle...

Page 4: ...CHECKOUT 31 5 TUNING GUIDE 33 Major Tuning 33 1 Tuning the active throttle range 33 2 Calibrating the controller speed measurement 35 3 Tuning the controller to the motor 35 4 Equalizing loaded and un...

Page 5: ...ring con guration with aux driver used for an EM brake 8 fig 3b Standard wiring con guration with aux driver used for a WalkAway relay 9 fig 4 Wiring for 3 wire potentiometer throttle 10 fig 5 Wiring...

Page 6: ......

Page 7: ...perior closed loop control for regulating vehicle speed Unique braking parameters allow simple intuitive deceleration tuning A full bridge eld winding control stage is combined with a half bridge arma...

Page 8: ...ntrol is enhanced through feedback from a Hall effect speed sensor Anti rollback function providing improved control when throttle is released on hills Anti stall function helps prevent motor commutat...

Page 9: ...al programmers and through the built in Status LED Driver for remote Status LED enables status information to be available at a dashboard Sealed package is rated at IP64 and IP67 Meets or exceeds EEC...

Page 10: ...r as clean and dry as possible When selecting the mounting position be sure to also take into consideration 1 that access is needed at the top of the controller to plug the programmer into its connect...

Page 11: ...ting 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 RUNAWAY...

Page 12: ...y through 453 or ITS input J1 14 Pot Low 453 to ground J1 15 Pot Wiper throttle wiper input or ITS input J1 16 LED Ground ground for external LED J1 17 Main Contactor contactor coil driver low side ou...

Page 13: ...art p n 16185 If a 1314 PC programming station is used the 1309 interface box and cable connect the computer to the controller p n 117465704 1314 1101 1314 PC Programming Station User CD ROM p n 11746...

Page 14: ...depend on how the F1 and F2 connections are made to the controller s two eld terminals and how the motor shaft is connected to the drive wheels through the vehicle s drive train Fig 3a Standard wirin...

Page 15: ...he system will therefore not meet EEC safety requirements 2 INSTALLATION WIRING Controller Fig 3b Standard wiring con guration for Curtis 1268 controller in an application with the WalkAway function 1...

Page 16: ...anning to use is not covered contact the Curtis of ce nearest you 3 Wire Potentiometer 5k 10k Throttle The 3 wire potentiometer is used in its voltage divider mode with the voltage source and return b...

Page 17: ...own in Figure 6 The Hall sensor circuit within the throttle creates an output current between 0 7mA and 1 6mA from min to max throttle The two wires are interchangeable 2 INSTALLATION WIRING Throttle...

Page 18: ...in the standard wiring diagrams pages 8 9 RATED INTERNAL RATED LOAD DIODE DRIVER PIN CURRENT VOLTAGE PROTECTION Main Contactor J1 17 2 0 A B yes Brake Light Relay J1 18 0 5 A B no Reverse Alarm J1 19...

Page 19: ...Voltage parameter The pull in voltage set by the Pull In Voltage parameter is used in place of the holding voltage for the rst 100 milliseconds When the aux driver is used with an EM brake the EMB De...

Page 20: ...switching the battery voltage at 25 mA Circuitry Protection Devices To protect the control circuitry from accidental shorts a low current fuse ap propriate for the maximum current draw should be conne...

Page 21: ...grammed to provide two different sets of operating characteristics which can be useful for operating in different condi tions such as slow precise indoor maneuvering in one mode and faster long distan...

Page 22: ...D MAX FLD MAP START NEG FLD MAP ST FIELD MAP END NEG FLD MAP EN FIELD RAMP NEG FLD RAMP FIELD DIR SWAP Fault Parameters KSI SRO ENABLE MODE AFTER KEY OVERVOLTAGE LOW VOLTAGE WARNING OPTION Output Driv...

Page 23: ...g modes the reverse decel rate ap plies to both M1 and M2 If the vehicle is slowing quicker than the decel rate for example at zero throttle traveling up a hill the output will decay at a rate of 0 8...

Page 24: ...er incapable of sensing vehicle rollback However even though the anti rollback function may not be activated the plug braking generated by the eld current will still act to slow the vehicle FLD BRAKE...

Page 25: ...rpm to speed parameter is a conversion factor used to generate a vehicle speed estimate from the speed sensor input motor RPM signal Use these equations to calculate the value to enter for RPM TO SPE...

Page 26: ...THROTTLE MAP setting refers to the controller output at half throttle the midpoint of the throttle s full active range the range between THROTTLE 0 and THROTTLE 100 3 PROGRAMMABLE PARAMETERS Throttle...

Page 27: ...y to the motor during regen braking opera tion During regen braking this parameter controls the regen current from the motor s armature into the battery The braking current limit is adjustable from 0...

Page 28: ...and is applicable at speeds at and above the BRAKE END speed The value is a percentage of the full regen current BRAKE MAX is used to strengthen vehicle braking at high speeds A high value will provid...

Page 29: ...brake map curve The value set for this parameter is a percentage of the regen current between the BRAKE MIN and BRAKE MAX values at the point that is halfway between the BRAKE END and BRAKE START spe...

Page 30: ...inimum allowed current in the motor s eld winding when the vehicle is traveling in the reverse direction FIELD MAX The maximum eld current limit parameter de nes the maximum allowed current in the mot...

Page 31: ...zero the motor s eld current increases linearly with increasing armature current thus emulating a series wound motor Decreasing the FIELD RAMP setting reduces the eld current at a given armature curre...

Page 32: ...s for Mode 1 greatly differ from those of Mode 2 switching from one mode to the other while driving may cause the vehicle performance to change drastically If MODE AFTER KEY is not enabled the mode ca...

Page 33: ...nd the warning beep conditions during anti rollback and overvoltage Pin 19 WARNING OPTION is programmable from 0 to 7 EXTERNAL LED ANTI ROLLBACK OVERVOLTAGE SETTING OUTPUT BEEP BEEP 0 ash no no 1 ash...

Page 34: ...plied for 0 1 second when the driver rst turns on to ensure proper closure Values for this parameter should be determined from relay EMB speci cations or advice from the device manufacturer AUX PULL I...

Page 35: ...e EM brake at high vehicle speeds under conditions when the main contactor is open for example if the keyswitch is turned off during driving or a fault is detected When it is enabled the controller ov...

Page 36: ...e In such cases the controller must recognize the condition quickly and turn the driver Off before it is permanently damaged by excessive current However because of the speed of the detection electric...

Page 37: ...mer is available connect it to the programmer connector 2 Turn the run store switch on The programmer should power up with an initial display If it does not check for continuity in the run store switc...

Page 38: ...or each switch Mode Switch tells you the physical status of the mode switch open or closed Mode is a monitor value that tells you the mode in which the vehicle is currently operating This may not corr...

Page 39: ...question about what any of them do MAJOR TUNING Five major performance characteristics are usually tuned on a vehicle 1 Tuning the Active Throttle Range 2 Calibrating the Controller Speed Measurement...

Page 40: ...y throttle until the display indicates that the pedal switch is On Measure the throttle voltage that is be ing produced at this threshold and make a note of this value step 8 Measure the voltage when...

Page 41: ...s in either mph or km h 3 Tuning the Controller to the Motor The 1268 controller has the exibility to be tuned to nearly any separately excited motor from any manufacturer The programmable parameters...

Page 42: ...proceed to Step 4 If however maintaining operationalconsistencyacrossmotortemperatureisnotaconcern and achieving maximum torque is skip to Step 5 step 4 For the most consistent operation across tempe...

Page 43: ...ts safe commutation region This operation is normally accompanied by a strong smell from the motor If the brushes and commutator bars are visible arcing may be visible The further outside the safe com...

Page 44: ...pply full throttle While driving the vehicle with full throttle applied ob serve the Speed In and Arm PWM readings in the Monitor menu Note vehicle speed will display as 0 8 for speeds below 1 0 If th...

Page 45: ...d Vehicle Speed on Downhill Grade step 1 Set the following parameters REGEN C L maximum speci ed by the motor specs NEG FLD MAP EN at or below REGEN C L NEG FIELD MAX FIELD MAX as set in procedure 3 s...

Page 46: ...lect Mode 1 While driving the vehicle adjust M1 ACCEL for the best overall acceleration response If the vehicle starts too slowly under all driving conditions M1 ACCEL should be reduced Remember the a...

Page 47: ...t low speeds step 2 Drive the vehicle at full speed on at ground and release the throttle paying attention to the feel of vehicle braking If the initial braking is too sudden increase the DECEL value...

Page 48: ...42 Curtis 1268 Manual Rev D 5 TUNING GUIDE Note BRAKE MIN and BRAKE MAX are percentages of REGEN C L BRAKE MAP is a percentage of the range between BRAKE MIN and BRAKE MAX...

Page 49: ...capability is exceeded under the conditions of load and ramp gradient vehicle speed will be limited by the motor s capability and the desired vehicle speed may not be attainable The system will nd a...

Page 50: ...PLUG C L step 3 Check that these braking parameter adjustments do not make the braking feel too abrupt on milder slopes bl Low Speed Field Braking The FLD BRAKE parameter provides an additional mechan...

Page 51: ...the vehicle on at ground to con rm that the extra brak ing feel provided by these adjustments is acceptable bm EM Brake Operation with optional EM brake During normal operation the EM brake is applied...

Page 52: ...rds If the vehicle rolls backwards excessively increase the FLD BRAKE MAX step 3 Drive down a mild slope and release the throttle The vehicle will slow down but may not reach a complete stop depending...

Page 53: ...hicle is brought in for maintenance The following 4 step process is recommended for diagnosing and trouble shooting an inoperative vehicle 1 visually inspect the vehicle for obvious problems 2 diagnos...

Page 54: ...emperature 1 Temperature 85 C or 25 C cutback 2 Excessive load on vehicle 3 Improper mounting of controller 4 Operation in extreme environments 2 4 MAIN DRIVER ON Main contactor coil held low 1 Main c...

Page 55: ...LE CAUSE 6 DIAGNOSTICS TROUBLESHOOTING LED DIAGNOSTICS A built in Status LED is visible through a window in the label on top of the controller When the controller detects a fault the Status LED ashes...

Page 56: ...controller by connecting a load such as a contactor coil or a horn across the controller s B and B terminals 3 Removeanydirtorcorrosionfromthepowerandsignalconnectorareas The controller should be wipe...

Page 57: ...to RF emissions Both types of output are pulse width modulated square waves with fast rise and fall times that are rich in harmonics Note contactor drivers that are not modulated will not contribute...

Page 58: ...ding effectiveness Electroless plating of plastic will yield a true metal and can thus be effective as an RF shield but it is usually more expensive than the coatings A contiguous metal enclosure with...

Page 59: ...providing suf cient distance be tween conductors and the ESD source so that a discharge will not occur or by providing an intentional path for the discharge current such that the circuit is isolated f...

Page 60: ...ammer can operate at only the User level whereas an OEM programmer has full access PC PROGRAMMING STATION 1314 The Programming Station is an MS Windows 32 bit application that runs on a standard Windo...

Page 61: ...ing FLD BRAKE RATE Sets how quickly eld current rises during eld braking EMB SPD CHECK Enable controller to attempt to stop vehicle before locking EMB after main contactor fault EMB SPD VALUE Threshol...

Page 62: ...00 Voltage at which throttle command is maxed out THROT FAULT LO Voltage under which a throttle fault occurs THROT FAULT HI Voltage over which a throttle fault occurs M1 FWD FLD MIN Minimum eld curren...

Page 63: ...in C MODE Controller operating mode Mode 1 or Mode 2 ARM CURRENT Motor armature current in amps FIELD CURRENT Motor eld current in amps ARM PWM Motor armature applied duty cycle as FIELD PWM Motor el...

Page 64: ...ay name with references provided to the parameter descriptions and to the appropriate Tuning Guide procedures The parameters are described individually in Section 3 It is important also to read the tu...

Page 65: ...on to heatsink 500 V ac minimum Logic enable and logic power input voltage minimum 16 8 V Logic enable and logic power input current no contactors engaged 160 mA without programmer 200 mA with program...

Page 66: ......

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