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Manual

Model

1228

MultiMode™ Motor Controller

Read Instructions Carefully!

Speciﬁcations are subject to change without notice.
© 2011 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.

36149 Rev F 10/11

Curtis Instruments, Inc.

200 Kisco Avenue

Mt. Kisco, NY 10549

www.curtisinstruments.com

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Summary of Contents for MultiMode 1228

Page 1: ...e without notice 2011 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 Instrument...

Page 2: ......

Page 3: ...us LED 13 Battery discharge indicator 14 Horn 14 Circuitry protection devices 14 Seat lift switch 14 3 PROGRAMMABLE PARAMETERS 15 Motor Parameters 17 Main Current Limit 17 Motor Resistance 17 Accelera...

Page 4: ...rottle Map 26 Fault Parameters 27 High Pedal Disable HPD 27 Brake Faults 28 Seat Lift Brake Faults 28 Fault Beep 28 Other Parameters 28 Seat Lift 28 Virtual Seat Lift 29 Beeper Solid 29 BDI Full Volta...

Page 5: ...grammer Diagnostics 43 LED Diagnostics 43 Troubleshooting Chart 45 8 MAINTENANCE 46 APPENDIX A Vehicle Design Considerations Regarding Electromagnetic Compatibility EMC and Electrostatic Discharge ESD...

Page 6: ...5V throttle 11 FIG 7 Wiring for Curtis ET XXX electronic throttle 11 FIG 8 Wiring to inhibit operation during battery charging 13 FIG 9 Effect of adjusting the neutral deadband parameter 24 FIG 10 Eff...

Page 7: ...rtis pro gramming device Use of the programmer offers diagnostic and test capability as well as con guration exibility 1 Fig 1 Curtis 1228 MultiMode electronic motor controller Like all Curtis motor c...

Page 8: ...ff while driving E Stop provides a faster deceleration for emergency stops Seat lift function simpli es the wiring required to implement seat lift in DME scooter applications Comprehensive fault detec...

Page 9: ...s of ce nearest you 1 OVERVIEW Working on electric vehicles is potentially dangerous You should pro tect yourself against runaways high current arcs and outgassing from lead acid batteries RUNAWAYS So...

Page 10: ...s This will give 6 mm 0 25 of exposed screw which can be increased according to the thickness of the mounting site 2 2 INSTALLATION WIRING Fig 2 Mounting dimensions Curtis 1228 controller Dimensions i...

Page 11: ...motor M1 and M2 connections The battery connections B B have one terminal each CONNECTIONS Low Current The low current logic control connections are provided by an 18 pin connector see pin list below...

Page 12: ...sed because the logic circuit is wired directly to the vehicle s battery pack Note When using the B pins 10 11 an appropriately sized fuse must be added to the circuit to avoid damage to the controlle...

Page 13: ...B pins 10 11 an appropriately sized fuse must be added to the circuit to avoid damage to the controller 2 INSTALLATION WIRING Fig 3b Alternative wiring con guration for low keyswitch current 9 A appl...

Page 14: ...INSTALLATION WIRING Applications without Seat Lift Feature The wiring presented in Figures 4a and 4b is the same as in Figures 3a and 3b except the components and wiring used to implement the seat lif...

Page 15: ...DE M1 M2 PUSH BRAKE KSI POT WIPER POT HIGH B B Connector detail B 2 INSTALLATION WIRING The wiring diagram presented in Figure 4b illustrates an alternative wiring that can be used in some application...

Page 16: ...ibration feature see page 23 Pots with less than 5 k total resistance change over the throttle s full stroke can be accommodated by programming the controller for reduced range throttle inputs via the...

Page 17: ...throttles Curtis ET XXX Electronic Throttle The recommended wiring for the Curtis ET XXX electronic throttle is shown in Figure 7 The ET XXX throttle provides a single ended 0 5V throttle signal and...

Page 18: ...rammed maximum reverse speed maximum reverse speed with speed limit pot in its maximum speed position to the programmed minimum reverse speed maximum reverse speed with speed limit pot in its minimum...

Page 19: ...to be pulled high Typically battery chargers have a dedicated third terminal that automatically provides inhibit If your battery charger does not have this third terminal inhibit can be wired as show...

Page 20: ...nhibit input see page 13 Horn The controller s horn driver Pin 16 is designed to drive a low current dc horn at 1 Hz The horn sounds a warning when the reverse direction is selected a series of beep t...

Page 21: ...es can be programmed to provide two different sets of operating characteristics which can be useful for operation in different conditions For example Mode 1 could be programmed such that the vehicle m...

Page 22: ...e Input Signal Type Throttle Autocalibration Throttle Deadband Throttle Gain Ramp Shape Static Throttle Map Fault Parameters p 27 High Pedal Disable HPD Brake Faults Seat Lift Brake Faults Fault Beep...

Page 23: ...e time it takes the controller to accelerate from zero to 100 output during forward travel at full throttle with the speed limit pot in its maximum speed position Larger values represent a longer acce...

Page 24: ...e is adjustable from 0 2 to 8 0 seconds Acceleration rates under 0 5 second provide abrupt acceleration and should only be used under special circumstances GEAR SOFTEN The gear soften feature allows s...

Page 25: ...d The minimum speed deceleration rate is adjustable from 0 2 to 8 0 seconds Deceleration rates under 0 5 second provide abrupt stops and should only be used under special circumstances E STOP The emer...

Page 26: ...al programmed deceleration rate the selected mode and the speed and direction of travel when KSI is switched off It is adjustable from 0 2 to 4 0 seconds BRAKE DELAY The brake delay parameter speci es...

Page 27: ...ot in its minimum speed position Reverse speed is not affected by which mode Mode 1 Mode 2 is selected Note If a speed limit pot is not used in your application see page 12 CREEP SPD Creep speed helps...

Page 28: ...will be the same whether the actual battery voltage is 28 volts or 23 volts or any value in between The speed scaler parameter is programmable between 20 0 V and 28 0 V THRTL TYPE The controller can b...

Page 29: ...ection until the horn turns off Note this position Adjust the pot in the other direction until the horn turns off Note this position Set the pot halfway between the two noted positions The pot is now...

Page 30: ...efault deadband setting is 10 0 The throttle wiper voltage range is approximately 4 volts measured rela tive to B This is true regardless of whether a single ended or wigwag throttle is used When a si...

Page 31: ...e Gain 1 Deadband 25 1 5V 0 5V 2 0V 3 0V 2 5V KEY Neutral 0 100 Deadband output output Notes Voltages shown are at the pot wiper relative to B Voltages are relative to a 5k pot 0 4V 4 6V 4 6V V100 Pot...

Page 32: ...ponse Setting the ramp shape parameter at 50 provides a linear response to throttle position Values below 50 reduce the throttle command at low throttle positions providing enhanced slow speed maneuve...

Page 33: ...60 HIGH PEDAL DIS The primary function of the high pedal disable HPD feature is to prevent the vehicle from moving if the controller is turned on with the throttle already applied HPD also serves as t...

Page 34: ...hat uses a brake disable relay in its seat lift circuit you should program the seat lift brake faults parameter Off Systems designed to be used with the new 1228 do not require this second relay which...

Page 35: ...rogrammer is being used during vehicle checkout VSL automatically resets to Off when the keyswitch is cycled For controllers without the VSL parameter seat lift operation can be tested only when the p...

Page 36: ...The tremor compensation parameter allows adjustment to limit the controller s response to sharp throttle movements such as movements resulting from hand tremors The tremor compensation parameter can...

Page 37: ...e throttle deadband and throttle gain parameter values that correspond to the absolute full range of your particular throttle mechanism It is advisable to include some buffer around the absolute full...

Page 38: ...ttle value This value should be 100 If it is less than 100 the throttle gain must be increased to attain full controller output at the maximum throttle position Select the Parameters Menu scroll down...

Page 39: ...sistance MOTOR R parameter and proceed to Step 3 However we strongly recommend that instead of using the theoretical value provided by the motor manufacturer you use the actual value as determined in...

Page 40: ...nstructions are provided for the following four tuning steps 5 Setting the maximum speeds 6 Setting the acceleration and deceleration rates 7 Adjusting load compensation 8 Fine tuning the vehicle s re...

Page 41: ...Now adjust DECEL MIN SPD the low speed forward deceleration characteristic Driving at full throttle with the speed limit pot still in its minimum speed position release the throttle to neutral Depend...

Page 42: ...aximum speed position drive in reverse at full throttle and then release the throttle to neutral Depending on how you liked the deceleration you experienced increase or decrease the REVDECEL MAX value...

Page 43: ...r accelera tion but instead initiate accelerations with a sharp jerk Therefore the tuning goal is a balance between adequate load disturbance response and normal ac celeration deceleration response Th...

Page 44: ...set to zero because they want complete linearity in response In setting this parameter you also may want to take into consideration that softened slack take up is easier on the transaxle gears and ma...

Page 45: ...e it at 4 or adjust it down to 3 or up to 5 as the nal piece of tuning Tremor compensation is most noticeable when the throttle is moved quickly from full to small but non neutral values The function...

Page 46: ...deceleration rate in seconds REV ACCEL MAX Reverse accel rate at maximum throttle requests in seconds REV ACCEL MIN Reverse accel rate at minimum throttle requests in seconds REV DECEL MAX Reverse dec...

Page 47: ...rn if HPD or brake fault On Off BEEPER SOLID Pin 16 output continuous rather than pulsed On Off SEAT LIFT Seat lift enable On Off BRAKE FLTS Electromagnetic brake driver wiring fault check On Off SL B...

Page 48: ...lphabetical order for easy reference BRAKE ON FAULT Electromagnetic brake coil open or driver short BRAKE OFF FAULT Electromagnetic brake coil short or driver open CURRENT SENSE FAULT A D current sens...

Page 49: ...for suggestions about possible causes of the various faults For information on the programmers see Appendix C If you are using the older 1307 programmer refer to existing documentation LED DIAGNOSTICS...

Page 50: ...tactor fault 2 4 main contactor driver On fault 3 1 HPD fault present for 10 seconds 3 2 brake On fault 3 3 precharge fault 3 4 brake Off fault 3 5 HPD High Pedal Disable fault 4 1 current sense fault...

Page 51: ...Brake coil resistance too high 2 4 MAIN ON FAULT main contactor driver On fault 1 Main contactor driver failed closed 3 1 PROC WIRING FAULT HPD fault present for 10 sec 1 Misadjusted throttle 2 Broke...

Page 52: ...vice can be used to access the controller s fault his tory le The programmer will read out all the faults that the controller has experienced since the last time the history le was cleared The faults...

Page 53: ...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 54: ...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 55: ...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 56: ...e and healthy environment and has been working diligently to ensure its compliance with WEEE legislation Curtis will comply with WEEE legislation by Designing its equipment with consideration to futur...

Page 57: ...free solders available to date due to the well documented issues such as tin whiskers and premature failure compared with leaded solder due to shock vibration and thermal cycling Curtis is closely mon...

Page 58: ...hereas 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 Windows PC Instructions for using the Programmi...

Page 59: ...7 IR COMP COEFF 0 100 percent page 22 KEY OFF DECEL 0 2 4 0 seconds page 20 MAIN C L 70 90 110 amps page 17 MAX SPD M1 20 100 percent page 20 MAX SPD M2 15 100 percent page 20 MIN SPD M1 0 60 percent...

Page 60: ...mer 150 mA with programmer KSI input current peak 1 5 A Logic input current typical 1 mA at 24 V Horn output current max 15 mA BDI output voltage and current max 0 5 V 2 mA LED output current max 15 m...

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