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22 

BRAKE INPUT CONFIGURATION 

Depending on the type of brake input used for the application, the different types of brake 

input configurations are listed in the table below. Electrical schematics are also included within 

the following pages. 

BRAKE INPUT 

CONFIGURATION 

 TYPE 

NO BRAKE POT INSTALLED

 

TYPE 0

 

PRESSURE TRANSDUCER/ 

ELECTRONIC 0-5V INPUT or 

3-WIRE POT

TYPE 1 

2 WIRE  0-5k 

Ω POT

 

TYPE 2 

SWITCH 

TYPE 3 

Summary of Contents for Curtis 1239 E

Page 1: ...e Suite B Ontario CA 91762 909 923 1973 Electrical Schematics and Documentation FOR CURTIS 1239 E VERSION CONTROLLERS SOFTWARE VERSIONS 5 32 AND HIGHER FOR SINGLE AND DUAL MOTOR APPLICATIONS REVISION A Date 6 09 2017 ...

Page 2: ...7 Type 3 Curtis PB 8 Throttle Assembly 18 Type 3 Curtis Electronic Model ET 126 or ET 134 with switch 19 Type 4 3 Wire Wigwag 20 Throttle Interlock Connection 21 Brake Input Configuration 22 Type 1 Pressure Transducer or Electronic or 3 Wire Pot 23 Type 2 2 Wire Pot 24 Optional Brake Light Configurations 25 Program Entries Parameters 29 Additional Notes 32 Monitor Items 33 Orion BMS Information 34...

Page 3: ... ELECTRICAL SCHEMATICS 1239 E CONTROLLERS The following quick start electrical schematics for both single and dual motor configurations have been generated to assist in quickly getting the drive system connected and running ...

Page 4: ...M NO 13 PRECHARGE GREY Pre charge resistor NOTE 2 Pre Charge Relay NOTE 2 NOTES 1 Use supplied contactor GIGAVAC Part GV200PA 1 Use only a Contactor WITHOUT PWM AND COIL SUPPRESSION FAILURE TO DO SO CAN CAUSE CONTROLLER FAILURE AND WILL VOID WARRANTY 2 Use supplied pre charge resistor and relay Tyco Electronics Part T9AP1D52 12 For coil connection connect to small terminals 3 Forward is CLOCKWISE ...

Page 5: ...is released Type 2 3 throttle only 13 Coil Return Coil Return Common to all relay coils Blue White This is the coil return pin at B potential for all the contactor and relay coils 16 Throttle Pot Wiper Pot Wiper Yellow White Wiper or throttle input 22 Switch 7 Forward_Switch_Input Active high connect to KSI to activate White Used by the Motor Control to select forward direction 25 12V Out Red Blue...

Page 6: ...UT KSI 35 PIN CONNECTOR R1 6 4 1 BLUE COIL RETURN BLUE WHITE ORANGE WHITE MAIN CONTACTOR COIL 13 PRECHARGE ORANGE NOTES 1 Use supplied contactor GIGAVAC Part GV200PA 1 Use only a Contactor WITHOUT PWM AND COIL SUPPRESSION FAILURE TO DO SO CAN CAUSE CONTROLLER FAILURE AND WILL VOID WARRANTY 2 Use supplied pre charge resistor and relay Tyco Electronics Part T9AP1D52 12 For coil connection connect to...

Page 7: ...er 1239 ONLY 6 Driver 1 Main_Contactor Orange White Main Contactor Coil Driver 7 I O Ground Black Blue Input and output ground reference 13 Coil Return Coil Return Common to all relay coils Blue White This is the coil return pin at B potential for all the contactor and relay coils 23 CANH CAN High Orange CAN bus high 35 CANL CAN Low Grey CAN bus low Quick Start Electrical Schematic Generic Softwar...

Page 8: ...8 GENERIC FULL ELECTRICAL SCHEMATICS 1239 E CONTROLLERS ...

Page 9: ...ONTROLLER ON ROAD VEHICLE CONVERSION PRIMARY DUAL MOTOR SCHEMATICS NONE none 4 11 16 A DRW SIZE APPLICABLE SOFTWARE CAD TYPE UNIT DRAWING TITLE SCALE DATE REVISION SHEET HPEVS OF SUPPLIER PART 1010 AUTO1239 PRI VER365 000 HW 1010AUTO1239 HPG Version 365 000 Up NOTES 1 Use supplied Contactor GIGAVAC Part GV200PA 1 Use only a contactor WITHOUT A PWM AND COIL SUPPRESSOIN FAILURE TO DO SO CAN CAUSE CO...

Page 10: ...Common to all relay coils Blue White This is the coil return pin at B potential for all the contactor and relay coils 14 Brake Switch Input Brake_Sw White Black Switch input used for brake rate 15 Throttle Pot High Pot High Black Wht Pot high connection for a 3 wire throttle pot 16 Throttle Pot Wiper Pot Wiper Yellow Wht Wiper or throttle input 17 Pot2 Wiper Brake Pot Wiper Yellow Red Brake input ...

Page 11: ...2 AWG GREEN 22 AWG RED 22 AWG BLACK 22 AWG ORANGE or BROWN BLUE 22 AWG BROWN 22 AWG YELLOW 22 AWG MULTIPLE CONDUCTOR CABLE GREY S5 S6 S7 S8 R8 DEUTSCH DTM 06 4S S9 MULTIPLE CONDUCTOR CABLE WHITE 1 6 5 8 R5 DEUTSCH DTM 06 2S S2 S3 P6 DEUTSCH DTM 04 2P 1 2 1 2 CAN HIGH ORANGE 20 AWG CAN LOW GRAY 20 AWG A1 A2 COM NO 1 VISIO 4 11 16 1 1 B 1239 E CONTROLLER SECONDARY DUAL MOTOR SCHEMATICS NONE A none D...

Page 12: ...Return Coil Return Common to all relay coils Blue White This is the coil return pin at B potential for all the contactor and relay coils 14 N C 15 N C 16 N C 17 N C 18 N C 19 N C 20 N C 21 CAN Term H CAN Termination Black CAN termination jumper 22 N C 23 CANH CAN High Orange CAN bus high 24 N C 25 12V Out Red Blue Unregulated low power 12V output 26 N C 27 N C 28 Serial TX White Serial transmit li...

Page 13: ...hematics are also included within the following pages THROTTLE CONFIGURATION TYPE ELECTRONIC without SWITCH CURTIS ET 126 ET 134 ELECTRONIC THROTTLE ASSEMBLY without SWITCH TYPE 1 2 WIRE with SWITCH 0 5k Ω TYPE 2 3 WIRE with SWITCH 0 5k Ω TYPE 3 Default CURTIS PB8 THROTTLE ASSEMBLY TYPE 3 CURTIS ET 126 ET 134 ELECTRONIC THROTTLE ASSEMBLY WITH SWITCH TYPE 3 WIG WAG 3 WIRE TYPE 4 ...

Page 14: ...reproduction of this drawing REV DESCRIPTION APPROVED A INITIAL RELEASE 1 22 2013 REVISIONS BLACK BLUE BLACK IN 1239 CTRL YELLOW WHITE PURPLE WHITE TYPE 1 ELECTRONIC THROTTLE GROUND SIGNAL 5V or 12V ELECTRONIC THROTTLE 1 22 13 1010 THROTTLE 001 NONE ELECTRONIC THROTTLE VISIO 1 1 A NONE A DRW SIZE APPLICABLE SOFTWARE CAD TYPE UNIT DRAWING TITLE SCALE DATE REVISION SHEET HPEVS OF SUPPLIER PART Pin 7...

Page 15: ...15 ...

Page 16: ...ial reproduction of this drawing REV DESCRIPTION APPROVED A INITIAL RELEASE 1 22 2013 B REVISION 11 27 2013 REVISIONS YELLOW WHITE PURPLE WHITE RED BLUE GREEN NORMALLY CLOSED INTERLOCK SWITCH When accelerator pedal IS PRESSED the interlock switch is released to its NORMAL position switch not activated thus completing the circuit since its green wire is connected to the normally closed NC connectio...

Page 17: ... complete or partial reproduction of this drawing TYPE 3 3 WIRE THROTTLE BLACK WHITE When accelerator pedal IS PRESSED the interlock switch is released to its NORMAL position switch not activated thus completing the circuit since its green wire is connected to the normally closed NC connection NC TYPE 3 3 WIRE THROTTLE POT HIGH REV DESCRIPTION APPROVED A INITIAL RELEASE 1 22 2013 B REVISION 11 27 ...

Page 18: ...18 ...

Page 19: ...EVS The recipient of this drawing agrees a to use the information contained herein for the purpose for which it was furnished by HPEVS b to return this drawing upon HPEVS request This notice shall appear on any complete or partial reproduction of this drawing N C ELECTRONIC THROTTLE CURTIS ELECTRONIC THROTTLE MODEL NUMBERS ET 126 OR ET 134 TYPE 3 VER 2 5 1 2 3 4 5 6 7 8 9 N C N C ORANGE GREEN WHIT...

Page 20: ...20 ...

Page 21: ...e Green wire is connected to the Normally Closed tab The red blue wire is connected to the common tab See picture below NOTE when the throttle IS ENGAGED the interlock switch is released to its NORMAL position switch not activated thus completing the circuit since its green wire is connected to the normally closed NC connection ...

Page 22: ...erent types of brake input configurations are listed in the table below Electrical schematics are also included within the following pages BRAKE INPUT CONFIGURATION TYPE NO BRAKE POT INSTALLED TYPE 0 PRESSURE TRANSDUCER ELECTRONIC 0 5V INPUT or 3 WIRE POT TYPE 1 2 WIRE 0 5k Ω POT TYPE 2 SWITCH TYPE 3 ...

Page 23: ...awing upon HPEVS request This notice shall appear on any complete or partial reproduction of this drawing DRWSIZE A CAD FILE CAD LOC CAD TYPE OPER NO UNIT DRAWING TITLE DETAIL DESIGN CHECKED SAFETY SCALE DATE REVISION SHEET HPEVS OF PRESSURE TRANSDUCER A BLACK BLUE BLACK 0N 1239 CNTRL YELLOW RED RED BLUE TYPE 1 PRESSURE TRANSDUCER GROUND SIGNAL 12V PRESSURE TRANSDUCER REV DESCRIPTION APPROVED A IN...

Page 24: ...agrees a to use the information contained herein for the purpose for which it was furnished by HPEVS b to return this drawing upon HPEVS request This notice shall appear on any complete or partial reproduction of this drawing DRWSIZE A CAD FILE CAD LOC CAD TYPE OPER NO UNIT DRAWING TITLE DETAIL DESIGN CHECKED SAFETY SCALE DATE REVISION SHEET HPEVS OF 2 WIRE BRAKE POT A REV DESCRIPTION APPROVED A I...

Page 25: ...l brake light configurations are used to activate the brake lights during regenerative braking or when the vehicle brakes are applied Based on the brake type configuration that is being utilized in the application use one of the following wiring configurations ...

Page 26: ...awing DRWSIZE A CAD FILE CAD LOC CAD TYPE OPER NO UNIT DRAWING TITLE DETAIL DESIGN CHECKED SAFETY SCALE DATE REVISION SHEET HPEVS OF OPTION 1 BRAKE SWITCH INPUT 1232 1234 1236 1238 E AND SE CONTROLLERS A ORANGE RED BLUE WHITE REV DESCRIPTION APPROVED A INITIAL RELEASE 2 19 2013 REVISIONS TO BRAKE LIGHT OEM BRAKE SWITCH 12V ACTIVE BRAKE LIGHT CONFIGURATION FOR ALL BRAKE TYPES 1 2 1239 E CONTROLLERS...

Page 27: ...of this drawing DRWSIZE A CAD FILE CAD LOC CAD TYPE OPER NO UNIT DRAWING TITLE DETAIL DESIGN CHECKED SAFETY SCALE DATE REVISION SHEET HPEVS OF OPTION 2 BRAKE LIGHT SWITCH 1239 E CONTROLLER A YELLOW RED REV DESCRIPTION APPROVED A INITIAL RELEASE 2 19 2013 REVISIONS FEMALE 3 16 QD BRAKE SWITCH INPUT pin 14 LABEL 14 WHITE BLACK MALE 3 16 QD ORANGE RED BLUE WHITE OEM BRAKE SWITCH 12V FOR BRAKE TYPE 3 ...

Page 28: ...HPEVS request This notice shall appear on any complete or partial reproduction of this drawing DRWSIZE A CAD FILE CAD LOC CAD TYPE OPER NO UNIT DRAWING TITLE DETAIL DESIGN CHECKED SAFETY SCALE DATE REVISION SHEET HPEVS OF A YELLOW RED SIGNAL REV DESCRIPTION APPROVED A INITIAL RELEASE 2 19 2013 REVISIONS FEMALE 3 16 QD BRAKE SWITCH INPUT pin 14 LABEL 14 WHITE BLACK MALE 3 16 QD TO BRAKE LIGHT BRAKE...

Page 29: ... 50 give the vehicle a faster more responsive feel at low throttle settings Brake Pedal Settings Brake Type 0 to 3 0 Select the brake type that is being utilized for the application being installed The selection availability is as follows a Type 0 No Brake input used Default b Type 1 3 wire pot or an electronic includes transducer or hall sensor c Type 2 2 wire 0 to 5k pot d Type 3 Switch Brake De...

Page 30: ...f Off Turn on auto scroll function on 840 display to show monitored items listed below Scroll Delay Time Seconds 1 to 10 4 Time that delays scroll function displaying the menu items below on the Spyglass 840 Display SOC N A On Off Off When turned on the State Of Charge SOC of battery pack will be displayed Acuity required Display Motor RPM N A On Off On When turned on the Motor RPM will be display...

Page 31: ...ernal combustion engine had that was removed from the vehicle Prg Mode Step Timer Seconds 1 0 to 10 0 4 0 The time in seconds that the program steps through program mode Generic CAN Message ID Dec 1537 to 1616 1537 CAN ID that the controller transmits Hex range 0x601 to 0x650 Software Version VCL Version 0 to 32767 Based on VCL software version Software Version OS Version 0 to 32767 Based on Opera...

Page 32: ...s If the Throttle voltage is lower in the forward direction than in the reverse direction swap the outer two legs of the throttle pot 2 Set the Forward Deadband parameter to 1 volts higher than the value noted 3 Set the Reverse Deadband parameter to 1 volt less than the value noted 4 Set the Forward Max parameter to 1 volt less than the full forward throttle voltage noted 5 Set the Reverse Max par...

Page 33: ...rrent During Operation Remaining Amphours AMP 0 to 500 Remaining Battery Amphours BDI Percentage 0 to 100 Battery state of charge Aux Battery Voltage Volt 0 to 20 Auxiliary battery voltage Charging Info Charger Output Current Ampere 0 to 100 Battery charger output current to the battery pack Charger Output Voltage Volt 0 to 1400 Battery charger output voltage to the battery pack Charger Status N A...

Page 34: ... BMS from mis wiring or misuse is not covered under warranty Immediately disconnect the BMS from the battery if the BMS is damaged 2 The BMS must have a means of controlling and shutting off any connected charger load source or any other means of charge and discharge Two shutoff mechanisms should be present to turn off a charger The charge safety signal is designed to be used as an emergency backu...

Page 35: ... application such that any failure is a safe failure For more information please read Failure Modes in the operational manual The integrator is responsible for the determination of suitability of this product for the application choice of all external components including but not limited to wire wiring methods and interconnects and complying with any regulations standards or codes The Orion BMS is...

Page 36: ... Fault DTC Weak Cell Fault Custom Flag for Orion BMS NOT Jr Charge Interlock DTC Temperature Sensor Fault DTC Weak Cell Fault Custom Flag 3 Highest Cell Voltage ID set by multiplying by 1 then divide by 1 Lowest Cell Voltage ID set by multiplying by 1 then divide by 1 Address 0x300 low cell voltage high byte set by multiply by 1 then divide by 10 low cell voltage set by multiply by 1 then divide b...

Page 37: ...r 2 Controller defective Set Controller current sensors have invalid reading Clear Cycle KSI 14 Precharge Failed ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 External load on capacitor bank B connection terminal that prevents the capacitor bank from charging Set Precharge failed to charge the capacitor bank to KSI voltage Clear Cycle Interlock input...

Page 38: ... voltage dropped below the Severe Undervoltage limit with FET bridge enabled Clear Bring capacitor voltage above Severe Undervoltage limit 18 Severe B 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 Ba...

Page 39: ...e undervoltage limit 24 B Overvoltage Cutback Reduced brake torque 1 Normal operation Fault shows that regen braking currents elevated the battery voltage during regen braking Controller is performance limited at this voltage 2 Battery parameters are misadjusted 3 Battery resistance too high for given regen current 4 Battery disconnected while regen braking 5 See Monitor Menu Battery Capacitor vol...

Page 40: ...ue 1 Motor temperature is at or above the programmed Temperature Hot setting and the requested current is being cut back 2 Motor Temperature Control Menu parameters are mis tuned 3 See Monitor Menu Motor Temperature and Inputs Analog2 4 If the application doesn t use a motor thermistor Temp Compensation and Temp Cutback should be programmed Off Set Motor temperature is at or above the Temperature ...

Page 41: ...ulty wiring Set Main contactor driver pin 6 is either open or shorted This fault can be set only when Main Enable ON Clear Correct open or short and cycle driver 32 Coil2 Driver Open Short ShutdownDriver2 1 Open or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring Set Driver 2 pin 5 is either open or shorted This fault can be set only when EM Brake Type 0 Clear Correct open...

Page 42: ...rtional driver pin 2 is either open or shorted Clear Correct open or short and cycle driver 36 Encoder Fault ShutdownEMBrake ShutdownThrottle 1 Motor encoder failure 2 Bad crimps or faulty wiring 3 See Monitor menu Motor Motor RPM Set Motor encoder phase failure detected Clear Cycle KSI 36 Sin Cos Sensor Fault ShutdownEMBrake ShutdownThrottle 1 SPMSM motor characterization not completed or poorly ...

Page 43: ... close 2 Main contactor tips are oxidized burned or not making good contact 3 External load on capacitor bank B connection terminal that prevents capacitor bank from charging 4 Blown B fuse Set With the main contactor commanded closed the capacitor bank voltage B connection terminal did not charge to B Clear Cycle KSI 41 Throttle Wiper High ShutdownThrottle 1 See Monitor Menu Inputs Throttle Pot 2...

Page 44: ...elow the fault threshold 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 See Monitor Menu Outputs Pot Low 2 Combined pot resi...

Page 45: ...45 ...

Page 46: ... 52 E7 Throttle Parameter Change Fault 1 Throttle parameter changed on enGage VII while system functioning Set enGage VII throttle parameter changed Clear Cycle KSI 53 Software License Violation 1 The software that has been installed violates the license agreement between the software and the controller Set The license of the installed software package does not match the license of the controller ...

Page 47: ...maximum allowed temperature of 160 C Clear Turn off system and wait for motor to cool Clear any situation that is causing the overheating issue 62 Secondary CAN Shutdown Fault 1 Fault from primary controller Set Primary controller has a fault Clear Determine what the fault is on the primary controller and clear Cycle KSI 65 Secondary CAN Communication Fault 1 No power to secondary controller 2 Bro...

Page 48: ...e error condition Clear Edit VCL application software to fix this error condition flash the new complied software and matching parameter defaults cycle KSI 69 External Supply Out of Range 1 External load on the 5V and 12V supplies draws either too much or too little current 2 Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mis tuned 3 See Monitor Menu Options Ext Supply Curren...

Page 49: ... operational 1 Time between CAN PDO messages received exceeded the PDO Timeout Period Set Time between CAN PDO messages received exceeded the PDO Timeout Period Clear Cycle KSI or receive CAN NMT message 73 Stall Detected ShutdownEMBrake Control Mode changed to LOS Limited Operating Strategy 1 Stalled Motor 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Problems with power supply for the ...

Page 50: ...t readings damaged Supervisor illegal switch inputs Clear Check for noise or voltage drift in all switch inputs check connections cycle KSI 78 Supervisor Incompatible ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake ShutdownPump 1 The main OS is not compatible with the Supervi...

Page 51: ...ar Cycle KSI 84 Following Error Fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 Motor speed was detected not following the commanded speed trajectory within the programmed limits 2 See Program menu 1 Speed Mode Speed Controller Following Error Limit and Following Error Time 3 See Monitor menu Motor Tuning Speed Error Set With Control Mode Select ...

Page 52: ...lt 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 started characterization procedure while motor rotating Set Mot...

Page 53: ...utdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 The Motor_Type parameter value is out of range Set Motor_Type parameter is set to an illegal value Clear Set Motor_Type to correct value and cycle KSI 91 VCL OS Mismatch ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 Shu...

Page 54: ...ctivate LOS control mode allowing limited motor control Clear Cycle KSI or if LOS mode was activated by the Stall Fault clear by ensuring encoder senses proper operation Motor RPM 0 and Throttle Command 0 94 EMR 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 Emergen...

Page 55: ...t parameter not set to 1 Speed Mode Express or 2 Speed Mode 2 Motor Technology and Feedback Type parameters do not match Set When the Dual Drive software is enabled the controller must be set to either Speed Mode Express or Speed Mode otherwise this fault is set Motor Technology 0 must be paired with Feedback Type 1 and Motor Technology 1 must be paired with Feedback Type 2 otherwise this fault is...

Page 56: ...ing torque Decreasing the brake max setting reduces the amount of voltage necessary to produce full braking torque 10 Brake Type Defines the brake input for the controller a Type 1 3 wire 0 to 5kohm pot or electronic 0 5v input or pressure transducer b Type 2 2 wire with switch 0 to 5kohm c Type 3 switch 11 CAN Controller Area Network A vehicle bus standard designed to allow microcontrollers and d...

Page 57: ...s exerted on the system 22 Neutral Braking Neutral braking occurs progressively when the throttle is reduced toward the neutral position or when no direction is selected The neutral braking parameter is adjustable from 0 to 100 of the regen current limit 23 Nominal Voltage Battery pack voltage not to exceed controller voltage ratings 24 Regenerative Braking Regenerative braking is used on electric...

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