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Curtis 1238E User Manual
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114
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual,
os
30
24 NOVEMBER 2015
8 — VCL
Fig. 15
Motor command diagr
am.
X
+
+
Motor
Control
Throttle
Type
Rev
erse Switch
Forward Switch
Throttle
T
ype
Processing
Forward Offset
Throttle Mapping
VCL_Throttle
Throttle_Multiplier
Throttle_Offset
OS
Throttle
Throttle
T
ype
= 5
or
VCL_
Throttle_
Enable = On
Throttle
Pot Ra
w
Forward Max
Forward Map
Forward Deadband
Reverse Deadband
Reverse Max
Reverse Map
Reverse Offset
Throttle Command
Control Mode Processing
Pot2 Ra
w
+10
0%
+100%
-100%
Throttle
Type
<4
and
Forward = Of
f
and
Rev
erse = On
and
TMap = 0
Throttle
Type
<4
and
Forward = On
and
Rev
erse = Off
and
TMap = 0
to Proportional Dr
iver
[see Fig.
17, page 119]
U Phase
W Phase
V Phase
Controller
T
orque
Command
Control
Mode
Select
= 0 or
1
and
AC_Pump_ Enable_
SpdM = On
and
Mapped_
Throttle
<0
Bold
= Parameters
Italics
= Other R/W V
ariables
BoldItalics
= Monitor V
ariables
Throttle_Command
Throttle
TMap
+1
-1
128
1
Brake_Command
Brake
Type
Brake
T
ype
Processing
Brake
OS Brake
Brake Command
Brake Mapping
VCL_Brake
Brake
Type
= 5
or
VCL_Brake_
Enable = On
+100%
0%
FullBrake
Brake Offset
Brake Max
Brake Map
Brake Deadband
0%
Brake Pedal
Enable
= On
Control Mode Select
= 0,
1, 2
0 = Speed Mode Express
1 = Speed Mode
2 =
T
orque Mode
[see Fig.
16, page 118]
Mapped
Throttle
Mapped Brake
ShutdownThrottle
or
ThrottleInvalid
or
Main Cont.
Not Closed
or
Interlock_State = Off
117
119
Table of Contents
Default Chapter
3
Table of Contents
3
Figures
4
Tables
4
1 Overview
5
Curtis AC Induction Motor Controllers
5
Fig. 1: Curtis 1232E/SE, 1234E/SE, 1236E/SE, 1238E Controllers
5
Getting the most out of Your Curtis Controller
6
2 Installation and Wiring
7
Mounting the Controller
7
Fig. 2A: Mounting Dimensions, Curtis 1232E/SE Controller
7
Fig. 2B: Mounting Dimensions, Curtis 1234E/SE Controller
8
Fig. 2C: Mounting Dimensions, Curtis 1236E/SE, 1238E Controllers
9
High Current Connections and Wiring Guidelines
10
Table 1 High Current Connections
10
Battery Cables (B+, B-)
11
High Current Wiring Recommendations
11
Motor Wiring (U, V, W)
11
CAN Bus (Pins 21, 23, 34, 35)
12
Low Current Wiring Recommendations
12
Position Feedback (Pins 7, 26, 31, 32)
12
Low Current Connections and Wiring Guidelines
12
Table 2: Low Current Connections
12
Controller Wiring: Basic Configuration
16
Basic Wiring Diagram, Curtis 1232E/SE, 34E/SE, 36E/SE, and 38E Motor Controllers
16
Fig. 3: Basic Wiring Diagram
16
Switch Input Wiring
17
Throttle Wiring
17
Throttle Type 2
18
Fig. 4: Wiring for Type 1 Throttles
18
Fig. 5: Wiring for Type 2 Throttles
19
Throttle Type 4
20
Fig. 6: Wiring for Type 3 Throttles
20
Throttle Type 5
21
Input/Output Specifications
22
Digital Inputs
22
Digital Input Specifications
23
Digital Input Impedance Circuits
23
Digital and PWM Outputs
24
Analog Inputs
24
Analog Inputs Specifications
25
Analog Output
25
Power Supply Outputs
25
Analog Output Specifications
25
KSI and Coil Return
26
Throttle and Brake Inputs
26
KSI and Coil Return Input Specifications
26
Throttle Input Specifications
26
Communications Ports
27
Position Feedback Input: Quadrature Encoder
27
Quadrature Encoder Input Specifications
27
Position Feedback Input: Sin/Cos Sensor
28
Sin/Cos Sensor Input Specifications
28
3 Programmable Parameters
29
Programming Menus
29
Motor Response Tuning
29
Parameter Change Faults
29
Programmable Parameter Menus: 1313 /1314 Programmer
30
Table 3: Programmable Parameter Menus
30
Electrical Frequency Constraint
33
Encoder Pulses/Revolution Constraint (Quadrature Encoder)
33
Motor Speed Constraints
33
Fig. 7 Acceleration Response Rate Diagram
37
Response Menu
37
Fig. 8 Braking Response Rate Diagram
38
Fine Tuning Menu
38
Position Hold Menu
39
Restraint Menu
39
Pump Parameters
40
Speed Limiter Menu
41
Fig. 9: Throttle Mapping, Torque Control Mode
44
Fig. 10: Effect of Gear Soften Parameter, Torque Control Mode
44
Fig. 11: Effect of Brake Taper Speed Parameter, Torque Control Mode
44
Current Limits Menu
45
Power Limiting Map Menu
46
Drive Limiting Map Menu
46
Fig. 12: Drive Current Limiting Map
46
Regen Limiting Map Menu
47
Fig. 13: Regen Current Limiting Map
47
Throttle Menu
48
Fig. 14: Throttle Adjustment
49
Brake Menu
51
EM Brake Control Menu
52
Drivers: Main Contactor Menu
54
Drivers: Proportional Driver Menu
56
Drivers: Driver 3 Menu
57
Drivers: Fault Checking Menu
58
Motor Menu
59
Motor: Control Algorithms Menu
59
Motor: 0-ACIM: Characterization Tests Menu
60
Motor: 0-ACIM: Field Weakening Control Menu
61
Motor: 0-ACIM: Swap Two Phases and Motor Type Parameters
62
Motor: 0-Acim: Los Menu
63
Motor: 1-SPM: Characterization Tests Menu
64
Motor Feedback Options
65
Motor Feedback 1-Encoder Menu
65
Motor Feedback 1-Encoder: Encoder Fault Setup Menu
66
Motor Feedback 2-Sin/Cos Menu
66
Motor Temperature Control Menu
67
Battery Menu
68
Dual Drive Menu
70
Vehicle Menu
71
Interlock Braking Menu
73
Can Interface Menu
74
Reset Controller Parameter
75
4A. MONITOR MENU
76
Table 4: Monitor Menu
76
Monitor Menu: INPUTS
78
Monitor Menu: OUTPUTS
81
Monitor Menu: BATTERY
82
Monitor Menu: MOTOR
83
Monitor Menu: CONTROLLER
84
Monitor Menu: CUTBACKS
86
Monitor Menu: MOTOR TUNING
86
Monitor Menu: VEHICLE
87
Monitor Menu: CAN STATUS
89
4B. CONTROLLER INFORMATION MENU
90
5 Initial Setup
91
Motor Temperature Sensor
92
Current Limits
92
Main Contactor
92
EM Brake
92
Motor Technology & Feedback Type
94
Faults
94
Setting Feedback Direction
94
Checking Direction of Rotation
95
Motor Characterization
95
Automated Acim Motor Characterization Procedure
97
Traction and Hydraulic Systems
97
6A. MOTOR CHARACTERIZATION: ACIM Motors
97
Motor Characterization Errors
98
Traction Systems Only
99
Hydraulic Systems Only
102
Automated SPM Motor Characterization Procedure
104
6B. MOTOR CHARACTERIZATION: SPM Motors
104
7 Tuning Guide
106
Vehicle Control Language (VCL)
110
Summary of VCL Basics
110
Variable Types
111
VCL Runtime Rates
113
I/O Control with VCL
113
Driver and Digital Outputs
114
Potentiometer Inputs
115
Interfacing the Throttle and Brake Commands
117
Throttle Processing
117
Fig. 15: VCL Motor Command Diagram
118
Brake Processing
120
Interfacing the Proportional Current Driver
121
Control Mode and Motor Control Processing
121
Fig. 16: VCL Control Mode Processing
122
Fig. 17: VCL Proportional Driver Processing
123
Using the Fault Handler in VCL
124
OEM-Defined User Faults
126
CAN Indexes for the User Fault Variables
129
Enable_Precharge()
130
VCL Function Specific to 1232E/SE, 1234E/SE, 1236E/SE, and 1238E Controllers
130
Disable_Precharge()
131
Clear_Digout()
132
Set_Digout()
132
Disable_Emer_Rev()
133
Enable_Emer_Rev()
133
Clear_Interlock()
134
Set_Interlock()
134
Setup_Pot_Faults()
135
Start_Pump()
136
Stop_Pump()
136
Automate Frequency Output
137
Diagnostics and Troubleshooting
138
Summary of LED Display Formats
139
Table 5 TYPES of LED DISPLAY
139
Table 6 TROUBLESHOOTING CHART
140
9 Diagnostics and Troubleshooting
141
10 Maintenance
149
Cleaning
149
Fault History
149
Electromagnetic Compatibility (EMC)
150
Emissions
150
Immunity
150
Electrostatic Discharge (ESD)
152
Programming Devices
155
PC Programming Station (1314)
155
Handhelf Programmer (1313)
155
Programmer Functions
155
Specifications
156
5
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Curtis 1238E Specifications
General
Brand
Curtis
Model
1238E
Category
Controller
Language
English
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