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Kohler Curtis F Series User Manual

Kohler Curtis F Series
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4 — PROGRAMMABLE PARAMETERS
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 138
MOTOR SETUP/QUADRATURE ENCODER — ENCODER FAULT SETUP MENU
PARAMETER ALLOWABLE RANGE DEFAULT DESCRIPTION
Fault Detection Enable
Encoder_Fault_Detection_
Enable
0x34E3 0x00
On/Off
On/Off
On Setting this parameter to On enables the encoder fault
checking. The three fault conditions checked are:
Encoder Fault (fault code 36).
Stall Detected (fault code 73).
Encoder Pulse Error (fault code 88).
Encoder Pulse Fault Detect
Time
Encoder_Pulse_Fault_Detect_
Time
0x34E5 0x00
0.0 – 3.0 s
0 – 94
0.5 sec Denes the minimum time it takes for the controller, while the
vehicle is in motion, to detect that the encoder and the Encoder
Steps parameter do not match. When the Encoder Steps setup is
incorrect, the motor controller cannot properly calculate the AC
motor eld orientation. The loss of eld orientation can cause the
motor to spin up toward full speed once any throttle is applied.
Applying the throttle and then releasing it, while the drive current
is signicant and the motor is still accelerating, sets this timer.
Note that the motor can spin to high rpms for several seconds
before conditions allow the controller to detect a fault.
The Encoder Pulse Error (fault code 88) is set when this fault occurs.
Setting the parameter to zero will disable this fault detection.
Fault Stall Time
Enc_Fault_Stall_Time
0x34E2 0x00
0 – 10 s
0 – 5000
5 sec Sets a timer when no motor encoder movement is detected. If no
motor movement (encoder pulse) is detected for the programmed
Fault Stall Time with high current applied a Stall Detected fault is
issued (fault code 73).
For example, when driving up a ramp and the vehicle ‘stalls’
because it is under-powered or overloaded (driver applying full
throttle), or if driven into an immovable object, these types of
conditions will set this fault.
MOTOR SETUP/QUADRATURE ENCODER — SPEED FILTER MENU
PARAMETER ALLOWABLE RANGE DEFAULT DESCRIPTION
Speed Filter Frequency
Speed_Filter_Frequency
0x3224 0x00
0.1 – 250 Hz
0.1 – 250
30.0 Hz Cutoff frequency for speed ltering. Note, this value is now in
hertz, when updating from old versions you may need to divide by
2pi (3.14159) to get the exact performance.

Table of Contents

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Kohler Curtis F Series Specifications

General IconGeneral
BrandKohler
ModelCurtis F Series
CategoryController
LanguageEnglish

Summary

1 — OVERVIEW

HOW TO USE THIS MANUAL

Guidance on navigating and utilizing the manual's content for effective controller application.

WHAT IS NEW IN FOS 4.5.0.0 ... HIGHLIGHTS

Summary of key enhancements and changes in the FOS 4.5.0.0 firmware version.

GETTING THE MOST OUT OF YOUR CURTIS CONTROLLER

Advice on optimizing controller application through understanding manual sections and tools.

2 — INSTALLATION AND WIRING

PHYSICALLY MOUNTING THE CONTROLLER

Instructions for proper physical installation and mounting of the controller for optimal performance and environmental protection.

PRECAUTIONS

Essential safety and design considerations for ensuring EMC compliance and preventing electrical issues.

HIGH CURRENT CONNECTIONS

Details on connecting high-current terminals (B+, B-, U, V, W) and recommended connection guidelines.

LOW CURRENT CONNECTIONS

Information on logic and low-power connections via AMPSEAL connectors, including pin assignments.

Rotor Position feedback

Guidance on wiring rotor position sensors, including signal wiring best practices and shielding.

CANbus

Best practices for CANbus wiring, including twisted-pair and shielded cable usage for reliable communication.

All other low power wiring

Recommendations for routing low-power wiring to avoid signal interference and protect against damage.

Protected voltages

Information on protected voltage ratings for low-power pins and crucial connection warnings to prevent damage.

3 — APPLICATION-SPECIFIC FEATURES

MOTOR SPEED CONSTRAINTS

Details on how electrical frequency, encoder pulses, and parameter settings limit maximum motor speed (RPM).

VOLTAGE LIMITS

Explanation of hardware and parameter-based voltage limits, including operating regions and thresholds.

BROWNOUT VOLTAGE

Information on the fixed brownout voltage level and controller actions when voltage falls below this threshold.

KSI AND B+ INPUT

Notes on KSI input connection to B+ terminal for controller power, precharge, and BDI usage.

BATTERY DISCHARGE INDICATOR

Explanation of the BDI algorithm for calculating battery state-of-charge (SOC) and its viewable parameters.

4 — PROGRAMMABLE PARAMETERS

PROGRAMMING MENUS

Overview of programmable parameters organized into nested menus for customization via CANbus connection.

PARAMETER CHANGE FAULTS [PCF]

Explanation of faults triggered when parameters are changed while the motor bridge is enabled.

MONITOR VARIABLES WITHIN PARAMETER MENUS

Information on specific monitor variables contained within parameter menus, which are read-only.

PROGRAMMING TOOLS

Details on PC-based Curtis Integrated Toolkit (CIT) and the Curtis 1313 handheld programmer.

5 — SYSTEM MONITOR MENU

MOTOR MENU

Displays real-time motor data including RPM, temperature, torque, power, and feedback signals.

VEHICLE MENU

Monitors vehicle speed, odometer, acceleration, and distance traveled, configurable in metric or English units.

FAULT HISTORY

Accesses and clears the controller's fault history file for diagnosing and verifying problem resolution.

6 — COMMISSIONING

INITIAL SETUP

Essential steps for setting up controller parameters and ensuring they are suited to the specific application.

TRACTION MOTOR SELECTION

Guidance on selecting and commissioning ACIM or PMAC motors, including compatibility and procedures.

AC Motor Characterization

Procedure for characterizing ACIM traction motors using a quadrature encoder or Sin/Cos sensor.

AC MOTOR TUNING GUIDE

Steps for tuning the AC traction motor performance by selecting control modes and adjusting parameters.

SETTING UP THE HYDRAULIC SYSTEM

Procedures for setting up hydraulic systems, including lift, lower, and load-hold valve controls.

7 — DIAGNOSTICS AND TROUBLESHOOTING

THE DIAGNOSTICS PROCESS

Methods for obtaining diagnostics information, including status indicators, programmer tool, and CAN emergency messages.

FAULT ACTIONS

Table detailing fault actions taken by the controller, including shutdown sequences and VCL references.

8 — MAINTENANCE

CLEANING

Procedure for routine cleaning of the controller exterior to protect against corrosion and electrical issues.

FAULT HISTORY

Accessing and clearing the controller's fault history file to diagnose and verify problem resolution.

APPENDIX A

CAN PDO MAP SETUP

Guidance on setting up PDO maps for F-Series controllers using the Curtis Integrated Toolkit™ for CAN communication.

APPENDIX B

ELECTROMAGNETIC COMPATIBILITY (EMC)

Information on emissions and immunity, and techniques to reduce EMC problems in products with Curtis controllers.

ELECTROSTATIC DISCHARGE (ESD) IMMUNITY

Necessary precautions to protect ESD-sensitive components from damage by providing sufficient distance or isolation.

DECOMMISSIONING AND RECYCLING THE CONTROLLER

Instructions for decommissioning and recycling the controller, following OEM and landfill directives.

APPENDIX C

EN 13849 COMPLIANCE

Overview of safety requirements and performance levels (PL) according to EN13849 for control systems.

APPENDIX D

CURTIS INTEGRATED TOOLKITTM

Description of CIT software for configuring and communicating with Curtis Instruments products via CAN network.

Choosing the CAN Interface Device Driver

Steps to select and install the appropriate CAN dongle driver for PC communication with the controller.

Creating a Project with a new F-Series controller

Step-by-step guide to opening the Project Explorer and creating a new project for F-Series controller configuration.

APPENDIX E

SPECIFICATIONS: CONTROLLER

Detailed specifications for AC F6-A, F4-A, and F2-A controllers, including electrical and mechanical data.

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