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Kohler Curtis F Series User Manual

Kohler Curtis F Series
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7 — DIAGNOSTICS AND TROUBLESHOOTING
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 200
Faults detected by VCL code (i.e., User 1-32 Fault) cannot be dened in Table 24 as they will vary
from application to application. OEM/Factory user faults are as dened by the user and documented
in the applications VCL program. Each of the 32 User Faults can be assigned the controller’s dened
single or multiple fault actions, or take actions as dened by the User (VCL Program). Refer to the
appropriate OEM documentation for information on these faults.
All faults, VCL references (i.e., Fault_Name_Active) are assigned a value in VCL: 0, 1, or 2. Each
value has a specic meaning:
Main Contactor Did Not Close
Main_Contactor_Did_Not_Close_Active
0 = Never set.
1 = Fault has occurred in the Fault History menu.
2 = Fault is active, and is in the Fault History.
User_1_Fault_Active
CAN Emergency Messages — Active Faults
Emergency messages are high priority CANopen objects that indicate the controller (the transmitting
device) has detected or cleared a fault.
Emergency messages are sent at the occurrence of each new fault (they are not cyclic), but no faster
than the Emergency Inhibit Time parameter setting allows*.
If several faults occur within the Emergency Inhibit Time or faster than the controller can transmit
them, then they are stored in a queue and transmitted when possible.
When all active** faults are cleared, a nal Emergency message is sent indicating the “all clear” status.
Note that the “all clear” message is only sent if there were previous faults during this operational
period (key on). It is not sent upon startup.
e Emergency Message Identier
e Emergency message identier consists of the Standard Function code, EMCY, in the top four
bits. e bottom 7-bits of the message identier contain the devices Node-ID.
Sync-Error Function code Node ID
11 10 9 8 7 6 5 4 3 2 1
0001b 0000001b – 1111110b
Emergency Message Data Bytes
Data 0 Data 1 Data 2 Data 3 Data 4 Data 5 Data 6 Data 7
Error Code Error
Register
Fault Record Object Index Fault Descriptor
Data Byte 0 & 1 – Error Code
e Error Code is a two byte construction where the MSB indicates the error category and the LSB
may contain a device specic code. e controller will report faults in these data bytes as:
0000h = All faults are cleared
FFXXh = e specic Fault Flash Code
62XXh = User Faults (1 – 32). As specified and implemented in the user/OEM VCL
and documentation.
* See Programmer: Application Setup » CAN Interface » Emergency Message Rate CAN_Open_Emergency_Inhibit_Time, 0x1015
0x00. The default is 16 ms.
** Not referring to the error log/fault history, but only faults that are currently active on the device.

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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