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Kohler Curtis F Series User Manual

Kohler Curtis F Series
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7 — DIAGNOSTICS AND TROUBLESHOOTING
pg. 201
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
e Flash Code listed in the rst column of Table 24 (Troubleshooting Chart index) includes the
hexadecimal representation of the code. For example:
(1) Flash code 1-2 for the CONTROLLER OVERCURRENT fault equates to 0x12, and is reported
in Data Bytes 0 & 1 using the Little-Endian format as FF12h (0xFF12). is is represented on the
controllers LEDs with the rst digit (“1”) the red LED and the second digit (“2”) the yellow LED.
e controller will “ash” the red LED 1-time followed by yellow LED 2-times (LEDs x1 x2) in the
decimal equivalent.
(2) Flash code 9-A for the INTERLOCK BRAKING SUPERVISION fault equates to 0x9A, and will
be reported in Data Bytes 0 & 1 as FF9Ah (0xFF9A). is is represented on the controller’s LEDs
with the rst digit (“9”) the red LED and the second digit (“A”) the yellow LED. e controller
will “ash” the red LED 9-times followed by yellow LED 10-times (LEDs x9 x10) in the decimal
equivalent (9h = 9d, Ah = 10d).
Data Byte 2 – Error Register
is byte mirrors the state of the LSB of the predened Error Register object 1001h. is byte is 00h
if there are no faults and 01h if there are any faults in the device.
Data Bytes 3 & 4 – Fault Record Object Index
e Fault Record Object is the faults CAN Object Index, thus distinguishing faults sharing the same
LED ash codes. For the controller, these objects are stored in indexes 2100h through 27FFh. When
no error is present (fault cleared) these bytes will be all 0000h.
Data Byte 5 through 7 – Descriptor
Data Byte 5 indicates the faults “type” as indicated in the Fault Code Troubleshooting Chart, Table 24.
Several examples of the CANbus error messages illustrate the CAN Emergency messages. Example
(1) is a single fault type, whereas example (2a-b) has two error types, which help to dene the root
cause of the fault. Example (3a-b) shares the same ash code, where the Fault Record Object provides
the actual fault detected.
1. CANbus Emergency Message: Motor_Temp_Sensor_Active | 0x2150 0x01
Motor Temp Sensor fault. Flash code 2-9 (LEDs: x2 x9)
Identier DLC Data
0A6 8 00 00 00 50 21 01 00 00
In this example, Device ID = 26h (38d). Note the “little-endian” byte-ordering for the error
code (flash code) and fault record object index. Data Byte 5 further defines the fault as per its
type. In this case, there is only a single type, resulting in 01. The 11-bit Identifier assembles as:
A6h = 00 01 | 0 1 0 0 1 1 0, where the top 4 bits are the Sync-Error Function code, and the bottom
7 bits are the Node ID, as explained above.
If this fault were to clear, while the controller is operational, the CANbus message will clear:
Identier DLC Data
0A6 8 00 00 00 00 00 01 00 00

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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