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Kohler Curtis F Series User Manual

Kohler Curtis F Series
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4 — PROGRAMMABLE PARAMETERS
pg. 67
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
APPLICATION SETUP — BRAKE MENU
PARAMETER ALLOWABLE RANGE DEFAULT DESCRIPTION
Brake Input
Brake_Pot_Percent
0x33D3 0x00
0.0 – 100.0 %
0 – 1000
Read Only Normalized percentage of the brake input. Similarly to the Throttle
Input variable, the controller processes the voltage at the assigned
Analog Input as a percentage, and not as a voltage (due to dynamic
testing), to determine the amount of motor braking (regen).
Note, the controller does not offer a specic brake input pin(s)
or circuit(s), as a default (Brake_Source = 0). Without a physical
throttle, the analog input at pin 16 can be a physical brake
input. Figure 13 illustrates using the 2-wire option as a brake
signal input on the 35-pin controllers.
Mapped Brake
Mapped_Brake
0x3350 0x00
0.0 – 100.0 %
0 – 32767
Read Only Mapped brake request. See Figure 23.
Brake Command
Brake_Command
0x33D2 0x00
0.0 – 100.0 %
0 – 32767
Read Only Brake request to slew rate block.
Note that the percent value is only positive for the Brake
Command. See Figure 23.
Brake Pedal Enable
Brake_Pedal_Enable
0x33C9 0x00
On/Off
On/Off
Off When this parameter is set to On, the Brake Input (from a brake
pedal input) forms the basis of the Brake Command. If using a
VCL Brake, set this parameter to Off.
Brake Min Input
Brake_Deadband_Percent
0x33C2 0x00
0 – 100 %
0 – 1000
15 % Denes the minimum brake input’s threshold. Increasing this
parameter will increase the neutral range (deadband). This
parameter is especially useful with the pedal assemblies that
do not reliably return to a well-dened neutral point because
it allows the “deadband” to be dened wide enough to ensure
that the controller cancels regen (motor braking) when the pedal
mechanism is released.
Brake Max Input
Brake_Max_Percent
0x33C6 0x00
0 – 100 %
0 – 1000
85 % Denes the brake input percentage required to produce 100%
controller regen. Decreasing this parameter setting reduces the
analog input percentage (voltage at the input) and therefore
the full stroke necessary to produce full controller regen. This
parameter accommodates reduced-range throttle assemblies.
Brake Map Shape
Brake_Map
0x33C5 0x00
0 – 100 %
0 – 32767
50 % Modies the vehicle’s response to a brake input. Setting the brake
map at 50% provides a linear output response to pedal position
(brake input). Values below 50% increase the controller regen
at low brake settings, providing enhanced slow speed braking.
Values above 50% give the vehicle a slower, less responsive feel
at low brake inputs.
The map value is the percentage of controller regen at half
throttle [(Min Input + Max Input)/2].
Brake Offset
Brake_Offset
0x33C8 0x00
0 – 100 %
0 – 32767
0 % Denes the initial controller response generated when rst
moving the brake out of the neutral deadband. For most vehicles,
a setting of 0 is appropriate. For heavy vehicles, however,
decreasing the offset may improve controllability by reducing the
amount of brake-input required to start the vehicle regen braking.
Brake Filter
Brake_Filter_Frequency
0x33DA 0x00
0.1 – 10.0 Hz
10 – 1000
0.6 Hz Sets the low pass lter’s cutoff frequency for the assigned brake
(analog) input. Higher values will make the brake more responsive
to quick changes. Lower values will make the brake less
responsive and subject to electrical noise.
VCL Brake Enable
VCL_Brake_Enable
0x33D1 0x00
On/Off
On/Off
Off When programmed On, the brake processing with fault detection
at the assigned analog input will operate normally; however,
the brake command will require VCL to dene the connection
between the Brake_Pot_Percent and VCL_Brake variables. This
allows VCL exibility and customization of throttle processing
while still allowing brake fault detection.
Quick Link:
Fig. 23 p.69

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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