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Kohler Curtis F Series User Manual

Kohler Curtis F Series
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4 — PROGRAMMABLE PARAMETERS
pg. 79
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
APPLICATION SETUP — MAIN CONTACTOR MENU
PARAMETER ALLOWABLE RANGE DEFAULT DESCRIPTION
Main Enable
Main_Enable
0x34C5 0x00
On/Off
On/Off
On When programmed On, the controller's native software
controls the main contactor when enabling the interlock. When
programmed Off, VCL controls the main contactor.
See the assignment parameter in Programmer/Controller Setup/
IO Assignments/Coil Drivers/Main Contactor Driver. The default is
Driver 3.
Note: With Main Enable programmed Off the controller will
not be able to open the main contactor in serious fault
conditions and the system will therefore not meet EEC
safety requirements.
Main State
Main_State
0x34C9 0x00
0 – 10
0 – 10
Read Only Main contactor state:
0 = open
1 = precharge
2 = weld check
3 = closing delay
4 = missing check
5 = closed (when Main Enable = On)
6 = delay
7 = arc check
8 = open delay
9 = fault
10 = closed (when Main Enable = Off)
Keyswitch Voltage
Keyswitch_Voltage
0x3398 0x00
0.00 – 105.00V
0 – 10500
Read Only Voltage at KSI (pin 1).
The value is in 0.01V steps.
Capacitor Voltage
Capacitor_Volts
CAN = 0x34C1 0x00
0.00 – 200.00V
0 – 20000
Read Only Voltage of the controller’s internal capacitor bank at the B+ terminal.
The value is in 0.01V steps.
Note that the precharge, main weld check and DNC tests affect this
reading when those actions are active.
Pull In Voltage
Main_Pull_In_Voltage
0x34C8 0x00
0 – 100 %
0 – 32767
0 % The main contactor pull-in-voltage parameter allows a high initial
voltage when the main contactor driver rst turns on to ensure
contactor closure. After 1 second, this peak voltage drops to the
contactor holding voltage. Typical is 100% to ensure closure.
Note: The Battery Voltage Compensated parameter (0x34C4)
controls whether the pull-in and holding voltages are battery
voltage compensated.
Holding Voltage
Main_Holding_Voltage
0x34C6 0x00
0 – 100 %
0 – 32767
0 % The main contactor holding-voltage parameter allows a reduced
average voltage to be applied to the contactor coil once it has
closed. Typical is 75-80% to conserve energy and coil heating.
Set this parameter (applied voltage) high enough to hold the
contactor closed during all vehicle shock and vibration conditions.
If the voltage is too low, the contactor tips may open when
subjected to shock and vibration conditions.
Note: The Battery Voltage Compensated parameter (0x34C4)
controls whether the pull-in and holding voltages are battery
voltage compensated.
Battery Voltage Compensated
Main_Driver_Battery_Voltage_
Compensated
0x34C4 0x00
On/Off
On/Off
On This parameter determines whether the main pull-in and holding
voltages are battery voltage compensated. When set On, the pull-
in and holding voltages are set relative to the set Nominal Voltage.
In other words the output voltage is adjusted to compensate for
swings in battery voltage so the percentage is relative to the set
Nominal Voltage not to the actual voltage.
For example suppose Nominal Voltage is set to 48V and Holding
Voltage is set to 75 % (36V) to the output driver. Now suppose the
bus voltage dips to 40V. If Battery Voltage Compensated = On, the
output will still be 36V (Nominal Voltage × Holding Voltage) to the
coil. If the Battery Voltage Compensated = Off, the output will be
30V (Actual Voltage × Holding Voltage) to the coil.

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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