Curtis 1232E User manual

Type
User manual

This manual is also suitable for

Manual
Models 1232E/34E/36E/38E
and 1232SE/34SE/36SE
Enhanced AC Controllers
for Induction Motors
and Surface Permanent Magnet Motors
Read Instructions Carefully!
Specications are subject to change without notice.
© 2015 Curtis Instruments, Inc. ® Curtis is a registered trademark of Curtis Instruments, Inc.
© The design and appearance of the products depicted herein are the copyright of Curtis Instruments, Inc. 53134, OS30 11/24/2015
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
» Software Version OS 30.0 «
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 iii
24 NOVEMBER 2015
CONTENTS
1. OVERVIEW ............................................................................. 1
2. INSTALLATION AND WIRING .......................................... 3
Mounting the Controller .................................................... 3
High Current Connections and Wiring Guidelines ............. 6
Low Current Connections and Wiring Guidelines .............. 8
Controller Wiring: Basic Configuration ........................... 12
Switch Input Wiring ......................................................... 13
rottle Wiring ................................................................. 13
Input/Output Specifications .............................................. 18
3. PROGRAMMABLE PARAMETERS ................................... 25
Program Menu ................................................................. 26
4a. MONITOR MENU ............................................................... 72
4b. CONTROLLER INFORMATION MENU ......................... 86
5. INITIAL SETUP .................................................................... 87
6a. MOTOR CHARACTERIZATION: ACIM Motors ............. 93
6b. MOTOR CHARACTERIZATION: SPM Motors .............. 100
7. TUNING GUIDE ............................................................... 102
8. VEHICLE CONTROL LANGUAGE................................. 106
9. DIAGNOSTICS AND TROUBLESHOOTING ............... 137
10. MAINTENANCE ................................................................ 145
appendix a Vehicle Design Considerations
appendix b EN13849 Compliance
appendix c Programming Devices
appendix d Specifications, 1232E/34E/36E/38E
and 1232SE/34SE/36SE Controllers
CONTENTS
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FIGURES
. 1: Curtis 1232E/SE, 1234E/SE, 1236E/SE, 1238E controllers ... 1
. 2a: Mounting dimensions, Curtis 1232E/SE controller ................. 3
. 2b: Mounting dimensions, Curtis 1234E/SE controller ................. 4
. 2c: Mounting dimensions, Curtis 1236E/SE, 1238E controllers ... 5
. 3: Basic wiring diagram ............................................................. 12
. 4: Wiring for Type 1 throttles .................................................... 14
. 5: Wiring for Type 2 throttles .................................................... 15
. 6: Wiring for Type 3 throttles .................................................... 16
. 7: Acceleration response rate diagram ........................................ 33
. 8: Braking response rate diagram ............................................... 34
. 9: rottle mapping, torque control mode ................................ 40
. 10: Eect of gear soften parameter, torque control mode ............. 40
. 11: Eect of brake taper speed parameter, torque control mode ... 40
. 12: Drive current limiting map .................................................... 42
. 13: Regen current limiting map ................................................... 43
. 14: rottle adjustment ............................................................... 45
. 15: VCL motor command diagram ........................................... 114
. 16: VCL control mode processing ............................................. 118
. 17: VCL proportional driver processing ..................................... 119
. B-1: Enhanced supervisory system ............................................... B-1
TABLES
 1: High current connections ....................................................... 6
 2: Low current connections ........................................................ 9
 3: Programmable parameter menus .......................................... 26
 4: Monitor menu ...................................................................... 72
 5: Types of LED display ......................................................... 135
 6: Troubleshooting chart ........................................................ 136
 D-1: Specifications, 1232E/34E/36E/38E
and 1232SE/34SE/36SE controllers .................................. D-1
FIGURES / TABLES
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 1
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OVERVIEW
Curtis 1232E/SE, 1234E/SE, 1236E/SE, and 1238E AC motor controllers
provide accurate, dependable, and highly ecient control of speed and torque
of AC induction motors (ACIM) and surface permanent magnet synchronous
motors (SPM).
ese AC controllers contain two microprocessors to provide exceptional
capability and functional safety. e primary microprocessor runs an advanced
eld-oriented AC motor control while simultaneously running VCL software in
an embedded logic controller. e second microprocessor continuously moni-
tors the operation of the system, redundantly measuring inputs, crosschecking
results, and verifying critical timing and operations.
VCL (Vehicle Control Language) is an innovative software programming
language developed by Curtis. Many electric vehicle functions are uniquely
built into the VCL code, and additional functions can be created by OEMs
as required. VCL opens new avenues of customization, allowing specic vehicle
application functions to be created quickly and easily within the motor controller
itself, often eliminating the need to use separate vehicle manager modules.
e CAN bus communications included within these controllers allow
these AC motor controllers to function as system CAN masters or CAN slaves
as part of an efficient distributed system. Inputs and outputs can be optimally
shared throughout the system, minimizing wiring and creating integrated
functions that often reduce the cost of the system.
ese controllers are the ideal solution for traction, hoist, dual drive, and
other motor drive and vehicle control needs.
1
1 — OVERVIEW
Fig. 1 Curtis AC induction motor controllers:
from left to right, models 1232SE, 1234E, 1236E, and 1238E.
e E and SE models look similar, and share the same standard features.
Like all Curtis controllers, the E and SE models oer superior operator control
of motor drive performance. Features include:
3 Closed-loop speed and torque control for both induction (ACIM) and
surface permanent magnet (SPM) motors
3 High efficiency, field-oriented motor control algorithms that enable
maximum possible motor torque generation for all operating conditions
More Features +
2 Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30
24 NOVEMBER 2015
3 Advanced Pulse Width Modulation technology for efficient use
of battery voltage, low motor harmonics, low torque ripple, and
minimized switching losses
3 Extremely wide torque/speed range including full regeneration capability
3 Full eld-weakening capability with ACIM motors;
full control up to no-load base speed with SPM motors
3 Smooth low speed control, including zero speed
3 Adaptation of control algorithm to motor temperature variation for
optimal performance and reduced motor heating
3 Power limiting maps allow performance customization for reduced motor
heating and consistent performance over varying battery state-of-charge
3 ermal cutback, warning, and automatic shutdown provide protection
to motor and controller
3 Insulated metal substrate power base provides superior heat transfer for
increased reliability
3 Built-in auto-characterization routines for eective in-vehicle optimization
of motor performance and eciency
3 Powerful operating system allows parallel processing of vehicle control tasks,
motor control tasks, and user congurable programmable logic (VCL)
3 A wide range of I/O can be applied wherever needed, for maximum
distributed system control
3 Built-in Dual Drive software allows easy setup and control of typical
dual-drive vehicles, without VCL
3 Internal battery-state-of-charge, hourmeter, and maintenance timers
3 CANopen compatible CAN bus connection; other CAN bus protocols
are configurable through VCL
3 Signicantly increased CAN master capabilities, VCL execution speed,
and VCL code space
3 Field-programmable, with ash downloadable main operating code
3 Easily programmable through the Curtis 1313 handheld programmer
and 1314 PC Programming Station
3 Rugged sealed housing and connectors meet IP65 environmental sealing
standards for use in harsh environments
3 Compliance with new Machinery Directives 2006/42/EC and EN13849-1.
Getting the most out of your Curtis controller
Read and apply the information in this manual. e Installation/Wiring, Initial
Setup, and Tuning Guide sections are critical to proper operation of your con-
troller. For technical support, contact the Curtis distributor where you obtained
your controller or the Curtis sales-support oce in your region.
1 — OVERVIEW
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 3
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2 — INSTALLATION & WIRING
2
Fig. 2a Mounting dimensions,
Curtis 1232E and 1232SE
motor controllers.
Note: The SE has a thicker base.
Dimensions in millimeters.
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
e outline and mounting hole dimensions for the 1232E/SE controller are shown in
Figure 2a, for the 1234E/SE controller in Figure 2b, and for the 1236E/SE and 1238E
controllers in Figure 2c. When an Ampseal plug housing is mated with the
35-pin logic receptacle, these controllers meet the IP65 requirements for envi-
ronmental protection against dust and water. Nevertheless, in order to prevent
external corrosion and leakage paths from developing, the mounting location
should be carefully chosen to keep the controller as clean and dry as possible.
It is recommended that the controller be fastened to a clean, at metal
surface with four 6 mm (1/4") diameter bolts, using the holes provided. A thermal
joint compound can be used to improve heat conduction from the controller
heatsink to the mounting surface. Additional heatsinking or fan cooling may
be necessary to meet the desired continuous ratings.
B-
U
71
169
180
5.5
7.0 thru, 4 plcs
140
129
5.5
V
W
B+
8
Status LED
window
1232E
75
12
1232SE
M6 x 1.0, 5 plcs
4 Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30
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Fig. 2b Mounting dimensions,
Curtis 1234E and 1234SE
motor controllers.
Note: The SE has a thicker base and taller terminals.
Dimensions in millimeters.
Working on electrical systems is potentially dangerous. Protect yourself against
uncontrolled operation, high current arcs, and outgassing from lead acid batteries:
UNCONTROLLED OPERATION — Some conditions could cause the motor to run out of
control. Disconnect the motor or jack up the vehicle and get the drive wheels off the
ground before attempting any work on the motor control circuitry.
HIGH CURRENT ARCS — Batteries can supply very high power, and arcing can occur if
they are short circuited. Always open the battery circuit before working on the motor
control circuit. Wear safety glasses, and use properly insulated tools to prevent shorts.
LEAD ACID BATTERIES — Charging or discharging generates hydrogen gas, which can
build up in and around the batteries. Follow the battery manufacturer’s safety recom-
mendations. Wear safety glasses.
+
CAUTION
2 — INSTALLATION & WIRING
1234SE
terminal
(5 plcs)
B-
U
8
75
212
5.5
Status LEDs
7.0 thru, 4 plcs
155
140.4
7.3
V
W
B+
201
80
11
1234E 1234SE
M6 x 1.0, 5 plcs
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 5
24 NOVEMBER 2015
Fig. 2c Mounting dimensions,
Curtis 1236E/SE and 1238E
motor controllers.
Dimensions in millimeters.
You will need to take steps during the design and development of your
end product to ensure that its EMC performance complies with applicable
regulations; suggestions are presented in Appendix A.
ese controllers contain ESD-sensitive components. Use appropriate
precautions in connecting, disconnecting, and handling the controller. See
installation suggestions in Appendix A for protecting the controller from ESD
damage.
2 — INSTALLATION & WIRING
B-
B+
FUSE
U
V
W
M8 x 1.25,
19
85
212
232
10
Status LEDs
7.0 thru,
4 plcs
165
145
255
275
1236E/SE
1238E
13 (typ.)
5 plcs
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2 — INSTALLATION & WIRING: High Current Connections
HIGH CURRENT CONNECTIONS
ere are ve high-current terminals, identied on the controller housing as
B+, B-, U, V, and W.
Table 1 High Current Connections
terminal function
B+ Positive battery to controller.
B- Negative battery to controller.
U Motor phase U.
V Motor phase V.
W Motor phase W.
Lug assembly: 1232E/SE and 1234E/SE models
Five aluminum M6 terminals are provided. Lugs should be installed as follows,
using M6 bolts sized to provide proper engagement (see diagram):
• Placethelugontopofthealuminumterminal, followed by
a high-load safety washer with its convex side on top. e
washer should be a SCHNORR 416320, or equivalent.
• Iftwolugsareusedonthesameterminal, stack them so the
lug carrying the least current is on top.
• Tightentheassemblyto10.2±1.1N·m(90±10in-lbs).
M6 BOLT
HIGH LOAD
SAFETY WASHER
LUG
M6 TERMINAL
SECTION VIEW
1232E/SE, 1234E
EXPLODED VIEW
10 mm MIN
DEPTH
18 mm MAX
DEPTH
SECTION VIEW
1234SE
11.75 mm MIN
DEPTH
19.75 mm MAX
DEPTH
1234SE
has larger
terminal
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 7
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High current wiring recommendations: all models
Battery cables (B+, B-)
ese two cables should be run close to each other between the controller
and the battery. Use high quality copper lugs and observe the recommended
torque ratings. For best noise immunity the cables should not run across the
center section of the controller. With multiple high current controllers, use a
star ground from the battery B- terminal.
Motor wiring (U, V, W)
e three phase wires should be close to the same length and bundled together
as they run between the controller and the motor. e cable lengths should be
kept as short as possible. Use high quality copper lugs and observe the recom-
mended torque ratings. For best noise immunity the motor cables should not
run across the center section of the controller. In applications that seek the lowest
possible emissions, a shield can be placed around the bundled motor cables and
connected to the B- terminal at the controller. Typical installations will readily
pass the emissions standards without a shield. Low current signal wires should
not be run parallel to the motor cables. When necessary they should cross the
motor cables at a right angle to minimize noise coupling.
Lug assembly: 1236E/SE and 1238E models
Five M8 terminals are provided. Lugs should be installed as follows, using M8
bolts sized to provide proper engagement (see diagram):
• Placethelugontopoftheterminal, followed by a safety
washer with its convex side on top. e washer should be a
SCHNORR 700800, or equivalent.
• Iftwolugsareusedonthesameterminal, stack them so the
lug carrying the least current is on top.
• Tightentheassemblyto9.6±0.9N·m(85±8in-lbs).
2 — INSTALLATION & WIRING: High Current Connections
M8 BOLT
SAFETY WASHER
LUG
M8 TERMINAL
SECTION VIEW EXPLODED VIEW
7.5 mm MIN DEPTH
13.75 mm MAX DEPTH
8 Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30
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LOW CURRENT CONNECTIONS
All low power connections are made through a single 35-pin AMPSEAL con-
nector. e mating plug housing is AMP p/n 776164-1 and the contact pins
are AMP p/n 770520-3. e connector will accept 20 to 16 AWG wire with
a 1.7 to 2.7mm diameter thin-wall insulation.
e 35 individual pins are characterized in Table 2.
2 — INSTALLATION & WIRING: Low Current Connections
13
24
1
23
35
12
J1
Low current wiring recommendations
Position feedback (Pins 7, 26, 31, 32)
All four wires (+5V, Feedback A, Feedback B, and I/O ground) should be bundled
together as they run between the motor and controller logic connector. ese
can often be run with the rest of the low current wiring harness. e encoder
cables should not be run near the motor cables. In applications where this is
necessary, shielded cable should be used with the ground shield connected to
the I/O ground (pin 7) at only the controller side. In extreme applications,
common mode filters (e.g. ferrite beads) could be used.
CAN bus (Pins 21, 23, 34, 35)
It is recommended that the CAN wires be run as a twisted pair. However, many
successful applications at 125 kbit/s are run without twisting, simply using two
lines bundled in with the rest of the low current wiring. CAN wiring should
be kept away from the high current cables and cross them at right angles when
necessary.
All other low current wiring
e remaining low current wiring should be run according to standard prac-
tices. Running low current wiring parallel to the high current wiring should
always be avoided.
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 9
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2 — INSTALLATION & WIRING: Low Current Connections
* e related VCL columns are vital when writing VCL code (see Section 8).
VCL “functions” are used to access the various I/Os; VCL “references” are
predefined names for specific pins.
Table 2 Low Current Connections
related vcl*
pin name description functions references
1 KSI Keyswitch input. Keyswitch_Voltage
Provides logic power for
the controller and power
for the coil drivers.
2 Prop. Driver Proportional driver. Automate_PWM Sw_13
This is a coil driver with Put_PWM PWM5
current control capability PD_Current
typically used for a PD_Output
proportional valve on a PD_Throttle
hydraulic manifold. VCL_PD_Throttle
Can also be used as a
digital input.
3 Driver 4 Generic driver #4; can Automate_PWM Sw_12
also be used as a digital Put_PWM PWM4
input. Has low frequency PWM4_Output
PWM capabilities.
4 Driver 3 Generic driver #3; can Automate_PWM Sw_11
also be used as a digital Put_PWM PWM3
input. Has low frequency PWM3_Output
PWM capabilities. Typically
used for pump contactor.
5 Driver 2 Generic driver #2; can Automate_PWM Sw_10
also be used as a digital Put_PWM PWM2
input. Has low frequency PWM2_Output
PWM capabilities and
a slightly higher current
rating.Typically used for
electromagnetic brake.
6 Driver 1 Generic driver #1; can Automate_PWM Sw_9
also be used as a digital Put_PWM PWM1
input. Has low frequency Set_Interlock PWM1_Output
PWM capabilities. Clear_Interlock Interlock_State
Typically used for main Main_State
contactor.
7 I/O Ground Input and output ground
reference.
8 Switch 2 Can be used as generic Sw_2
Analog 2 switch input #2 or as Analog2_Input
generic analog input #2. Motor_Temperature
Typically used as the
motor temperature
analog input.
9 Switch 3 Generic switch input #3. Sw_3
Typically used as the
interlock switch.
10 Switch 4 Generic switch input #4. Sw_4
11 Switch 5 Generic switch input #5. Sw_5
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12 Switch 6 Generic switch input #6. Sw_6
13 Coil Return This is the coil return pin
(at B+ potential) for all
the contactor coils.
14 Switch 16 Generic switch input #16. Sw_16
15 Throttle Pot High Pot high connection for
a 3-wire throttle pot.
16 Throttle Pot Wiper Pot wiper connection for Setup_Pot Throttle_Pot_Raw
the throttle pot. Setup_Pot_Faults
17 Pot2 Wiper Pot wiper connection for Setup_Pot Pot2_Raw
the brake pot. Setup_Pot_Faults
18 Pot Low Common pot low Pot_Low_Output
connection for the throttle
and brake pots.
19 Digital Out 6 An On/Off output driver. Set_DigOut Sw_14
Can also be used Clear_DigOut DigOut6
as a digital input. Dig6_Output
20 Digital Out 7 An On/Off output driver Set_DigOut Sw_15
Can also be used Clear_DigOut DigOut7
as a digital input. Dig7_Output
21 CAN Term H High connection for the
CAN termination jumper.
22 Switch 7 Generic switch input #7. Sw_7
Typically used as the
Forward switch.
23 CANH CAN bus high. Setup_CAN
Setup_Mailbox
Send_Mailbox
etc.
24 Switch 1 Can be used as generic Sw_1
Analog 1 switch input #1 or as Analog1_Input
generic analog input #1.
Typically used for
emergency reverse switch
(if applicable).
25 +12V Out Unregulated low power Ext_Supply_Current
+12V output.
26 +5V Out Regulated low power 5_Volts_Output
+5V output. Ext_Supply_Current
27 Pot2 High Pot high connection for
a 3-wire brake pot.
28 Serial TX Serial transmit line for Setup_Serial
  displayorashupdate.
2 — INSTALLATION & WIRING: Low Current Connections
Table 2 Low Current Connections, cont’d
related vcl
pin name description functions references
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 11
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2 — INSTALLATION & WIRING: Low Current Connections
Table 2 Low Current Connections, cont’d
related vcl
pin name description functions references
29 Serial RX Serial receive line for Setup_Serial
  ashupdate.
30 Analog Output * Low power, low frequency Automate_PWM PWM6
0–10V analog output. Put_PWM Analog_Output
31 Position Feedback A Quadrature encoder input Motor_RPM
phase A (ACIM motors). MotorspeedA
Sin/cos sensor input Encoder_Sin_Input_
sine (SPM motors). Compensated
32 Position Feedback B Quadrature encoder input Motor_RPM
phase B (ACIM motors). MotorspeedB
Sin/cos sensor input Encoder_Cos_Input_
cosine (SPM motors). Compensated
33 Switch 8 Generic switch input #8. Sw_8
Typically used as the
Reverse switch.
34 CAN Term L Low connection for the
CAN bus termination
jumper.
35 CANL CAN bus low. Setup_CAN
Setup_Mailbox
Send_Mailbox
etc.
* Pin 30 not connected on 1232E/SE controllers.
12 Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30
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Fig. 3 Basic wiring diagram, Curtis 1232E/SE, 34E/SE, 36E/SE, and 38E motor controllers.
2 — INSTALLATION & WIRING: Standard Wiring Diagram
CONTROLLER WIRING: BASIC CONFIGURATION
A basic wiring diagram is shown in Figure 3. rottle and brake are shown in
the diagram as 3-wire potentiometers; other types of throttle and brake inputs
are easily accommodated, and are discussed in the following throttle wiring
section.
e main contactor coil must be wired directly to the controller as shown
in Figure 3 to meet EEC safety requirements. e controller can be programmed
1232E/34E/36E/38E, 1232SE/34SE/36SE
CONTROLLER
SWITCH 16
J1-14
SWITCH 8
J1-33
REVERSE
SWITCH 7
J1-22
FORWARD
SWITCH 6
J1-12
SWITCH 5
J1-11
SWITCH 4
J1-10
SWITCH 3
J1-9
INTERLOCK
SWITCH 2 / ANALOG 2
J1-8
SWITCH 1 / ANALOG 1
J1-24
I/O GROUND
J1-7
THROTTLE POT HIGH
J1-15
THROTTLE POT WIPER
J1-16
POT2 HIGH
J1-27
POT2 WIPER
J1-17
POT LOW
J1-18
THROTTLE POT
BRAKE POT
AC
MOTOR
MAIN
J1-19
J1-3
J1-4
J1-5
J1-6
J1-13
PROP. DRIVER
DRIVER 4
DRIVER 3
DRIVER 2
DRIVER 1
KSI
COIL RETURN
MAIN
BRAKE
PROP. VALVE
J1-1
KSI
POSITION
FEEDBACK
**
J1-26
J1-31
J1-32
J1-7
J1-23
J1-35
J1-21
J1-34
CAN PORT
Connect jumper for 120 Ω
CAN bus termination
J1-25
J1-28
J1-29
J1-7
SERIAL PORT
(4-pin Molex)
4
3
1
2
CURTIS
MODEL 840
DISPLAY
8
6
5
EMERG. REV.
KEYSWITCH
B+
V
+5V
POSITION FEEDBACK B
CAN TERM L
CAN L
+12V
RX
I/O GROUND
U
W
POSITION FEEDBACK A
I/O GROUND
CAN TERM H
B-
CAN H
TX
PUMP
EMERGENCY
STOP
J1-20
DIGITAL DRIVER 6
J1-2
DIGITAL DRIVER 7
ANALOG OUT (0–10V) *
J1-30
MOTOR
TEMPERATURE
SENSOR
Note: KTY sensor shown.
The banded end must be
connected to I/O ground.
*
1232E and 1232SE do not include ANALOG OUT.
BATTERY
(24V–96V)
** quadrature encoder (ACIM motors)
sin/cos sensor (SPM motors)
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 13
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2 — INSTALLATION & WIRING: Throttle Wiring
to check for welded or missing contactor faults and uses the main contactor
coil driver output to remove power from the controller and motor in the event
of various other faults. If the main contactor coil is not wired to Pin 6 of
the 35-pin connector as shown, 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.
Note that the basic wiring diagram is designed for generic applications
and may not fully meet the requirements of your system. ese controllers
have very exible I/O and wiring configurations; you may wish to contact your
Curtis distributor or support engineer to discuss your particular application.
SWITCH INPUT WIRING
e following inputs are dedicated to specific functions when the parameter
settings are as shown:
Switch 1: Emergency Reverse input if the EMR Enable = On
and EMR Type = 0 or 2 (see page 68).
Switch 3: Interlock input if Interlock Type = 0 (see page 50).
Switch 5: Lift input (depends on VCL program).
Switch 6: Lower input (depends on VCL program).
Switch 7: Forward input if Throttle Type = 1–3 (see page 44).
Switch 8: Reverse input if Throttle Type = 1–3 (see page 44).
THROTTLE WIRING
In this manual, the term throttle is used in two senses: as another name for the
drive throttle, and as a generic term covering both the drive throttle and the
brake throttle. Wiring is the same, whether the throttle in question is used for
braking or for acceleration.
Various throttles can be used with these controllers. ey are characterized
as one of five types in the programming menu of the 1313/1314 programmer.
Type 1: 2-wire 5kΩ–0 potentiometers
Type 2: single-ended 0–5V throttles, current source throttles,
3-wire potentiometers, and electronic throttles
Type 3: 2-wire 0–5kΩ potentiometers
Type 4: wigwag 0–5V throttles and 3-wire potentiometers
Type 5: VCL input (VCL_Throttle or VCL_Brake)
e two throttle inputs (drive throttle and brake throttle) are programmed
independently.
14 Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30
24 NOVEMBER 2015
For potentiometers, the controller provides complete throttle fault
protection that meets all applicable EEC regulations. For voltage throttles, the
controller protects against out-of-range wiper values, but does not detect wiring
faults; it is therefore the responsibility of the OEM to provide full throttle fault
protection in vehicles using voltage throttles.
rottle types 1–3 use the forward and reverse inputs (switches 7 and 8) in
addition to the throttle pot input to define the throttle command (see Figure 15,
page 114). rottle types 4 and 5 do not use the forward and reverse inputs.
Wiring for the most common throttles is described in the following text
and shown in the accompanying illustrations. If a throttle you are planning to
use is not covered, contact your Curtis distributor or support engineer.
Throttle Type 1
For these 2-wire resistive potentiometers, shown in Figure 4, full throttle request
corresponds to 0 Ω measured between the pot wiper pin and the Pot Low pin.
2 — INSTALLATION & WIRING: Throttle Wiring
Fig. 4 Wiring for Type 1
throttles.
Pot Low input (Pin 18)
Pot Wiper input (Pin 16 or 17)
5kΩ–0
FASTER
Broken wire protection is provided by the controller sensing the current ow
from the pot wiper input (pin 16 or 17) through the potentiometer and into
Pot Low (pin 18). If the Pot Low input current falls below 0.65 mA, a throttle
fault is generated and the throttle request is zeroed. Note: Pot Low (pin 18)
must not be tied to ground (B-).
Throttle Type 2
With these throttles, the controller looks for a voltage signal at the wiper input.
Zero throttle request corresponds to 0 V and full throttle request to 5 V. A variety
of devices can be used with this throttle input type, including voltage sources,
current sources, 3-wire pots, and electronic throttles. e wiring for each is
slightly dierent, as shown in Figure 5, and they have varying levels of throttle
fault protection.
When a voltage source is used as a throttle, it is the responsibility of the
OEM to provide appropriate throttle fault detection. For ground-referenced
0–5V throttles, the controller will detect open breaks in the wiper input but
cannot provide full throttle fault protection.
To use a current source as a throttle, a resistor must be added to the
circuit to convert the current source value to a voltage; the resistor should be
sized to provide a 0–5V signal variation over the full current range. It is the
responsibility of the OEM to provide appropriate throttle fault detection.
Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30 15
24 NOVEMBER 2015
2 — INSTALLATION & WIRING: Throttle Wiring
Fig. 5 Wiring for Type 2
throttles.
Curtis ET-XXX Electronic Throttle
GREEN
ORANGE
BLACK
BLACK/WHITE
WHITE
WHT/BRN
B+
KEYSWITCH
connector
WHT/GRN
Reverse input (Pin 33)
KSI (Pin 1)
Throttle Pot Wiper input (Pin 16)
Forward input (Pin 22)
I/O Ground Return (Pin 7)
Voltage Source
Current Source
3-wire Potentiometer
+
+
-
SENSOR OUTPUT (0–5V)
SENSOR
SENSOR GROUND
I/O Ground Return (Pin 7)
Pot Wiper input (Pin 16 or 17)
Sensor-referenced 0–5V source Ground-referenced 0–5V source
Pot Wiper input (Pin 16 or 17)
I/O Ground Return (Pin 7)
Pot Wiper input (Pin 16 or 17)
I/O Ground Return (Pin 7)
Rthrottle
Isource
1kΩ–10kΩ
FASTER
NOTE: Pins 15 and 16 are used together in the throttle pot; Pins 27 and 17 in the brake pot.
Pot Low input (Pin 18)
Pot High output (Pin 15 or 27)
Pot Wiper input (Pin 16 or 17)
16 Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os 30
24 NOVEMBER 2015
When a 3-wire potentiometer is used, the controller provides full fault
protection in accordance with EEC requirements. e pot is used in its voltage
divider mode, with the controller providing the voltage source and return. Pot
High provides a current limited 5V source to the pot, and Pot Low provides
the return path. is is the throttle shown in the basic wiring diagram (Figure 3)
for the drive throttle and for the brake throttle.
e ET-XXX electronic throttle is typically used only as a drive throttle.
e ET-XXX contains no built-in fault detection, and the controller will de-
tect only open wiper faults. It is the responsibility of the OEM to provide any
additional throttle fault detection necessary.
Throttle Type 3
For these 2-wire resistive potentiometers, shown in Figure 6, full throttle request
corresponds to 5 kΩ measured between the pot wiper pin and the Pot Low pin.
2 — INSTALLATION & WIRING: Throttle Wiring
Broken wire protection is provided by the controller sensing the current ow
from the wiper input (pin 16 or 17) through the potentiometer and into Pot
Low (pin 18). If the Pot Low input current falls below 0.65 mA, a throttle
fault is generated and the throttle request is zeroed. Note: Pot Low (pin 18)
must not be tied to ground (B-).
Throttle Type 4
Type 4 throttles operate in wigwag style. No signals to the controllers forward
and reverse inputs are required; the direction is determined by the wiper input
value. Only 0–5V voltage sources and 3-wire potentiometers can be used as
Type 4 throttles. e controller interface for Type 4 throttles is the same as for
the corresponding Type 2 throttles; see Figure 5.
In a Type 4 throttle, the neutral point must be set up somewhere in the
center of the throw, with increasing voltage beyond this point providing increas-
ing forward command and voltages below this point providing increasing reverse
command. For example, you might set the Forward Deadband at 2.6 V with
Forward Max at 4 V, and Reverse Deadband at 2.4 V with Reverse Max at 1 V.
When a 3-wire pot is used, the controller provides full fault protection.
When a voltage throttle is used, the controller will detect open breaks in the
wiper input but cannot provide full throttle fault protection.
Fig. 6 Wiring for Type 3
throttles.
Pot Low input (Pin 18)
Pot Wiper input (Pin 16 or 17)
0–5kΩ
FASTER
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