Curtis 1222 Manuel utilisateur

Manual

Model 1222

Electric Steering Controller

Read Instructions Carefully!

Speciﬁcations are subject to change without notice.

Curtis Instruments, Inc.

200 Kisco Avenue

Mt. Kisco, NY 10549

www.curtisinstruments.com

» Software Version OS 15.0 «

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CONTENTS

1. OVERVIEW ..............................................................................1

2. INSTALLATION AND WIRING .............................................4

Mounting the Controller .....................................................4

High Current Connections and Wiring Guidelines ..............6

Low Current Connections and Wiring Guidelines ...............8

Controller Wiring: Safety Requirements ...........................11

Input/Output Speciﬁcations ...............................................13

3. PROGRAMMABLE PARAMETERS .....................................17

Program Menu ..................................................................18

4a. MONITOR MENU ................................................................57

4b. CONTROLLER INFORMATION MENU ...........................70

4c. CONTROLLER FUNCTIONS MENU .................................71

5. COMMISSIONING ...............................................................72

6. INTERFACE WITH MASTER CONTROLLER ...................93

7. DIAGNOSTICS AND TROUBLESHOOTING ....................99

8. MAINTENANCE .................................................................110

APPENDIX A Vehicle Design Considerations

APPENDIX B EN 14839 Compliance

APPENDIX C Programming Devices

APPENDIX D Speciﬁcations, 1222 Controller

CONTENTS

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FIGURES

fig. 1: Curtis 1222 controller .............................................................. 1

fig. 2: Mounting dimensions, Curtis 1222 controller ........................ 4

fig. 3a: Wiring diagram ...................................................................... 11

fig. 3b: Software control diagram ....................................................... 12

fig. 4: Command Input Device “0” signal ﬂow ................................ 24

fig. 5: Command Input Device “1” signal ﬂow ................................ 25

fig. 6: Command Input Device “2” signal ﬂow ................................ 27

fig. 7: Command Input Device “3” signal ﬂow ................................ 29

fig. 8: Command Input Device “4” signal ﬂow ................................ 30

fig. 9: Steer Command Map ............................................................. 31

fig. 10: Position Feedback Device “0” signal ﬂow ............................... 37

fig. 11: Position Feedback Device “1” signal ﬂow ............................... 38

fig. 12: Position Feedback Device “2” signal ﬂow ............................... 41

fig. 13: Position Feedback Device “3” signal ﬂow ............................... 42

fig. 14: Position Control signal ﬂow ................................................... 53

fig. 15: Velocity Control signal ﬂow ................................................... 53

fig. 16: Steering Sensitivity Map ......................................................... 54

fig. 17a: Input Command signal ﬂow .................................................. 96

fig. 17b: Position Feedback signal ﬂow ................................................. 97

fig. 17c: Position/Velocity Control signal ﬂow ..................................... 98

fig. B-1: Supervisory system ................................................................B-1

TABLES

table 1: High current connections ....................................................... 7

table 2: Low current connections ...................................................... 10

table 3: Programmable parameter menus .......................................... 18

table 4: Monitor menu ...................................................................... 57

table 5: Types of LED display ........................................................ 100

table 6: Troubleshooting chart ......................................................... 101

table D-1: Speciﬁcations, 1222 controllers .........................................D-1

FIGURES / TABLES

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OVERVIEW

The Curtis Model 1222 is an AC induction motor controller for electric

power steering (EPS) systems. In these “steer by wire” systems, the AC steering

gearmotor functions as an actuator to change the angle of the vehicle’s steered

wheel(s) and thus change the direction of travel. The 1222 performs as the

steering system controller, interpreting the steering command input and wheel

position feedback, then driving the steering motor to move the steered wheel(s)

to the desired position.

The Curtis 1222 controller is designed for use as an electric power steer-

ing controller for 300–1400W AC induction gearmotors with overall gear

reductions between 50:1 and 800:1 on vehicles using Curtis VCL AC motor

controllers. Intended applications are material handling vehicles such as reach

trucks, order pickers, stackers, “man up” warehouse trucks, and other similar

industrial vehicles.

1 — OVERVIEW

Fig. 1 Curtis 1222 electric

steering controller.

Advanced Motor Control

✓ Absolute Position (pedestrian stacker) or Relative Position

(reach truck) control modes.

✓ Supports >360° multi-turn steering mode.

✓ Indirect Field Orientation (IFO) vector control algorithm

provides maximum possible torque while ensuring maximum

efﬁciency and accurate current control.

More Features ☞

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✓ 16 kHz PWM switching frequency ensures silent operation

across the 0–200Hz stator frequency range.

✓ Advanced PWM techniques produce low motor harmonics,

low torque ripple, and minimized heating losses, resulting

in high efﬁciency.

✓ 70A RMS 2-minute current output.

✓ 24–48V nominal supply voltage.

Versatile Steering Input and Feedback Options

✓ Steering command input via CAN, dual redundant

quadrature encoder, sine/cosine sensor, sawtooth sensor,

or analog voltage inputs.

✓ Steered angle feedback via dual redundant homing switch,

quadrature encoder, sine/cosine sensor, sawtooth sensor, or

analog voltage inputs.

✓ Fully programmable input/output ratio mapping.

✓ Conﬁgurable homing methods, center offset, auto-center,

and end-stop protection.

✓ Programmable force feedback driver for command input

devices featuring variable friction tactile feedback (TFD).

Maximum Safety

✓ Dual redundant conﬁguration of all safety-related parts.

✓ Two microprocessors, each with its own EEPROM memory.

✓ Separate input paths to each micro for all input and feedback

signals.

✓ 5A high-side fault output driver, consisting of two switches

connected in series; each switch is controlled by one micro

with independent supervision.

✓ Meets the requirements of the latest international functional

safety standards.

Unmatched Flexibility

✓ CANopen system communications.

✓ 35-pin AMPSEAL logic connector.

✓ Software includes a library of pre-deﬁned AC steering motor

types from various manufacturers.

✓ Programmable motor temperature input prevents thermal

damage to motor and supports all commonly used thermistors.

1 — OVERVIEW

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✓ Integrated hourmeter and diagnostic log functions.

✓ +5V and +10V low-power supplies for input sensors, etc.

✓ Curtis 1313 handheld programmer and 1314 PC Programming

Station provide easy programming and powerful system diagnostic

and monitoring capabilities.

✓ Integrated Status LED gives instant diagnostic indication.

✓ Field upgradeable software.

Robust Reliability

✓ Insulated Metal Substrate (IMS) powerbase ensures superior

heat transfer.

✓ Intelligent thermal cutback and overvoltage/undervoltage

protection functions maintain steering while reducing traction

speed until severe over/under limits are reached.

✓ Rugged sealed housing and AMPSEAL connector meet IP65

environmental standards for use in harsh environments.

✓ Reverse polarity protection on battery connections

and short circuit protection on all output drivers.

Familiarity with your Curtis controller will help you install and operate it prop-

erly. We encourage you to read this manual carefully. If you have questions,

please contact your local Curtis representative.

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2 — INSTALLATION & WIRING

Fig. 2 Mounting

dimensions, Curtis 1222

motor controller.

Dimensions in millimeters (and inches)

INSTALLATION AND WIRING

MOUNTING THE CONTROLLER

The outline and mounting hole dimensions for the 1222 controller are shown

in Figure 2. The controller meets the IP65 requirements for environmental

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, ﬂat metal

surface with four 6mm (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.

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2 — INSTALLATION & WIRING

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

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.

The 1222 controller contains ESD-sensitive components. Use appro-

priate precautions in connecting, disconnecting, and handling the controller.

See installation suggestions in Appendix A for protecting the controller from

ESD damage.

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2 — INSTALLATION & WIRING: High Current Connections

HIGH CURRENT CONNECTIONS

There are ﬁve high-current terminals, identiﬁed 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 AC steer motor phase U.

V AC steer motor phase V.

W AC steer motor phase W.

Lug assembly

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. The

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).

High current wiring recommendations

Battery cables (B+, B-)

These 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.

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