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Curtis 1268 Manual

Electronic motor controller
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Manual
Model 1268
Electronic Motor Controller
Read Instructions Carefully!
Specifications are subject to change without notice.
© 2012 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.
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
37873 Rev D 3/12

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Summary of Contents for Curtis 1268

  • Page 1 Specifications are subject to change without notice. © 2012 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. 37873 Rev D 3/12...

  • Page 3: Table Of Contents

    Brake Minimum: M1, M2, Reverse Brake Maximum: M1, M2, Reverse Brake Start: M1, M2, Reverse Brake End: M1, M2, Reverse Brake Map: M1, M2, Reverse Field Mapping Parameters..........24 Forward Field Minimum: M1, M2 Reverse Field Minimum Curtis 1268 Manual, Rev. D...
  • Page 4 Low-speed field braking .........44 EM brake operation ..........45 6. DIAGNOSTICS AND TROUBLESHOOTING....47 7. MAINTENANCE ..............50 Vehicle Design Considerations APPENDIX A Programming Devices & Menus APPENDIX B Programmable Parameter Index APPENDIX C Specifications, 1268 Controller APPENDIX D Curtis 1268 Manual, Rev. D...
  • Page 5 FIGURES FIGURES fig. 1: Curtis 1268 electronic motor controller......1 fig. 2: Mounting dimensions, Curtis 1268 controller ....4 fig. 3a: Standard wiring configuration — with aux driver used for an EM brake......... 8 fig. 3b: Standard wiring configuration —...

  • Page 7: Overview

    1 — OVERVIEW OVERVIEW Curtis 1268 controllers are separately excited motor speed controllers designed for use in a variety of transport vehicles. These programmable controllers are simple to install, efficient, and cost effective. Typical applications include heavy-duty golf carts, personnel transports, burden carriers, and other utility vehicles.
  • Page 8 1 — OVERVIEW Like all Curtis motor controllers, the 1268 offers superior operator control of the vehicle’s motor drive speed. Features include: ✓ Regenerative braking, providing longer operation on a single battery charge and reducing motor brush wear and motor heating ✓...
  • Page 9 ✓ Sealed package is rated at IP64 and IP67 ✓ Meets or exceeds EEC fault detect requirements. Familiarity with your Curtis controller will help you install and operate it properly. We encourage you to read this manual carefully. If you have ques- tions, please contact the Curtis office nearest you.

  • Page 10: Installation And Wiring

    Controller INSTALLATION AND WIRING MOUNTING THE CONTROLLER The outline and mounting hole dimensions for the 1268 controller are shown in Figure 2. The controller can be oriented in any position, and meets the IP64/IP67 ratings for environmental protection against dust and water. However, the lo- cation should be carefully chosen to keep the controller as clean and dry as possible.
  • Page 11 EMC performance complies with applicable regulations; suggestions are presented in Appendix A. The 1268 controller contains ESD-sensitive components. Use appropri- ate precautions in connecting, disconnecting, and handling the controller. See installation suggestions in Appendix A for protecting the controller from ESD damage.

  • Page 12: Connections: Low Current

    2 — INSTALLATION & WIRING: Controller CONNECTIONS Low Current Connections Three low current connectors are built into the 1268 controller. They are located in a row on the top of the controller: J1 Logic connector J2 Speed Sensor connector J3 Programmer connector The 24-pin connector provides the logic control connections.

  • Page 13: Connections: High Current

    A 4-pin low power connector is provided for an optional programmer. A com- Rx Data J3-1 plete handheld programmer kit, including the appropriate connecting cable J3-2 with mating connector, can be ordered from Curtis: Tx Data J3-3 p/n 168961101 for the User Programmer (model 1311-1101) +15V...

  • Page 14: Wiring: Controller

    RX DATA J3-1 GROUND J2-4 J3-2 SPEED INPUT TX DATA J2-5 J3-3 SENSOR +15V +15V J2-6 J3-4 1268 CONTROLLER Fig. 3a Standard wiring configuration for Curtis 1268 controller, in an application with an EM brake. Curtis 1268 Manual, Rev. D...

  • Page 15: Fig. 3B: Standard Wiring Configuration

    RX DATA J3-1 GROUND J2-4 J3-2 SPEED INPUT TX DATA J2-5 J3-3 SENSOR +15V +15V J2-6 J3-4 1268 CONTROLLER Fig. 3b Standard wiring configuration for Curtis 1268 controller, in an application with the WalkAway function. ™ Curtis 1268 Manual, Rev. D...

  • Page 16: Wiring: Throttle

    EEC requirements. Thus, no additional fault protection is required on any throttle type used with the 1268 controller. If the throttle you are planning to use is not covered, contact the Curtis office nearest you.

  • Page 17: Fig. 6 Wiring For Its Throttle

    1.6mA from min to max throttle. The two wires are interchangeable. Fig. 6 Wiring for ITS throttle. Pot High input (Pin 13) Pot Low input (Pin 15) Note: ITS throttles can only be used with 1268 models that are specifi- cally designed for them. Curtis 1268 Manual, Rev. D...

  • Page 18: Wiring: Drivers

    Throttle WIRING: Drivers The 1268 controller provides four drivers (at Pins 17, 18, 19, 23) for the main contactor, brake light relay, reverse alarm, and aux contactor/relay. These four outputs are low-side drivers, designed to energize inductive coils or a piezo- electric reverse alarm.

  • Page 19: Wiring: External Led Output

    B+. The pedal interlock switch is connected to the throttle mecha- nism, thus guaranteeing zero controller output when the operator releases the throttle. This adds a safety feature to protect against throttle failures that could otherwise cause unintended controller output (vehicle motion). Curtis 1268 Manual, Rev. D...

  • Page 20: Contactor, Switches, And Other Hardware

    CONTACTOR, SWITCHES, and OTHER HARDWARE Main Contactor A main contactor is required for use with any 1268 controller. The main contac- tor allows the controller and motor to be disconnected from the battery. This provides a significant safety feature in that the battery power can be removed from the drive system if a controller or wiring fault is detected.

  • Page 21: Programmable Parameters

    Programming can be done with a 1313 handheld programmer or a 1314 PC Programming Station. The 1311 handheld programmer and the dis- continued 1307 handheld programmer are also fully compatible with the 1268 controller. See Appendix B for more information about the programmers.

  • Page 22: Field Brake Max

    DRV OVRCUR DIS PLUG C/L WALKAWAY C/L Brake Mapping Parameters BRAKE MIN (M1, M2, REV) BRAKE MAX (M1, M2, REV) BRAKE START (M1, M2, REV) BRAKE END (M1, M2, REV) BRAKE MAP (M1, M2, REV) Curtis 1268 Manual, Rev. D...

  • Page 23: Acceleration/Deceleration Parameters

    If the vehicle does not slow to the speed defined by (down a steep hill, for example) field braking FLD BRAKE SPD will not occur as the threshold will not be reached. Curtis 1268 Manual, Rev. D...
  • Page 24 EMB DELAY the EM brake driver turns off, causing the brake to engage—if it has not already been applied due to the vehicle having stopped or started to roll back. Curtis 1268 Manual, Rev. D...

  • Page 25: Speed Parameters

    The tachometer poles parameter configures the speed sensor, and should be set to the number of magnetic poles in the speed sensor magnet. TACHO POLES adjustable from 4 to 20; see speed sensor description (page 14) for information about sensor types. Curtis 1268 Manual, Rev. D...

  • Page 26: Throttle Parameters

    Controller output begins when the throttle is moved beyond THROTTLE 0% and continues to increase—following the curve defined by the THROTTLE MAP setting—as the throttle input increases, and reaches maximum output when the throttle input crosses the threshold. THROTTLE 100% Curtis 1268 Manual, Rev. D...

  • Page 27: Current Limit Parameters

    The motor force created from this function is intended to limit the vehicle’s rolling speed, but may not be sufficient to slow heavy vehicles on steep Curtis 1268 Manual, Rev. D...

  • Page 28: Brake Mapping Parameters

    This parameter can be set to allow the controller BRAKE MAX to use a higher braking power at higher speeds. Decreasing the value increases the braking torque the vehicle BRAKE END can produce at medium speeds. Curtis 1268 Manual, Rev. D...

  • Page 29: Fig. 8 Brake Map Structure

    “Brake Start.” The as the vehicle approaches a stop. braking force is typically set to decrease as the vehicle slows down. Curtis 1268 Manual, Rev. D...

  • Page 30: Field Mapping Parameters

    field current starts to increase from the FIELD MIN value. Care should be taken to ensure that high values do not FIELD MAP START move the motor’s operating characteristics outside its safe commutation area. Curtis 1268 Manual, Rev. D...

  • Page 31: Fig. 9 Field Map Structure

    (default setting, for wiring shown in Figure 3) = off FIELD DIR SWAP Field current flows from F2 » F1 in the Forward direction. = on FIELD DIR SWAP Field current flows from F1 » F2 in the Forward direction. Curtis 1268 Manual, Rev. D...

  • Page 32: Fault Parameters

    At this threshold voltage, the drive current will taper off until it reaches the controller’s internal threshold for safe operation. This will ensure proper operation of all electronics whenever the vehicle is driven. Curtis 1268 Manual, Rev. D...

  • Page 33: Warning Option

    LED (Pin 22) and the warning beep conditions during anti-rollback and overvoltage (Pin 19). is programmable from 0 to 7: WARNING OPTION EXTERNAL LED ANTI ROLLBACK OVERVOLTAGE SETTING OUTPUT BEEP BEEP flash flash flash flash solid solid solid solid Curtis 1268 Manual, Rev. D...

  • Page 34: Output Driver Parameters

    For example, a relay coil rated for 24V could be used in a 48V system if is set to 3 AUX HOLDING (48V * 0.35 = 16.8V), as 16.8V is well above typical dropout voltage. The Curtis 1268 Manual, Rev. D...

  • Page 35: Electromagnetic Brake Speed Check

    EM brake driver will not turn off until vehicle speed is detected as having reduced to the set EMB SPD VALUE EMB SPD VALUE is set below 1.0 mph, the EM brake driver will not turn off until the vehicle reaches rest. Curtis 1268 Manual, Rev. D...

  • Page 36: Driver Overcurrent Detection

    When the parameter is programmed On, overcurrent detection is disabled. This leaves the main contactor and auxiliary drivers unpro- tected from coil shorts and miswiring. However, it may be desirable to set the parameter On temporarily during EMI testing. Curtis 1268 Manual, Rev. D...

  • Page 37: Installation Checkout

    The motor should begin to turn in the selected direction. If it turns in the wrong direction, first verify the wiring to the forward and reverse switches. If the direction switch wiring is correct, turn off the controller, Curtis 1268 Manual, Rev. D...
  • Page 38 8. Verify that all options, such as static return to off (SRO), electromagnetic brake (or WalkAway ), and reverse signal are as desired. ™ 9. If you used a programmer, disconnect it when you have completed the checkout procedure, to minimize battery discharge. Curtis 1268 Manual, Rev. D...

  • Page 39: Tuning Guide

    5 — TUNING GUIDE TUNING GUIDE The 1268 controller is a very powerful vehicle control system. Its wide variety of adjustable parameters allow many aspects of vehicle performance to be opti- mized. This section provides explanations of what the major tuning parameters do and instructions on how to use these parameters to optimize the performance of your vehicle.
  • Page 40 Ensure that the Throttle % returns to 0% when the throttle is released and that no throttle fault appears in the Faults menu. step 11. Refer to Section 3, page 20, and set the parameter THROTTLE MAP for desired performance. Curtis 1268 Manual, Rev. D...

  • Page 41: Calibrating The Controller Speed Measurement

    (in either mph or km/h). Tuning the Controller to the Motor The 1268 controller has the flexibility to be tuned to nearly any separately excited motor from any manufacturer. The programmable parameters allow full control of the motor’s maximum armature current during driving and braking;...
  • Page 42 Operating the motor at lower field currents than specified will result in operation outside the motor’s safe commutation region and will cause arcing between the brushes and com- mutator, significantly reducing motor and brush life. Curtis 1268 Manual, Rev. D...
  • Page 43 The typical default field map settings are as follows. Further tuning of the field maps is described in procedures 5 , 7 , and 9 . Curtis 1268 Manual, Rev. D...

  • Page 44: Equalizing Loaded And Unloaded Vehicle Speed

    For high speeds, a lower is usually necessary to allow FIELD MIN the vehicle to achieve true closed loop speed control and not be limited by the field current. Skip to Step 5. Curtis 1268 Manual, Rev. D...

  • Page 45: Confirming Loaded Vehicle Speed On Downhill

    See brake mapping examples on page 41. step 3. Repeat the procedure for the Mode 2 forward speed and for reverse speed. Separate brake mapping parameters are provided for each speed ( M1 FWD SPEED M2 FWD SPEED REV SPEED Curtis 1268 Manual, Rev. D...

  • Page 46: Fine Tuning

    MAIN C/L precision-maneuvering mode to obtain comfortable vehicle response. Because are not mode-specific, you may need to re-tune Mode 1 THROTTLE MAP FIELD MAX if you make adjustments to these two parameters when tuning Mode 2. Curtis 1268 Manual, Rev. D...

  • Page 47: Response To Full Throttle Release

    Note: The setting of the brake mapping and parameters will also affect the DECEL feel of the vehicle deceleration during partial throttle releases. After completing procedure 7 for full throttle release, make sure the deceleration during partial throttle release is acceptable. Curtis 1268 Manual, Rev. D...
  • Page 48 5 — TUNING GUIDE Note: are percentages of BRAKE MIN BRAKE MAX REGEN C/L is a percentage of the range between BRAKE MAP BRAKE MIN BRAKE MAX Curtis 1268 Manual, Rev. D...

  • Page 49: Transitioning From Flat Ground To Downhill

    Note:To determine whether the controller’s armature current is at its set value during ramp climbing, read the Arm Current in the programmer’s Monitor menu. Curtis 1268 Manual, Rev. D...

  • Page 50: Bk Walkaway ™ Braking

    Note: This use of field braking is covered separately in Procedure bm . This procedure tunes the field braking parameters to provide additional braking at low speeds in situations (a) and (b). Curtis 1268 Manual, Rev. D...

  • Page 51: Bm Em Brake Operation

    FLD BRAKE SPD (even though the main contactor may still be closed) and is useful in prevent- ing the vehicle from continuing to roll forward. Additionally, if the controller Curtis 1268 Manual, Rev. D...
  • Page 52 EM brake timing is acceptable. To avoid unnecessarily abrupt stops, the parameters should be set so that when driving on flat ground the vehicle reaches rest before the EM brake is applied. Curtis 1268 Manual, Rev. D...

  • Page 53: Diagnostics And Troubleshooting

    6 — DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1268 controller provides diagnostics information to assist technicians in troubleshooting drive system problems. This information is displayed on the handheld programmer (or PC Programming Station), and it is also available in the form of fault codes issued by the controller’s built-in Status LED and the...
  • Page 54 Contactor driver or aux driver 1. Contactor or aux coil shorted. overcurrent. M- SHORTED Internal M- short to B-. 1. Controller defective. AUX RELAY DNC Aux relay did not close. 1. Aux relay missing or wire to coil open. Curtis 1268 Manual, Rev. D...
  • Page 55 This feature is designed to help service personnel identify intermittent faults when no programmer is available. These same fault codes will also be flashed by the external fault LED (connected to Pin 22), if one is included in the system. Curtis 1268 Manual, Rev. D...

  • Page 56: Maintenance

    7 — MAINTENANCE MAINTENANCE There are no user serviceable parts in the Curtis 1268 controller. No attempt should be made to open, repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty. It is recommended that the controller be kept clean and dry and that its diagnostics history file be checked and cleared periodically.

  • Page 57: Appendix A Vehicle Design Considerations

    Signals with high frequency content can produce significant emissions if con- nected to a large enough radiating area (created by long wires spaced far apart). Contactor drivers and the motor drive output from Curtis controllers can contribute to RF emissions. Both types of output are pulse width modulated square waves with fast rise and fall times that are rich in harmonics.
  • Page 58 field. This coupling can be reduced by placing the controller as far as possible from the noise source or by enclosing the controller in a metal box. Some Curtis controllers are enclosed by a heatsink that also provides shielding around the controller circuitry, while others are partially shielded or unshielded.
  • Page 59 ELECTROSTATIC DISCHARGE (ESD) Curtis PMC motor controllers contain ESD-sensitive components, and it is therefore necessary to protect them from ESD (electrostatic discharge) damage. Most of these control lines have protection for moderate ESD events, but must be protected from damage if higher levels exist in a particular application.

  • Page 60: Appendix B Programming Devices & Menus

    PROGRAMMING DEVICES & MENUS Curtis programmers provide programming, diagnostic, and test capabilities for the 1268 controller. The power for operating the programmer is supplied by the host controller via a 4-pin connector. When the programmer powers up, it gathers information from the controller.
  • Page 61 Troubleshooting Chart in Section 6. The other programmer menus are self-explanatory. Program Menu (not all items available on all controllers) The 1268’s programmable parameters are listed here in the order in which they are displayed by the programming device. M1 MAIN C/L Drive current limit in Mode 1.
  • Page 62 Field current during WalkAway operation. ™ KSI SRO ENABLE Keyswitch must be off at power-up (yes/no). DRV OVRCURR DIS Driver overcurrent detection disable (on/off ). FIELD DIR SWAP Swaps polarity of motor field output (on/off ). Curtis 1268 Manual, Rev. D...
  • Page 63 Keyswitch: on/off. FORWARD INPUT Forward switch: on/off. REVERSE INPUT Reverse switch: on/off. MODE SWITCH Mode switch: on/off. AUX CONTACTOR WalkAway relay or EM brake at pin 23: on/off. ™ MAIN DRIVER Main contactor driver: high/low. Curtis 1268 Manual, Rev. D...
  • Page 64 APPENDIX C: PARAMETER INDEX APPENDIX C PROGRAMMABLE PARAMETER INDEX The 1268 controller’s programmable parameters are listed below in alphabetical order (by programmer display name), with references provided to the parameter descriptions and to the appropriate Tuning Guide procedures. The parameters are described individually in Section 3. It is important also to read the tuning procedures in Section 5, as many parameters are highly interdependent with other parameters.
  • Page 65 APPENDIX A: EMC & ESD DESIGN CONSIDERATIONS APPENDIX D: SPECIFICATIONS APPENDIX D SPECIFICATIONS SPECIFICATIONS: 1268 CONTROLLER Nominal input voltage 36V or 48V PWM operating frequency 16 kHz Electrical isolation to heatsink 500 V ac (minimum) Logic enable and logic power input voltage (minimum) 16.8 V...

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