Curtis MultiMode 1228 Manual
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Curtis MultiMode 1228 Manual

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Manual
Model 1228
MultiMode™ Motor Controller
Read Instructions Carefully!
Specifications are subject to change without notice.
© 2011 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
36149 Rev F 10/11

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Summary of Contents for Curtis MultiMode 1228

  • Page 1 Specifications are subject to change without notice. © 2011 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. 36149 Rev F 10/11...

  • Page 3: Table Of Contents

    Wiring: Applications with Seat Lift ........6 Wiring: Applications without Seat Lift .......8 Throttle Wiring ..............10 5kΩ, 3-wire potentiometer throttle......10 5V throttle ..............10 Curtis ET-XXX electronic throttle ......11 Speed limit pot............12 Switches and Other Hardware ...........12 Keyswitch..............12 Push switch ..............12 Brake release switch............13 Inhibit................13...
  • Page 4 Beginning the Setup Procedures ........31 Throttle ................31 Basic Vehicle Checkout............33 Determining Motor Resistance ..........33 5. VEHICLE PERFORMANCE ADJUSTMENT.......34 Setting the Maximum Speeds ..........34 Setting the Acceleration and Deceleration Rates ....34 Adjusting Load Compensation ..........37 Fine-Tuning the Vehicle’s Response Smoothness....38 Curtis 1228 Manual, Rev. F...
  • Page 5 Troubleshooting Chart ............45 8. MAINTENANCE ..............46 Vehicle Design Considerations Regarding APPENDIX A Electromagnetic Compatibility (EMC) and Electrostatic Discharge (ESD) .....A-1 Curtis WEEE & RoHS Statement .....B-1 APPENDIX B Programming Devices ........C-1 APPENDIX C Index to Programmable Parameters ....D-1 APPENDIX D Specifications............E-1...
  • Page 6 Wiring for 5KΩ, 3-wire potentiometer ........10 . 6: Wiring for 5V throttle ............11 . 7: Wiring for Curtis ET-XXX electronic throttle ......11 . 8: Wiring to inhibit operation during battery charging ....13 . 9: Effect of adjusting the neutral deadband parameter ....24 .

  • Page 7: Overview

    The 1228 controller is fully programmable by means of a Curtis pro- gramming device. Use of the programmer offers diagnostic and test capability as well as configuration flexibility.
  • Page 8 “Push-Too-Fast” feature guards against unpowered vehicle runaway by ✓ powering up and regulating motor voltage to limit vehicle speed ✓ Inhibit input disables the controller and puts the vehicle in a safe state during charging, etc. Curtis 1228 Manual, Rev. F...
  • Page 9 Thermally protected Reverse polarity protected (battery input) ✓ 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 the Curtis office nearest you.

  • Page 10: Installation And Wiring

    M4 × 20 mm (#8 × 0.75") screws. This will give 6 mm (0.25") of exposed screw, which can be increased according to the thickness of the mounting site. Fig. 2 Mounting 4.8 (0.19) dia., 2 plcs dimensions, Curtis 1228 controller. (3.60) (0.27) LOGIC PROG 6.8 (0.27)

  • Page 11: Connections: High Current

    A 4-pin low power connector is provided for the programmer. This connec- tor is also used to implement the seat lift feature. When you want to use the programmer, unplug the seat lift connector and plug in the programmer. Curtis 1228 Manual, Rev. F...

  • Page 12: Wiring: Applications With Seat Lift

    SEAT LIFT SWITCH BRAKE SEAT LIFT MOTOR N.C. optional switch operated by mechanical TRACTION brake release MOTOR BATTERY CHARGER CONNECTOR 2.4 kΩ, 0.5 W SEAT LIFT BATTERIES RELAY Fig. 3a Standard wiring configuration, Curtis 1228 controller. Curtis 1228 Manual, Rev. F...
  • Page 13 MOTOR N.C. optional switch operated by mechanical TRACTION brake release MOTOR BATTERY CHARGER CONNECTOR 2.4 kΩ, 0.5 W SEAT LIFT BATTERIES RELAY Fig. 3b Alternative wiring configuration, for low keyswitch current (≤ 9 A) applications. Curtis 1228 Manual, Rev. F...

  • Page 14: Wiring: Applications Without Seat Lift

    POT HIGH INHIBIT BRAKE TRACTION MOTOR optional switch operated by mechanical brake release BATTERY CHARGER CONNECTOR 2.4 kΩ, 0.5 W BATTERIES Fig. 4a Standard wiring configuration, Curtis 1228 controller, in applications with no seat lift. Curtis 1228 Manual, Rev. F...
  • Page 15 BRAKE TRACTION MOTOR optional switch operated by mechanical brake release BATTERY CHARGER CONNECTOR 2.4 kΩ, 0.5 W BATTERIES Fig. 4b Alternative wiring configuration, for low keyswitch current (≤ 9 A) applications, with no seat lift. Curtis 1228 Manual, Rev. F...

  • Page 16: Throttle Wiring

    Throttle Type parameter is programmed; see page 22. Wiring for the 3-wire pot, voltage throttle, and Curtis ET-XXX electronic throttle is described in the following text. If the throttle you are planning to use is not covered, contact the Curtis office nearest you.

  • Page 17: Curtis Et-Xxx Electronic Throttle

    5V throttles. Curtis ET-XXX Electronic Throttle The recommended wiring for the Curtis ET-XXX electronic throttle is shown in Figure 7. The ET-XXX throttle provides a single-ended 0–5V throttle signal and a signal indicating whether it is in forward or reverse. The controller must be programmed as a Type 4 throttle for use with the ET-XXX (see page 22).

  • Page 18: Speed Limit Pot

    The push switch must go from off to on while the vehicle is stopped; if the push switch is turned on while the vehicle is moving, the electromagnetic Curtis 1228 Manual, Rev. F...

  • Page 19: Brake Release Switch

    The recommended resistor—designed to limit driver current to 15 mA when active—is 2.4 kΩ, 0.5 W. Alternatively, an LED with a built-in resistor can be used; it should be rated for 24V or 36V operation, depending on the controller model. Curtis 1228 Manual, Rev. F...

  • Page 20: Battery Discharge Indicator

    A seat lift switch can be used to short Pins 1 and 3 of the 4-pin connector (J9), thus activating the throttle-controlled seat lift function. The mating connector for J9 is a 4-pin Molex Mini-Fit Jr., p/n 39-01-2045. Seat lift should not be turned on while the vehicle is moving. Curtis 1228 Manual, Rev. F...

  • Page 21: Programmable Parameters

    PROGRAMMABLE PARAMETERS The 1228 controller has a number of parameters that can be programmed by means of a Curtis programming device. These programmable parameters al- low the vehicle’s performance characteristics to be customized to best fit the needs of individual vehicle operators. For information on programmers, see Appendix C.
  • Page 22 Parameters Menu, see Section 6: Pro- Seat Lift Brake Faults grammer Menus. Fault Beep Other Parameters ....... p. 28 Seat Lift Virtual Seat Lift Beeper Solid BDI Full Voltage BDI Empty Voltage BDI Reset Voltage Sleep Delay Tremor Compensation Curtis 1228 Manual, Rev. F...

  • Page 23: Motor Parameters

    The minimum-speed forward acceleration rate is adjustable from 0.2 to 8.0 seconds. Acceleration rates under 0.5 second provide abrupt acceleration and should only be used under special circumstances. Curtis 1228 Manual, Rev. F...

  • Page 24: Maximum-Speed Reverse Acceleration Rate

    The soft start parameter is adjustable from 0% to 100%, with 100% providing a great deal of softening and 0% eliminating the feature. The trade- off in increasing the soft start value is that acceleration response may be slowed somewhat, especially at higher values. Curtis 1228 Manual, Rev. F...

  • Page 25: Braking Parameters

    The maximum-speed deceleration rate is adjustable from 0.2 to 4.0 seconds. Curtis 1228 Manual, Rev. F...

  • Page 26: Minimum-Speed Reverse Deceleration Rate

    60% speed at full throttle in Mode 1. Note: If a speed limit pot is not used in your application, see page 12. Curtis 1228 Manual, Rev. F...

  • Page 27: Minimum Speed, M1/M2

    Note: the vehicle must be manually pushed fast enough so that the motor voltage reaches approximately 15 V in order for the push feature to be activated. Curtis 1228 Manual, Rev. F...

  • Page 28: Ir Compensation

    = 5kΩ ✓ ✓ inverted single-ended pot; maximum speed = 0 single-ended voltage throttle; ✓ maximum speed = 5V inverted single-ended voltage throttle; ✓ maximum speed = 0 Requires resistor; see Figure 6, page 11. Curtis 1228 Manual, Rev. F...

  • Page 29: Throttle Autocalibration

    Curtis 1228 Manual, Rev. F...
  • Page 30 0.5 V 4.5 V 4.0 V 5 kΩ 0.4 V 4.6 V 4.2 V 7 kΩ 0.3 V 4.7 V 4.4 V Detailed guidelines for adjusting the throttle deadband parameter are presented in Section 4. Curtis 1228 Manual, Rev. F...

  • Page 31: Throttle Gain

    The throttle gain parameter can be set with values from 1.0 to 10.0. The throttle gain value is the ratio of the pot’s full 5kΩ to the resistance of the throttle’s range of travel (G = R ). A setting of 1.0 thus represents a travel Curtis 1228 Manual, Rev. F...

  • Page 32: Ramp Shape (Static Throttle Map)

    Six ramp shapes (20, 30, 40, 50, 60, and 70%) are shown as examples in Figure 11. Fig. 11 Ramp shape (throttle map) with maxi- RAMP SHAPE MAX. SPEED (100%) mum speed set at 100%. THROTTLE POSITION (percent) Curtis 1228 Manual, Rev. F...

  • Page 33: Fault Parameters

    (4) if the inhibit switch is activated while the vehicle is being driven. If HPD is programmed Off, this protection feature is disabled. Note: All DME scooter applications must have the HPD feature programmed On to satisfy the industry’s safety requirements. Curtis 1228 Manual, Rev. F...

  • Page 34: Brake Faults

    (i.e., sets the brake), and operates in Mode 1, regardless of mode switch position. The seat lift switch connector plugs into J9 (the 4-pin connector). The controller transitions from traction mode to seat lift mode when the seat lift switch is closed. Curtis 1228 Manual, Rev. F...

  • Page 35: Virtual Seat Lift

    The BDI empty voltage parameter sets the battery voltage considered to be a 0% state-of-charge; when the battery pack remains under this voltage consis- tently, the BDI will read 0% state of charge. It is typically set to about 85% of BDI full voltage. Curtis 1228 Manual, Rev. F...

  • Page 36: Bdi Reset Voltage

    Although designed primarily to help end users with hand tremor prob- lems, this parameter can be used more generally to smooth out overall vehicle responsiveness for steadier driving. Curtis 1228 Manual, Rev. F...

  • Page 37: Initial Setup

    THRTL DEADBAND If you are using a wigwag throttle, you should center it before proceeding with the throttle tuning procedures. Instructions for wigwag throttle centering (using the Throttle Autocalibration parameter) are presented on page 23. Curtis 1228 Manual, Rev. F...
  • Page 38 Select a direction and operate the throttle. The motor should begin to turn in the selected direction. If it does not, verify the wiring to the throttle and motor. The motor should run proportionally faster with increasing throttle. If not, refer to Section 7. Curtis 1228 Manual, Rev. F...

  • Page 39: Basic Vehicle Checkout

    Motor R value that MOTOR R was displayed in the Monitor Menu. 4-h. Before moving on to Section 5, Vehicle Performance Adjustment, be sure to set the back to its default setting. MAIN C/L Curtis 1228 Manual, Rev. F...

  • Page 40: Vehicle Performance Adjustment

    This is accomplished by defining ac- celeration/deceleration rates at each end of the speed limit pot’s range. The Curtis 1228 Manual, Rev. F...
  • Page 41 Reverse acceleration and deceleration rates 6-e. First, set the . Select Mode 1 and set the speed limit pot to REV ACCEL MIN its minimum speed position. For low speed testing, we suggest that you Curtis 1228 Manual, Rev. F...
  • Page 42 E STOP forward deceleration rate, replacing the regular forward deceleration rate. 6-k. Drive fast and suddenly release the throttle. You will experience the decel- eration behavior determined by the forward deceleration rate. Curtis 1228 Manual, Rev. F...

  • Page 43: Adjusting Load Compensation

    7-d. If the vehicle is still moving on a modest ramp when the brake gets set, is set too low. IR COMP COEFF 7-e. If the vehicle speed varies dramatically when cresting a hill, IR COMP COEFF is most likely set too low. Curtis 1228 Manual, Rev. F...

  • Page 44: Fine-Tuning The Vehicle's Response Smoothness

    The tremor compensation function somewhat overlaps the gear softening functions. However, the tremor compensation function is active all the time, while the two gear softening functions are active only during a gear slack transition, i.e., a torque direction reversal. Curtis 1228 Manual, Rev. F...
  • Page 45 3 or up to 5 as the final piece of tuning. Tremor compensation is most noticeable when the throttle is moved quickly from full to small (but non-neutral) values. The function is bypassed in the neutral state to ensure responsive linear deceleration when the driver commands a stop. Curtis 1228 Manual, Rev. F...

  • Page 46: Programmer Menus

    6 — PROGRAMMER MENUS: Parameters Menu PROGRAMMER MENUS The universal Curtis programming devices allow you to program, test, and diagnose Curtis programmable controllers. For information about the program- mers, see Appendix C. The 1228’s programmable parameters are listed below in the order in which they are displayed by the programming device.
  • Page 47 Type 0: wigwag (5kΩ pots or 5V throttles) Type 1: inverted wigwag (5kΩ pots or 5V throttles) Type 2: single-ended pots (0–5kΩ) Type 3: inverted single-ended pots (5kΩ–0) Type 4: single-ended voltage throttles (0–5V) Type 5: inverted single-ended voltage throttles (5V–0). Curtis 1228 Manual, Rev. F...

  • Page 48: 1228 Monitor Menu

    Capacitor bank voltage < minimum operating voltage PROC/WIRING FAULT HPD fault present >10 seconds SPD LIMIT POT FAULT Speed limit pot input voltage out of range THERMAL CUTBACK Cutback, due to over-/under-temperature THROTTLE FAULT 1 Throttle input voltage out of range Curtis 1228 Manual, Rev. F...

  • Page 49: Diagnostics And Troubleshooting

    ( 1 , 4 ) ( 1 , 4 ) ( 1 , 4 ) The codes are listed in Table 2. Refer to the troubleshooting chart (Table 3) for suggestions about possible causes of the various faults. Curtis 1228 Manual, Rev. F...

  • Page 50: Table 2 Status Led Fault Codes

    † = Must use programmer to clear, as follows: select Parameters Menu, alter data value of any parameter, cycle keyswitch. : Only one fault is indicated at a time, and faults are not queued up. NOTE Curtis 1228 Manual, Rev. F...

  • Page 51: Troubleshooting Chart

    1. EEPROM failure or fault. 2. Short in motor or in motor wiring. 3. Controller failure. * * Jack up vehicle and retest to confirm diagnosis. Clean connections, inspect system wiring, and retest. Curtis 1228 Manual, Rev. F...

  • Page 52: Maintenance

    8 — MAINTENANCE MAINTENANCE There are no user serviceable parts in the Curtis 1228 controller. No attempt should be made to open, repair, or otherwise modify the controller. Do- ing so may damage the controller and will void the warranty. However, it is recommended that the controller’s fault history file be checked and cleared...

  • Page 53: Electromagnetic Compatibility (Emc)

    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 54 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 55 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 56 The requirement to mark equipment with the WEEE symbol (the crossed-out wheeled bin) went into effect as of August 13, 2005. As of this date, Curtis In- struments began the process of marking all products that fall within scope of this directive with the WEEE symbol, as shown opposite.
  • Page 57 Curtis firmly believes that the operating environments, safety requirements, and reliability levels required of automotive electronics are directly analogous to that of our speed controller products. As such, Curtis will not be switching to a lead-free solder process until lead-free solder pastes and techniques are available that meet the requirements of the RoHS study groups and ELV Automotive In- dustry bodies.

  • Page 58: Appendix C Programming Devices

    APPENDIX C: PROGRAMMING DEVICES APPENDIX C PROGRAMMING DEVICES Curtis programmers provide programming, diagnostic, and test capabilities for the 1228 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 59 — page 30 OFF/ON — page 29 Main C/L min value depends on model: 20 for 1228-24XX; 34 for 1228-25XX & -29XX; and 30 for 1228-34XX. Throttle types: 0=wigwag, 1=inverted wigwag, 2=0–5kΩ, 3=5kΩ–0, 4=0-5V, 5=5V–0. Curtis 1228 Manual, Rev. F...

  • Page 60: Appendix E Specifications

    MODEL VOLTAGE RATING RATING RATING @ 20 AMPS CUTBACK CUTOFF NUMBER (volts) (amps) (amps) (amps) (volts) (volts) (volts) 1228-24XX 0.45 0.15 1228-25XX 0.15 1228-29XX 1228-34XX 0.30 Actual value of 1-minute rating depends on MOSFET heating. Curtis 1228 Manual, Rev. F...

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