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Curtis 1220 Manual

Electric steering controller for brushed pm motor
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Manual
Model 1220
Electric Steering Controller
for Brushed PM Motor
Read Instructions Carefully!
Specifications 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.
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
53218 Rev C 11/2015

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  • Page 1 Specifications 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. 53218 Rev C 11/2015...

  • Page 3: Table Of Contents

    3. PROGRAMMABLE PARAMETERS ........10 Program Menu ..............11 4. MONITOR MENU ...............23 5. COMMISSIONING ..............27 6. DIAGNOSTICS AND TROUBLESHOOTING ....37 7. MAINTENANCE ..............41 Vehicle Design Considerations appendix a Programming Devices appendix b Specifications, 1220 Controller appendix c Curtis 1220 Manual, Rev. C...
  • Page 4 FIGURES fig. 1: Curtis 1220 controller ............. 1 fig. 2: Mounting dimensions, Curtis 1220 controller ......4 fig. 3a: Wiring diagram, using motor encoder for position feedback ... 6 fig. 3b: Wiring diagram, using analog pots for position feedback ..7 fig.

  • Page 5: Overview

    1 — OVERVIEW OVERVIEW The Curtis Model 1220 controller is designed to drive a brushed permanent magnet motor for electric power steering (EPS). The 1220 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.
  • Page 6 Unmatched Flexibility 3 Integrated hourmeter and diagnostic log functions. 3 Curtis 840 Spyglass can be connected to show traction and steering information such as BDI, hour meter, fault, traction speed, and steered wheel angle. 3 +5V low-power supply for input sensors, etc.
  • Page 7 3 Reverse polarity protection on battery connections. 3 Inputs protected against shorts to B+ and B-. 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.

  • Page 8: Installation And Wiring

    INSTALLATION AND WIRING MOUNTING THE CONTROLLER The 1220 controller can be oriented in any position, but the mounting location should be carefully chosen to keep the controller clean and dry. If a clean, dry mounting location cannot be found, a cover must be used to shield the controller from water and contaminants.

  • Page 9: High Current Connections

    Steer Motor Encoder Phase B Feedback Pot Low Position Analog 1 Steering Angle Output Command Analog 2 Command Pot Low Rx1 (from programmer) 4-pin Molex 39-28-8040 Tx1 (to programmer / 840) Fault Output 2-pin Molex Home Switch 39-28-8020 Curtis 1220 Manual, Rev. C...

  • Page 10: Controller Wiring

    Controller Wiring CONTROLLER WIRING As shown in the wiring diagrams (Figs. 3a, 3b), the 1220’s keyswitch power must go through the traction controller so that when the keyswitch is turned off both controllers turn off. The fault output (Pin J3-1) must be able to shut down the traction system in the case of a serious fault, in order to meet inter- national safety requirements.

  • Page 11: Fig. 3B: Wiring Diagram, Using Analog Pots For Position Feedback

    2 — INSTALLATION & WIRING: Controller Wiring These wiring diagrams (Figs. 3a, 3b) show generic applications and may not fully meet the requirements of your system. You may wish to contact your local Curtis representative to discuss your particular application. J1-4 Interlock Input PROGRAMMER...

  • Page 12: Input/Output Specifications

    Min HIGH threshold voltage +5V Supply (pin J1-7) This pin is the power supply connection to the Command Input Device and the Position Feedback Device. Command supply voltage +5 V ± 10% Maximum current draw 70 mA Curtis 1220 Manual, Rev. C...
  • Page 13 5 mA Programmer connections (J2 connector) The Curtis programmer plugs into the 4-pin connector, J2. Rx is the data input connection to/from the programmer. Input pull down resistance (to B- ground) 5 kΩ ± 10% Tx is the data input connection to/from the programmer.

  • Page 14: Programmable Parameters

    3 — PROGRAMMABLE PARAMETERS PROGRAMMABLE PARAMETERS The 1220 controller has a number of parameters that can be programmed using a Curtis 1313 handheld programmer or 1314 Programming Station. The pro- grammable parameters allow the steering performance to be customized to fit the needs of specific applications.

  • Page 15: Program Menu

    When the Redundant Input is programmed Off, only a single steer command device (the Command Input Device) is used and steer command redundancy is disabled. Command Analog 1 (primary) Command Analog 2 (redundant) Command Pot Low Command Analog Input Curtis 1220 Manual, Rev. C...

  • Page 16: Fig. 4 Command Signal Flow

    (from left to right in the diagram above) as: X = Command Analog Left and Y = -100% X = Command Analog Center and Y = 0% X = Command Analog Right and Y = 100%. Curtis 1220 Manual, Rev. C...

  • Page 17: Fig. 5 Steer Command Map

    Steer command map. Although any map shape can be set up, it is recommended that the map al- ways be set so that a Steer Command of zero % equals a Steer Command (deg) of zero. Curtis 1220 Manual, Rev. C...
  • Page 18 If encoder position feedback is used, an encoder and a home switch are required. The electrical requirements for the encoder are as shown. 360° electrical (1 cycle) > 66 μs Channel A Channel B 90° ±30° 180° ±18° Curtis 1220 Manual, Rev. C...

  • Page 19: Fig. 6 Position Feedback Signal Flow, With Analog Pot

    (from left to right in the diagram above) as: X = Position Left Stop and Y = Left Stop (deg) X = Position Center and Y = 0% X = Position Right Stop and Y = Right Stop (deg) Curtis 1220 Manual, Rev. C...

  • Page 20: Fig. 7: Position Feedback Signal Flow, With Encoder

    Home from Home Quadrature Decoder Encoder Filter B Steer Motor φ Encoder Phase B Swap Encoder Direction (Pin J1-9) Home Position Encoder Steps Center Offset (deg) Fig. 7 Position feedback signal flow, with motor encoder. Curtis 1220 Manual, Rev. C...
  • Page 21 Method 4 uses a Home switch that is On if the wheel is just on it and Off if the wheel is not on it. At the start of homing the wheel will move in the Curtis 1220 Manual, Rev. C...
  • Page 22 Shutdown” or “Hold then Shutdown” is triggered (see Table 4, Troubleshooting Chart). When one of these faults is detected, the Fault Steering Timeout sets a delay from when either of these fault actions is set to when the fault output turns off. Curtis 1220 Manual, Rev. C...
  • Page 23 When a 1313 programmer is connected to the traction controller, Steering Angle Output Interlock a Communication Lost fault (code 63) is issued on the 1220. If Steering Angle Output Interlock = On, the Steering Angle Output (pin J1-12) is fixed at 10V to limit the traction motor speed.
  • Page 24 When the motor overheats, the drive current is cut back until it reaches Cutback Gain the programmed Current Rating. The Cutback Gain determines how quickly this cutback will be initiated once the programmed Max Current Time has expired. A higher setting provides faster cutback. Curtis 1220 Manual, Rev. C...
  • Page 25 If the gain is set too high, you may experience oscillations as the controller tries to control velocity. If it is set too low, the motor may take a long time to approach the exact commanded velocity Curtis 1220 Manual, Rev. C...

  • Page 26: Fig. 8 Steering Sensitivity Map

    Yes / No When set to Yes, will reset all programmable parameters Restore Parameters to their factory default settings. Yes / No When set to Yes, will set the hourmeter to zero hours. Clear Hourmeter Curtis 1220 Manual, Rev. C...

  • Page 27: Monitor Menu

    —Motor Voltage —5V Out INPUTS and OUTPUTS ... . . p. 25 —Main Driver —Main Coil Feedback —Fault Output —Fault Output Feedback —Interlock Switch —Home Switch Curtis 1220 Manual, Rev. C...
  • Page 28 Flag indicating the Stop position has Stop Position Reached been reached. -2147483648 – 2147483648 Encoder counts from home position. Encoder Counts from Home 0 – 5.50 V Position feedback Analog 1 input voltage. Position Analog 1 Input Curtis 1220 Manual, Rev. C...
  • Page 29 If it does not match the Fault Output status, a fault is issured. Off / On Flag indicating the interlock switch status. Interlock Switch Off / On Flag indicating the home switch status. Home Switch Curtis 1220 Manual, Rev. C...
  • Page 30 Monitor Menu: CONTROLLER → Status DISPLAY VARIABLE RANGE DESCRIPTION Off / On Flag indicating the interlock status. Interlock Off / On Flag indicating the status of communcation Traction Controller between the steer controller and the traction Connected controller. Curtis 1220 Manual, Rev. C...

  • Page 31: Commissioning

    5 — COMMISSIONING COMMISSIONING The 1220 steer controller can be used in a variety of vehicles, which differ in characteristics and in their input and feedback devices. Before driving the ve- hicle, it is important that the commissioning procedures be carefully followed to ensure that the controller is set up to be compatible with your application.
  • Page 32 The procedures in the third section require the steer motor to turn, so the 1220 interlock (the steer interlock) must be set to On. The vehicle drive wheels continue to be jacked up off the ground to they can spin freely and steer freely from stop to stop.
  • Page 33 = 5%. Velocity Ki Verify that the 1220 interlock = Off (Monitor » Inputs & Outputs » Interlock Switch) and the traction controller interlock = Off. If either interlock is On, either change the interlock input to the controllers or adjust the Interlock Type parameter until the interlock variables are both Off.
  • Page 34 In vehicles where the steered wheel is in the back, these directions are reversed. Steering “right” (+) results in vehicle turning right. FRONT WHEEL DRIVE Forward direction of travel Steering “left” (-) results in vehicle turning right. REAR WHEEL DRIVE Curtis 1220 Manual, Rev. C...
  • Page 35 Off. Redundant Input Device Set the parameter to the type of input you will be using: Redundant Input Redundant Input = Single input only = Redundant input Curtis 1220 Manual, Rev. C...
  • Page 36 Command Analog 1 Input positions. setting must be above the maximum voltage Command Analog Fault Max seen on when steered to the maximum left or right Command Analog 1 Input positions. Curtis 1220 Manual, Rev. C...
  • Page 37 Position Feedback Device Setup (see pages 14–16) Manually enable the steer interlock, so that the 1220 will begin steering; the traction interlock can remain Off. Verify that the 1220 interlock is now On (Monitor » Inputs&Outputs »...
  • Page 38 Encoder Single Pulse Period = 60*10 /(Max Steer Motor RPM*Encoder PPR) should be > 66μs. Example: Max Steer Motor RPM = 3000. 60*10 /(3000*Encoder PPR) > 66 Encoder PPR < 303 Curtis 1220 Manual, Rev. C...
  • Page 39 All faults must be cleared before lowering the vehicle drive wheels to the ground. Use Section 6 for help in troubleshooting. Contact your Curtis customer sup- port engineer to resolve any remaining issues about faults before continuing.
  • Page 40 Drive the vehicle through a wide range of turning and speed scenarios, and adjust the Motor Control Tuning » Sensitivity Map » , and Low Speed Mid Speed parameters to create the desired sensitivity map. High Speed Curtis 1220 Manual, Rev. C...

  • Page 41: Diagnostics And Troubleshooting

    6 — DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS & TROUBLESHOOTING The 1220 controller detects a wide variety of fault conditions. Faults with the steering controller typically affect the traction controller as well, as shown in the troubleshooting chart. Faults are displayed on the handheld programmer. If you have a LED device attached to the Status LED driver (pin J1-1), the fault codes will be flashed by that device.

  • Page 42: Table 4 Troubleshooting Chart

    Stop. Close but it did not. 2. Internal relay tips oxidized. Hardware 1. Hardware error detected. Cycle KSI. Shutdown. Stop. Fault 2. Motor voltage out of range. 3. IIC communication failed. 4. Power MOSFETs shorted. Curtis 1220 Manual, Rev. C...
  • Page 43 3. Encoder Phase B on polarity encoder is open. Home Position 1. Home switch defective. Cycle KSI. Shutdown. Stop. Not Found 2. Mounting or wiring defective. Communication 1. Handshake with traction controller Cycle KSI. Shutdown Stop. Fault failed at startup. Curtis 1220 Manual, Rev. C...
  • Page 44 1. Incorrect parameter settings. Cycle KSI. Warning then Stop. Error 2. Position feedback device defective. Shutdown. 3. Steer motor defective. Parameter 1. Parameter settings are in conflict Cycle KSI. Shutdown. Stop. Conflict with each other. Curtis 1220 Manual, Rev. C...

  • Page 45: Maintenance

    7 — MAINTENANCE MAINTENANCE There are no user serviceable parts in Curtis 1220 controllers. 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 and connections be kept clean and dry and that the controller’s fault history file be checked and cleared periodically.

  • Page 46: 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 47 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 48 ELECTROSTATIC DISCHARGE (ESD) Curtis 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 49: Appendix B Programming Devices

    PROGRAMMING DEVICES Curtis programmers provide programming, diagnostic, and test capabilities for the 1220 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 50 APPENDIX C: SPECIFICATIONS APPENDIX C SPECIFICATIONS Table C-1 SPECIFICATIONS: 1220 CONTROLLERS Nominal input voltage 24 V PWM operating frequency 15.6 kHz Electrical isolation to heatsink 500 V (minimum) Storage ambient temperature range -40°C to 85°C (-40°F to 185°F) Operating ambient temperature range -40°C to 50°C (-40°F to 122°F)

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