HPEVS Curtis 1239 E Electrical Schematics And Documentation

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620 Magnolia Ave

Suite B

Ontario, CA 91762

(909) 923-1973

Electrical Schematics and

Documentation

FOR CURTIS 1239 "E" VERSION

SOFTWARE VERSIONS 5.32

CONTROLLERS

AND HIGHER

FOR SINGLE AND DUAL MOTOR

APPLICATIONS

REVISION: A

Date 6/09/2017

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Page 1 620 Magnolia Ave Suite B Ontario, CA 91762 (909) 923-1973 Electrical Schematics and Documentation FOR CURTIS 1239 “E” VERSION SOFTWARE VERSIONS 5.32 CONTROLLERS AND HIGHER FOR SINGLE AND DUAL MOTOR APPLICATIONS REVISION: A Date 6/09/2017...
Page 2: Table Of Contents
Table of Contents Quick Start Electrical Schematics……………………………………….…..……….………………..………3 Generic Full Schematics 1239 “E” Controllers………………………..…………….…………..…………8 Throttle Configuration….……..……………….………..…………….……………………………….…………13 Type 1 Electronic without switch.………………………………..………………………………..14 Type 1 Curtis Electronic Throttle Model ET-126 or ET-134……..……………...…………15 Type 2 2-Wire Pot..……………………………………………………………..……………..………..16 Type 3 3-Wire Pot……………………………………………………………..………………..……….17 Type 3 Curtis PB-8 Throttle Assembly……………………………..…………………………….18 Type 3 Curtis Electronic Model ET-126 or ET-134 with switch………………..………..19 Type 4 3-Wire Wigwag………………………………………………………..………………………..20 Throttle Interlock Connection………………….…..……………..………….……………..………….……..21...
Page 3: Quick Start Electrical Schematics
QUICK START GENERIC ELECTRICAL SCHEMATICS 1239 “E” CONTROLLERS The following quick start electrical schematics for both single and dual motor configurations have been generated to assist in quickly getting the drive system connected and running.
Page 4 (individually and collectively “HPEVS”), and contains highly proprietary, confidential, and trade secret information of HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing.
Page 5 Quick Start Electrical Schematic Generic Software Pin Out Specific for 1239 "E" Controllers Single Motor or Primary in Dual Motor Applications Pin # Name Function Terminations Wire color Detailed Description Keyswitch_Input Blue Keyswitch input. Provides logic power for the controller and power for the coil drivers.
Page 6 (individually and collectively “HPEVS”), and contains highly proprietary, confidential, and trade secret information of HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing.
Page 7 Quick Start Electrical Schematic Generic Software Pin Out Specific for 1239 "E" Secondary Controller in Dual Motor Applications Pin # Name Function Terminations Wire color Detailed Description Keyswitch input. Provides logic power for the controller Keyswitch_Input Blue and power for the coil drivers. Connect to primary harness at the Blue KSI wire.
Page 8: Generic Full Schematics 1239 "E" Controllers
GENERIC FULL ELECTRICAL SCHEMATICS 1239 “E” CONTROLLERS...
Page 9 “HPEVS”), and contains highly proprietary, confidential, and trade secret information of HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by HPEVS (b) to return this drawing...
Page 10 Generic Software 538 Switch Pin Out Specific for 1239 Controller Single Motor or Primary in Dual Motor Applications Pin # Name Function Terminations Wire color Detailed Description Keyswitch input. Provides logic power for the controller and power Keyswitch_Input Blue for the coil drivers. Prop.
Page 11 NOTICE: This drawing is the property of Hi Performance Electric Vehicle Systems Inc., and/or its REVISIONS subsidiaries and affiliates (individually and collectively “HPEVS”), and contains highly proprietary, confidential, and trade secret information of HPEVS. The recipient of this drawing agrees (a) to use the DESCRIPTION APPROVED information contained herein for the purpose for which it was furnished by HPEVS (b) to return this DUAL MOTOR –...
Page 12 Generic Software Switch Pin Out Specific for 1239 Controller. Secondary Controller in Dual Motor Applications Pin # Name Function Terminations Wire color Detailed Description Keyswitch input. Provides logic power for the controller and power for the coil drivers. Connect to primary Keyswitch_Input Blue harness at the Blue KSI wire.
Page 13: Throttle Configuration
THROTTLE CONFIGURATION Depending on the type of throttle used for the application, the different types of throttle configurations are listed within the table below. Electrical schematics are also included within the following pages. THROTTLE CONFIGURATION TYPE ELECTRONIC without SWITCH CURTIS ET-126/ET-134 ELECTRONIC TYPE 1 THROTTLE ASSEMBLY without SWITCH 2 WIRE with SWITCH 0-5k Ω...
Page 14: Type 1 Electronic Without Switch
HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the INITIAL RELEASE 1/22/2013 purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing. TYPE 1...
Page 16: Type 2 2-Wire Pot
HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the INITIAL RELEASE 1/22/2013 purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing. REVISION...
Page 17: Type 3 3-Wire Pot
HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the INITIAL RELEASE 1/22/2013 purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing. REVISION...
Page 19: Type 3 Curtis Electronic Model Et-126 Or Et-134 With Switch
HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing.
Page 21: Throttle Interlock Connection
THROTTLE INTERLOCK CONNECTION The throttle interlock connection is required for both 2 and 3 wire throttle pot assemblies. The Green wire is connected to the Normally Closed tab. The red/blue wire is connected to the common tab. See picture below. NOTE: when the throttle IS ENGAGED the interlock switch is released to its NORMAL position (switch not activated) thus completing the circuit since its green wire is connected to the normally closed (NC) connection.
Page 22: Brake Input Configuration
BRAKE INPUT CONFIGURATION Depending on the type of brake input used for the application, the different types of brake input configurations are listed in the table below. Electrical schematics are also included within the following pages. BRAKE INPUT CONFIGURATION TYPE NO BRAKE POT INSTALLED TYPE 0 PRESSURE TRANSDUCER/...
Page 23: Type 1 Pressure Transducer Or Electronic Or 3-Wire Pot
HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the INITIAL RELEASE 2/19/2013 purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing. BLACK/ BLUE (BLACK 0N...
Page 24: Type 2 2-Wire Pot
HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the INITIAL RELEASE 2/19/2013 purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing. TYPE 2...
Page 25: Optional Brake Light Configurations
OPTIONAL ACTIVE BRAKE LIGHT CONFIGURATIONS These optional brake light configurations are used to activate the brake lights during regenerative braking or when the vehicle brakes are applied. Based on the brake type configuration that is being utilized in the application, use one of the following wiring configurations.
Page 26 INITIAL RELEASE 2/19/2013 purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing. ACTIVE BRAKE LIGHT CONFIGURATION FOR ALL BRAKE TYPES (1-2) 1239 "E"...
Page 27 HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the INITIAL RELEASE 2/19/2013 purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing. FOR BRAKE TYPE 3 1239 "E"...
Page 28 HPEVS. The recipient of this drawing agrees (a) to use the information contained herein for the INITIAL RELEASE 2/19/2013 purpose for which it was furnished by HPEVS (b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing. FOR BRAKE TYPE 3 CONFIGURATION 1239 “E”...
Page 29: Program Entries (Parameters)
Program Entries Generic 532 (Parameters) Notes Level 1 Parameter Level 2 Parameter Units Parameter Range Default Setting User Settings Speed Settings Forward Speed 200 to 8500 6500 Defines the maximum requested motor rpm at full throttle with forward selected. Reverse Speed 200 to 8500 6500 Defines the maximum requested motor rpm at full throttle with reverse selected.
Page 30 Notes Level 1 Parameter Level 2 Parameter Units Parameter Range Default Setting Idle Setup Idle Enable On/Off on = motor idle will be turned on Enables clutch switch so that clutch needs to be depressed to start vehicle Clutch Start Enable On/Off Idle Speed 300 to 1000...
Page 31 Notes Level 1 Parameter Level 2 Parameter Units Parameter Range Default Setting Dual Drive Based on using This parameter turns dual drive off or on. Turn on for a dual motor. Dual Drive Mode On/Off either single motor or dual motor Time alloted for the secondary controller(s) to respond to the primary controller Response Timeout 50 to 1000...
Page 32: Additional Notes
ADDITIONAL NOTES Setup for Type 4 WigWag Throttle 1: Using a handheld Programmer or the 1314 Programming Station, Go to "Monitor", then "Inputs" and note at the Throttle Pot Voltage reading with the throttle in the neutral, full forward and full reverse positions.
Page 33: Monitor Items
Generic 532 Software Monitor Items Notes Level 1 Parameter Level 2 Parameter Units Parameter Range Dual Drive On = A secondary controller has been detected in a dual Dual Drive State On/Off drive system CAN Communication On = BMS is communicating to the controller through the BMS Communicating On/Off CAN Bus...
Page 34: Orion Bms Information
ORION BATTERY MANAGEMENT SYSTEM (BMS) The Orion BMS is a full featured lithium ion battery management system that is specifically designed to meet the tough requirements of protecting and managing battery packs for electric vehicles. We have incorporated the Orion BMS into our software packages and strongly suggest using their BMS to protect your investment. Wiring Diagram: The wiring diagrams for both the Orion BMS and Orion BMS Jr.
Page 35 warranty and some incorrect wiring may pose a personal safety risk or fire risk from energy from the battery pack. Please see the section “Verifying the wiring” for methods of testing to ensure the voltage taps are wired properly. Immediately disconnect the Orion BMS from cells if it is incorrectly wired. Leaving the Orion BMS connected to cells when incorrectly wired may drain incorrectly wired cells, even when the unit is turned off which may permanently damage connected cells.
Page 36: Orion Bms Byte Structure
Orion BMS Byte Structure From HPEVS Orion BMS Custom Messages for use with HPEVS ADDRESS ID 0x300 0x301 Length in bytes Byte0 Low Cell Voltage High Pack SOC Byte1 Low Cell Voltage High Temperature Byte2 High Cell Voltage High Byte3...
Page 37: Fault Codes
Generic Software "E" Controller Faults PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) External short of phase U, V, or W Set: Phase current exceeded Controller Overcurrent motor connections the current measurement 2) Motor parameters are mis-tuned limit ShutdownMotor;...
Page 38 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) See Monitor menu » Controller: Set: Heatsink temperature Controller Severe Overtemp Temperature. above +95°C. ShutdownMotor; 2) Controller is operating in an Clear: Bring heatsink ShutdownMainContactor; extreme environment. temperature ShutdownEMBrake;...
Page 39 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) Normal operation. Fault shows that Set: Capacitor bank voltage the batteries need recharging. dropped below the Controller performance is limited at Undervoltage limit with the this voltage. FET bridge enabled Clear: Bring capacitor voltage 2) Battery parameters are misadjusted 3) Non-controller system drain on...
Page 40 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1. External load impedance on Digital Set: Digital Output 6 (pin 19) Output 6 driver (pin 19) is too low. current exceeded 15 mA. Digital Out 6 Overcurrent Clear: Remedy the overcurrent Digital Output 6 driver cause and use the VCL will not turn on.
Page 41 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) Open or short on driver load Set: Driver 1 (pin 6) is either 2) Dirty connector pins open or shorted. This fault can 3) Bad crimps or faulty wiring be set only when Main Enable = OFF Clear: Correct open or short...
Page 42 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) Open or short on driver load. Set: Driver 3 (pin 4) is either Coil3 Driver Open/Short 2) Dirty connector pins. open or shorted. ShutdownDriver3. Clear: Correct open or short, 3) Bad crimps or faulty wiring.
Page 43 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Set: Just prior to the main 1) Main contactor tips are welded Main Contactor Welded closed contactor closing, the 2) Motor phase U or V is disconnected capacitor bank voltage (B+ ShutdownMotor;...
Page 44 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) See Monitor Menu >> Inputs: Pot2 Set: Pot2 wiper (pin 17) voltage is higher than the high 2) Pot2 wiper voltage too high fault threshold (can be changed with the VCL function Setup_Pot_Faults() ) Clear: Bring Pot2 wiper voltage Pot2 Wiper High...
Page 46 Software License Violation the controller the controller. Clear: Contact HPEVS 1) No power to secondary controller. Set: Secondary controller not 2) Broken wire in the CAN BUS wiring. powered. Broken wire on 3) Faulty secondary controller.
Page 47 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) CAN Bus wire/connector broken. Set: CAN Bus communication 2) Power to the enGage VII has been failure from the BMS to the lost controller Clear: Check CAN Bus wiring E7 COMM Fault for broken wires and connectors.
Page 48 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) VCL code encountered a runtime Set: Runtime VCL code error VCL error condition VCL Run Time Error 2) See Monitor Menu >> Controller: Clear: Edit VCL application ShutdownMotor; VCL Error Module and VCL Error.
Page 49 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) Internal controller fault. Set: Internal controller fault OS General detected. ShutdownMotor; Clear: Cycle KSI. ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake; ShutdownPump. 1) Time between CAN PDO messages Set: Time between CAN PDO received exceeded the PDO Timeout messages received exceeded...
Page 50 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Supervisor Fault Set: Mismatched redundant 1) The Supervisor has detected a mismatch in redundant readings. readings; ShutdownMotor; 2) Internal damage to Supervisor damaged Supervisor; illegal ShutdownMainContactor; microprocessor. switch inputs. ShutdownEMBrake;...
Page 51 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) Internal controller fault in the Set: Internal controller fault voltage supply for the driver circuits. detected. Clear: Cycle KSI. Driver Supply Fault ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump. 1) Motor speed was detected not Set: With Control Mode Select following the commanded speed...
Page 52 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1.) Motor characterization failed Set: Motor characterization during characterization process. See failed during the motor Monitormenu » Controller: Motor characterization process. Characterization Error for cause: Correct fault; cycle KSI. Clear: 0=none Notes:...
Page 53 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) Encoder Steps parameter does not Set: Motor lost IFO control and Encoder Steps Count Fault match the actual motor encoder. accelerated ShutdownMotor; without throttle command. ShutdownMainContactor; Clear: Ensure the Encoder ShutdownEMBrake;...
Page 54 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) Vehicle movement sensed after Set: After the EM Brake was the EM Brake has been commanded to commanded to set and time EM Brake Failed to Set set. has elapsed to allow the brake ShutdownEMBrake;...
Page 55 PROGRAMMER LCD DISPLAY Code POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1) Dual Motor Enable parameter set Set: When the Dual Drive On and Control Mode Select software is enabled, the parameter not set to 1 (Speed Mode controller must be set to Express) or 2 (Speed Mode).
Page 56: Glossary Of Terms
GLOSSARY OF TERMS 1. Accel Rate: sets the rate (in seconds) at which the motor torque increases to full when full throttle is applied. Larger values represent slower response. 2. Acuity: Battery Monitoring System from Curtis Instruments. 3. Amphour Capacity: Amphour capacity of battery pack based on Amphour rating of battery. 4.
Page 57 15. Descent Control: By using a pushbutton switch the downhill speed of the vehicle can be controlled. 16. EncA & B: two signals from the encoder for which the controller determines direction of rotation and speed of the motor. 17. enGage VII: a display manufactured by Curtis Instruments that is microprocessor based, CAN compatible instrument with full Input/output capability.