Curtis Instruments F Series User manual

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Specications are subject to change without notice.
© 2020 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. 53234, RevA August 2020
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
Manual
F Series Motor Controller
With VCL
For Controllers: AC F4-A Model
» Software Device Profile: 2.4.x.x «

Curtis AC F4-A Motor Controller – August 2020
pg. ii
CHAPTERS
1: OVERVIEW ...................................................................................................................................... 1
HOW TO USE THIS MANUAL .......................................................................................................... 2
GETTING THE MOST OUT OF YOUR CURTIS CONTROLLER ............................................................. 2
2: INSTALLATION AND WIRING ............................................................................................................ 3
PHYSICALLY MOUNTING THE CONTROLLER................................................................................... 3
PRECAUTIONS .............................................................................................................................. 4
HIGH CURRENT CONNECTIONS ..................................................................................................... 4
LOW CURRENT CONNECTIONS...................................................................................................... 6
ROTOR POSITION FEEDBACK (PINS 18, 26, 31, 32) ................................................................. 7
CANBUS (PINS 21, 34 AND 28, 29).......................................................................................... 7
ALL OTHER LOW POWER WIRING............................................................................................ 7
PROTECTED VOLTAGES........................................................................................................... 8
CONTROLLER INPUTS AND OUTPUTS...................................................................................... 9
CONTROLLER WIRING DIAGRAM (EXAMPLES) ........................................................................ 10
LOW CURRENT 35-PIN CONNECTOR ELECTRICAL SPECIFICATIONS ....................................... 13
DIGITAL (SWITCH) INPUTS ..................................................................................................... 13
ANALOG INPUTS.................................................................................................................... 15
POTENTIOMETER INPUTS WITH DYNAMIC TESTING................................................................ 16
PWM AND DIGITAL DRIVERS .................................................................................................. 17
POWER SUPPLY OUTPUTS ..................................................................................................... 19
KEYSWITCH AND COIL SUPPLY .............................................................................................. 20
CAN PORTS........................................................................................................................... 21
MOTOR POSITION SENSOR INPUTS ....................................................................................... 22
MOTOR TEMPERATURE INPUT ............................................................................................... 24
TABLE OF CONTENTS

Curtis AC F4-A Motor Controller – August 2020 pg. iii
TABLE OF CONTENTS cont’d
3: APPLICATION-SPECIFIC FEATURES................................................................................................. 25
MOTOR SPEED CONSTRAINTS ..................................................................................................... 25
VOLTAGE LIMITS .......................................................................................................................... 26
OVER-VOLTAGE REGION......................................................................................................... 27
SEVERE OVER-VOLTAGE REGION............................................................................................ 27
UNDER-VOLTAGE REGION ...................................................................................................... 27
OUTPUT-DISABLED REGION................................................................................................... 28
BROWNOUT VOLTAGE ............................................................................................................ 28
BATTERY DISCHARGE INDICATOR................................................................................................. 28
4: PROGRAMMABLE PARAMETERS .................................................................................................... 29
PROGRAMMABLE PARAMETERS .................................................................................................. 29
PROGRAMMING MENUS............................................................................................................... 29
PARAMETER CHANGE FAULTS [PCF]............................................................................................. 29
MONITOR VARIABLES WITHIN PARAMETER MENUS ...................................................................... 29
PROGRAMMING TOOLS................................................................................................................ 29
MENU CHART FORMAT ................................................................................................................ 30
TERMINOLOGY ............................................................................................................................ 30
SDO WRITE MESSAGE.................................................................................................................. 32
PARAMETER MENUS.................................................................................................................... 33
SPEED MODE EXPRESS ......................................................................................................... 40
SPEED MODE ........................................................................................................................ 41
APPLICATION SETUP.................................................................................................................... 48
CONTROLLER SETUP ................................................................................................................... 85
AC MOTOR SETUP MENU............................................................................................................ 109

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TABLE OF CONTENTS cont’d
5: SYSTEM MONITOR........................................................................................................................ 116
6: COMMISSIONING .......................................................................................................................... 127
INITIAL SETUP ............................................................................................................................ 127
TO BEGIN ............................................................................................................................. 128
CONTROL MODE SELECTION ................................................................................................ 128
PARAMETER SETTINGS – METHOD OVERVIEW...................................................................... 128
AC TRACTION MOTOR SETUP GUIDE..................................................................................... 129
CONTROLLER SETUP GUIDE ................................................................................................. 131
TRACTION THROTTLE SETUP................................................................................................ 133
VOLTAGE THROTTLE ............................................................................................................. 136
AUTOMATED ACIM (MOTOR) CHARACTERIZATION PROCEDURE ................................................... 142
TRACTION SYSTEMS................................................................................................................... 143
TUNING GUIDE............................................................................................................................ 147
SELECTING THE CONTROL MODE ......................................................................................... 147
0 − SPEED MODE EXPRESS TUNING..................................................................................... 147
1 − SPEED MODE TUNING .................................................................................................... 148
OTHER PARAMETER TUNING................................................................................................. 149
SETTING UP THE HYDRAULIC SYSTEM ........................................................................................ 150
HYDRAULIC LIFT AND LOWER COMMAND INPUTS....................................................................... 150
LIFT & LOWER SWITCH INPUTS ............................................................................................ 151
LIFT SWITCH INPUT, WITH A PROPORTIONAL LOWERING VALVE............................................. 153
7: DIAGNOSTICS AND TROUBLESHOOTING........................................................................................ 155
THE DIAGNOSTICS PROCESS ...................................................................................................... 155
TROUBLESHOOTING CHART INDEX.............................................................................................. 160
FAULT ACTIONS .......................................................................................................................... 164
8: MAINTENANCE ............................................................................................................................. 183
CLEANING................................................................................................................................... 183
FAULT HISTORY........................................................................................................................... 183

TABLE OF CONTENTS cont’d
Curtis AC F4-A Motor Controller – August 2020 pg. v
APPENDIX A...................................................................................................................................... 184
CANOPEN PDO MAPPING OBJECT DESCRIPTION......................................................................... 184
EXAMPLE FOR RPDO MAPPING WITH THE CIT CIT PROGRAMMER ............................................... 186
EXAMPLE FOR TPDO MAPPING WITH THE PROGRAMMER............................................................ 188
EXAMPLE FOR RPDO MAPPING WITH SDO WRITES...................................................................... 189
APPENDIX B ..................................................................................................................................... 191
ELECTROMAGNETIC COMPATIBILITY (EMC) ................................................................................. 191
ELECTROSTATIC DISCHARGE (ESD) IMMUNITY ............................................................................ 192
DECOMMISSIONING AND RECYCLING THE CONTROLLER............................................................. 192
APPENDIX C ..................................................................................................................................... 193
EN 13849 COMPLIANCE ............................................................................................................. 193
APPENDIX D ..................................................................................................................................... 195
CURTIS INTEGRATED TOOLKITTM.................................................................................................. 195
CREATING A PROJECT WITH A NEW F-SERIES CONTROLLER................................................. 197
VEHICLE CAN-PORT WIRING........................................................................................................ 204
APPENDIX E...................................................................................................................................... 205
SPECIFICATIONS: CONTROLLER .................................................................................................. 205

Curtis AC F4-A Motor Controller – August 2020
pg. vi
TABLES
TABLE 1: HIGH POWER CONNECTIONS................................................................................................ 4
TABLE 2: THE AMPSEAL CONNECTOR COMPONENTS & PART NUMBERS............................................. 6
TABLE 3: AMPSEAL CONNECTIONS PROTECTED VOLTAGES ................................................................ 8
TABLE 4: LOGIC AND LOW-CURRENT CONNECTIONS .......................................................................... 9
TABLE 5: SWITCH (DIGITAL) INPUTS ELECTRICAL SPECIFICATIONS..................................................... 13
TABLE 6: ANALOG INPUTS ELECTRICAL SPECIFICATIONS ................................................................... 15
TABLE 7: POTENTIOMETER INPUT/CONFIGURATION ELECTRICAL SPECIFICATIONS ............................. 17
TABLE 8: DRIVER OUTPUTS ELECTRICAL SPECIFICATIONS.................................................................. 18
TABLE 9: POWER-SUPPLY OUTPUTS ELECTRICAL SPECIFICATIONS .................................................... 19
TABLE 10: KEYSWITCH AND COIL SUPPLY ELECTRICAL SPECIFICATIONS............................................ 20
TABLE 11: CAN PORTS ELECTRICAL SPECIFICATIONS ........................................................................ 21
TABLE 12: DIGITAL/QUADRATURE ENCODER ELECTRICAL SPECIFICATIONS ........................................ 22
TABLE 13: SIN/COS SENSOR DEVICE ELECTRICAL SPECIFICATIONS ................................................... 23
TABLE 14: MOTOR TEMPERATURE SENSOR SPECIFICATIONS............................................................. 24
TABLE 15: PROGRAMMABLE PARAMETERS MENUS: CURTIS INTEGRATED TOOLKITTM/1313 HHP ........ 33
TABLE 16: SYSTEM MONITOR VARIABLES ........................................................................................ 116
TABLE 17: FAULT ACTIONS................................................................................................................ 164
TABLE 18: FAULT CODE TROUBLESHOOTING CHART ......................................................................... 166
TABLE E-1: SPECIFICATIONS: AC F4-A CONTROLLER......................................................................... 205
TABLE OF CONTENTS cont’d

pg. vii
FIGURES
FIGURE 1: AC F4-A MOTOR CONTROLLER ........................................................................................... 1
FIGURE 2: AC F4-A DIMENSIONS......................................................................................................... 3
FIGURE 3: BATTERY POWER AND MOTOR PHASE TERMINAL CONNECTIONS........................................ 5
FIGURE 4: 35-PIN AMPSEAL CONNECTOR ........................................................................................... 6
FIGURE 5: 35-PIN AMPSEAL CONNECTION ASSIGNMENTS .................................................................. 7
FIGURE 6: AC F4-A BASIC WIRING DIAGRAM ...................................................................................... 10
FIGURE 7: AC F4-A CAN TILLER HEAD WIRING DIAGRAM .................................................................... 11
FIGURE 7A: AC F4-A ISOLATED CAN .................................................................................................. 12
FIGURE 8: ACCELERATION RATE RESPONSE ....................................................................................... 44
FIGURE 9: BRAKING RESPONSE RATE................................................................................................. 45
FIGURE 10: THROTTLE ADJUSTMENTS DIAGRAM .............................................................................. 50
FIGURE 11: THROTTLE SIGNAL PROCESSING ..................................................................................... 52
FIGURE 12: BRAKE SIGNAL PROCESSING ........................................................................................... 55
FIGURE 13: EMERGENCY REVERSE SUPERVISION FUNCTION.............................................................. 70
FIGURE 14: INTERLOCK BRAKE SUPERVISION SPEED LIMIT FOR POSITIVE INITIAL SPEED................... 72
FIGURE 15: INTERLOCK BRAKE SUPERVISION SPEED LIMIT FOR NEGATIVE INITIAL SPEED ................. 73
FIGURE 16: INTERLOCK BRAKE SUPERVISION DISTANCE CHECK ........................................................ 73
FIGURE 17: HYDRAULIC SYSTEM DIAGRAM, WITH LOAD-HOLD A
ND PROPORTIONAL LOWER VALVES............................................................................. 75
FIGURE 18: HYDRAULIC SYSTEM DIAGRAM, WITH A FIXED (ON/OFF) LOAD-HOLD VALVE..................... 76
FIGURE 19: LIFT-INPUT SIGNAL CHAIN (PROCESSING) ....................................................................... 77
FIGURE 20: LIFT-LOWERING SIGNAL CHAIN (PROCESSING)................................................................. 77
FIGURE 21: INPUT 10 DIGITAL AND ANALOG SIGNAL CHAIN................................................................ 87
FIGURE 22: DRIVE CURRENT LIMITING MAP ...................................................................................... 107
FIGURE 23: REGEN CURRENT LIMITING MAP..................................................................................... 108
FIGURE 24: THROTTLE RELATED PARAMETERS – SETUP OPTIONS.................................................... 134
TABLE OF CONTENTS cont’d
Curtis AC F4-A Motor Controller – August 2020

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TABLE OF CONTENTS cont’d
FIGURE 25: WIRING FOR 3-WIRE POTENTIOMETER THROTTLES ........................................................ 135
FIGURE 26: WIRING FOR 2-WIRE POTENTIOMETER THROTTLES ........................................................ 136
FIGURE 27: CURTIS FP-SCV-0022 HALL-EFFECT THROTTLE.............................................................. 137
FIGURE 28: WIRING FOR VOLTAGE TYPE THROTTLES ......................................................................... 138
FIGURE 29: THE PROPORTIONAL VALVE SIGNAL CHAIN...................................................................... 151
FIGURE 30: THE LOAD HOLD VALVE SIGNAL CHAIN ........................................................................... 151
FIGURE 31: CURTIS INTEGRATED TOOLKITTM PROGRAMMER PRESENT
AND FAULT HISTORY SEQUENCE EXAMPLE................................................................. 156
FIGURE C-1: SUPERVISORY SYSTEM IN THE CURTIS AC MOTOR CONTROLLER.................................. 193
Curtis AC F4-A Motor Controller – August 2020

1 — OVERVIEW pg. 1
Return to TOC Curtis AC F4-A Motor Controller – August 2020
1 — OVERVIEW
e AC F4-A is CAN-based induction-motor controller. Available in either 24 volt or 36-48 volt
models, this compact motor controller delivers unmatched performance with a exible feature set.
e Model AC F4-A is fully optimized for use as a traction controller on class III pedestrian-operated
powered pallet trucks. It provides vehicle designers with the ability to fully dene and control the
detailed dynamic performance of their vehicle’s drivetrain, and also provides comprehensive vehicle
management and CAN manager capabilities. Model AC F4-A is also suitable for traction or hydraulic
pump control on other types of battery powered vehicles.
Together with the new Curtis model 3140/3141 CAN LCD display and the new user-friendly Curtis
Integrated ToolkitTM, the Curtis model AC F4-A is the ultimate Class III truck control system.
Easily enhance any application by using Curtis’s Vehicle Control Language (VCL). e F4’s setup and
diagnostic tasks use the new PC-based Curtis Integrated Toolkit™ program (CIT) or the CAN-based
Curtis 1313 handheld programmer (1313HHP).
Figure 1
AC F4-A Motor
Controller

1 — OVERVIEW
Curtis AC F4-A Motor Controller – August 2020 Return to TOC
pg. 2
HOW TO USE THIS MANUAL
is manual describes how to:
• Properly mount and wire the F4-A controller
• Understand the congurable inputs and outputs
• Apply specic features to match an application
• Access and change parameters
• View and use monitor variables
• Preform the initial setup
• Setup the PDO Mapping
• Diagnose and troubleshoot faults
• Select and use the available programming and diagnostic tools
GETTING THE MOST OUT OF YOUR CURTIS CONTROLLER
Thoroughly read and refer to this manual to apply and configure the F4-A controller.
Understanding the installation & wiring guidelines, the parameter settings, the VCL functions,
the initial setup & commissioning, and using the diagnostic and troubleshooting guide are critical
to a successful application.
This manual describes the typical usage of the F4-A controller. If the intended application is
not illustrated or discussed within this manual, contact the Curtis distributor or the regional
Curtis sales-support oce for additional technical support. e Curtis sales and support oce-
contact information is available from the Curtis Instruments website under the International tab.
https://www.curtisinstruments.com/international/
3141 CAN Gauge