Curtis 1220 User manual

Manual
Model 1220
Electric Steering Controller
for Brushed PM Motor
Read Instructions Carefully!
Specications 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
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com

Curtis 1220 Manual, Rev. C iii
CONTENTS
1. OVERVIEW..............................................................................1
2. INSTALLATION AND WIRING ..........................................4
Mounting the Controller ....................................................4
High Current Connections ..................................................5
Low Current Connections ..................................................5
Controller Wiring ...............................................................6
Input/Output Specifications ...............................................8
3. PROGRAMMABLE PARAMETERS ....................................10
Program Menu ..................................................................11
4. MONITOR MENU ...............................................................23
5. COMMISSIONING ..............................................................27
6. DIAGNOSTICS AND TROUBLESHOOTING .................37
7. MAINTENANCE ..................................................................41
appendix aVehicle Design Considerations
appendix bProgramming Devices
appendix cSpecifications, 1220 Controller
CONTENTS

iv Curtis 1220 Manual, Rev. C
FIGURES
. 1: Curtis 1220 controller ............................................................. 1
. 2: Mounting dimensions, Curtis 1220 controller ........................ 4
. 3a: Wiring diagram, using motor encoder for position feedback ... 6
. 3b: Wiring diagram, using analog pots for position feedback ........ 7
. 4: Command signal ow ........................................................... 12
. 5: Steer command map ............................................................. 13
. 6: Position feedback signal ow, with analog pot ...................... 15
. 7: Position feedback signal ow, with encoder ........................... 16
. 8: Steering sensitivity map ......................................................... 22
TABLES
 1: Programmable parameter menus ......................................... 11
 2: Functions menu .................................................................. 22
 3: Monitor menu ..................................................................... 23
 4: Troubleshooting chart ......................................................... 38
 C-1: Specifications, 1220 controllers ......................................... C-1
FIGURES / TABLES

Curtis 1220 Manual, Rev. C 1
OVERVIEW
e Curtis Model 1220 controller is designed to drive a brushed permanent
magnet motor for electric power steering (EPS). e 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.
e steering motor must be speed reduced to get the high torque required
to rotate the drive wheel. Typically this is done with a gearbox around 50:1
and a chain or gear with an additional reduction of around 4:1. e steering
command comes either from a linear potentiometer or an analog voltage sen-
sor. e wheel position feedback comes either from a linear potentiometer, an
analog voltage sensor, or an encoder with a home switch.
1
1 — OVERVIEW
Fig. 1 Curtis 1220 electric
steering controller.
e 1220 works only with Curtis AC traction controllers with embed-
ded VCL. A “handshake” with the traction controller is required at startup to
enable operation.
Intended applications are material handling vehicles such as reach trucks,
order pickers, stackers, “man up” warehouse trucks, and other similar industrial
vehicles.

2Curtis 1220 Manual, Rev. C
Advanced Motor Control
3Absolute position control mode.
316 kHz PWM switching frequency ensures silent operation.
3Advanced PWM techniques produce low motor harmonics,
low torque ripple, and minimized heating losses, resulting
in high eciency.
3Congurable homing methods, center oset, and end-stop
protection.
324V, 40 A 2-minute current rating.
324V nominal supply voltage.
Maximum Safety
3Dual steering command inputs and dual analog position
inputs for redundant check.
3Fault output can be used to turn o traction controller’s
main contactor or interlock connection.
3Steered wheel position (angle) output can be used to limit
the traction motor speed.
3Following error check ensures the wheel position tracks
the steering command.
3Power On Self-Test: FLASH, ALU, EEPROM, software
watchdog, RAM, etc.
3Power On Hardware Check: Motor Open, Motor Short,
and MOSFET short.
3Periodic Self-Tests: EEPROM parameters, Motor Open,
and command and feedback devices.
Unmatched Flexibility
3Integrated hourmeter and diagnostic log functions.
3Curtis 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.
3Curtis 1313 handheld programmer and 1314 PC
Programming Station provide easy programming and
powerful system diagnostic and monitoring capabilities.
3External Status LED driver gives instant diagnostic
indication.
1 — OVERVIEW

Curtis 1220 Manual, Rev. C 3
Robust Reliability
3Intelligent thermal cutback and overvoltage/undervoltage
protection functions maintain steering while reducing traction
speed until severe over/under limits are reached.
3Standard Mini-Fit Molex Jr. and Faston terminals provide
proven, robust wiring connections.
3Electronics sealed to IP65.
3Reverse polarity protection on battery connections.
3Inputs 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.
Working on electrical systems is potentially dangerous. Protect yourself against
uncontrolled operation, high current arcs, and outgassing from lead acid batteries:
UNCONTROLLED OPERATION — Some conditions could cause the motor to run out of
control. Disconnect the motor or jack up the vehicle and get the drive wheels off the
ground before attempting any work on the motor control circuitry.
HIGH CURRENT ARCS — Batteries can supply very high power, and arcing can occur if
they are short circuited. Always open the battery circuit before working on the motor
control circuit. Wear safety glasses, and use properly insulated tools to prevent shorts.
LEAD ACID BATTERIES — Charging or discharging generates hydrogen gas, which can
build up in and around the batteries. Follow the battery manufacturer’s safety recom-
mendations. Wear safety glasses.
+
CAUTION
1 — OVERVIEW
e Curtis Model 1220 does not satisfy EN1175-1:1998+A1:2010 Article 5.9.6
as it is not a Category 3 device under EN ISO13849-1:2008. It should not be
used on any vehicle within the scope of Machinery Directive 2006/42/EC that
will be operated within the European Economic Area (EEA).
+
CAUTION

4Curtis 1220 Manual, Rev. C
2 — INSTALLATION & WIRING
2
Fig. 2 Mounting
dimensions, Curtis 1220
motor controller.
Dimensions in millimeters (and inches)
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
e 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.
e outline and mounting hole dimensions are shown in Fig. 2. e con-
troller should be mounted by means of the two mounting holes at the opposing
corners of the heatsink, using M4 (#8) screws.
You will need to take steps during the design and development of your
end product to ensure that its EMC performance complies with applicable
regulations; suggestions are presented in Appendix A.
e 1220 controller contains ESD-sensitive components. Use appro-
priate precautions in connecting, disconnecting, and handling the controller.
See installation suggestions in Appendix A for protecting the controller from
ESD damage.

Curtis 1220 Manual, Rev. C 5
2 — INSTALLATION & WIRING: High Current Connections
CONNECTIONS: High Current
Four 1/4” Faston terminals are provided for the high current connections.
e motor connections (M1, M2) and battery
connections (B+, B-) have one terminal each.
CONNECTIONS Low Current
e low current connections are made through three connectors: J1, J2, and J3.
J1 J2 J3
M1 M2 B- B+
1 Status LED
2 Steer Motor Encoder Phase A
3 Position Analog 2
4 Interlock Input
5 KSI
6 Command Analog 1
7 +5V
8 Rx2 (from traction controller)
9 Steer Motor Encoder Phase B
10 Feedback Pot Low
11 Position Analog 1
12 Steering Angle Output
13 Command Analog 2
14 Command Pot Low
1 Rx1 (from programmer)
2 GND
3 Tx1 (to programmer / 840)
4 B+
1 Fault Output
2 Home Switch
J1
14-pin Molex
39-28-8140
1 2 3 4 5 6 7
8 9 10 11 12 13 14
1 2
3 4
1
2
J2
4-pin Molex
39-28-8040
J3
2-pin Molex
39-28-8020
Mating connectors:
Molex Mini-Fit-Jr
receptacle p/n
J1 39-01-2140
J2 39-01-2040
J3 39-01-2020
with appropriate
45750-series
crimp terminals.

6Curtis 1220 Manual, Rev. C
Fig. 3a Basic wiring diagram, using motor encoder for feedback device.
2 — INSTALLATION & 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
o both controllers turn o. e 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.
1220 CONTROLLER
J1-6
J1-7
KSI
J1-5
Home Switch
J3-2
J1-11
Interlock Input
J1-4
MOTOR
J1-1 Status LED
J3-1
J2-4
J2-3
J2-2
J2-1
KEYSWITCH
Fault Output
B+
GND
Rx1
M1
M2
BATTERY
(24V)
B+
B-
Tx1
EMERGENCY
STOP
+5V
J1-7
J1-12
J1-8
Rx2
Steering Angle
Output
CURTIS
AC
TRACTION
CONTROLLER
J1-13
J1-14
Command Analog 2
Command Analog 1
+5V
Command Pot Low
STEER
MOTOR
ENCODER
STEER COMMAND
POTS
J1-7 I/O GND
TRACTION
MAIN
CONTACTOR
COIL
J1-9 Interlock
J1-1 KSI
SW1/ANA1 J1-24
Tx J1-28
J1-13 Coil Return
INTERLOCK SWITCH
STATUS LED
Encoder
Phase A
J1-2
Encoder
Phase B
J1-9
Feedback
Pot Low
J1-10
HOME SWITCH
J1-3
M
Main Driver J1-6
840
+12V J1-25
J1-8 GND
Power
Supply Input J1-5
Receive J1-6
PROGRAMMER
J2-4
123xE/1298
POWER
FUSE
CONTROL
FUSE