Curtis 1232E User manual

Manual
Models 1232E/34E/36E/38E
and 1232SE/34SE/36SE
Enhanced AC Controllers
for Induction Motors
and Surface Permanent Magnet Motors
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. 53134, OS30 11/24/2015
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
» Software Version OS 30.0 «

Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os30 iii
24 NOVEMBER 2015
CONTENTS
1. OVERVIEW............................................................................. 1
2. INSTALLATION AND WIRING .......................................... 3
Mounting the Controller .................................................... 3
High Current Connections and Wiring Guidelines............. 6
Low Current Connections and Wiring Guidelines.............. 8
Controller Wiring: Basic Configuration ........................... 12
Switch Input Wiring ......................................................... 13
rottle Wiring................................................................. 13
Input/Output Specifications.............................................. 18
3. PROGRAMMABLE PARAMETERS ................................... 25
Program Menu ................................................................. 26
4a. MONITOR MENU............................................................... 72
4b. CONTROLLER INFORMATION MENU ......................... 86
5. INITIAL SETUP.................................................................... 87
6a. MOTOR CHARACTERIZATION: ACIM Motors ............. 93
6b. MOTOR CHARACTERIZATION: SPM Motors.............. 100
7. TUNING GUIDE ............................................................... 102
8. VEHICLE CONTROL LANGUAGE................................. 106
9. DIAGNOSTICS AND TROUBLESHOOTING............... 137
10. MAINTENANCE................................................................ 145
appendix aVehicle Design Considerations
appendix bEN13849 Compliance
appendix cProgramming Devices
appendix dSpecifications, 1232E/34E/36E/38E
and 1232SE/34SE/36SE Controllers
CONTENTS

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FIGURES
. 1: Curtis 1232E/SE, 1234E/SE, 1236E/SE, 1238E controllers ... 1
. 2a: Mounting dimensions, Curtis 1232E/SE controller ................. 3
. 2b: Mounting dimensions, Curtis 1234E/SE controller ................. 4
. 2c: Mounting dimensions, Curtis 1236E/SE, 1238E controllers ... 5
. 3: Basic wiring diagram ............................................................. 12
. 4: Wiring for Type 1 throttles .................................................... 14
. 5: Wiring for Type 2 throttles .................................................... 15
. 6: Wiring for Type 3 throttles .................................................... 16
. 7: Acceleration response rate diagram ........................................ 33
. 8: Braking response rate diagram ............................................... 34
. 9: rottle mapping, torque control mode ................................ 40
. 10: Eect of gear soften parameter, torque control mode............. 40
. 11: Eect of brake taper speed parameter, torque control mode ... 40
. 12: Drive current limiting map .................................................... 42
. 13: Regen current limiting map ................................................... 43
. 14: rottle adjustment ............................................................... 45
. 15: VCL motor command diagram ........................................... 114
. 16: VCL control mode processing ............................................. 118
. 17: VCL proportional driver processing ..................................... 119
. B-1: Enhanced supervisory system ............................................... B-1
TABLES
 1: High current connections....................................................... 6
 2: Low current connections ........................................................ 9
 3: Programmable parameter menus .......................................... 26
 4: Monitor menu...................................................................... 72
 5: Types of LED display ......................................................... 135
 6: Troubleshooting chart ........................................................ 136
 D-1: Specifications, 1232E/34E/36E/38E
and 1232SE/34SE/36SE controllers .................................. D-1
FIGURES / TABLES

Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os30 1
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OVERVIEW
Curtis 1232E/SE, 1234E/SE, 1236E/SE, and 1238E AC motor controllers
provide accurate, dependable, and highly ecient control of speed and torque
of AC induction motors (ACIM) and surface permanent magnet synchronous
motors (SPM).
ese AC controllers contain two microprocessors to provide exceptional
capability and functional safety. e primary microprocessor runs an advanced
eld-oriented AC motor control while simultaneously running VCL software in
an embedded logic controller. e second microprocessor continuously moni-
tors the operation of the system, redundantly measuring inputs, crosschecking
results, and verifying critical timing and operations.
VCL (Vehicle Control Language) is an innovative software programming
language developed by Curtis. Many electric vehicle functions are uniquely
built into the VCL code, and additional functions can be created by OEMs
as required. VCL opens new avenues of customization, allowing specic vehicle
application functions to be created quickly and easily within the motor controller
itself, often eliminating the need to use separate vehicle manager modules.
e CAN bus communications included within these controllers allow
these AC motor controllers to function as system CAN masters or CAN slaves
as part of an efficient distributed system. Inputs and outputs can be optimally
shared throughout the system, minimizing wiring and creating integrated
functions that often reduce the cost of the system.
ese controllers are the ideal solution for traction, hoist, dual drive, and
other motor drive and vehicle control needs.
1
1 — OVERVIEW
Fig. 1 Curtis AC induction motor controllers:
from left to right, models 1232SE, 1234E, 1236E, and 1238E.
e E and SE models look similar, and share the same standard features.
Like all Curtis controllers, the E and SE models oer superior operator control
of motor drive performance. Features include:
3Closed-loop speed and torque control for both induction (ACIM) and
surface permanent magnet (SPM) motors
3High efficiency, field-oriented motor control algorithms that enable
maximum possible motor torque generation for all operating conditions
More Features +

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3Advanced Pulse Width Modulation technology for efficient use
of battery voltage, low motor harmonics, low torque ripple, and
minimized switching losses
3Extremely wide torque/speed range including full regeneration capability
3Full eld-weakening capability with ACIM motors;
full control up to no-load base speed with SPM motors
3Smooth low speed control, including zero speed
3Adaptation of control algorithm to motor temperature variation for
optimal performance and reduced motor heating
3Power limiting maps allow performance customization for reduced motor
heating and consistent performance over varying battery state-of-charge
3ermal cutback, warning, and automatic shutdown provide protection
to motor and controller
3Insulated metal substrate power base provides superior heat transfer for
increased reliability
3Built-in auto-characterization routines for eective in-vehicle optimization
of motor performance and eciency
3Powerful operating system allows parallel processing of vehicle control tasks,
motor control tasks, and user congurable programmable logic (VCL)
3A wide range of I/O can be applied wherever needed, for maximum
distributed system control
3Built-in Dual Drive software allows easy setup and control of typical
dual-drive vehicles, without VCL
3Internal battery-state-of-charge, hourmeter, and maintenance timers
3CANopen compatible CAN bus connection; other CAN bus protocols
are configurable through VCL
3Signicantly increased CAN master capabilities, VCL execution speed,
and VCL code space
3Field-programmable, with ash downloadable main operating code
3Easily programmable through the Curtis 1313 handheld programmer
and 1314 PC Programming Station
3Rugged sealed housing and connectors meet IP65 environmental sealing
standards for use in harsh environments
3Compliance with new Machinery Directives 2006/42/EC and EN13849-1.
Getting the most out of your Curtis controller
Read and apply the information in this manual. e Installation/Wiring, Initial
Setup, and Tuning Guide sections are critical to proper operation of your con-
troller. For technical support, contact the Curtis distributor where you obtained
your controller or the Curtis sales-support oce in your region.
1 — OVERVIEW

Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os30 3
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2 — INSTALLATION & WIRING
2
Fig. 2a Mounting dimensions,
Curtis 1232E and 1232SE
motor controllers.
Note: The SE has a thicker base.
Dimensions in millimeters.
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
e outline and mounting hole dimensions for the 1232E/SE controller are shown in
Figure2a, for the 1234E/SE controller in Figure2b, andforthe1236E/SEand1238E
controllers in Figure 2c. When an Ampseal plug housing is mated with the
35-pin logic receptacle, these controllers meet the IP65 requirements for envi-
ronmental protection against dust and water. Nevertheless, in order to prevent
external corrosion and leakage paths from developing, the mounting location
should be carefully chosen to keep the controller as clean and dry as possible.
It is recommended that the controller be fastened to a clean, at metal
surface with four 6 mm (1/4") diameter bolts, using the holes provided. A thermal
joint compound can be used to improve heat conduction from the controller
heatsink to the mounting surface. Additional heatsinking or fan cooling may
be necessary to meet the desired continuous ratings.
B-
U
71
169
180
5.5
∅7.0 thru, 4 plcs
140
129
5.5
V
W
B+
8
Status LED
window
1232E
75
12
1232SE
M6 x 1.0, 5 plcs

4Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os30
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Fig. 2b Mounting dimensions,
Curtis 1234E and 1234SE
motor controllers.
Note: The SE has a thicker base and taller terminals.
Dimensions in millimeters.
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
2 — INSTALLATION & WIRING
1234SE
terminal
(5 plcs)
B-
U
8
75
212
5.5
Status LEDs
∅7.0 thru, 4 plcs
155
140.4
7.3
V
W
B+
201
80
11
1234E 1234SE
M6 x 1.0, 5 plcs

Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE Manual, os30 5
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Fig. 2c Mounting dimensions,
Curtis 1236E/SE and 1238E
motor controllers.
Dimensions in millimeters.
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.
ese controllers contain ESD-sensitive components. Use appropriate
precautions in connecting, disconnecting, and handling the controller. See
installation suggestions in Appendix A for protecting the controller from ESD
damage.
2 — INSTALLATION & WIRING
B-
B+
FUSE
U
V
W
M8 x 1.25,
19
85
212
232
10
Status LEDs
∅7.0 thru,
4 plcs
165
145
255
275
1236E/SE
1238E
13 (typ.)
5 plcs

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2 — INSTALLATION & WIRING: High Current Connections
HIGH CURRENT CONNECTIONS
ere are ve high-current terminals, identied on the controller housing as
B+, B-, U, V, and W.
Table 1 High Current Connections
terminal function
B+ Positive battery to controller.
B- Negative battery to controller.
UMotor phase U.
VMotor phase V.
WMotor phase W.
Lug assembly: 1232E/SE and 1234E/SE models
Five aluminum M6 terminals are provided. Lugs should be installed as follows,
using M6 bolts sized to provide proper engagement (see diagram):
• Placethelugontopofthealuminumterminal, followed by
a high-load safety washer with its convex side on top. e
washer should be a SCHNORR 416320, or equivalent.
• Iftwolugsareusedonthesameterminal, stack them so the
lug carrying the least current is on top.
• Tightentheassemblyto10.2±1.1N·m(90±10in-lbs).
M6 BOLT
HIGH LOAD
SAFETY WASHER
LUG
M6 TERMINAL
SECTION VIEW
1232E/SE, 1234E
EXPLODED VIEW
10 mm MIN
DEPTH
18 mm MAX
DEPTH
SECTION VIEW
1234SE
11.75 mm MIN
DEPTH
19.75 mm MAX
DEPTH
1234SE
has larger
terminal