Kohler Curtis F Series User manual

Read Instructions Carefully!
Specications are subject to change without notice.
© 2022 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. 53240, Rev A April 2022
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
Manual
F Series Motor Controller
For Controllers: AC F4-A Model, AC F6-A Model
AC F2-A Model
» Software Device Profile: 4.5.0.0 «

Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
pg. ii
CHAPTERS
1: OVERVIEW ...................................................................................................................................... 1
HOW TO USE THIS MANUAL .......................................................................................................... 3
WHAT IS NEW IN FOS 4.4.0.0 ... HIGHLIGHTS ............................................................................... 4
GETTING THE MOST OUT OF YOUR CURTIS CONTROLLER ............................................................. 4
2: INSTALLATION AND WIRING ............................................................................................................ 5
PHYSICALLY MOUNTING THE CONTROLLER................................................................................... 5
PRECAUTIONS .............................................................................................................................. 7
HIGH CURRENT CONNECTIONS ..................................................................................................... 8
LOW CURRENT CONNECTIONS...................................................................................................... 9
ROTOR POSITION FEEDBACK................................................................................................. 12
CANBUS ................................................................................................................................ 12
ALL OTHER LOW POWER WIRING........................................................................................... 12
PROTECTED VOLTAGES.......................................................................................................... 12
CONTROLLER INPUTS AND OUTPUTS..................................................................................... 14
CONTROLLER WIRING DIAGRAM (EXAMPLES) ........................................................................ 16
LOW CURRENT CONNECTOR ELECTRICAL SPECIFICATIONS .................................................. 20
DIGITAL (SWITCH) INPUTS ..................................................................................................... 20
ANALOG INPUTS.................................................................................................................... 22
POTENTIOMETER INPUTS WITH DYNAMIC TESTING................................................................ 23
PWM AND DIGITAL DRIVERS .................................................................................................. 24
POWER SUPPLY OUTPUTS ..................................................................................................... 26
KEYSWITCH AND COIL SUPPLY .............................................................................................. 27
CAN PORTS........................................................................................................................... 27
MOTOR POSITION SENSOR INPUTS ....................................................................................... 28
SINE/COSINE SIGNAL TRACKING............................................................................................ 30
MOTOR TEMPERATURE INPUT ............................................................................................... 31
TABLE OF CONTENTS

Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 pg. iii
TABLE OF CONTENTS cont’d
3: APPLICATION-SPECIFIC FEATURES................................................................................................. 32
MOTOR SPEED CONSTRAINTS ..................................................................................................... 32
VOLTAGE LIMITS .......................................................................................................................... 33
OVER-VOLTAGE REGION......................................................................................................... 34
SEVERE OVER-VOLTAGE REGION............................................................................................ 34
UNDER-VOLTAGE REGION ...................................................................................................... 34
OUTPUT-DISABLED REGION................................................................................................... 35
BROWNOUT VOLTAGE ............................................................................................................ 35
KSI AND B+ INPUT................................................................................................................. 35
BATTERY DISCHARGE INDICATOR................................................................................................. 35
4: PROGRAMMABLE PARAMETERS .................................................................................................... 36
PROGRAMMABLE PARAMETERS .................................................................................................. 36
PROGRAMMING MENUS............................................................................................................... 36
PARAMETER CHANGE FAULTS [PCF]............................................................................................. 36
MONITOR VARIABLES WITHIN PARAMETER MENUS ...................................................................... 36
PROGRAMMING TOOLS................................................................................................................ 36
MENU CHART FORMAT ................................................................................................................ 37
TERMINOLOGY ............................................................................................................................ 37
SDO WRITE MESSAGE.................................................................................................................. 39
CONTROL MODE SELECT INDEX .................................................................................................. 41
SPEED MODE EXPRESS ......................................................................................................... 51
SPEED MODE ........................................................................................................................ 52
TORQUE MODE...................................................................................................................... 59
APPLICATION SETUP.............................................................................................................. 62
CONTROLLER SETUP............................................................................................................ 103
MOTOR SETUP ..................................................................................................................... 130

Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
pg. iv
TABLE OF CONTENTS cont’d
5: SYSTEM MONITOR MENU ............................................................................................................. 145
6: COMMISSIONING .......................................................................................................................... 156
INITIAL SETUP ............................................................................................................................ 156
TO BEGIN ............................................................................................................................. 157
CONTROL MODE SELECTION ................................................................................................ 158
PARAMETER SETTINGS – METHOD OVERVIEW...................................................................... 158
TRACTION MOTOR SETUP GUIDE.......................................................................................... 159
CONTROLLER SETUP GUIDE ................................................................................................. 161
TRACTION THROTTLE SETUP................................................................................................ 163
VOLTAGE THROTTLE ............................................................................................................. 166
AUTOMATED ACIM (MOTOR) CHARACTERIZATION PROCEDURE ................................................... 172
AC MOTOR SYSTEMS ................................................................................................................. 172
AUTOMATED PMAC (MOTOR) COMMISSIONING PROCEDURE....................................................... 179
AC MOTOR TUNING GUIDE .......................................................................................................... 183
SELECTING THE CONTROL MODE ......................................................................................... 183
0 − SPEED MODE EXPRESS TUNING..................................................................................... 183
1 − SPEED MODE TUNING .................................................................................................... 184
2 − TORQUE MODE TUNING.................................................................................................. 185
OTHER PARAMETER TUNING................................................................................................. 186
SETTING UP THE HYDRAULIC SYSTEM ........................................................................................ 187
HYDRAULIC LIFT AND LOWER COMMAND INPUTS....................................................................... 187
LIFT & LOWER SWITCH INPUTS ............................................................................................ 188
LIFT SWITCH INPUT, WITH A PROPORTIONAL LOWERING VALVE............................................. 190
7: DIAGNOSTICS AND TROUBLESHOOTING........................................................................................ 194
THE DIAGNOSTICS PROCESS ...................................................................................................... 194
TROUBLESHOOTING CHART INDEX.............................................................................................. 199
FAULT ACTIONS .......................................................................................................................... 203
TROUBLESHOOTING CHART........................................................................................................ 205

TABLE OF CONTENTS cont’d
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 pg. v
8: MAINTENANCE ............................................................................................................................. 239
CLEANING................................................................................................................................... 239
FAULT HISTORY........................................................................................................................... 239
APPENDIX A...................................................................................................................................... 240
CANOPEN PDO MAPPING OBJECT DESCRIPTION................................................................... 240
EXAMPLE FOR RPDO MAPPING WITH THE CIT PROGRAMMER............................................... 242
EXAMPLE FOR TPDO MAPPING WITH THE PROGRAMMER ..................................................... 244
EXAMPLE FOR RPDO MAPPING WITH SDO WRITES...................................................................... 245
APPENDIX B ..................................................................................................................................... 247
ELECTROMAGNETIC COMPATIBILITY (EMC) ................................................................................. 247
ELECTROSTATIC DISCHARGE (ESD) IMMUNITY ............................................................................ 248
DECOMMISSIONING AND RECYCLING THE CONTROLLER............................................................. 248
APPENDIX C ..................................................................................................................................... 249
EN 13849 COMPLIANCE ............................................................................................................. 249
APPENDIX D ..................................................................................................................................... 252
CURTIS INTEGRATED TOOLKITTM.................................................................................................. 252
CREATING A PROJECT WITH A NEW F-SERIES CONTROLLER................................................. 254
VEHICLE CAN PORT WIRING ........................................................................................................ 261
APPENDIX E...................................................................................................................................... 262
SPECIFICATIONS: CONTROLLER............................................................................................ 262

Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
pg. vi
TABLES
TABLE 1: HIGH POWER CONNECTIONS................................................................................................ 8
TABLE 2: THE AMPSEAL CONNECTOR COMPONENTS & PART NUMBERS............................................ 10
TABLE 3: THE AMPSEAL CONNECTOR COMPONENTS & PART NUMBERS............................................ 10
TABLE 4: THE AMPSEAL CONNECTION PROTECTED VOLTAGES – 23 PIN CONTROLLERS..................... 13
TABLE 5: AMPSEAL CONNECTIONS PROTECTED VOLTAGES – 35 PIN CONTROLLERS ........................ 13
TABLE 6: LOGIC AND LOW CURRENT CONNECTIONS-F2A .................................................................. 14
TABLE 7: LOGIC AND LOW-CURRENT CONNECTIONS-F4/6-A ............................................................ 15
TABLE 8: DIGITAL (SWITCH) INPUTS ELECTRICAL SPECIFICATIONS..................................................... 20
TABLE 9: ANALOG INPUTS ELECTRICAL SPECIFICATIONS ................................................................... 22
TABLE 10: POTENTIOMETER INPUT/CONFIGURATION ELECTRICAL SPECIFICATIONS ........................... 24
TABLE 11: DRIVER OUTPUTS ELECTRICAL SPECIFICATIONS................................................................ 25
TABLE 12: POWER-SUPPLY OUTPUTS ELECTRICAL SPECIFICATIONS .................................................. 26
TABLE 13: KEYSWITCH AND COIL SUPPLY ELECTRICAL SPECIFICATIONS............................................ 27
TABLE 14: CAN PORTS ELECTRICAL SPECIFICATIONS ........................................................................ 28
TABLE 15: DIGITAL/QUADRATURE ENCODER ELECTRICAL SPECIFICATIONS ........................................ 29
TABLE 16: SIN/COS SENSOR DEVICE ELECTRICAL SPECIFICATIONS ................................................... 30
TABLE 17: MOTOR TEMPERATURE SENSOR SPECIFICATIONS............................................................. 31
TABLE 18: PROGRAMMABLE PARAMETERS MENUS: CURTIS INTEGRATED TOOLKITTM/1313 HHP ........ 41
TABLE 19: SYSTEM MONITOR VARIABLES ........................................................................................ 145
TABLE 20: ACIM TEST TABLE ............................................................................................................ 174
TABLE 21: MOTOR CHARACTERIZATION AND PARAMETER MISMATCH ERROR TYPES........................ 175
TABLE 22: TROUBLESHOOTING CHART INDEX................................................................................... 199
TABLE 23: FAULT ACTIONS................................................................................................................ 203
TABLE 24: FAULT CODE TROUBLESHOOTING CHART ......................................................................... 205
TABLE E-1: SPECIFICATIONS: AC F6-A, F4-A AND F2-A CONTROLLERS ............................................. 262
TABLE OF CONTENTS cont’d

pg. vii
FIGURES
FIGURE 1: AC F2-A MOTOR CONTROLLER........................................................................................... 1
FIGURE 2: AC F4-A MOTOR CONTROLLER........................................................................................... 2
FIGURE 3: AC F6-A MOTOR CONTROLLER........................................................................................... 3
FIGURE 4: AC F2-A DIMENSIONS......................................................................................................... 5
FIGURE 5: AC F4-A DIMENSIONS......................................................................................................... 6
FIGURE 6: AC F6-A DIMENSIONS......................................................................................................... 7
FIGURE 7: BATTERY POWER AND MOTOR PHASE TERMINAL CONNECTIONS........................................ 8
FIGURE 8: 23-PIN AMPSEAL CONNECTOR ........................................................................................... 9
FIGURE 9: 35-PIN AMPSEAL CONNECTOR ........................................................................................... 9
FIGURE 10: 23-PIN AMPSEAL CONNECTION ASSIGNMENTS ............................................................... 11
FIGURE 11: 35-PIN AMPSEAL CONNECTION ASSIGNMENTS ............................................................... 11
FIGURE 12: AC F2-A BASIC WIRING DIAGRAM .................................................................................... 16
FIGURE 13: AC F4-A, F6-A BASIC WIRING DIAGRAM........................................................................... 17
FIGURE 14: AC F2-A CAN TILLER HEAD WIRING DIAGRAM .................................................................. 18
FIGURE 15: AC F4-A, F6-A ISOLATED CAN. TILLER HEAD WIRING DIAGRAM ....................................... 19
FIGURE 16: ACCELERATION RESPONSE RATE..................................................................................... 55
FIGURE 17: BRAKING RESPONSE RATE............................................................................................... 56
FIGURE 18: CREEP MODE THROTTLE — TORQUE MODE.................................................................... 61
FIGURE 19: GEAR SOFTEN — TORQUE MODE .................................................................................... 61
FIGURE 20: BRAKE TAPER SPEED — TORQUE MODE ......................................................................... 61
FIGURE 21: THROTTLE ADJUSTMENTS DIAGRAM .............................................................................. 64
FIGURE 22: THROTTLE SIGNAL PROCESSING ..................................................................................... 66
FIGURE 23: BRAKE SIGNAL PROCESSING ........................................................................................... 69
FIGURE 24: EMERGENCY REVERSE SUPERVISION FUNCTION.............................................................. 84
FIGURE 25: INTERLOCK BRAKE SUPERVISION SPEED LIMIT FOR POSITIVE INITIAL SPEED................... 86
TABLE OF CONTENTS cont’d
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022

pg. viii
TABLE OF CONTENTS cont’d
FIGURE 26: INTERLOCK BRAKE SUPERVISION SPEED LIMIT FOR NEGATIVE INITIAL SPEED ................. 87
FIGURE 27: INTERLOCK BRAKE SUPERVISION DISTANCE CHECK ........................................................ 87
FIGURE 28: HYDRAULIC SYSTEM DIAGRAM, WITH LOAD-HOLD AND
PROPORTIONAL LOWER VALVES ............................................................................... 89
FIGURE 29: HYDRAULIC SYSTEM DIAGRAM, WITH A FIXED (ON/OFF) LOAD-HOLD VALVE..................... 90
FIGURE 30: LIFT-INPUT SIGNAL CHAIN (PROCESSING) ....................................................................... 91
FIGURE 31: LIFT-LOWERING SIGNAL CHAIN (PROCESSING)................................................................. 91
FIGURE 32: INPUT 10 DIGITAL AND ANALOG SIGNAL CHAIN............................................................... 113
FIGURE 33: DRIVE CURRENT LIMITING MAP ...................................................................................... 128
FIGURE 34: REGEN CURRENT LIMITING MAP..................................................................................... 129
FIGURE 35: THROTTLE RELATED PARAMETERS – SETUP OPTIONS.................................................... 164
FIGURE 36: WIRING FOR 3-WIRE POTENTIOMETER THROTTLES ........................................................ 165
FIGURE 37: WIRING FOR 2-WIRE POTENTIOMETER THROTTLES ........................................................ 166
FIGURE 38: CURTIS FP-SCV-0022 HALL-EFFECT THROTTLE.............................................................. 167
FIGURE 39: WIRING FOR VOLTAGE TYPE THROTTLES ......................................................................... 168
FIGURE 40: THE PROPORTIONAL VALVE SIGNAL CHAIN...................................................................... 188
FIGURE 41: THE LOAD HOLD VALVE SIGNAL CHAIN ........................................................................... 188
FIGURE 42: CURTIS INTEGRATED TOOLKITTM PROGRAMMER PRESENT
AND FAULT HISTORY SEQUENCE EXAMPLE .............................................................. 195
FIGURE C-1 : SUPERVISORY SYSTEM IN THE CURTIS AC MOTOR CONTROLLER................................. 249
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022

1 — OVERVIEW pg. 1
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
1 — OVERVIEW
e Curtis F2-A and F4/6-A motor controllers provide accurate, dependable, and highly ecient control
of speed and torque of AC induction motors (ACIM) and permanent magnet AC motors (PMAC).
ese traction controllers are optimized for both class III pedestrian-operated (F2-A) and rider-
powered (F4/6-A) pallet trucks. They provide vehicle designers with the ability to fully define
and control the detailed dynamic performance of their vehicle’s drivetrain, and also provide
comprehensive vehicle management and CAN manager capabilities. ese models are also suitable
for traction or hydraulic pump control on other types of battery powered vehicles, based upon the
power requirements. e AC-F2-A is a 23-pin model. e AC F4/6-A is a 35-pin model oering a
higher-count I/O and a second CAN port.
Together with the Curtis model 3140/3141 CAN LCD display and the Curtis Integrated ToolkitTM,
these Curtis models are the ultimate Class III truck control system.
Easily enhance any application by using Curtis’s Vehicle Control Language (VCL). e 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 F2-A Motor
Controller

1 — OVERVIEW
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 2
Figure 2
AC F4-A Motor
Controller