Curtis 1222 Manuale utente
Manual
Model 1222
Electric Steering Controller
Read Instructions Carefully!
Specifications are subject to change without notice.
© 2013 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. 53122, OS15 1/29/13
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
» Software Version OS 15.0 «
Curtis 1222 Manual, os 15 iii
29 JANUARY 2013 DRAFT
CONTENTS
1. OVERVIEW ..............................................................................1
2. INSTALLATION AND WIRING .............................................4
Mounting the Controller .....................................................4
High Current Connections and Wiring Guidelines ..............6
Low Current Connections and Wiring Guidelines ...............8
Controller Wiring: Safety Requirements ...........................11
Input/Output Specifications ...............................................13
3. PROGRAMMABLE PARAMETERS .....................................17
Program Menu ..................................................................18
4a. MONITOR MENU ................................................................57
4b. CONTROLLER INFORMATION MENU ...........................70
4c. CONTROLLER FUNCTIONS MENU .................................71
5. COMMISSIONING ...............................................................72
6. INTERFACE WITH MASTER CONTROLLER ...................93
7. DIAGNOSTICS AND TROUBLESHOOTING ....................99
8. MAINTENANCE .................................................................110
APPENDIX A Vehicle Design Considerations
APPENDIX B EN 14839 Compliance
APPENDIX C Programming Devices
APPENDIX D Specifications, 1222 Controller
CONTENTS
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FIGURES
fig. 1: Curtis 1222 controller .............................................................. 1
fig. 2: Mounting dimensions, Curtis 1222 controller ........................ 4
fig. 3a: Wiring diagram ...................................................................... 11
fig. 3b: Software control diagram ....................................................... 12
fig. 4: Command Input Device “0” signal flow ................................ 24
fig. 5: Command Input Device “1” signal flow ................................ 25
fig. 6: Command Input Device “2” signal flow ................................ 27
fig. 7: Command Input Device “3” signal flow ................................ 29
fig. 8: Command Input Device “4” signal flow ................................ 30
fig. 9: Steer Command Map ............................................................. 31
fig. 10: Position Feedback Device “0” signal flow ............................... 37
fig. 11: Position Feedback Device “1” signal flow ............................... 38
fig. 12: Position Feedback Device “2” signal flow ............................... 41
fig. 13: Position Feedback Device “3” signal flow ............................... 42
fig. 14: Position Control signal flow ................................................... 53
fig. 15: Velocity Control signal flow ................................................... 53
fig. 16: Steering Sensitivity Map ......................................................... 54
fig. 17a: Input Command signal flow .................................................. 96
fig. 17b: Position Feedback signal flow ................................................. 97
fig. 17c: Position/Velocity Control signal flow ..................................... 98
fig. B-1: Supervisory system ................................................................B-1
TABLES
table 1: High current connections ....................................................... 7
table 2: Low current connections ...................................................... 10
table 3: Programmable parameter menus .......................................... 18
table 4: Monitor menu ...................................................................... 57
table 5: Types of LED display ........................................................ 100
table 6: Troubleshooting chart ......................................................... 101
table D-1: Specifications, 1222 controllers .........................................D-1
FIGURES / TABLES
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OVERVIEW
The Curtis Model 1222 is an AC induction motor controller for electric
power steering (EPS) systems. In these “steer by wire” systems, the AC steering
gearmotor functions as an actuator to change the angle of the vehicle’s steered
wheel(s) and thus change the direction of travel. The 1222 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.
The Curtis 1222 controller is designed for use as an electric power steer-
ing controller for 300–1400W AC induction gearmotors with overall gear
reductions between 50:1 and 800:1 on vehicles using Curtis VCL AC motor
controllers. Intended applications are material handling vehicles such as reach
trucks, order pickers, stackers, “man up” warehouse trucks, and other similar
industrial vehicles.
1
1 — OVERVIEW
Fig. 1 Curtis 1222 electric
steering controller.
Advanced Motor Control
✓ Absolute Position (pedestrian stacker) or Relative Position
(reach truck) control modes.
✓ Supports >360° multi-turn steering mode.
✓ Indirect Field Orientation (IFO) vector control algorithm
provides maximum possible torque while ensuring maximum
efficiency and accurate current control.
More Features ☞
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✓ 16 kHz PWM switching frequency ensures silent operation
across the 0–200Hz stator frequency range.
✓ Advanced PWM techniques produce low motor harmonics,
low torque ripple, and minimized heating losses, resulting
in high efficiency.
✓ 70A RMS 2-minute current output.
✓ 24–48V nominal supply voltage.
Versatile Steering Input and Feedback Options
✓ Steering command input via CAN, dual redundant
quadrature encoder, sine/cosine sensor, sawtooth sensor,
or analog voltage inputs.
✓ Steered angle feedback via dual redundant homing switch,
quadrature encoder, sine/cosine sensor, sawtooth sensor, or
analog voltage inputs.
✓ Fully programmable input/output ratio mapping.
✓ Configurable homing methods, center offset, auto-center,
and end-stop protection.
✓ Programmable force feedback driver for command input
devices featuring variable friction tactile feedback (TFD).
Maximum Safety
✓ Dual redundant configuration of all safety-related parts.
✓ Two microprocessors, each with its own EEPROM memory.
✓ Separate input paths to each micro for all input and feedback
signals.
✓ 5A high-side fault output driver, consisting of two switches
connected in series; each switch is controlled by one micro
with independent supervision.
✓ Meets the requirements of the latest international functional
safety standards.
Unmatched Flexibility
✓ CANopen system communications.
✓ 35-pin AMPSEAL logic connector.
✓ Software includes a library of pre-defined AC steering motor
types from various manufacturers.
✓ Programmable motor temperature input prevents thermal
damage to motor and supports all commonly used thermistors.
1 — OVERVIEW
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✓ Integrated hourmeter and diagnostic log functions.
✓ +5V and +10V low-power supplies for input sensors, etc.
✓ Curtis 1313 handheld programmer and 1314 PC Programming
Station provide easy programming and powerful system diagnostic
and monitoring capabilities.
✓ Integrated Status LED gives instant diagnostic indication.
✓ Field upgradeable software.
Robust Reliability
✓ Insulated Metal Substrate (IMS) powerbase ensures superior
heat transfer.
✓ Intelligent thermal cutback and overvoltage/undervoltage
protection functions maintain steering while reducing traction
speed until severe over/under limits are reached.
✓ Rugged sealed housing and AMPSEAL connector meet IP65
environmental standards for use in harsh environments.
✓ Reverse polarity protection on battery connections
and short circuit protection on all output drivers.
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.
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2 — INSTALLATION & WIRING
2
Fig. 2 Mounting
dimensions, Curtis 1222
motor controller.
Dimensions in millimeters (and inches)
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
The outline and mounting hole dimensions for the 1222 controller are shown
in Figure 2. The controller meets the IP65 requirements for environmental
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, flat metal
surface with four 6mm (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.
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2 — INSTALLATION & WIRING
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
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.
The 1222 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.
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29 JANUARY 2013 DRAFT
2 — INSTALLATION & WIRING: High Current Connections
HIGH CURRENT CONNECTIONS
There are five high-current terminals, identified 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.
U AC steer motor phase U.
V AC steer motor phase V.
W AC steer motor phase W.
Lug assembly
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. The
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).
High current wiring recommendations
Battery cables (B+, B-)
These two cables should be run close to each other between the controller
and the battery. Use high quality copper lugs and observe the recommended
torque ratings. For best noise immunity the cables should not run across the
center section of the controller. With multiple high current controllers, use a
star ground from the battery B- terminal.
Indice
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