80 - Service Manual EP20P Elec Anglais PDF
80 - Service Manual EP20P Elec Anglais PDF
80 - Service Manual EP20P Elec Anglais PDF
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CONTAIN
Electrical architecture 3
CAN BUS 4
CIRCUIT DIAGRAMS 5
EP20P 5
Components 12
Components location 12
Electro brake 13
Description 13
Contactors 18
Sensors 18
Input/Output 22
Monitor menu 85
Maintenance 98
Controller exchange 99
Connections 100
Display 146
DIAGNOSTIC 148
By LED 149
By display 151
Gerbeurs Capacité - Tension Ref Ref Ref carte Bus Ref Outil
kg Variateur Variateur timon diagnostiq
Traction & de ue
pompe Direction
Stackers Capacity - Voltage Traction & Steering Butterfly Bus Diag. tool
kg pump controller PCB P/N
controller P/N
P/N
EP 20 P 2000 24V 54000517 54000544 J552807 CAN J397711
80.3CAN BUS
Tiller head PCB , traction controller, steering controller are connected to Can Bus.
As well diagnostic tool J397711 is connected to the Can Bus when it is used.
80.4Circuit diagrams
80.4.1 EP20P
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Accélération/ traction
Lavage/ lift
Descente/ lowering
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Klaxon / horn
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80.5 Components
80.5.3.1 Description
Tiller print board is a multi-functional tiller head controller board.
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Main Purpose:
- Butterfly for forward and backward speed control (by Can Bus)
- Butterfly for neutral brake and reverse braking(by Can Bus)
- Belly button (direct switch to the controller)
- Lift/Low(by Can Bus)
- Initial Lift/Low(by Can Bus)
- Tortoise mode(by Can Bus)
Picture A: View and Orientation for rotation left and rotation right, Connectors JP14 and JP15 must be
connected
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Attention!: During the teach procedure of the PCB is the communication to the controller
interrupted
4/ To teach the mechanical neutral position of the speed control be sure that the butterfly is in mechanical
neutral position, then push the button Lift 2 on JP14 to enter the neutral band,
(If nothing is connected on JP14, use tortoise button by disconnecting him and connecting him on JP14)
-->value is stored
5/ Turn the Butterfly up to the mechanical stop in “rotation right”, see Picture A
6/ Hold on the Butterflies in this position and push Lift 2 on JP14 to enter the value
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(If nothing is connected on JP14, use tortoise button by disconnecting him and connecting him on JP14)
-->value is stored,
8/ Hold on the Butterflies in this position and push Lower 2 on JP15 to enter the value
value is stored,
(If nothing is connected on JP15, use tortoise button by disconnecting him and connecting him on JP15)
9a/ Optional: Teach process of proportional-switches: Press each of them slowly until end of way and hold it
for 1 second
10/ Move the jumper from position “T(each)” PIN 3-4 to position “P(arking)” PIN 7-8,
12/ Switch OFF the power supply and check truck proper working
80.5.3.4 Contactors
80.5.3.4.1 Line contactor
Impedance = 46 Ω
Impedance = 17 Ω
80.5.3.5 Sensors
80.5.3.5.1 Square proximity switches
Square proximity switches are used to detect platform status, arm status, dead man on platform
Arm status
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This switch stop pump when lift get maximum position (before mechanical and hydraulic stop)
Its pin 1 is positive, pin 2 is signal, pin 3 is negative, input signal is switching value.
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Drive controller power connectors screws tightening torque is 10.2 ±1.1 N·m
80.5.4.1.3 Input/Output
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Max Speed 100 – 8000 Defines the maximum requested motor rpm at full
Max_Speed_SpdMx rpm throttle. Partially- applied throttle is scaled
0x3840 0x00 100 – 8000 proportionately; e.g., 40% applied throttle
corresponds to a request for 40% of the set Max
Speed Value.
If Max_Speed_SpdMx is set <10 rpm (through
VCL or CAN), the throttle request is zeroed
NOTE: The maximum motor rpm is subject to the
constraints
Kp 0 – 100% Determines how aggressively the speed
Kp_SpdMx controller attempts to match the speed of the
0 – 8192
0x3841 0x00 motor to the commanded speed. Larger values
provide tighter control.
If the gain is set too high, you may experience
oscillations as the controller tries to control speed.
If it is set too low, the motor may behave sluggishly
and be difficult to control.
Ki 5 – 100% The integral term (Ki) forces zero steady state
Ki_SpdMx error, so the motor will run at exactly the
50 – 1000
0x3842 0x00 commanded speed. Larger values provide tighter
control.
If the gain is set too high, you may experience
oscillations as the controller tries to control speed.
If it is set too low, the motor may take a long time
to approach the exact commanded speed.
Accel Rate 0.1 – 30.0 s Sets the rate (in seconds) at which the speed
Accel_Rate_SpdMx command increases when throttle is applied.
100 – 30000
0x3843 0x00 Larger values represent slower response.
Decel Rate 0.1 – 30.0 s Sets the rate (in seconds) that is used to slow down
Decel_Rate_SpdMx the vehicle when the throttle is reduced. Larger
100 – 30000
0x3847 0x00 values represent slower response.
Brake Rate 0.1 – 30.0 s Sets the rate (in seconds) at which the vehicle
Brake_Rate_SpdMx slows down when brake is applied or when throttle
100 – 30000
0x3848 0x00 is applied in the opposite direction. Larger values
represent slower response.
Pump Enable* On / Off This parameter should be programmed On to
|AC_Pump_Enable_SpdM operate a pump motor rather than a vehicle drive
On / Off
|AC_Pump_Enable_SpdM_ motor. The speed-controller responsiveness and
Bit0 [Bit 0]
stability are enhanced for pump-motor
0x3896 0x00 applications.
Regen Lower Enable* On / Off This parameter works together with Pump Enable
Regen_Lower_Enable_S On / Off as follows:
pdM 1) When Pump Enable = On and Regen
Regen_Lower_Enable_S Lower Enable = On, the pump motor can turn in
pdM_Bit0 [Bit 0] both the forward and the reverse direction. In
0x3877 0x00 this case, the pump can be used as the Lower
function (reverse). The pump motor, when
“driven in reverse by a load” will also regen
current in a similar fashion to a drive-motor
regenerative braking.
2) When Pump Enable = On and Regen
Lower Enable = Off, the pump motor can turn
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Max Speed Accel 0.1 – 30.0 s In some applications, the Max Speed value is
Max_Speed_Accel_S changed frequently, through VCL or over the
100 – 30000
pdM CANbus. The Max Speed Accel parameter controls
0x384A 0x00 the rate at which the maximum speed setpoint is
allowed to change when the value of
Max Speed is raised. The rate set by this parameter
is the time to ramp from 0 rpm to Typical Max Speed
rpm.
For example, suppose Max Speed is raised from
1000 rpm to 4000 rpm. If Typical Max Speed is 5000
rpm and the rate is 10.0 seconds, it will take
10.0 X (4000–1000) ÷ 5000 = 6.0 seconds to ramp
from 1000 rpm to 4000 rpm.
Max Speed Decel 0.1 – 30.0 s This parameter works like the Max Speed Accel
Max_Speed_Decel_S parameter, except that it controls the rate at which
100 – 30000
pdM the maximum speed setpoint is allowed to change
0x3846 0x00 when the value of Max Speed is lowered.
For example, suppose you change Max Speed from
4500 rpm to 2500 rpm. If Typical Max Speed is 5000
rpm, and the rate is 5.0 seconds, it will take
5.0 X (4500–2500) ÷ 5000 = 2.0 seconds to ramp
from 4500 rpm to 2500 rpm.
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Entry Rate 5 – 100% When the vehicle transitions from forward speed to
Entry_Rate_Position_Ho reverse speed or from reverse speed to forward
50 – 1000
ld speed (for example when coming to a stop going up a
0x383B 0x00 steep ramp) Position Hold is automatically entered
immediately at zero speed regardless of this
parameter.
This parameter applies when the vehicle needs to be
brought to a stop without the assistance of gravity (for
example when moving forward down a ramp).
This rate determines how quickly zero speed is
attained after the ramped speed request reaches
zero. Setting this parameter too high will make the
stop seem very abrupt and may even cause the
vehicle to roll back slightly. When the parameter is set
lower the vehicle take longer to come to a stop and
enter Position Hold mode.
Exit Rollback 0 – 100% This function is applicable when the Torque Preload
Reduction Enable function has been Disabled (Off) or the Torque
0 – 2048
Exit_Rollback_Reduction Preload Cancel Delay timer has expired (see EM
0x3844 0x00 Brake menu). Exit Rollback Reduction is only intended
for use with EM Brake Type = 2, for EM Brake Type =
1 (or 0) set Exit Rollback Reduction = 0.
Exit Rollback Reduction introduces an additional
control function for the speed controller to reduce
rollback on a ramp after a throttle command is
applied from a stop. For example, suppose the
vehicle is on a ramp facing upwards and, after a
forward throttle request, the vehicle rolls back slightly
before climbing the ramp (again, assuming the
torque preload function is inactive). As the vehicle
rolls back,
this additional term will be added to the torque request
until forward speed is sensed, to attempt to minimize
rollback. The effect increases with percentage, and is
disabled when = 0%. Setting the value too high may
introduce temporary oscillations.
If the Torque Preload Cancel Delay parameter
expires before the throttle is re- engaged, the torque
preload [Position Hold] memory will be cleared. In
such a case, setting Exit Rollback Reduction to > 0%
will reduce unintended roll. (see page 51).
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Ki 5 – 100% The integral term (Ki) forces zero steady state error,
Ki_TrqM so the motor speed will be limited to Max Speed.
50 – 1000
0x3025 0x00 Larger values provide faster control.
If the gain is set too high, you may experience
oscillations as the controller tries to limit speed. If it
is set too low, it may take a long time for the motor to
approach Max Speed from overspeed.
Kd 0 – 100% Provides damping as the vehicle approaches top
Kd_TrqM speed, thereby reducing overshoot. If Kd is set too
0 – 8192
0x3836 0x00 high, the vehicle may take too long to reach top
speed. If Kd is set too low, the vehicle may overshoot
top speed, especially when traveling downhill.
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cause oscillations.
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Reversal Soften 0 – 100% Larger values create a softer reversal from regen
Reversal_Soften braking to drive when near zero speed. This helps
0 – 3000
0x3074 0x00 soften the transition when the regen and drive
current limits are set to different values
Note: This parameter is not mode-specific and
appears in two places. Changing the value of this
torque-mode parameter affects the parameter listed
in: Program » Speed Mode » Response » Fine
Tuning » Reversal Soften.
Max Speed Decel 0.1 – 30.0 s In some applications, the Max Speed value is
Max_Speed_Decel_Trq changed frequently, through VCL or over the
100 – 30000
M CANbus. The Max Speed Decel parameter controls
0x3835 0x00 the rate at which the maximum speed setpoint is
allowed to change when the value of
Max Speed is lowered. The rate set by this parameter
is the time to ramp from Typical Max Speed rpm to 0
rpm.
For example, suppose you change Max Speed from
3000 rpm to 1000 rpm. If Typical Max Speed is 5000
rpm, and the rate is 5.0 seconds, it will take
5.0 X (3000–1000) ÷ 5000 = 2.0 seconds to ramp
from 3000 rpm to 1000 rpm.
THROTTLE MENU
PARAMETER ALLOWABLE RANGE DESCRIPTION
Throttle Type PCF 1–5 These E and SE controllers accept a variety of throttle
inputs. The throttle type
Throttle_Type 1–5 parameter can be programmed as follows:
0x3000 0x00
1. 2-wire rheostat, 5 kΩ–0 input
2. single-ended 3-wire 1 kΩ–10 kΩ
potentiometer, or 0–5 V voltage source
3. 2-wire rheostat, 0–5 kΩ input
4. wigwag 3-wire 1 kΩ–10 kΩ potentiometer, or
0–5 V voltage source
5. VCL input (VCL_Throttle)
NOTE: Do not change this parameter while the
controller is powering the motor. Any time this
parameter is changed a Parameter Change Fault
(fault code 49) is set and must be cleared by
cycling power; this protects the controller and the
operator.
Forward Deadband 0.00 – 5.00 V Defines the wiper voltage at the throttle deadband
threshold. Increasing the Forward_Deadband 0 – 32767 throttle deadband setting will
increase the neutral range. This parameter 0x3001 0x00 is especially useful with
throttle assemblies that do not reliably return to a
well-defined neutral point, because it allows the
deadband to be defined
wide enough to ensure that the controller goes into
neutral when the throttle mechanism is released.
Forward Map 0 – 100% Modifies the vehicle’s response to the throttle input.
Setting the throttle map
Forward_Map 0 – 32767 at 50% provides a linear output response to throttle
position. Values below
0x3002 0x00 50% reduce the controller output at low throttle
settings, providing enhanced slow speed
maneuverability. Values above 50% give the vehicle
a faster, more responsive feel at low throttle settings.
The map value is the percentage of controller
output at half throttle [(deadband + max)/2].
Forward Max 0.00 – 5.00 V Defines the wiper voltage required to produce 100%
controller output.
Forward_Max 0 – 32767 Decreasing the throttle max setting reduces the wiper
voltage and therefore
0x3003 0x00 the full stroke necessary to produce full controller
output. This parameter allows reduced-range
throttle assemblies to be accommodated
Forward Offset 0 – 100% Defines the initial controller output generated when
the throttle is first rotated
Forward_Offset 0 – 32767 out of the neutral deadband. For most vehicles, a
setting of 0 is appropriate.
0x3004 0x00 For heavy vehicles, however, increasing the offset
may improve controllability by reducing the amount
of throttle required to start the vehicle moving.
Reverse Deadband 0.00 – 5.00 V
Reverse_Deadband 0 – 32767
0x3005 0x00
Reverse Map 0 – 100%
Reverse_Map 0 – 32767
0x3006 0x00 The four Throttle Reverse parameters are the same
as their Throttle Forward counterparts, and apply
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BRAKE MENU
PARAMETER ALLOWABLE RANGE DESCRIPTION
Brake Pedal Enable On / Off Determines whether the brake input and algorithm are
enabled, making the
|Brake_Pedal_Enable On / Off brake throttle part of the motor control command.
|OptionBits1 [Bit 3]
0x306A 0x00
Brake Type PCF 1–5 These E and SE controllers accept a variety of brake
inputs. The brake type
Brake_Type 1–5 parameter can be programmed as follows:
0x300A 0x00
1. 2-wire rheostat, 5 kΩ–0 input
2. Single-ended 3-wire 1 kΩ–10 kΩ
potentiometer, 0–5 V voltage source
3. 2-wire rheostat, 0–5 kΩ input
4. (not applicable)
5. VCL input (VCL_Brake)
NOTE: Do not change this parameter while the
controller is powering the motor. Any time this
parameter is changed a Parameter Change Fault
(fault code 49) is set and must be cleared by
cycling power; this protects the controller and the
operator.
Brake Deadband 0.00 – 5.00 V
Brake_Deadband 0 – 32767
0x300B 0x00
Brake Map 0 – 100%
Brake_Map 0 – 32767
0x300C 0x00 The four Brake throttle adjustment parameters
Brake Max 0.00 – 5.00 V are the same as their Drive throttle
Brake_Max 0 – 32767 counterparts; see descriptions and Figure 14.
0x300D 0x00
Brake Offset 0 – 100%
Brake_Offset 0 – 32767
0x300E 0x00
Brake Filter 0.5 – 125.0 Hz Sets the low pass filter cutoff frequency for the pot2
wiper input. Higher
Brake_Filter 131 – 32767 values will make the brake more responsive to quick
changes. Lower values
0x3031 0x00 will make the brake less responsive to electrical
noise.
VCL Brake Enable On / Off When programmed On, the brake processing with
fault detection will
|VCL_Brake_Enable On / Off operate normally; however, the brake command will
require VCL to define
|VCL_Brake_Enable_Bit0 [Bit 0] the connection between the OS_Brake and
VCL_Brake variables. This allows
0x301E 0x00 VCL flexibility and customization of throttle
processing, while still allowing Brake_Type 1–3
with brake fault detection. Figure 15 (page 105)
illustrates these brake chains.
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Position Hold Settling Time 0 – 5000 Determines how long the position hold function
Position_Hold_Settling_Time ms is allowed to operate before the EM brake is
0x3024 0x00 0 – 156 set. This time should be set long enough for the
position hold to settle.
This parameter appears twice in the menu
structure. Changing the value of this
parameter affects this (same) parameter in the
Position Hold menu, page 38.
This parameter is re-named for os31. It is
the same as the previous Set Speed
Settling Time parameter.
NOTE *
Brake Set Time 40 – Estimated time for the EM brake to physically
EM_Brake_Set_Time 2000 ms set after the holding voltage is released. This
0x30DB 0x00 5 – 250 determines how long the controller waits, after
removing voltage from the brake, before
released the torque. This should be set longer
than the actual brake setting time to ensure
the vehicle doesn’t move before the brake fully
engages.
This is a new parameter for os31.
Torque Release Time 40 – Time to release torque after EM Brake has
EM_Brake_Torque_Release_Time 2000 ms set and motor has stopped
0x30DC 0x00 5 – 250 (EMBrakeEngagedAndStopped state).
This is a new parameter for os31.
Brake Release Time 40 – Estimated time for the EM brake to physically
EM_Brake_Release_Time 2000 ms release after the pull- in voltage is applied.
0x3073 0x00 5 – 250 This is used to ensure the position hold torque
buildup is complete before the brake releases.
When set too low, the vehicle may experience
rollback on EM brake release.
This parameter is re-named for os31. It is
the same as the previous Release Delay
parameter
Torque Preload Time 0 – 800 Estimated worst-case time to build up the
ms torque required to hold
EM_Brake_Torque_Preload_Time 0 – 100 the vehicle stationary on a hill prior to EM brake
release.
0x3090 0x00 This is used in conjunction with Release Delay
to determine when
to release the brake and allow the speed
request to slew away from
zero.
This parameter is re-named for os31. It is
the same as the
previous Torque Preload Delay parameter
NOTE *
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Torque Preload Enable On / Off When enabled, this function eliminates
|EM_Brake_Torque_Preload_Enabl rollback when the throttle is re-engaged on a
e On / Off
ramp by forcing the vehicle to first enter
|EM_Brake_Torque_Preload_Enabl
e_Bit0 [Bit 0] position- hold before setting the EM brake,
and then “remembering” the amount of torque
0x389D 0x00
that was necessary to hold it on the ramp.
When throttle is re-engaged, this value is
loaded in the motor before the EM brake is
released. The torque value is cleared
automatically when KSI power is cycled.
Off = When a valid throttle input is received,
the speed controller will start with no
torque preload as soon as the Release
Delay expires. This will allow some
rollback when the EM brake releases.
This rollback can be reduced by raising
the Exit Rollback Reduction parameter in
the Position Hold Menu (page 38).
On = When a valid throttle input is received,
the speed controller will start with a pre-set
torque as measured by position-hold when
the vehicle came to a stop.
NOTE *
Save Torque Preload On/Off This parameter controls whether the EM
|Save_Torque_Preload Brake torque preload is saved over a
On/Off
|Save_Torque_Preload_Bit0 [Bit 0] keyswitch cycle. If
0x38C9 0x00 Torque_Preload_Cancel_Delay is nonzero
and this parameter = On, the timer starts
again upon
startup (KSI cycle) such that the countdown is
from the full value of the
Torque_Preload_Cancel_Delay parameter.
This is a new parameter for os31.
NOTE: *This parameter is applicable only when Speed Mode or Speed Mode Express is selected and
either Position Hold Enable = On or EM Brake Type = 2.
MOTOR MENU
PARAMETER ALLOWABLE DESCRIPTI
RANGE ON
Typical Max Speed 500 – 8000 Set this parameter to the typical maximum motor
Typical_Max_Speed rpm speed of the vehicle. This value does not need to be
0x304D 0x00 500 – 8000 set precisely; an estimate will do. All of the vehicle
response rates are normalized to Typical Max
Speed.
For example, suppose Typical_Max_Speed is fixed
at 6000 rpm, and Full_Accel_Rate_LS_SpdM = 3.0
seconds:
If Max_Speed_SpdM = 6000 rpm, it will take 3.0
seconds to accelerate from zero to top speed
(6000 rpm).
If Max_Speed_SpdM = 3000 rpm, it will take 1.5
seconds to accelerate from zero to top speed
(3000 rpm).
If Max_Speed_SpdM = 1000 rpm, it will take 0.5
seconds to accelerate to accelerate from zero to
top speed (1000 rpm)
LOS Decel Rate 2.0 – 15.0 Defines the rate (in seconds) at which the frequency
Enc_LOS_Decel_Rate s decreases when throttle is released, while operating
0x3087 0x00 2000 – in LOS mode.
15000
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Max Test Speed 1000 – 6000 This parameter is used to set the maximum motor
rpm speed allowed during SPM
PMAC_AutoChar_Max_T 1000 – 6000 motor characterization.
est_Speed*
0x38C1 0x00 See Chapter 8B for the complete description of the
SPM motor
characterization procedure and how this parameter is
used.
Max Test Current 10 – 30% This parameter is used to set the maximum motor
speed allowed during SPM
PMAC_AutoChar_Max_T 3277 – 9831 motor characterization.
est_Current*
0x38C2 0x00 See Chapter 8B for the complete description of the
SPM motor
characterization procedure and how this parameter is
used.
OPTIONS
MOTOR FEEDBACK
Feedback Type 1–2 Set this parameter to the type of position feedback
Feedback_Type device in your vehicle:
1–2
0x382E 0x00
1 = quadrature
encoder 2 =
Sin/Cos sensor.
NOTE: A Parameter Mismatch Fault will result unless
the Feedback Type matches the Motor Technology
setting :
If Motor Technology = 0 (ACIM), then Feedback Type
must = 1 (quadrature encoder). If Motor Technology =
1 (SPM), then Feedback Type must = 2 (Sin/Cos
sensor).
Swap Feedback On / Changes the motor encoder’s effective direction of
Direction PCF Off rotation. The encoder provides data used to
Swap_Feedback_Directi On / calculate motor position and speed. This parameter
on OptionBits3 [Bit 0] Off must be set such that when the motor is turning
0x306C 0x00 forward, the controller reports back a positive motor
speed.
Positive motor speed must be in the forward
direction in order for the emergency reverse
feature to operate properly.
WARNING
NOTE: Do not change this parameter while the
controller is powering the motor. Any time this
parameter is changed a Parameter Change Fault
(fault code 49) is set and must be cleared by cycling
power; this protects the controller and the operator.
Adjusting this parameter can be hazardous. For
instructions, see Chapter 7, Step 10 (page 83).
Sin Cos Fault Time 10 – 1000 ms A Sin Cos Sensor fault (fault 36) will be generated if
Sin_Cos_Fault_Time the sensor is outside the tolerance for 10ms during
10 – 1000
0x38CE 0x00 this amount of time.
This is a new parameter for os31.
Sin Min* 0 – 100% Minimum output by the Sin/Cos sensor on the Sin
Feedback_Sin_Min channel. Input detected at Position Feedback A
0 – 1023
0x3863 0x00 (pin 31). The value is set during the SPM motor
characterization procedure. The default value is
zero.
Sin Max* 0 – 100% Maximum output by the Sin/Cos sensor on the Sin
Feedback_Sin_Max channel. Input detected at Position Feedback A
0 – 1023
0x385C 0x00 (pin 31). The value is set during the SPM motor
characterization procedure. The default value is
zero.
Cos Min* 0 – 100% Minimum output by the Sin/Cos sensor on the Cos
Feedback_Cos_Min channel. Input detected at Position Feedback B
0 – 1023
0x385F 0x00 (pin 32). The value is set during the SPM motor
characterization procedure. The default value is
zero.
Cos Max* 0 – 100% Maximum output by the Sin/Cos sensor on the Cos
Feedback_Cos_Max channel. Input detected at Position Feedback B
0 – 1023
0x382F 0x00 (pin 32). The value is set during the SPM motor
characterization procedure. The default value is
zero.
*These are read-only parameters, useful when cloning controllers to verify these settings, and if
the proper SPM (PMAC) auto-characterization was preformed.
The four Sin/Cos Min and Max parameters’ default value is zero. This prevents the running of
SPM/PMAC motors without performing the auto- characterization.
See Chapter 8B for the SPM/PMAC Auto Characterization procedure.
Contact your Curtis distributor or support engineer to resolve any Sin/Cos sensor errors or their
parameter values.
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Motor: Temperature control menu
Battery menu
VEHICLE MENU
Quick Links:
Monitor » Vehicle Speed Vehicle Odometer Time to Speed 1 Time to Speed 2 Time to Distance 1 Time
to Distance 2 Time to Distance 3
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EMR Enable On / Off Determines whether the emergency reverse function is active.
|EMR_Enable On / Off On = emergency reverse is enabled.
|OptionBits1 Off = emergency reverse is disabled.
[Bit 1]
0x306A 0x00
EMR Type 0–3 Determines where the input comes from for emergency reverse.
EMR_Type 0–3 0 = emergency reverse activated by switch 1 (pin 24).
0x3036 0x00 1 = emergency reverse is activated by VCL functions
\Enable_Emer_Rev() and Disable_Emer_Rev().
2 = emergency reverse activated by switch 1 (pin 24), but only if
the vehicle is moving forward (forks trailing) when emergency
reverse is activated.
3 = emergency reverse is activated by VCL functions
Enable_Emer_Rev() and Disable_Emer_Rev(), but only if the
vehicle is moving forward (forks trailing) when emergency
reverse is activated.
EMR Dir On / Off Determines whether the interlock switch must be turned off after
Interlock
|EMR_Dir_Int On / Off emergency reverse before the vehicle can be driven again.
erlock
|EMR_Dir_Int On = interlock and throttle and direction must all be cleared.
erlock_Bit0
[Bit 0]
0x389F 0x00 Off = only throttle and direction must be cleared.
EMR Time 0.0 – 30.0 s Defines how long emergency reverse is allowed to be active
Limit 0 – 3750 after the vehicle is moving in the reverse direction. This timer
EMR_Time_L will restart if the vehicle ever goes forward while emergency
imit reverse is still active. The allowable range is 0–30 seconds,
0x303B 0x00 where 30 seconds is a special case of no time out.
When emergency reverse times out, the Emer Rev Timeout fault
is set. Cycling the emergency reverse input will clear the Emer
Rev Timeout fault.
To stop the vehicle after an EMR event (not move in reverse
direction), set this parameter to 0.
EMR Speed 50 – 6000 Defines the maximum reverse speed of the motor (in motor
EMR_Speed rpm rpm), when emergency reverse is active. The motor speed in
0x3038 0x00 50 – 6000 reverse during an emergency reverse event will be the lesser of
EMR_Speed and either Max_Speed_SpdMx (for Speed Mode
Express) or Max_Speed_SpdM (for Speed Mode).
Emergency Reverse is not valid for Torque Mode. See Fig.16,
81/174
CLONING CONTROLLERS
(for copying parameter settings to multiple controllers)
Once a controller has been programmed to the desired settings, these settings can
be transferred as a group to other controllers, thus creating a family of “clone”
controllers with identical settings.
Cloning only works between controllers with the same model number and
software version. For example, the 1313/1314 programmer can read all the
information from a 1236E-5421 controller and write it to other 1236E-5421
controllers; however, it cannot write that same information to 1236E- 5521 or
1236SE-5621 controllers.
To perform cloning, plug the programmer (1313 or 1314) into the controller that has
the desired settings. While the steps using the 1313 versus the 1314 are slightly
different in terms of screen images, the basic concept is the same: Save the
parameters from the controller to clone, which is the act of saving a “.CPF” file (Curtis
Program File) using the Save/Save As . . . operations. When saving the CPF file,
chose a file name with meaning as this CPF file is used to write (clone) its data to
subsequent controllers.
For example, using the 1314 PC Programming Station, with the controller to be
updated connected, select “open” in the File menu, then navigate to the above
mentioned (saved) CPF file, which will be loaded (indicated) below the menus bar. In
the Communication menu, select the “Save file to connected system (F6)” icon, and
follow the prompts to copy the settings into the controller being cloned (i.e., the
“connected System” or controller). The 1313 is slightly different, working off the SD
card where the CPF file was saved versus the PC’s hard drive, and then using the
“Restore” feature to download the settings into the controller being cloned.
For cloning Dual Drive controllers, the Master controller parameters will also be
loaded into Slave controller, then the parameters for the Slave-vs-Master must be
adjusted using the 1313/1314, as corresponds to the differences between the master
and slave dual-drive controllers. See the separate Dual Drive manual, p/n 53097-DD,
for the specific steps to preform for cloning/setup of the Master and Slave Dual-Drive
controllers.
Note: Using either programmer (1313/1314), the prompts will offer “Advanced Cloning” .
...
Advanced Cloning is advisable ONLY under the direction of your Curtis distributor or
support engineer, because it restores all parameters, including those at a higher
(hidden level). Due to possible conflicts, select “No” in the 1313 prompt, or do not
“check” the box in the 1314).
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Through its Monitor menu, the diagnostic tool provides access to real-time data during vehicle
operation. This information is helpful during diagnostics and troubleshooting, and also while
adjusting programmable parameters and the vehicle’s initial setup
Monitor Menu: INPUTS
VARIABLE DISPLAY DESCRIPTI
RANGE ON
Throttle Command –100.0 – Throttle request to slew rate block.
Throttle_Command 100.0%
0x3216 0x00 –32767 –
32767
Throttle Multiplier –200.0 – Multiplies or divides the throttle signal; useful in VCL
200.0% throttle processing
Throttle_Multiplier –256 – 256 (see Throttle Processing on page 104 and Figure 15
0x3213 0x00 on page 105).
Mapped Throttle –100.0 – Mapped throttle request.
100.0%
Mapped_Throttle –32767 – (see Throttle Processing on page 104 and Figure 15
0x3211 0x00 32767 on page 105).
Throttle Pot 0.00 – 5.50 Voltage at throttle pot wiper (pin 16).
Throttle_Pot_Raw V
0x3215 0x00 0 – 36044
Brake Command 0.0 – Brake request to slew rate block.
100.0%
Brake_Command 0 – 32767 (see Brake Processing on page 106 and Figure 15
0x321A 0x00 on page 105)
Mapped Brake 0.0 – Mapped brake request.
100.0%
Mapped_Brake 0 – 32767 (see Brake Processing on page 106 and Figure 15
0x3212 0x00 on page 105)
Pot2 Raw 0.00 – 5.50 Voltage at pot2 wiper (pin 17).
Pot2_Raw V
0x3217 0x00 0 – 36044
PD Throttle 0.00 – Proportional driver current request.
100.00 %
PD_Throttle 0 – 32766 (see Interfacing the Proportional Current Driver and
0x3210 0x00 Figure 17 on page 109)
Steer Pot 0.00 – 6.25 Voltage at steer pot wiper (pin 17) on Dual Drive
V traction slave.
Steer_Pot_Raw 0 – 32767 (reference the Dual Drive supplement manual:
0x38BB 0x00 53097_E&SEDD_os31)
Steer Angle –90 – 90 Steer angle degrees calculated in Dual Drive traction
Steer_Angle master.
–90 – 90
0x38BA 0x00
Interlock On / Off Interlock input on or off. The source of the interlock
input is determined by
|Interlock_State On / Off the Interlock Type parameter.
|System_Flags1 [Bit 0] from Switch 3 (pin 9) if Interlock Type = 0
0x322B 0x00 from VCL function if Interlock Type = 1
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0x3226 0x00
Switch 16 On / Off Switch 16 on or off (pin 14).
|Sw_16 On / Off
|Switches [Bit 15]
0x3226 0x00
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80.5.4.5 Maintenance
Controller has no user repair parts. Do not try to open, repair or alter the controller. Otherwise it may
damage the controller and also invalid the guarantee.
It’s suggested to keep the controller clean and dry, periodically check and get rid of diagnose historical files.
Cleaning
Periodically clean the outside controller is good for preventing corrosion or other controller fault from dirty,
dust and chemical, which is part of the environment and always exist in battery power supply system.
Be careful when operating the truck power supplied by battery. Including but not limit to the following:
correct training, wear goggles, do not wear loose clothing and jewelry.
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Carry out maintenance according to the following cleaning procedure. Never clean the controller with high
pressure washer.
– Connect load(like contactor coil or horn) between controller B+ and B- to discharge controller capacity.
– Clean dirt or corrosive on the power and signal binding post. Wipe the controller with wet cloth, dry the
controller before connecting the battery. Controller can’t suffer the water impact with pressure.
WARNING
Strictly prohibit water in the product. Strictly prohibit operating with electricity. Strictly prohibit reverse
polarity. Strictly prohibit motor short circuit.
when mounting the controller, apply heat conduction silicon grease to its bottom.
1. Contrôle de la batterie :
a. Tension et densité batterie chargée.
b. Isolation par rapport au châssis
2. Contrôle du moteur
3. Contrôle des faisceaux de puissance moteur et batterie
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80.5.5.1 Connections
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0 = Analog Sensor
1 = Quadrature Encoder
(0x34F000, 0 – 1 Position
8bits) Encoder 2A
1 = Quadrature Encoder
Method 0
Method 1
Home
Switch
Home Switch
Method 2 Method 3
(0x33AA00, 2400 –
16bits) 6000
Main DNC 0 – 10.0V Sets the threshold used for the ongoing
Threshold check that ensures the main contactor
(0x34C300, 0 – 1000 remains closed while in operation. The
16bits) Main DNC Threshold is the maximum
voltage difference between the
Keyswitch and Capacitor voltages.
Open Delay 0 – 40.0s The open delay can be set to allow the
(0x34CA00, steer relay to remain closed for a
16bits) 0 – 400 period of time (the open delay) after the
interlock is turned off. The delay is
useful for preventing unnecessary
cycling of the relay.
Error Time 0.1 – 10.0s Defines how long Error Tolerance (deg)
(0x379700, can be exceeded if the steered wheel is
16bits) 25 – 2500 not moving in the right direction with a
Wheel Speed equal to or greater than
the Speed Tolerance.Since the first
derivative (Wheel Speed) is inherently
noisy, the timer is implemented as a
count-up/count-down timer (Following
Error Time accumulated) where the
fault time is set by the parameter Error
Time.Example: If Error Tolerance (deg)
= 5 and Speed Tolerance = 10, the
Following Error Time Accumulated will
count up when the Error Tolerance is
>5 and the Wheel Speed <10.
Following Error Time Accumulated will
count down if either the Error Tolerance
≤ 5 or the Wheel Speed ≥10. Error
Time must be set long enough for the
steered wheel to reverse direction and
reach the minimum speed (Speed
Tolerance) under the worst case
conditions.
Boost Time 0 – 10.0s Set the maximum time that the boost
(0x343500, current is allowed.
16bits) 0 – 625
Gear Ratio 0 – 500.0 Defines the total gear ratio of gear box,
(0x368600, including its speed reducing
16bits) 0 – 8000 mechanism.
(0x368400,
16bits)
−1 – 4 1 = 250 Kbps
2 = 500 Kbps
3 = 800 Kbps
4 = 1 Mbps
TPDO2
Mapping
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(see sub
menu below)
(0x160003, 0 –
32bits) 0xFFFFFFF
F
(0x160004, 0 –
32bits) 0xFFFFFFF
F
(0x160005, 0 –
32bits) 0xFFFFFFF
F
Map 6 0– No mapping.
0xFFFFFFF
(0x160006, F
32bits)
0–
0xFFFFFFF
F
Map 7 0– No mapping.
0xFFFFFFF
(0x160007, F
32bits)
0–
0xFFFFFFF
F
Map 8 0– No mapping.
0xFFFFFFF
(0x160008, F
32bits)
0–
0xFFFFFFF
F
0–
0xFFFFFFF
F
Map 7 0– No mapping.
0xFFFFFFF
(0x1A0007, F
32bits)
0–
0xFFFFFFF
F
Map 8 0– No mapping.
0xFFFFFFF
(0x1A0008, F
32bits)
0–
0xFFFFFFF
F
0–
0xFFFFFFF
F
0–
0xFFFFFFF
F
Map 7 0– No mapping.
0xFFFFFFF
(0x1A0107, F
32bits)
0–
0xFFFFFFF
F
Map 8 0– No mapping.
0xFFFFFFF
(0x1A0108, F
32bits)
0–
0xFFFFFFF
F
Reset hour OFF / ON When set to Yes, will set the hour meter
meter to zero hours.
(0x4E6600, 0 / 1
16bits)
Through its Monitor menu, the diagnostic tool provides access to real-time data during vehicle
operation. This information is helpful during diagnostics and troubleshooting, and also while
adjusting programmable parameters and the vehicle’s initial setup.
At startup this switch determines with wether the wheel came is left or right positioned compare to toggle
switch.
If it is on the right, steering motor will turn anticlockwise in order to switch toggle switch for steering wheel
initialization.
If it is on the right, steering motor will turn anticlockwise in order to switch toggle switch for steering wheel
initialization.
Sensor calibration
When power is on of the truck, the driving system will adjust the driving wheel
in the middle position automatically. You can check if the driving wheel is in the
middle or not by the Zero position switch. If the zero position switch is facing the
circle on the gear, as picture 1 shows, it means the driving wheel is in the middle.
whose status should look like picture 2. If it failed to match, it can be adjust by the
Both encoders are integrated in the sensor at the top of the steering motor.
The pin 1 of the angle sensor is positive, pin2, 3 are signals, pin 4 is negative,The input signal is analog
(0-5V).
Step 2: If the wheel is left skewed, please rotate the angle sensor right. If the wheel is right skewed, then
rotate the angle sensor left. Until the zero position switch is facing the circle on the gear.
80.5.5.8 Display
Display shows:
Niveau batterie
Hourmeter green
Horamètre
If there are 2 error code at the same time, for example”3.1, 3.6”, The first 3.1 means
the error in driving controller, the second 3.6 means the error in steering controller.
Single error code”SET 3.6” means the error in steering controller. SET refers steering
controller. Single error code”TRA 3.8” means the error in traction controller. TRA refers
driving controller.
80.6Diagnostic
Diagnostic tool P/N: J397711
Diagnostic organigram
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Le variateur de traction peut détecter les pannes ou informations d’erreurs dans les différentes situations.
①by reading the two fault codes displayed on the instrument (the first two fault code for drive controller, the
second two fault code for steering controller)
The pair of LEDs built into the Traction controller (one red, one yellow) produce flash codes displaying all
the currently set faults in a repeating cycle.
80.6.1.1 By LED
Affichage Information
LED light is off Controller power is not on; or vehicle has dead
battery; or other severe damage.
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LED light is often red Controller failed to supervise or did not load
software. Restart KSI cycle, load software if
necessary.
Red and yellow lights flash alternately in a repeated interval when there detects fault. Each code consists of
two digits. The red LED flashes once to indicate that the first digit of the code will follow; the yellow LED
then flashes the appropriate number of times for the first digit. The red LED flashes twice to indicate that
the second digit of the code will follow; the yellow LED flashes the appropriate number of times for the
second digit.
In the handheld programmer fault menu, display word “Undervoltage Cutback”; and the current battery
voltage display on the monitor menu(“Keyswitch Voltage”).
✱ ✲✲ ✱✱ ✲✲✲
The numerical codes used by the yellow LED are listed in the troubleshooting chart (Table 6), which also
lists possible fault causes and describes the conditions that set and clear each fault.
Troubleshooting
– Fault code
– Troubleshooting
When there is fault, if it’s affirmed not the wiring error or truck malfunction, you can try to restart through key
switch. If fault still exists, please turn down key switch, check if the connector of pin 35 connects right or
gets dirt, after repair and clean , reconnect, and then start again.
80.6.1.2 By display
Error code and its meaning
Usually, the steering electrical controller default will cause the error code 3.1 of
driving electrical controller. For an example”3.1, 4.1”, if the error code 4.1 of steering
electrical controller be solved, driving electrical controller 3.1 will disappear at the same
time.
Error code 4.1 means:The input power of the analog port of the steering electrical
controller is out of range. The analog input signal of this port comes from the angle
sensor. Therefore, when this fault occurs, the first step is to detect whether the wiring the harness related to
the angle sensor is broken or disconnected. The second step is to easure the input signal of the angle
sensor to see if it is within the range of 0.1-5V. If not, replace the angle sensor,pls.
TRA5.2 is a custom error tiller communication error of the drive electrical controller .
Solutions: 1. Check whether the CAN communication wires between the drive electrical
the controller and the tiller are disconnected or connected. 2. Measure whether the
resistance at both ends of the CAN communication wires is 60 ohms or not , Whether the
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voltage is about 2.5V or not, 3. Check whether the power supply of the tillere is normal, 4.
TRA4.7 is an error of the operation sequence of the drive electrical controller. The
causes of this error are: the key switch, interlock switch, direction switch, and accelerator
input sequence failure; solution: 1. Check the operation sequence of each switch to
eliminate the operation problem; 2. Check the status of each switch, if there is an
Diagnostic tool is a handheld tool that allows user programming, testing and
diagnosing the traction motor controller, refer to the following picture. Program
setting handheld terminal owns one menu navigation key, one data Inc/Dec key and
Display window includes a seven-line 128 × 64 pixel LCD screen, this screen
can show the test and pictures at the same time, visible in the lightest condition,
Program is driven by the menu, and enters the next menu by pressing menu
navigation button. When the program is connected to motor controller, all motor
Display screen:It can show seven-line tests and pictures at the same time.
Menu navigation key: Move the cursor on the screen up or down to pass the menu
Bookmark key:Three bookmark keys allow you to return fast or reach your favor or
often use menu interface without through the menu navigation. Press on the relevant
bookmark button for 4 seconds, it can store relevant menu interface to this button.
Press the relevant bookmark key, it can skip to the corresponding menu interface of
your chosen bookmark. After closing the programmer, the bookmark button will not
be kept.
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switch.
17 Severe Undervoltage 1.Setup error of battery Reason: When MOSFEET
Driving torque reduce parameter. axle working, capacitor
2. Power consumption
voltage is lower than the
of non controller system. minimum voltage limit.
3.Too large battery
impedance. Troubleshooting : Raise the
“OFF”.
29 Motor Temp Sensor Fault 1. Motor temperature Reason:Input voltage value
Max. speed drops to LOS sensor is connected wrongly. of motor temperature sensor
status and motor 2. If motor does not apply is 0 or larger than 10V.
temperature cutback temperature sensor, Troubleshooting: Adjust input
invalid. programming parameter “Temp voltage value of motor
Troubleshooting:Correct
open or
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39 Main Contactor Did Not 1.Main contactor does not Reason:When the main
Close close contactor is closed, capacitor
Motor stops working 2. Contactor contacts
voltage does not charge B+
Main contactor have oxidized, melted, or voltage.
disconnects connection status is Troubleshooting:Check the
Electromagnetic brake unstable. contactor, restart the key
disconnects Throttle 3.External load on the switch.
capacitor.
invalid
4.Fuse protector disconnects.
Brake
Pump stops working
41 Throttle Wiper High 1. Throttle pot wiper voltage Reason: Throttle pot wiper(pin
Throttle invalid too high 16) voltage is higher than the
high fault threshold(can be
changed
with the VCL function
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stop
PD stops
Brake
Pump
stops
4 HPD/Sequencing Fault 1. Wrong sequence setting Reason:The wrong input of
7 Throttle invalid of key start, interlock, direction key start, interlock, direction
and throttle input sequence and throttle cause HPD and
setting. sequencing fault.
2. Wiring, switch key, interlock,
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Accelerator the
stops software.
Brake
Pump stops
9 Dualmotor Parameter Enable parameter of Reason:When the dual
9 Mismatch drive software enabled,
dualmotor is set as ON, and
Close main control mode should set as
control mode selecting
contactor Close 0(Speed Mode Express) or
parameter not set as 0
EM brake Close 1(Speed Mode), otherwise
(Speed Mode Express) or 1
accelerator (Speed Mode) there will be fault.
Brake and close the pump Troubleshooting:Adjust to
proper
value and switch KSI.
① through the instrument display on two two fault code to obtain the fault information (the first two
fault code for walking controller, the second two fault code for steering controller);
Handheld programmer will be cleared after shows that since the last time to now all the history of
the fault information.The programmer shows wrong name.
In the handheld programmer error menu will display the word "Command Analog1 Out of
Range".Actual voltage according to the monitor menu (the Command Input » Analog Input » Analog
to 1).
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Programmer
Code display Probable fault reason
Fault display
23 Motor Polarity Fault
Steering 1. Steering motor is the cathode.
stops Drive 2. The encoder phase sequence counter.
stops
36 Motor Stalled 1.Steering system resistance is
Steering
too large. 2.To meet the
stops Drive
mechanical limit.
stops
3.The median detection switch failure.
37 Motor Open
Steering 1.Steering motor cable connector contact is
stops Drive not good. 2.The steering motor carbon
stops brush poor contact.
Unité: N·m
Classe
Bolt’s
diameter
4.6 5.6 6.6 8.8
·Bolt’s grade can be found in the head of the bolt, if it can’t be found, the grade is 8.8.