Manual
Model 1220
Electric Steering Controller
for Brushed PM Motor
Read Instructions Carefully!
Specications are subject to change without notice.
© 2015 Curtis Instruments, Inc. ® Curtis is a registered trademark of Curtis Instruments, Inc.
© The design and appearance of the products depicted herein are the copyright of Curtis Instruments, Inc. 53218 Rev C 11/2015
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
CONTENTS
1. OVERVIEW ..............................................................................1
2. INSTALLATION AND WIRING ..........................................4
Mounting the Controller ....................................................4
High Current Connections ..................................................5
Low Current Connections ..................................................5
Controller Wiring ...............................................................6
Input/Output Specifications ...............................................8
3. PROGRAMMABLE PARAMETERS ....................................10
Program Menu ..................................................................11
4. MONITOR MENU ...............................................................23
5. COMMISSIONING ..............................................................27
CONTENTS
6. DIAGNOSTICS AND TROUBLESHOOTING .................37
7. MAINTENANCE ..................................................................41
appendix a Vehicle Design Considerations
appendix b Programming Devices
appendix c Specifications, 1220 Controller
Curtis 1220 Manual, Rev. C iii
FIGURES / TABLES
FIGURES
. 1: Curtis 1220 controller ............................................................. 1
. 2: Mounting dimensions, Curtis 1220 controller ........................ 4
. 3a: Wiring diagram, using motor encoder for position feedback ... 6
. 3b: Wiring diagram, using analog pots for position feedback ........ 7
. 4: Command signal ow ........................................................... 12
. 5: Steer command map ............................................................. 13
. 6: Position feedback signal ow, with analog pot ...................... 15
. 7: Position feedback signal ow, with encoder ........................... 16
. 8: Steering sensitivity map ......................................................... 22
TABLES
1: Programmable parameter menus ......................................... 11
2: Functions menu .................................................................. 22
3: Monitor menu ..................................................................... 23
4: Troubleshooting chart ......................................................... 38
C-1: Specifications, 1220 controllers ......................................... C-1
iv
Curtis 1220 Manual, Rev. C
1
Fig. 1 Curtis 1220 electric
steering controller.
1 — OVERVIEW
OVERVIEW
e Curtis Model 1220 controller is designed to drive a brushed permanent
magnet motor for electric power steering (EPS). e 1220 performs as the
steering system controller, interpreting the steering command input and wheel
position feedback, then driving the steering motor to move the steered wheel(s)
to the desired position.
e steering motor must be speed reduced to get the high torque required
to rotate the drive wheel. Typically this is done with a gearbox around 50:1
and a chain or gear with an additional reduction of around 4:1. e steering
command comes either from a linear potentiometer or an analog voltage sensor. e wheel position feedback comes either from a linear potentiometer, an
analog voltage sensor, or an encoder with a home switch.
ded VCL. A “handshake” with the traction controller is required at startup to
enable operation.
order pickers, stackers, “man up” warehouse trucks, and other similar industrial
vehicles.
Curtis 1220 Manual, Rev. C
e 1220 works only with Curtis AC traction controllers with embed-
Intended applications are material handling vehicles such as reach trucks,
1
1 — OVERVIEW
Advanced Motor Control
3 Absolute position control mode.
3 16 kHz PWM switching frequency ensures silent operation.
3 Advanced PWM techniques produce low motor harmonics,
low torque ripple, and minimized heating losses, resulting
in high eciency.
3
Congurable homing methods, center oset, and end-stop
protection.
3 24 V, 40 A 2-minute current rating.
3 24 V nominal supply voltage.
Maximum Safety
3 Dual steering command inputs and dual analog position
inputs for redundant check.
Fault output can be used to turn o traction controller’s
3
main contactor or interlock connection.
3 Steered wheel position (angle) output can be used to limit
the traction motor speed.
3 Following error check ensures the wheel position tracks
the steering command.
3 Power On Self-Test: FLASH, ALU, EEPROM, software
watchdog, RAM, etc.
Power On Hardware Check: Motor Open, Motor Short,
3
and MOSFET short.
3 Periodic Self-Tests: EEPROM parameters, Motor Open,
and command and feedback devices.
Unmatched Flexibility
3 Integrated hourmeter and diagnostic log functions.
3 Curtis 840 Spyglass can be connected to show traction
and steering information such as BDI, hour meter, fault,
traction speed, and steered wheel angle.
2
3
+5V low-power supply for input sensors, etc.
3 Curtis 1313 handheld programmer and 1314 PC
Programming Station provide easy programming and
powerful system diagnostic and monitoring capabilities.
3
External Status LED driver gives instant diagnostic
indication.
Curtis 1220 Manual, Rev. C
1 — OVERVIEW
Robust Reliability
3 Intelligent thermal cutback and overvoltage/undervoltage
protection functions maintain steering while reducing traction
speed until severe over/under limits are reached.
3 Standard Mini-Fit Molex Jr. and Faston terminals provide
proven, robust wiring connections.
Electronics sealed to IP65.
3
3 Reverse polarity protection on battery connections.
3 Inputs protected against shorts to B+ and B-.
Familiarity with your Curtis controller will help you install and operate it properly. We encourage you to read this manual carefully. If you have questions,
please contact your local Curtis representative.
CAUTION
CAUTION
+
+
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 recommendations. Wear safety glasses.
e Curtis Model 1220 does not satisfy EN1175-1:1998+A1:2010 Article 5.9.6
as it is not a Category 3 device under EN ISO13849-1:2008. It should not be
used on any vehicle within the scope of Machinery Directive 2006/42/EC that
will be operated within the European Economic Area (EEA).
Curtis 1220 Manual, Rev. C
3
2 — INSTALLATION & WIRING
2
Fig. 2 Mounting
dimensions, Curtis 1220
motor controller.
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
e 1220 controller can be oriented in any position, but the mounting location
should be carefully chosen to keep the controller clean and dry. If a clean, dry
mounting location cannot be found, a cover must be used to shield the
controller from water and contaminants.
e outline and mounting hole dimensions are shown in Fig. 2. e controller should be mounted by means of the two mounting holes at the opposing
corners of the heatsink, using M4 (#8) screws.
Dimensions in millimeters (and inches)
end product to ensure that its EMC performance complies with applicable
regulations; suggestions are presented in Appendix A.
priate precautions in connecting, disconnecting, and handling the controller.
See installation suggestions in Appendix A for protecting the controller from
ESD damage.
4
You will need to take steps during the design and development of your
e 1220 controller contains ESD-sensitive components. Use appro-
Curtis 1220 Manual, Rev. C
2 — INSTALLATION & WIRING: High Current Connections
CONNECTIONS: High Current
Four 1/4” Faston terminals are provided for the high current connections.
e motor connections (
connections (
B+, B-) have one terminal each.
M1, M2) and battery
M1 M2 B- B+
CONNECTIONS Low Current
e low current connections are made through three connectors: J1, J2, and J3.
J1 J2 J3
1 Status LED
2 Steer Motor Encoder Phase A
Mating connectors:
Molex Mini-Fit-Jr
receptacle p/n
J1 39-01-2140
J2 39-01-2040
J3 39-01-2020
with appropriate
45750-series
crimp terminals.
3 Position Analog 2
4 Interlock Input
5 KSI
6 Command Analog 1
7 +5V
8 Rx2 (from traction controller)
9 Steer Motor Encoder Phase B
10 Feedback Pot Low
11 Position Analog 1
12 Steering Angle Output
13 Command Analog 2
14 Command Pot Low
1 2 3 4 5 6 7
8 9 10 11 12 13 14
J1
14-pin Molex
39-28-8140
1 2
3 4
1
2
1 Rx1 (from programmer)
2 GND
3 Tx1 (to programmer / 840)
4 B+
1 Fault Output
2 Home Switch
Curtis 1220 Manual, Rev. C
J2
4-pin Molex
39-28-8040
J3
2-pin Molex
39-28-8020
5
2 — INSTALLATION & WIRING: Controller Wiring
1220 CONTROLLER
CONTROLLER WIRING
As shown in the wiring diagrams (Figs. 3a, 3b), the 1220’s keyswitch power
must go through the traction controller so that when the keyswitch is turned
o both controllers turn o. e fault output (Pin J3-1) must be able to shut
down the traction system in the case of a serious fault, in order to meet international safety requirements.
J1-4
J3-2
J1-5
J1-1
J1-3
J1-11
J1-7
J1-2
J1-9
J1-10
J1-7
J1-6
J1-13
J1-14
Interlock Input
Home Switch
KSI
Status LED
+5V
Encoder
Phase A
Encoder
Phase B
Feedback
Pot Low
+5V
Command Analog 1
Command Analog 2
Command Pot Low
INTERLOCK SWITCH
HOME SWITCH
STATUS LED
STEER
MOTOR
ENCODER
STEER COMMAND
POTS
B+
Tx1
GND
Rx1
Fault Output
Steering Angle
Output
Rx2
M1
M2
B+
B-
J2-4
J2-3
J2-2
J2-1
J3-1
J1-12
J1-8
TRACTION
MAIN
CONTACTOR
COIL
Main Driver J1-6
SW1/ANA1 J1-24
Receive J1-6
Power
Supply Input
+12V J1-25
Tx J1-28
POWER
FUSE
840
J1-5
CURTIS
TRACTION
CONTROLLER
123xE/1298
M
J1-8 GND
J1-7 I/O GND
AC
CONTROL
EMERGENCY
STOP
BATTERY
(24V)
PROGRAMMER
J1-9 Interlock
J1-13 Coil Return
J1-1 KSI
MOTOR
FUSE
KEYSWITCH
Fig. 3a Basic wiring diagram, using motor encoder for feedback device.
6
Curtis 1220 Manual, Rev. C
INTERLOCK SWITCH
STATUS LED
POSITION FEEDBACK
POTS
STEER COMMAND
POTS
J1-4
J1-5
J1-1
J3-2
J1-2
J1-9
J1-7
J1-11
J1-3
J1-10
J1-7
J1-6
J1-13
J1-14
2 — INSTALLATION & WIRING: Controller Wiring
ese wiring diagrams (Figs. 3a, 3b) show generic applications and may not
fully meet the requirements of your system. You may wish to contact your local
Curtis representative to discuss your particular application.
Interlock Input
KSI
Status LED
+5V
Position Analog 1
Position Analog 2
Feedback Pot Low
+5V
Command Analog 1
Command Analog 2
Command Pot Low
1220 CONTROLLER
B+
Tx1
GND
Rx1
Fault Output
Steering Angle
Output
Rx2
M1
M2
B+
B-
J2-4
J2-3
J2-2
J2-1
J3-1
J1-12
J1-8
TRACTION
MAIN
CONTACTOR
COIL
Main Driver J1-6
SW1/ANA1 J1-24
Receive J1-6
Power
Supply Input
+12V J1-25
Tx J1-28
POWER
FUSE
J1-5
TRACTION
CONTROLLER
123xE/1298
840
CURTIS
AC
M
PROGRAMMER
J1-8 GND
J1-7 I/O GND
J1-9 Interlock
J1-13 Coil Return
J1-1 KSI
MOTOR
CONTROL
FUSE
EMERGENCY
STOP
BATTERY
(24V)
KEYSWITCH
Fig. 3b Basic wiring diagram, using position feedback pots for feedback device.
Curtis 1220 Manual, Rev. C
7
2 — INSTALLATION & WIRING: I/O Signal Specifications
INPUT/OUTPUT SIGNAL SPECIFICATIONS
e electrical characteristics of the input/output signals wired to the J1, J2,
and J3 connectors are described below.
KSI (pin J1-5)
e keyswitch (KSI) must be connected to B+ via a switch. is pin feeds the
internal power supply and can be used for general on/o and for the power
supply to the Fault Output pin.
Input current at Nominal Battery Voltage (50 – 200 mA) + Fault Output current
Digital inputs (pins J1-4 and J3-2)
e digital inputs must be connected to B+ via a switch, or they can be driven
by outputs from other systems.
Input current at Nominal Battery Voltage approx. 0.2 – 0.7 mA (depending on
nominal battery voltage
Input filter R-C time constant max 5 ms
Max LOW threshold voltage 5.0 V
Min HIGH threshold voltage 12 V
De-bouncing time (in software) 10 – 25 ms
Analog inputs (pins J1-3, J1-6, J1-11, J1-13)
e analog inputs are used for analog input commands from any analog input
device, e.g., potentiometer, Hall sensor.
Input resistance (to B- ground) 50 kΩ ± 10%
Input current (wheel in center position) max 100 μA ± 10%
Input filter R-C time constant max 5 ms
Voltage range 0 – 5.5 V
Minimum resolution 12 bit
Steer Motor Encoder inputs (pins J1-2, J1-9)
ese inputs are used for the A and B signals of the Steer Motor Encoder device.
Input current (to Encoder Ground) 1.5 mA ± 20%
Input filter R-C time constant 1 μs
Max LOW threshold voltage 0.5 V
Min HIGH threshold voltage 2 V
+5V Supply (pin J1-7)
is pin is the power supply connection to the Command Input Device and
the Position Feedback Device.
Command supply voltage +5 V ± 10%
Maximum current draw 70 mA
8
Curtis 1220 Manual, Rev. C
2 — INSTALLATION & WIRING: I/O Signal Specifications
Pot Low (pins J1-10, J1-14)
e Command and Feedback Pot Low pins are connected to I/O GND. ey
are not protected against short circuits to B+.
Fault Output (pin J3-1)
e Fault Output has independent supervision via the MCU, and can be used
for power supply of the traction main contactor coil. is output has reverse
polarity protection.
Max output current 1.5 A
Max voltage drop (to KSI) at 1.5 A 2 V
Steering Angle Output (pin J1-12)
is pin will output an analog signal to the traction controller for traction
speed limit.
Analog output range 5 – 9 V ± 10% (2.5 V when not ready)
Max ripple voltage (p-p) 0.2 V
Max output current 5 mA
Programmer connections (J2 connector)
e Curtis programmer plugs into the 4-pin connector, J2.
Rx is the data input connection to/from the programmer.
Input pull down resistance (to B- ground) 5 kΩ ± 10%
Tx is the data input connection to/from the programmer.
Logic Level O:
Min output sink current 2.8 mA
Max output voltage at current < 2.8 mA 0.6 V
Logic Level 1:
Min output source current 0.4 mA
Max output voltage at current < 0.4 mA 3.5 V
Curtis 1220 Manual, Rev. C
9
3 — PROGRAMMABLE PARAMETERS
e 1220 controller has a number of parameters that can be programmed using
3
a Curtis 1313 handheld programmer or 1314 Programming Station. e programmable parameters allow the steering performance to be customized to fit
the needs of specific applications. e programmable parameters are grouped
into nested hierarchical menus, as shown in Table 1.
PROGRAMMABLE PARAMETERS
Table 1 Programmable Parameter Menus
COMMAND DEVICE .................... p. 11
—Redundant Input
—Command Analog Left
—Command Analog Center
—Command Analog Right
—Command Analog Fault Min
—Command Analog Fault Max
—Command Map ................. p. 13
—Left Stop (deg)
—P1 Input
—P1 Output (deg)
—P2 Input
—P2 Output (deg)
—P3 Input
—P3 Output (deg)
—P4 Input
—P4 Output (deg)
—P5 Input
—P5 Output (deg)
—P6 Input
—P6 Output (deg)
—Right Stop (deg)
FEEDBACK DEVICE ..................... p. 14
—Position Feedback Device
—Analog ........................... p. 15
—Redundant Input
—Position Left Stop
—Position Center
—Position Right Stop
—Position Fault Min
—Position Fault Max
—Encoder .......................... p. 16
—Encoder Steps
—Swap Encoder Direction
—Encoder Fault Check
—Center Offset (deg)
—Homing ................... p. 17
—Homing On Interlock
—Homing Direction Method
—Homing Speed
—Homing Compensation (deg)
VEHICLE CONFIGURATION .......... p. 18
—Interlock Type
—Sequencing Delay
—Fault Output Control
—Fault Steering Timeout
—Relay Driver .................... p. 19
—Main On Interlock
—Pull-In Voltage
—Holding Voltage
—Open Delay
—Traction Settings .............. p. 19
—Traction Motor Max Speed
—Interlock Enable Speed
—Speed Limit Angle (deg)
—Steering Angle Output Interlock
CURRENT .................................. p. 20
—Drive Current Limit
—Regen Current Limit
—Boost
MOTOR ..................................... p. 20
—Gear Ratio
—Max Speed
—Stall Steering Speed
—Stall PWM
—Stall Timeout
—Current Rating
—Max Current Time
—Cutback Gain
MOTOR CONTROL TUNING .......... p. 21
—Following Error Tolerance (deg)
—Following Error Time
—Position Kp
—Velocity Kp
—Velocity Ki
—Sensitivity Map ................ p. 22
—LS Sensitivity
—HS Sensitivity
—Low Speed
—Mid Speed
—High Speed
We strongly urge you to read Section 5, Initial Setup, before adjusting any of the
parameters. Even if you opt to leave most of the parameters at their default settings,
CAUTION
+
it is imperative that you perform the procedures outlined in Section 5, which
set up the basic system characteristics for your application.
10
Curtis 1220 Manual, Rev. C
3 — PROGRAMMABLE PARAMETERS: Command Device Parameters
COMMAND DEVICE
ALLOWABLE
PARAMETER RANGE DESCRIPTION
Redundant Input Off / On This parameter determines whether there will be a redundant steer
command input.
Off = Single input, to Command Analog 1 (pin J1-6)
On = Redundant inputs to Command Analog 1&2 (pins J1-6, J1-13).
It is best practice to wire the primary and redundant input signals in an “X”
conguration (0–5V and 5V–0).
When the Redundant Input is programmed Off, only a single steer
command device (the Command Input Device) is used and steer command
redundancy is disabled.
+5V
Command Analog 1 (primary)
Command Analog 2 (redundant)
Command Pot Low
Command Analog Input
Curtis 1220 Manual, Rev. C
11
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