Curtis 1222 User Manual
Manual
Model 1222
Electric Steering Controller
»
Software Version OS 15.0
«
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
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
2 9 J A N U A R Y 2 0 1 3 D R A F T
CONTENTS
1. OVERVIEW ..............................................................................1
CONTENTS
2. INSTALLATION AND WIRING .............................................
Mounting the Controller .....................................................4
High Current Connections and Wiring Guidelines ..............6
Low Current Connections and Wiring Guidelines ...............8
Controller Wiring: Safety Requirements ...........................
Input/Output Specifications ...............................................
3. PROGRAMMABLE PARAMETERS .....................................
Program Menu ..................................................................
4a. MONITOR MENU ................................................................
4b. CONTROLLER INFORMATION MENU ...........................
11
13
17
18
57
70
4c. CONTROLLER FUNCTIONS MENU .................................71
COMMISSIONING ...............................................................72
5.
6. INTERFACE WITH MASTER CONTROLLER ...................
93
4
7. DIAGNOSTICS AND TROUBLESHOOTING ....................
MAINTENANCE .................................................................110
8.
APPENDIX A Vehicle Design Considerations
APPENDIX B EN 14839 Compliance
APPENDIX C Programming Devices
APPENDIX D Specifications, 1222 Controller
99
Curtis 1222 Manual, os 15 iii
FIGURES / TABLES
FIGURES
fig. 1: Curtis 1222 controller .............................................................. 1
2 9 J A N U A R Y 2 0 1 3 D R A F T
fig. 2: Mounting dimensions, Curtis 1222 controller ........................
fig. 3a: Wiring diagram ......................................................................
fig. 3b: Software control diagram .......................................................
11
12
fig. 4: Command Input Device “0” signal flow ................................ 24
fig. 5: Command Input Device “1” signal flow ................................
fig. 6: Command Input Device “2” signal flow ................................
fig. 7: Command Input Device “3” signal flow ................................
fig. 8: Command Input Device “4” signal flow ................................
fig. 9: Steer Command Map .............................................................
fig. 10: Position Feedback Device “0” signal flow ...............................
fig. 11: Position Feedback Device “1” signal flow ...............................
fig. 12: Position Feedback Device “2” signal flow ...............................
fig. 13: Position Feedback Device “3” signal flow ...............................
fig. 14: Position Control signal flow ...................................................
fig. 15: Velocity Control signal flow ...................................................
fig. 16: Steering Sensitivity Map .........................................................
25
27
29
30
31
37
38
41
42
53
53
54
4
fig. 17a: Input Command signal flow ..................................................
fig. 17b: Position Feedback signal flow .................................................
fig. 17c: Position/Velocity Control signal flow .....................................
96
97
98
fig. B-1: Supervisory system ................................................................B-1
TABLES
table 1: High current connections ....................................................... 7
table 2: Low current connections ......................................................
table 3: Programmable parameter menus ..........................................
table 4: Monitor menu ......................................................................
table 5: Types of LED display ........................................................
table 6: Troubleshooting chart .........................................................
table D-1: Specifications, 1222 controllers .........................................
10
18
57
100
101
D-1
iv
Curtis 1222 Manual, os 15
1
Fig. 1 Curtis 1222 electric
steering controller.
2 9 J A N U A R Y 2 0 1 3 D R A F T
1 — OVERVIEW
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.
-
Curtis 1222 Manual, os 15
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
☞
1
1 — OVERVIEW
2 9 J A N U A R Y 2 0 1 3 D R A F T
✓ 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
2
✓ 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.
Curtis 1222 Manual, os 15
2 9 J A N U A R Y 2 0 1 3 D R A F T
✓ 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 properly. We encourage you to read this manual carefully. If you have questions,
please contact your local Curtis representative.
Curtis 1222 Manual, os 15
3
2 — INSTALLATION & WIRING
2
Fig. 2 Mounting
dimensions, Curtis 1222
motor controller.
2 9 J A N U A R Y 2 0 1 3 D R A F T
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.
4
Dimensions in millimeters (and inches)
Curtis 1222 Manual, os 15
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING
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 appropriate precautions in connecting, disconnecting, and handling the controller.
See installation suggestions in Appendix A for protecting the controller from
ESD damage.
C A U T IO N
☞
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.
Curtis 1222 Manual, os 15
5
2 9 J A N U A R Y 2 0 1 3 D R A F T
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.
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):
Table 1 High Current Connections
• 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
• If two lugs are used on the same
SCHNORR 416320, or equivalent.
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).
6
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.
Curtis 1222 Manual, os 15
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: High Current Connections
Motor wiring (U, V, W)
The three phase wires should be close to the same length and bundled together
as they run between the controller and the motor. The cable lengths should be
kept as short as possible. Use high quality copper lugs and observe the recom
mended torque ratings. For best noise immunity the motor cables should not
run across the center section of the controller. In applications that seek the
lowest possible emissions, a shield can be placed around the bundled motor
cables and connected to the
B- terminal at the controller. Typical installations
will readily pass the emissions standards without a shield. Low current signal
wires should not be run next to the motor cables. When necessary they should
cross the motor cables at a right angle to minimize noise coupling.
-
Curtis 1222 Manual, os 15
7
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: Low Current Connections
LOW CURRENT CONNECTIONS
All low power connections are made through a single 35-pin AMPSEAL con
nector. The mating plug housing is AMP p/n 776164-1 and the contact pins
are AMP p/n 770520-3. The connector will accept 20 to 16 AWG wire with
a 1.7 to 2.7mm diameter thin-wall insulation.
The 35 individual pins are characterized in Table 2.
J1
Low current wiring recommendations
Command input encoder and Steer motor encoder
The encoder wires should be bundled together as they run between the motor
and controller logic connector. These can often be run with the rest of the low
current wiring harness. The encoder cables should not be run near the motor
cables. In applications where this is necessary, shielded cable should be used
with the ground shield connected to the I/O ground (pin 18 or pin 30) at only
the controller side. In extreme applications, common mode filters (e.g. ferrite
beads) could be used.
-
CAN connection
The two CAN wires should be connected directly to the corresponding CAN
pins on the traction controller: running from pin 23 (CAN High) on the
steering controller to pin 23 (CAN High) on the traction controller, and from
pin 35 (CAN Low) on the steering controller to pin 35 (CAN Low) on the
traction controller.
Note: The 1222 controller has no internal 120
Ω CAN terminating
resistor. Typically the wiring of the CAN bus nodes is a daisy chain topology
with 120
such that the 1222 is the last node in the chain, an external 120
Ω CAN terminating resistors at each end. If the vehicle wiring is done
Ω terminating
resistor should be provided by the OEM in the wiring harness.
CAN wiring should be kept away from the high current cables and cross
it at right angles when necessary.
All other low current wiring
The remaining low current wiring should be run according to standard practices.
Running low current wiring next to the high current wiring should always be
avoided.
8
Curtis 1222 Manual, os 15
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: Low Current Connections
Table 2 Low Current Connections
PIN NAME DESCRIPTION
1 Keyswitch Provides logic power for the controller and power
2 Contactor Driver Driver for steer contactor.
3 [reserved] Not used.
4 [reserved] Not used.
5 Force Feedback Driver Driver for force feedback coil.
6 [reserved] Not used.
7 Ground Ground.
8 Command Analog 1 Primary steer command pot.
9 Interlock Input 1 Primary interlock switch input.
10 Home Input 2 Primary home switch input.
11 Interlock Input 3 Supervisory interlock switch input.
12 Home Input 4 Supervisory home switch input.
for the coil drivers.
13 Coil Return This is the coil return pin for all the contactor coils.
14 Command Encoder 1A Steer Command Encoder 1 input phase A.
15 +10V Regulated low power +10V output.
16 Position Analog 5 Primary position feedback pot.
17 Position Analog 6 Supervisory position feedback pot.
18 Ground Ground.
19 Command Analog 3 Supervisory steer command pot.
20 Command Encoder 2B Steer Command Encoder 2 input phase B.
21 +5V Regulated low power +5V output.
22 Motor Temperature Sensor Motor temperature sensor.
23 CAN High CAN bus high.
24 Fault Output Steer fault output.
25 Command Encoder 1B Steer Command Encoder 1 input phase B.
Curtis 1222 Manual, os 15
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2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: Low Current Connections
Table 2 Low Current Connections, cont’d
PIN NAME DESCRIPTION
26 Steer Motor Encoder 4A Steer Motor Encoder 4 input phase A.
27 Steer Motor Encoder 4B Steer Motor Encoder 4 input phase B.
28 TX Serial transmit line.
29 RX Serial receive line.
30 Ground Ground.
31 Steer Motor Encoder 3A Steer Motor Encoder 3 input phase A.
32 Steer Motor Encoder 3B Steer Motor Encoder 3 input phase B.
33 Command Encoder 2A Steer Command Encoder 2 input phase A.
34 +5V Regulated low power +5V output.
35 CAN Low CAN bus low.
10
Curtis 1222 Manual, os 15
2 9 J A N U A R Y 2 0 1 3 D R A F T
1222 CONTROLLER
J1-8
J1-21
Home Input 4
J1-12
Home Input 2
J1-10
Interlock Input 3
J1-11
Interlock Input 1
J1-9
Command Encoder 1A
J1-14
Command Encoder 1B
J1-25
Command Encoder 2A
J1-33
Command Encoder 2B
J1-20
Ground
J1-18
AC
STEER
MOTOR
J1-1
Keyswitch
STEER MOTOR
ENCODER 3
and
ENCODER 4
**
J1-31
J1-32
J1-26
J1-27
J1-2
J1-24
J1-15
J1-28
J1-29
J1-7
SERIAL
SERIAL PORT
(4-pin Molex)
4
3
1
2
KEYSWITCH
V
Steer Motor Encoder 3A
Steer Motor Encoder 4A
Fault Output
+10V
RX
Ground
U
W
Steer Motor Encoder 3B
Steer Motor Encoder 4B
Contactor Driver
BATTERY
(24–48V)
B+
B-
TX
EMERGENCY
STOP
+5V
J1-21
J1-23
J1-35
CAN Low
CAN High
CURTIS
AC
TRACTION
CONTROLLER
J1-19
J1-18
Command Analog 3
Command Analog 1
+5V
Ground
STEER
COMMAND
ENCODER 1
and
ENCODER 2
*
J1-34
J1-16
J1-17
J1-7
+5V
Position Analog 6
Position Analog 5
Ground
STEER COMMAND
POTS
*
Reserved
J1-3
Reserved
J1-4
Force Feedback Driver
J1-5
MOTOR
TEMPERATURE
SENSOR
POSITION
FEEDBACK
POTS
**
J1-34
+5V
J1-30
Ground
STEER
CONTACTOR
J1-13
Coil Return
J1-6
EM BRAKE
TRACTION
MAIN
CONTACTOR
STEER
CONTACTOR
J1-5
J1-13
J1-1
J1-23
J1-35
N.O.
N.C.
**
Encoder 4 is not used if
the feedback pots are used.
Reserved
J1-6
J1-9
J1-22
Motor Temp Sensor
*
Mutually exclusive;
use either pots or encoders.
INTERLOCK SWITCH
HOMING SWITCH
†
†
†
An external 120Ω resistor may
be required at the 1222 end of
the CAN bus; see page 15.
FORCE
FEEDBACK
COIL
Coil Return
J1-13
2 — INSTALLATION & WIRING: Controller Wiring
CONTROLLER WIRING: Safety Requirements
As shown in the wiring diagram (Figure 3a), the 1222’s keyswitch power must
go through the traction controller so that when the keyswitch is turned off both
controllers turn off. The fault output (Pin 24) should be able to shut down
the traction system in the case of a serious fault; otherwise the system may not
meet the international safety requirements listed in Table D-1.
As shown in the wiring diagram, two steer command devices and two
position feedback devices are used. The 1222 supervises and matches each
Fig. 3a Wiring diagram, Curtis 1222 electric steering controller.
Curtis 1222 Manual, os 15
11
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: Controller Wiring
device input to its counterpart (steering to steering, feedback to feedback). If
any of these input pairs do not match, the 1222 begins its fault sequence to
bring the vehicle to a stop.
As shown in the software control diagram (Figure 3b), the safety critical
parts are included twice to provide redundancy:
· two microprocessors
· separate paths to each micro for the command and feedback signals
· cross checks on the normalized steer command
· cross checks on the normalized wheel position.
A following error check ensures that the wheel position tracks the steer command.
Although not shown in the wiring diagram, the analog inputs can be
used for single sine/cosine sensors or sawtooth sensors instead of for redundant
pairs of pots. Each single sensor has two levels of fault detection, which provide
redundancy; see description of Tolerance parameter in Sin/Cos Sensor menus
(pages 26 and 41) and in Sawtooth Sensor menus (pages 28 and 42).
The wiring diagram (Figure 3a) is designed for 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. In cases where
the wiring deviates from the wiring shown in Figure 3a, it is up to the OEM
to evaluate the overall system safety.
Fig. 3b Software control diagram.
12
Curtis 1222 Manual, os 15
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: I/O Signal Specifications
INPUT/OUTPUT SIGNAL SPECIFICATIONS
The input/output signals wired to the 35-pin connector can be grouped by
type as follows; their electrical characteristics are discussed below.
— digital inputs
— driver outputs
— analog inputs
— power supply outputs
— keyswitch and coil return inputs
— communications port inputs/outputs
— encoder inputs.
Digital inputs
The digital inputs must be wired to switch to B+ (not to ground). All digital
inputs are protected against shorts to B+ or B-.
A home switch is required if encoder position feedback is used (Pos
ition
Feedback Device = 1).
DIGITAL INPUT SPECIFICATIONS
LOGIC
SIGNAL NAME PIN THRESHOLDS
Interlock Input 1 9 Rising edge= 10.7 kΩ 10–65 V ± 8 kV (air
Home Input 2 10 5 V max discharge)
Interlock Input 3 11 Falling edge=
Home Input 4 12 1.5 V min
INPUT VOLTAGE ESD
IMPEDANCE RANGE TOLERANCE
Driver outputs
The fault output shuts down the traction system if the 1222 has a fault. This
output switches B+ to the high side of the traction main contactor and EM
brake; without this signal, the system shuts down.
All driver outputs are protected against shorts to B+ or B-.
DRIVER OUTPUT SPECIFICATIONS
SIGNAL NAME PIN TYPE FREQUENCY
Contactor Driver 2 Low Side 16 kHz 2 A max 65 V ± 8 kV (air
Force Feedback Driver 5 Low Side 16 kHz 2 A max 65 V discharge
Fault Output 24 High Side n/a 5 A max 65 V
OUTPUT
OUTPUT PROTECTED ESD
CURRENT VOLTAGE TOLERANCE
Curtis 1222 Manual, os 15
13
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: I/O Signal Specifications
Analog inputs
The command and position analog inputs are used when the steer command and
position feedback devices are pots or sine/cosine sensors or sawtooth sensors.
J1-22
The motor temperature sensor input provides a constant current appro
priate for a thermistor sensor. Some standard predefined motor temperature
sensors are supported in software (see Sensor Type parameter, page 49). Note:
The industry standard KTY temperature sensors are silicon temperature sensors
J1-7
with a polarity band; the polarity band of a KTY sensor must be the end
connected to I/O Ground (pin 7).
All analog inputs are protected against shorts to B+ or B-.
OPERATING
SIGNAL NAME PIN VOLTAGE
Command Analog 1 8 0 to 10 V 100 kΩ 65 V ± 8 kV (air
Command Analog 3 19 discharge)
Position Analog 5 16
Position Analog 6 17
Motor Temp Sensor 22
ANALOG INPUT SPECIFICATIONS
INPUT PROTECTED ESD
IMPEDANCE VOLTAGE TOLERANCE
-
Power supply outputs
The +5V supply is used for all steer command and position feedback devices.
The +10V supply is provided for the handheld programmer; it should not be
used for steer command or position feedback devices because voltage could
change when the programmer is plugged in. Both power supply outputs are
protected against shorts to B+ or B-.
POWER SUPPLY OUTPUT SPECIFICATIONS
OUTPUT
SIGNAL NAME PIN VOLTAGE
+5V 21, 34 5 V ±10% 100 mA max * 65 V ± 8 kV (air
+10V 15 10 V ±10% 100 mA max
Ground 7, 18, 30 n/a n/a n/a
The total combined current from +5V and +10V outputs should not exceed 150 mA.
*
OUTPUT PROTECTED ESD
CURRENT VOLTAGE TOLERANCE
65 V discharge)
*
14
Curtis 1222 Manual, os 15
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: I/O Signal Specifications
Keyswitch input and coil return
Keyswitch power to the 1222 is provided through the coil return of the traction
controller. This ensures that the steer controller is not turned Off unless the
traction controller is Off. Both controllers shut down in the event of a fault.
Coil suppression for the traction controller is provided when the traction
main contactor and EM brake are wired to the fault output (pin 24). However,
you may wish to use coil suppression diodes to reduce EMI emissions.
Coil Return should be wired to the positive battery side of the steer
contactor so that switching noise associated with PWM operation of the
contactor is localized to the contactor wiring only.
Reverse polarity protection is ensured only when the keyswitch input and
coil return are wired as shown in Figure 3a (page 11).
KEYSWITCH AND COIL RETURN INPUT SPECIFICATIONS
OPERATING
SIGNAL NAME PIN VOLTAGE
Keyswitch 1 Between under- 50–500 mA 65 V ± 8 kV (air
and overvoltage + coil return current discharge)
Coil Return 13
cutbacks
MAX INPUT PROTECTED ESD
CURRENT VOLTAGE TOLERANCE
10 A
.
65 V
Communications ports
Separate CAN and serial ports provide complete communications and programming capability for all user available controller information.
Note: The 1222 controller has no internal 120
Ω CAN terminating resis-
tor. Typically the wiring of the CAN bus nodes is a daisy chain topology with
120Ω CAN terminating resistors at each end. If the vehicle wiring is done such
that the 1222 is the last node in the chain, then an external 120
Ω terminating
resistor should be provided by the OEM in the wiring harness.
The Curtis programmer plugs into a connector wired to pins 28 and 29,
along with ground (pin 7) and the +10V power supply (pin 15); see wiring
diagram, Figure 3a.
COMMUNICATIONS PORT SPECIFICATIONS
SUPPORTED
SIGNAL NAME PIN PROTOCOL/DEVICES
CAN High 23 CANopen up to 1 Mbps -5 V to ± 8 kV (air
CAN Low 35 (MaxV + 10 V) discharge)
with < 30 V
differentially
Tx 28
Rx 29
1314 PC Program-
1313 Handheld as required, -0.3 to 12 V ± 8 kV (air
Programmer, 9.6 to 56 kbps discharge)
ming Station
DATA RATE VOLTAGE TOLERANCE
PROTECTED ESD
Curtis 1222 Manual, os 15
15
2 9 J A N U A R Y 2 0 1 3 D R A F T
2 — INSTALLATION & WIRING: I/O Signal Specifications
Encoder inputs
These inputs are used when the steer command and position feedback devices
are encoders. Command Encoders 1 and 2 are for steer commands, and Steer
Motor Encoders 3 and 4 are for feedback.
Pairs (A, B) of control lines are internally configured to read quadrature
type encoders. The encoders are typically powered from the 5V supply (pin 21),
but can be powered from any external supply (from 5V up to B+) as long as
the logic threshold requirements are met.
Note: Steer Motor Encoder 3 is always required, even when redun
dant analog feedback inputs are used (feedback pots or sine/cosine sensors
or sawtooth sensors). Encoder 3 must be directly connected to the motor shaft
as it is used for motor control; it must have a minimum of 32 ppr. Encoder 4,
if it is used, can be connected to either the motor shaft or the steered wheel; if
it is connected to the steered wheel, it should have a minimum resolution of
0.5 counts/degree (equivalent to 45 ppr).
-
ENCODER INPUT SPECIFICATIONS
LOGIC
SIGNAL NAME PIN THRESHOLDS
Command Encoder 1A 14 Rising edge= 1 kΩ 2 kHz 65 V ± 8 kV (air
Command Encoder 1B 25 4 V max discharge)
Falling edge=
1 V min
Command Encoder 2A 33
Command Encoder 2B 20
Steer Motor Encoder 3A 31 10 kHz
Steer Motor Encoder 3B 32
Steer Motor Encoder 4A 26
Steer Motor Encoder 4B 27
INPUT MAX PROTECTED ESD
IMPEDANCE FREQ. VOLTAGE TOLERANCE
16
Curtis 1222 Manual, os 15
3
2 9 J A N U A R Y 2 0 1 3 D R A F T
3 — PROGRAMMABLE PARAMETERS
PROGRAMMABLE PARAMETERS
The 1222 controller has a number of parameters that can be programmed using a Curtis 1313 handheld programmer or 1314 Programming Station. The
programmable parameters allow the steering performance to be customized to
fit the needs of specific applications.
PARAMETER MENU CHARTS
The programmable parameters are grouped into nested hierarchical menus, as
shown in Table 3. The menu charts contain descriptions of each parameter.
PARAMETER ATTRIBUTES
Some parameters are subject to one or both of the following conditions, as
noted in the menu charts.
Parameter Change Fault (PCF)
When a new value is written, a Parameter Change Fault (code 49) is issued.
This is true both for writes via a CAN message and for writes via the serial bus
(using the 1313/1314 programmer). For safety purposes, the Parameter Change
Fault forces the vehicle operator to cycle power; cycling power clears the fault.
Subject parameters are marked
Requires Idle State (RIS)
To successfully write the parameter, a Device State = 0 (Not Ready to Switch
On), 2 (Switch On Disabled), 3 (Ready to Switch On) or 14 (Fault) is required.
This is true both for writes via a CAN message and for writes via the serial bus
(using the 1313/1314 programmer). The 1222 will reply with an Abort message
to any write attempted when the Device State is not one of those listed above.
The 1222 will not process the aborted write message, which means the new
parameter value will not be written. Subject parameters are marked
MENU CHART FORMAT
Individual parameters are presented as follows in the menu charts:
•
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.
n
Parameter name Allowable range Parameter Description of the parameter’s
as it appears in the in the attribute function and, where applicable,
programmer display programmer’s units (PCF, RIS) suggestions for setting it
⇓ ⇓ ⇓ ⇓
Analog1 Center 0 – 10.00 V
0x400A 0x00 0 – 1023 a steer position command of center (Steer Command = 0°).
⇑ ⇑
CAN Object index Allowable range
and sub-index in CAN units
Curtis 1222 Manual, os 15
Defines the Analog 1 wiper voltage required to produce
•
n
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3 — PROGRAMMABLE PARAMETERS
2 9 J A N U A R Y 2 0 1 3 D R A F T
Table 3 Programmable Parameter Menus
COMMAND DEVICE
Command Input Device ................ p. 20
Supervision Input Device ............. p. 20
0 – Analog1 and 3 ....................... p. 23
—Analog1 Left
—Analog1 Center
—Analog1 Right
—Analog1 Fault Min
—Analog1 Fault Max
—Analog3 Left
—Analog3 Center
—Analog3 Right
—Analog3 Fault Min
—Analog3 Fault Max
1 – Encoder1 and 2 ..................... p. 25
—Left Stop to Center
—Right Stop to Center
—Swap Encoder1 Direction
—Swap Encoder2 Direction
Sin/Cos Sensor ...................... p. 26
2 –
—Left Angle (deg)
—Center Angle (deg)
—Right Angle (deg)
—Offset
—Amplitude
—Swap Direction
—Absolute Mode
—Fault Min
—Fault Max
—Tolerance
3 – Sawtooth Sensor ................... p. 28
—Left Angle (deg)
—Center Angle (deg)
—Right Angle (deg)
—Min Volts
—Max Volts
—Swap Direction
—Absolute Mode
—Fault Min
—Fault Max
—Tolerance
4 – CAN .................................... p. 30
—CAN Steer Center Offset
—CAN2 Steer Center Offset
—CAN Steer Left Stop to Center
—CAN Steer Right Stop to Center
—CAN Steer Swap Direction
—CAN2 Steer Swap Direction
—Absolute Mode
Command Map ........................... p. 31
—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)
Force Feedback Device ................ p. 33
—Enable
—End Stop
—End Stop Vibe
—Vibe On Time
—Vibe Off Time
—Min Voltage
—Max Voltage
—Max Torque
FEEDBACK DEVICE
Position Feedback Device ............ p. 34
Supervision Feedback Device ....... p. 34
0 – Analog5 and 6 ....................... p. 37
—Analog5 Left Stop
—Analog5 Center
—Analog5 Right Stop
—Analog5 Fault Min
—Analog5 Fault Max
—Analog6 Left Stop
—Analog6 Center
—Analog6 Right Stop
—Analog6 Fault Min
—Analog6 Fault Max
1 – Encoder3 and 4
—Encoder3 Counts/Degree
—Encoder4 Counts/Degree
—Swap Encoder3 Direction
—Swap Encoder4 Direction
—Auto Center Type
—Center Offset (deg)
—Homing ........................... p. 39
—Input Type
—Home on Interlock
—Homing Direction Method
—Homing Cam Angle (deg)
—Homing Speed
—Homing Timeout
2 – Sin/Cos Sensor
—Offset
—Amplitude
—Swap Direction
—Center Position (deg)
—Fault Min
—Fault Max
—Tolerance
3 – Sawtooth Sensor .................. p. 42
—Center Position (deg)
—Min Volts
—Max Volts
—Swap Direction
—Fault Min
—Fault Max
—Tolerance
.................... p. 38
.................... p. 41
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3 — PROGRAMMABLE PARAMETERS
Table 3 Programmable Parameter Menus, cont’d
VEHICLE CONFIGURATION .......... p. 43
—Nominal Voltage
—Interlock Type
—Fault Steering Timeout
—Steer Contactor Driver ....... p. 44
—Contactor Control Type
—Pull-In Voltage
—Holding Voltage
—Open Delay
—Checks Enable
—Sequencing Delay
—Traction Speed Input .......... p. 45
—Input Type
—Type 1 – Encoder 1
—Encoder1 Steps
—Swap Encoder1 Direction
—Interlock Enabled Speed
SUPERVISION
—5V Current Min
—5V Current Max
—Steer Command Tolerance (deg)
—Wheel Position Tolerance (deg)
—Encoder Position Tolerance (deg)
—Home Reference Tolerance (deg)
—Stall Steering Speed
—Stall Timeout
—
—Error Tolerance (deg)
—Speed Tolerance (deg/s)
—Error Time
............................ p. 46
Following Error ................. p. 47
MOTOR ..................................... p. 48
—Max Speed
—Max Current
—Encoder3 Steps
—Swap Encoder3 Direction
—Temperature Control
—Sensor Enable
—Sensor Type
—Sensor Temp Offset
—Temperature Hot
—Temperature Max
—Sensor Fault Traction Cutback
—
User-Defined Temp Sensor .. p. 50
—Sensor 1
—Temp 1
. . . . .
—Sensor 7
—Temp 7
.......... p. 49
CANopen ................................... p. 51
—CAN Required
—Node ID
—Node ID Supervisor
—Baud Rate
—Producer Heartbeat Time
—PDO1 Timeout Time
MOTOR CONTROL TUNING ............ p. 52
—Position Kp
—Velocity Kp
—Velocity Ki
—Steering Sensitivity
........... p. 54
—LS Sensitivity
—HS Sensitivity
—Low Speed
—Mid Speed
—High Speed
—Field Weakening Control
..... p. 55
—FW Base Speed
—Field Weakening
—Weakening Rate
—Min Field Current
—Motor Type ..................... p. 56
C A U T IO N
☞
Curtis 1222 Manual, os 15
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,
it
is imperative that you perform the procedures outlined in Section 5, which
set up the basic system characteristics for your application
.
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2 9 J A N U A R Y 2 0 1 3 D R A F T
3 — PROGRAMMABLE PARAMETERS: Command Input Parameters
INPUT DEVICE PARAMETER
ALLOWABLE
PARAMETER RANGE DESCRIPTION
PCF
RIS
Command Input Device 0 – 4
0x4003 0x00 0 – 4 and supervisory user steer commands:
Supervision Input Device
0x40E4 0x00 0 – 5 to two potentiometers as redundant inputs.
0 – 5
These two parameters determine which inputs will be used as the primary
•
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•
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0 = Pot input, where Analog 1 and Analog 3 inputs are connected
When an analog steering command is used, two channels
are required.
NAME PIN FUNCTION
Analog 1 8 Primary analog input command
Analog 3 19 Supervisory analog input command
It is best practice to wire the primary and supervisory input sig
nals in an “X” configuration (0–5V and 5V–0). However, the 1222
has independent maps and will support redundant signals that
move in the same direction.
-
1 = Encoder input, where Encoder 1 and Encoder 2 inputs are
connected to two quadrature encoders as redundant inputs.
When an encoder steering command is used, two quadra
ture encoders are required. In the table below, “+” and “-” indicate
encoder phase differences (“-” being some amount of phase shift
from “+”). This means that the primary and supervisory encoders
do not have to have the same alignment.
NAME PIN FUNCTION
Encoder 1A 14 Primary quadrature encoder command A+
Encoder 1B 25 Primary quadrature encoder command A-
Encoder 2A 33 Supervisory quadrature encoder command B+
Encoder 2B 20 Supervisory quadrature encoder command B-
-
x
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2 9 J A N U A R Y 2 0 1 3 D R A F T
3 — PROGRAMMABLE PARAMETERS: Command Input Parameters
INPUT DEVICE PARAMETER, cont’d
2 = Sin/Cos Sensor command, where Analog 1 and Analog 3 inputs
are connected to a sine-cosine transducer. The transducer could
be mounted to a steering wheel or a tiller arm. The sensor may
be set up as either an absolute or relative position device, using
the Absolute Mode parameter (see page 26).
When this steering command is used, sine and cosine
channels are both required (and together serve as the primary
and supervisory devices).
NAME PIN FUNCTION
Analog 1 8 Sine input (Command Analog 1)
Analog 3 19 Cosine input (Command Analog 3)
3 = Sawtooth Sensor command, where Analog 1 and Analog 3 inputs
are connected to a sawtooth transducer. The transducer could
be mounted to a steering wheel or a tiller arm. The sensor may
be set up as either an absolute or relative position device, using
the Absolute Mode parameter (see page 28).
When this steering command is used, primary sawtooth and
offset sawtooth channels are both required (and together serve
as the primary and supervisory devices).
NAME PIN FUNCTION
Analog 1 8 Primary sawtooth input (Command Analog 1)
Analog 3 19 Offset sawtooth input (Command Analog 3)
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2 9 J A N U A R Y 2 0 1 3 D R A F T
3 — PROGRAMMABLE PARAMETERS: Command Input Parameters
INPUT DEVICE PARAMETER, cont’d
4 = CAN Sensor command, where the input to the 1222 comes via
a CAN bus message (i.e., “steer-by-wire”). The CAN sensor
may be set up as either an absolute or relative position device,
using the Absolute Mode parameter (see page 30).
CAN Index Sub-Index FUNCTION
0x4445 0x00 Primary CAN Steer Command
0x44D6 0x00 Supervisory CAN Steer Command
The CAN indexes for both steer commands should be set up with
the generic CANopen PDO mapping objects. For EN 13849 it is
recommended that the CAN steer commands be sent in separate
PDO messages and that the supervisory CAN2 steer command
be the opposite polarity and that the CAN2 Steer Swap Direction
parameter be set for the supervisory command only.
This option is available only for the Supervision Input Device
IMPORTANT
☞
When the Supervision Input Device is set to 5, steer
5 = None. No supervisory steer command device is connected.
Only a single steer command device (the primary) is used.
parameter. Using this setting will make the system
non-compliant with EN 13849.
command supervision is disabled. This option is provided
to allow systems not compliant with EN 13849 to be set up
without having to supply connections to the supervisory inputs
from the single primary input device.
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2 9 J A N U A R Y 2 0 1 3 D R A F T
3 — PROGRAMMABLE PARAMETERS:
COMMAND INPUT DEVICE 0 – ANALOG1 and 3
ALLOWABLE
PARAMETER RANGE DESCRIPTION
Analog1 Left 0 – 10.00 V
0x4008 0x00 0 – 1023 command of full left (Steer Command = -100% = Left Stop).
Analog1 Center 0 – 10.00 V
0x400A 0x00 0 – 1023 command of center (Steer Command = 0% = 0°).
Analog1 Right 0 – 10.00 V
0x4009 0x00 0 – 1023 command of full right (Steer Command = 100% = Right Stop).
Analog1 Fault Min 0 – 10.00 V Sets the minimum threshold for the Analog 1 steer command pot input.
0x400E 0x00 0–1023 If the Analog 1 steer command pot voltage goes below this threshhold for
Analog1 Fault Max 0 – 10.00 V Sets the maximum threshold for the Analog 1 steer command pot input.
0x400F 0x00 0 – 1023 If the Analog 1 steer command pot voltage rises above this threshhold for
PCF
RIS
Defines the Analog 1 wiper voltage required to produce a steer position
• n
Defines the Analog 1 wiper voltage required to produce a steer position
• n
Defines the Analog 1 wiper voltage required to produce a steer position
• n
60 ms, a fault is issued.
60 ms, a fault is issued.
Command Input Parameters
Analog3 Left 0 – 10.00 V
0x409F 0x00 0 – 1023 command of full left (Steer Command = -100% = Left Stop).
Analog3 Center 0 – 10.00 V
0x40A1 0x00 0 – 1023 command of center (Steer Command = 0% = 0°).
Analog3 Right 0 – 10.00 V
0x40A0 0x00 0 – 1023 command of full right (Steer Command = 100% = Right Stop).
Analog3 Fault Min 0 – 10.00 V Sets the minimum threshold for the Analog 3 steer command pot input.
0x400B 0x00 0 – 1023 If the Analog 3 steer command pot voltage falls below this threshhold for
Analog3 Fault Max 0 – 10.00 V Sets the maximum threshold for the Analog 3 steer command pot input.
0x400C 0x00 0 – 1023 If the Analog 3 steer command pot voltage rises above this threshhold for
Defines the Analog 3 wiper voltage required to produce a steer position
• n
Defines the Analog 3 wiper voltage required to produce a steer position
• n
Defines the Analog 3 wiper voltage required to produce a steer position
• n
60 ms, a fault is issued.
60 ms, a fault is issued.
Curtis 1222 Manual, os 15
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2 9 J A N U A R Y 2 0 1 3 D R A F T
3 — PROGRAMMABLE PARAMETERS: Command Input Parameters
Fig. 4 Command Input Device “0” signal flow (Analog 1 shown; Analog 3 is similar).
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2 9 J A N U A R Y 2 0 1 3 D R A F T
3 — PROGRAMMABLE PARAMETERS: Command Input Parameters
COMMAND INPUT DEVICE 1 – ENCODER1 and 2
ALLOWABLE
PARAMETER RANGE DESCRIPTION
Left Stop to Center -32768 – 0
0x4094 0x00 -32768 – 0 command from the center position (Steer Command = 0% = 0°) to
PCF
RIS
Defines the total steer command encoder counts to produce a steer
• n
the full left position (Steer Command = -100% = Left Stop).
Left Stop to Center is always a negative number.
Right Stop to Center 0 – 32767
0x406D 0x00 0 – 32767 command from the center position (Steer Command = 0% = 0°) to
Swap Encoder1 Direction On / Off
0x406C 0x00 On / Off input.
Swap Encoder2 Direction On / Off
0x4069 0x00 On / Off input.
Defines the total steer command encoder counts to produce a steer
• n
the full right position (Steer Command = 100% = Right Stop).
Right Stop to Center is always a positive number.
Changes the direction (left or right) of the Encoder 1 steer command
• n
Changes the direction (left or right) of the Encoder 2 steer command
• n
Fig. 5 Command Input Device “1” signal flow (Encoder 1 shown; Encoder 2 is similar).
Curtis 1222 Manual, os 15
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2 9 J A N U A R Y 2 0 1 3 D R A F T
3 — PROGRAMMABLE PARAMETERS: Command Input Parameters
COMMAND INPUT DEVICE 2 – SIN/COS SENSOR
ALLOWABLE
PARAMETER RANGE DESCRIPTION
Left Angle (deg) -1800.0° – 0.0°
0x40CC 0x00 -20480–0 required to produce a steer command of full left (Steer Command = -100%).
PCF
RIS
In Absolute Position mode, this parameter defines the position (in degrees)
• n
In Absolute Position mode, this parameter should be adjusted within the
range -180.0° – 0.0°.
In Relative Position mode, the parameter defines the number of turns
(in degrees) required to produce a steer command from center to full left
(Steer Command = -100%).
Center Angle (deg) -180.0° – 180.0°
0x40D2 0x00 -2048–2047 required to produce a steer command of center position (Steer Command =
Right Angle (deg) 0.0° – 1800.0°
0x40CD 0x00 0–20479 required to produce a steer command of full right (Steer Command = 100%).
Offset 0 – 10.00 V
0x40CE 0x00 0 – 1023 sin/cos sensor. This value is usually available in the sensor specifications,
Amplitude 0 – 10.00 V
0x40DE 0x00 0 – 1023 for the sin/cos sensor input signals.
Swap Direction On / Off
0x406A 0x00 On / Off the wires to pins 8 and 19.
Absolute Mode On / Off
0x40F0 0x00 On / Off The sensor is in relative position mode when this parameter is set to Off.
In Absolute Position mode, this parameter defines the position (in degrees)
• n
0%).
In Relative Position mode, this parameter is not used.
In Absolute Position mode, this parameter defines the position (in degrees)
• n
In Absolute Position mode, this parameter should be adjusted within the
range 0.0° – 180.0°.
In Relative Position mode, the parameter defines the number of turns
(in degrees) required to produce a steer command from center to full right
(Steer Command = 100%).
Set this parameter to the midpoint voltage of the sine wave output of the
• n
and is typically half the voltage supply to the sensor.
Set this parameter to one half of the expected peak-to-peak voltage
• n
Use this parameter to invert the signal to avoid physically swapping
• n
The sensor is in absolute position mode when this parameter is set to On.
• n
Fault Min 0 – 10.00 V Sets the minimum threshold for the Analog 1 and Analog 3 inputs of the
0x400B 0x00 0 – 1023 sin/cos sensor. If either the Analog 1 or Analog 3 voltage falls below this
threshold for 60 ms, a fault is issued.
Fault Max 0 – 10.00 V Sets the maximum threshold for the Analog 1 and Analog 3 inputs of the
0x400C 0x00 0 – 1023 sin/cos sensor. If either the Analog 1 or Analog 3 voltage rises above this
threshold for 60 ms, a fault is issued.
Tolerance 0 – 10.00 V The sine and cosine signals are used together to calculate the absolute
0x40DF 0x00 0 – 1023 position, i.e. arctan (Analog 1 / Analog 3). This calculated position is then
used to back-calculate the expected sine and cosine inputs, based on
the Amplitude parameter. If the difference between these expected inputs
(Command Sin/Cos Sensor Angle 2) and the actual inputs (Command
Sin/Cos Sensor Angle) is greater than the set Tolerance voltage for 60 ms,
a fault is issued. This provides a second level of fault detection and triggers
a separate SinCos Command fault.
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Curtis 1222 Manual, os 15
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