Curtis 1310 User Manual

1310 Manual

M A N U A L

M O D E L

CURTIS INSTRUMENTS, INC.

200 Kisco Avenue Mt. Kisco, New York 10509 USA Tel. 914.666.2971 Fax 914.666.2188

1310

V E H I C L E S YS T E M

C ON T R O L L E R w i t h V C L

1310 Manual, p/n 36488001

Rev. A: August 2007

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www.curtisinstruments.com

CONTENTS

OVERVIEW............................................................................................................................................................................... 3

Features include.................................................................................................................................................................. 4

INSTALLATION AND WIRING........................................................................................................................................... 5

MOUNTING THE CONTROLLER..................................................................................................................................5

HIGH CURRENT CONNECTIONS................................................................................................................................ 7

LOW CURRENT CONNECTIONS..................................................................................................................................8

CONTROLLER WIRING: BASIC CONFIGURATION.............................................................................................. 13

INPUT/OUTPUT SIGNAL SPECIFICATIONS............................................................................................................ 16

Digital Inputs............................................................................................................................................................... 16

Digital Outputs............................................................................................................................................................17

Analog Inputs.............................................................................................................................................................. 17

Analog Outputs...........................................................................................................................................................18

Power............................................................................................................................................................................ 18

PROGRAMMABLE PARAMETERS....................................................................................................................................19

PROGRAM MENU...........................................................................................................................................................19

Battery Discharge Indicator algorithm.......................................................................................................................... 20

CAN Open Interface.........................................................................................................................................................21

INTERNAL DATA................................................................................................................................................................. 22

MONITOR MENU............................................................................................................................................................22

CONTROLLER INFORMATION MENU..................................................................................................................... 24

VEHICLE CONTROL LANGUAGE....................................................................................................................................25

INTRODUCTION............................................................................................................................................................. 25

VARIABLE TYPES & QUANTITIES..............................................................................................................................26

VCL RUNTIME RATES................................................................................................................................................... 27

SPECIFIC VCL FUNCTIONS & EXTENSIONS........................................................................................................... 28

Pot Wiper Inputs......................................................................................................................................................... 28

Analog Inputs............................................................................................................................................................. 29

Analog Outputs..........................................................................................................................................................30

Digital Outputs...........................................................................................................................................................32

Encoder Inputs............................................................................................................................................................ 34

Real Time Clock (RTC)............................................................................................................................................... 37

UNIQUE I/O & VCL USAGE..........................................................................................................................................39

I/O CONTROL WITH VCL............................................................................................................................................. 39

Digital Inputs............................................................................................................................................................... 39

Digital Outputs............................................................................................................................................................41

Encoder Inputs............................................................................................................................................................ 42

Arrays........................................................................................................................................................................... 43

DIAGNOSTICS AND TROUBLESHOOTING...................................................................................................................44

MAINTENANCE................................................................................................................................................................... 46

APPENDIX A - Design Considerations.............................................................................................................................. 47

APPENDIX B - Programmer.................................................................................................................................................49

APPENDIX C - Specifications...............................................................................................................................................51

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OVERVIEW

1- OVERVIEW

1

Curtis 1310 provides unprecedented flexibility and ease of use in a full featured programmable Vehicle System Controller. Containing FLASH memory, a powerful microcontroller and a wide range of inputs and outputs, the 1310 can be custom programmed to provide application specific vehicle functions, from the most complex to the most unique. Custom software for the 1310 is developed with the powerful yet easy to learn Curtis VCL (Vehicle Control Language).

The Curtis 1310 Vehicle System Controller integrates and and expands systems through its industry standard CAN bus communication port. The Curtis 1310 seamlessly works in conjunction with Curtis CAN based SepEx and AC motor controllers such as the, 1243, 1244, 1234, 1236 and 1238.

Model 1310 can be applied to electric vehicles, non-electric vehicles or stationary control systems.

Fig. 1. The Curtis 1310 Vehicle System Controller

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Features include

✔ The powerful, user-friendly programming language, VCL (Vehicle Control Language),

developed by Curtis, allows custom software to be quickly and easily developed by an OEM for unique applications.

✔ CAN bus port allows customized vehicle systems and control. ✔ FLASH memory allows easy field upgrades and customization on the assembly line. ✔ CAN Open compatible communication protocol provides control and feedback to Curtis

CAN-based Motor Controllers, as well as many other CAN based products.

✔ Extended Software functions of VCL simplify the integration of OEM requirements (BDI,

Hour Meters, PID, RAMP, POT, CAN etc.).

✔ Comprehensive Input and Output Selection ✔ Two analog outputs (0 to 10 volts at up to 20 mA). ✔ Serial Port for communication with the Curtis Programmer or Curtis Model 840 "Spyglass"

display.

✔ Two quadrature encoder inputs. ✔ Up to 22 Digital Switch Inputs and up to 16 Output Channels (up to 3 amps sink per

channel) are available to a maximum input/output combination of 22 channels.

✔ Two proportional valve control outputs are available (16 output model only). ✔ Four software-configurable analog input channels available for any combination of 2- and 3-

wire pot inputs or 0 to 5 volt inputs.

✔ Real-Time Clock with battery back-up (option). ✔ Built-in coil flyback diodes. ✔ Software and hardware watchdog circuits ensure proper software operation. ✔ Rugged aluminum housing

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2- INSTA L L ATI ON AND WIRING

INSTALLATION AND WIRING

2

MOUNTING THE CONTROLLER

The Curtis 1310 mounts securely to the vehicle or system using 4 #8 or M4 screws. Care should be taken to prevent water from splashing or resting on the connector area. If possible, the connector area should be mounted downward and guarded from water and dust born contaminants which can degrade the electrical connections.

Fig 2. Controller Mounting

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Working on electrical systems is potentially dangerous. You should protect yourself against uncontrolled operation, high current arcs, and outgassing from lead acid batteries:

UNCONTROLLED OPERATION — Some conditions could cause the system to run out of control. Disconnect motors, open valves and jack up the vehicle to get the drive wheels off the ground before attempting any work on vehicle control circuitry or software.

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 system electrical 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.

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; see Appendix B for suggestions on managing EMC.

The Curtis 1310 Vehicle System Controller contains ESD-sensitive components. Use appropriate precautions in connecting, disconnecting, and handling the controller. See installation suggestions in Appendix B for protecting the controller from ESD damage.

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HIGH CURRENT CONNECTIONS

The Curtis 1310 has several options from supply power to the controller. Since the 1310 Vehicle System Controller has many outputs, it is possible to draw a significant load from the battery. The B- high power tab must be used as the controller ground reference if more than 2 amps current is expected in the total system. Likewise, if the system could draw more than 2 amps of current from the B+, the B+ high power tab must be used to power the controller. If the driven loads are inductive, the load's power must be connected to B+ high power tab and the B+ high power tab must be connected to the battery (as shown in the standard wiring diagram).

When using the high power connections tabs, be careful not to bend or break the tab while tightening the bolt. For best results, use a pressure washer (convex side up) under the bolt head. This will help prevent the joint from loosening over time.

To help prevent overheating the joint, insure the that wire cable gage is sufficient to carry the continuous and maximum loads that will be seen by the 1310.

Table 1. High Current Connections

NAME DESCRIPTION

B+ Battery positive connection tab

Internally connected to J1-24. See table 1

B- Battery Negative connection tab

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LOW CURRENT CONNECTIONS

All low current (logic) connections are made through Molex Mini Fit Jr connectors. J1 is a 24 pin connector and contains most of the standard inputs and outputs. J2 is 6 pin connector dedicated to the CAN bus. J3 is a 4 pin connector dedicated to the Curtis serial bus port, used with the 1311 and 1314 programmers and the 840 Spyglass gage. J4 is a 16 pin connector for the analog input/outputs and encoder connections.

Low current wiring recommendations

Encoders

All four encoder wires should be bundled from the encoder to the controller connector. These can often be run with the rest of the low current wiring harness. The encoder cables should not be run near battery or motor cables. In applications where this is necessary, shielded cable should be used with the ground shield connected to the I/O ground at only the controller side. In extreme applications, common mode filters (e.g. Ferrite beads) could be used.

CAN bus

It is recommended that the CAN wires be run as a twisted pair. However, many applications at 125 kBaud are run without twisting, simply using two lines bundled in with the rest of the low current wiring. 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.

Notes on the following tables

The proceeding tables are grouped by connector. They define the pin, signal name and basic function (description) of that signal. Often special VCL functions can be used to access or setup or use of these signals. The VCL Functions column notes these when appropriate. Each signal has a predetermined variable name or set of variable names that allow the VCL access to the value or control over the signal. These names are in the VCL References column

Partial Option Models

Model 1310-5210 is not “fully stuffed”. This model has Outputs 9 through 16 and Inputs 1 though 13, 16, and 19 through 22 available. Outputs 14 and 15 have over 200kΩ output impedance.

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Table 2. J1 Connections- Input/Outputs

PIN NAME DESCRIPTION

1 Input/Output 1

2 Input/Output 2

3 Input/Output 3

4 Input/Output 4

5 Input/Output 5

6 Input/Output 6

7 Input/Output 7

8 Input/Output 8

9 Input/Output 9

10 Input/Output 10

11 Input/Output 11

A digital input with an open collector high frequency PWM output. This output also provides output current feedback. Signal is pulled to B- when output is on.

A switch to B+ digital input with an open collector high frequency PWM output. Signal is pulled to B- when output is on.

A switch to B+ digital input with an open collector low frequency PWM output. Signal is pulled to B- when output is on.

RELATED VCL

FUNCTIONS REFERENCES

Put_PWM Automate_PWM Get_ADC

Put_PWM Automate_PWM

SW_1 SW_1_UP SW_1_Down PWM1 ADC15_Output

SW_2 SW_2_UP SW_2_Down PWM2 ADC16_Output

SW_3 SW_3_UP SW_3_Down PWM3

SW_4 SW_4_UP SW_4_Down PWM4

SW_5 SW_5_UP SW_5_Down PWM5

SW_6 SW_6_UP SW_6_Down PWM6

SW_7 SW_7_UP SW_7_Down PWM7

SW_8 SW_8_UP SW_8_Down PWM8

SW_9 SW_9_UP SW_9_Down PWM9

SW_10 SW_10_UP SW_10_Down PWM10

SW_11 SW_11_UP SW_11_Down PWM11

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12 Input/Output 12

13 Input/Output 13

14 Input/Output 14

15 Input/Output 15

16 Input/Output 16

17 Input 17

18 Input 18

19 Input 19

20 Input 20

21 Input 21

22 Input 22

23 B-

24 B+

Table 2. J1 Connections- Input/Outputs

A switch to B+ digital input with an open collector low frequency PWM output. Signal is pulled to B- when output is on.

A switch to B+ digital input (pulled low to B-). Switch this pin to B+ to read as ON.

A switch to ground digital input (pulled high to +15v). Switch this pin to B- to read as OFF.

Can be used as a low power (<2 amp) ground reference or for the switch inputs 12 – 22 B- reference.

Can be used to power the system (<2 amps) or for B+ reference for switches, etc.

Put_PWM Automate_PWM

Setup_BDI ADC13_Output

SW_12 SW_12_UP SW_12_Down PWM12

SW_13 SW_13_UP SW_13_Down PWM13

SW_14 SW_14_UP SW_14_Down PWM14

SW_15 SW_15_UP SW_15_Down PWM15

SW_16 SW_16_UP SW_16_Down PWM16

SW_17 SW_17_UP SW_17_Down

SW_18 SW_18_UP SW_18_Down

SW_19 SW_19_UP SW_19_Down

SW_20 SW_20_UP SW_20_Down

SW_21 SW_21_UP SW_21_Down

SW_22 SW_22_UP SW_22_Down

KSI_Filtered KSI_Raw

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Table 3. J2 Connections- CAN Bus

PIN NAME DESCRIPTION

1 CAN Hi

2 CAN Lo

3 GND

4 +5V

5 Term H

6 Term L

Positive CAN Bus rail Setup_CAN

Negative CAN bus rail Setup_CAN

Ground reference

+5v for remote module(s)

Connect Term H to Term L to create an end-of-bus termination (adds a 120Ω resistor across CAN Hi and CAN Lo)

See above

RELATED VCL

FUNCTIONS REFERENCES

Setup_Mailbox Send_Mailbox etc...

Table 4. J3 Connections- Serial Port

PIN NAME DESCRIPTION

1 RxD

2 GND

3 TxD

4 PWR

Serial receive line for programmer and spyglass communications

Communications ground

Serial Transmit line for programmer and spyglass communications

+12v Power The output current of this pin and +5volts (J4-15) is combined and monitored at ADC12 .

RELATED VCL

FUNCTIONS REFERENCES

Setup_Serial Put_Spy_Message

ADC12_Output

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Table 5. J4 Connections- Specialty I/O

PIN NAME DESCRIPTION

1 Encoder 1A

2 Encoder 1B

3 Encoder 2A

4 Encoder 2B

5 Pot High

6 Wiper 1

7 Wiper 2

8 Wiper 3

9 Wiper 4

10 Pot Low

11 Analog Output 1

2 Analog Output 2

Pulse count input or Channel A for encoders

Channel B for encoders SW_24

Pulse count input or Channel A for encoders

Channel B for encoders SW_26

The high voltage reference for the 4 potentiometer inputs

A generic 0-5 volt input which can also be setup for as a potentiometer wiper input

Low voltage reference for the 4 potentiometer inputs

0-10 volt analog output Put_DAC

13 Not Used

14 PWR_UP

15 +5V

16 GND

B+ input can be used to power up the

1310.

+5 volts to power sensors. Can supply up to 200ma. The output current is monitored at ADC11.

Ground reference

RELATED VCL

FUNCTIONS REFERENCES

Setup_Encoder Get_Enc_Count Get_Enc_Vel Get_Enc_Dir Get_Enc_Error

Get_Pot Get_ADC

Get_Pot Setup_Pot Setup_Pot_Filtered Get_ADC

Get_Pot Get_ADC

Automate_DAC

Get_ADC ADC7_Output

Get_ADC ADC11_Output

ENC1 ENC1_Count ENC1_Dir ENC1_Vel ENC_Error SW_23

ENC2 ENC2_Count ENC2_Dir ENC2_Vel ENC_Error SW_25

POT_High ADC1 ADC1_Output

POT1_Output ADC2_Output

POT2_Output ADC3_Output

POT3_Output ADC4_Output

POT4_Output ADC5_Output

POT_Low ADC6_Output

DAC1

DAC2

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CONTROLLER WIRING: BASIC CONFIGURATION

This wiring diagram shown is a generalized diagram. Its purpose is to show a variety of basic uses for the various 1310 Inputs and Outputs. It also provides a standard (although not the only) power and battery connections. The following paragraphs walk though the diagram.

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Power Connection The Battery is connected to to 1310 power tabs though a fuse and a key switch. The power tabs are used because there are inductive loads on the system (Aux Contactor and Proportional Value coils) and the current could exceed 3amps. The fuse is required to protect the wiring as the 1310 could draw significant power if there were a short or failure in the unit.

The key switch is used to “start” the system. Both the B+ High Power Tab and the B+ signal at J1-24 are used as the Key Switch Input. When the key switch is closed, the B+/ KSI input goes high, the 1310 power supply brings up the 1310 and the BDI functions are enabled.

Outputs The system shown has 2 high power outputs and 2 LEDs, that run of key switch power.

Using the PWM outputs to drive the LEDs allows the the brightness of the LEDs to be varied. The frequency is too high for the human eye to see any flickering. Note that a dropping resistor must be used because even low duty cycle PWM applies full battery voltage is short bursts, and this will destroy the LED without a dropping resistor limiting the current. Note the internal impedance to ground of the driver will cause leakage current to flow through the LEDs even when the output driver is off. Refer to Digital Output Specifications following when calculating this leakage current. This leakage current can be enough (> 2 ma) to light high efficiency LEDs. Model 1310-5210 provides two output drivers (Outputs 14 and 15) that do not have leakage current issues and may therefore be the best suited for driving LEDs.

The first power output drives a proportional valve coil. Outputs 1 and 2 are special in that they have internal current feedback lines. VCL can use this signal in a PID loop to regulate current, which is necessary to properly control the position (and flow) in a proportional valve. Outputs 1 through 4 also run at a higher frequency and thus can provide a smoother current (less ripple).

The second power output drives a basic contactor coil. It is connected to output 2, which has a current feedback signal. In this case, the VCL can use the current feedback signal to ensure that the coil is connected and drawing the proper current when on. In this way, enhanced fault diagnostic can be performed.

Switch Inputs All of the Outputs can be used as active high inputs (“on” when connected to B+). There are 4 special inputs that are active low (“on” when connected to B-). If an Output is being used as an input (such as is the case on Input/Output 15) the VCL must take care not to turn on that output or a direct short to B+ could be established through the switch and the internal FET driver.

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Analog Inputs Three types of analog inputs are used. The first two inputs use a 0-5 volt input. The next is a 3wire connection for a potentiometer using both Pot High and Pot Low and the third is a 2-wire potentiometer or rheostat.

Note that in all cases, the VCL code must be written to provide the necessary wiring and potentiometer fault checking. To accomplish this, the 1310 provides the measured voltage readings of Pot High and Pot Low connections. Monitoring these values will can indicate if there is a shorted to B+ or B-. Using the Pot High and Pot Low connections for the potentiometer or rheostat will also provide a small lower and (when using Pot High) upper bound to the analog input. Knowing this, proper range checking in VCL can be performed for additional fault diagnostics.

Encoder and Pulse Inputs. The 1310 has 2 quadrature encoder inputs. Using A and B channels with a quadrature encoder allows velocity, position (count) and direction detection. Tyeing the A and B channels together, as shown on encoder input 2, allows the input to measure a single pulse train. In this configuration, the 1310 will count up (ENC_Count mode) or measure speed magnitude (Enc_Velocity mode). In both cases, the ENC2_DIR variable is not valid.

Power for the encoder can be derived form the +5 Volt output and Ground pins found on J4. The +5 volt output has an output current measurement. VCL can use this value to determine if the encoder and/or any other sensors are connected and drawing the proper current. This can be used to provide additional fault diagnostics.

Note: If the encoder inputs are setup in velocity mode, the direction flag will not be accurate below a low speed threshold. The direction bit may stay in the last direction and may not return to 0 when the speed is at zero. The VCL code must be written to read the velocity variable and double check the direction bit in this case.

Analog Outputs The 2 analog outputs can be used to interface to analog throttle input motor controllers or other devices, Here, Analog Output 1 is used to control the 1204 Motor Controller throttle input. Note that most throttle inputs are 0-5 volts while the 1310 can provide up to 10 volts.

Analog Output 2 is being used to drive a Curtis gage (enGage 2 or simple voltmeter). VCL code can use this output to display a wide range of data, from the state of the battery charge, potion of the potentiometer wipers or speed of the encoder.

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INPUT/OUTPUT SIGNAL SPECIFICATIONS

The input/output signals wired to the J1 through J4 connectors can be grouped by type as follows; their electrical characteristics are discussed below.

• Digital inputs

• Digital outputs

• Analog inputs

• Analog outputs

• Power

• Communications ports

Digital Inputs

These signal lines can be used as digital (ON/OFF ) inputs. Normally, the ON signal is made by a connection direct to B+ and OFF is direct to B-. Inputs 1 through 18 will pull low (OFF) if no connection is made. Inputs 19 through 26 will pull high (ON) if no connection is made.

Inputs 1 through 18 are associated with driver outputs. Inputs 19 through 26 are low voltage “TTL” level inputs and can be used when connecting to other low voltage (5v) logic circuits or sensors. The encoder channels are normally used for pulse count inputs from quadrature (2 channel) encoders, but they may also be used as 5v logic level digital inputs. Take careful note of their much lower voltage range.

DIGITAL INPUT SPECIFICATIONS

SIGNAL NAME PIN

Input/Output 1-16 J1-1

thru

22

Input 17-18 J1-17

thru

18

Input 19-22 J1-19

thru

22

Encoder Inputs Inputs 23-26

J4-1

thru

4

Logic

Thresholds

24-48V models:

Low = 7.5v

High = 15.8v

48-96V models:

Low = 14.1v High = 29.7v

24-48V models:

Low = 7.5v

High = 15.8v

48-96V models:

Low = 14.1v High = 29.7v

All models

High = 3.8v

Low = 1.8v

Rising edge

= 3.0v

Falling Edge

= 2.0v

Input

Impedance

24-48V models:

about 5.4 kΩ

48-96V models:

about 22kΩ

*see note below

24-48V models:

about 5.4 kΩ

48-96V models:

about 22kΩ

All models

about 4.5kΩ

All models

about 4.7kΩ

Voltage

Range

24-48V models:

-0.5 to 64v

48-96V models:

-0.5 to 124v

24-48V models:

-0.5 to 64v

48-96V models:

-0.5 to 124v

24-48V models:

-0.5 to 64v

48-96V models:

-0.5 to 124v

All models

-0.5 to 5.5 v

Tolerance of above values; ±5% * Outputs 14 and 15 on Model 1310-5210 have over 200kΩ output impedance

ESD

Tolerance

± 8 kV

(air discharge)

± 8 kV

(air discharge)

± 8 kV

(air discharge)

± 8 kV

(air discharge)

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Curtis 1310 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual