Kohler Curtis F Series User Manual

7 — DIAGNOSTICS AND TROUBLESHOOTING
Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022 Return to TOC
pg. 198
7 — DIAGNOSTICS AND TROUBLESHOOTING
e Troubleshooting Chart, Table 24, describes the fault ash codes. e faults list is in the numerical
ash code order. e fault’s name, VCL name and CAN Object Index are listed, including the fault types.
Possible causes, the set and clear conditions and the fault actions are listed. Fault actions are “what the
controller will do” when the fault is active. Table 23 lists the fault actions and their associated 'bits' when
using the System_Action variable (0x4E00 0x00). Table 22 is a quick index to the faults by ash codes.
Faults, aer the set condition(s) have been resolved, are usually cleared by cycling the keyswitch (On-
O-On), yet can be handled using the applicable VCL Reset function, or the CAN NMT Reset function.
ese are collectively referred to as Reset Controller.
THE DIAGNOSTICS PROCESS
Obtain diagnostics information in either of three ways: (1) by observing the fault codes ashed by the
controller’s status indicator, (2) by reading the indicated fault ( ) in the Curtis Integrated Toolkit
TM
Programmer tool, or (3) the CAN Emergency Messages.
e status indicator is a translucent window on the cover, which blinks red and yellow LEDs. Its
illumination indicates the following information:
O: Controller is not powered on, or is severely damaged.
Slow yellow blinking: Controller is operating normally.
Solid yellow or orange: Controller is in ash program mode, or corrupted soware is
preventing the unit from completing the startup sequence (boot process).
Red/yellow ashing pattern: Fault code, review the fault table.
Solid red: Internal hardware fault detected by the supervisor or primary microprocessor, or
the controller has no soware loaded.
Fast ashing red: Non-production/experimental/custom device prole soware.
e Troubleshooting Chart Index, Table 22, indicates both the controller’s LED ash sequences and
the CANbus Emergency Message hexadecimal Error Code values. e fault ash pattern is decimal.
For example, the Driver 1 Fault is assigned the ash code 10-1, which illuminates in a sequence of
10 red LED ashes (x10) followed by 1 yellow LED ash (x1) before repeating. e hexadecimal
code is 0xA1, which will be the Error Code value in the CAN Emergency message, explained below.
When using the Curtis Integrated Toolkit
TM
Programmer tool to diagnose faults, the active faults are at
the top of the menu panel. If a fault has more than one possible cause, it indicates the “type” number.
Within the System Monitor menu, the Fault History menu provides additional information; Count
indicates the number of occurrences since the Clear History was performed. e menu item Time
indicates the KSI hours, provided in seconds (#sec/3600 = hours) when the present fault occurred,
while the menu’s First Time item keeps track of the fault’s rst occurrence, should multiple faults
follow before the history is cleared. e Type, as listed at the top of the menu panel, is repeated and
is the current “fault type” for faults having more than one type. Figure 42 is an example of the CIT
Programmer’s fault-diagnosis usage. e illustrated sequence, panels le to right, are for the two
types of the Main Contactor Did Not Close fault, which are also illustrated in the CAN Emergency
Messages – Active Faults section, as examples (2a) and (2b) below.
1
Panel 1: An Active Fault with Type 1. First occurrence (Count = 1) with Time and First
Time are equal. e active fault Type matches.
2
Panel 2: Second occurrence of the same fault Type as in panel 1. Note the Time dierences,
with First Time matching between panels 1 and 2.

Kohler Curtis F Series Specifications

General

Brand	Kohler
Model	Curtis F Series
Category	Controller
Language	English

Summary

1 — OVERVIEW

HOW TO USE THIS MANUAL

Guidance on navigating and utilizing the manual's content for effective controller application.

WHAT IS NEW IN FOS 4.5.0.0 ... HIGHLIGHTS

Summary of key enhancements and changes in the FOS 4.5.0.0 firmware version.

GETTING THE MOST OUT OF YOUR CURTIS CONTROLLER

Advice on optimizing controller application through understanding manual sections and tools.

2 — INSTALLATION AND WIRING

PHYSICALLY MOUNTING THE CONTROLLER

Instructions for proper physical installation and mounting of the controller for optimal performance and environmental protection.

PRECAUTIONS

Essential safety and design considerations for ensuring EMC compliance and preventing electrical issues.

HIGH CURRENT CONNECTIONS

Details on connecting high-current terminals (B+, B-, U, V, W) and recommended connection guidelines.

LOW CURRENT CONNECTIONS

Information on logic and low-power connections via AMPSEAL connectors, including pin assignments.

Rotor Position feedback

Guidance on wiring rotor position sensors, including signal wiring best practices and shielding.

CANbus

Best practices for CANbus wiring, including twisted-pair and shielded cable usage for reliable communication.

All other low power wiring

Recommendations for routing low-power wiring to avoid signal interference and protect against damage.

Protected voltages

Information on protected voltage ratings for low-power pins and crucial connection warnings to prevent damage.

3 — APPLICATION-SPECIFIC FEATURES

MOTOR SPEED CONSTRAINTS

Details on how electrical frequency, encoder pulses, and parameter settings limit maximum motor speed (RPM).

VOLTAGE LIMITS

Explanation of hardware and parameter-based voltage limits, including operating regions and thresholds.

BROWNOUT VOLTAGE

Information on the fixed brownout voltage level and controller actions when voltage falls below this threshold.

KSI AND B+ INPUT

Notes on KSI input connection to B+ terminal for controller power, precharge, and BDI usage.

BATTERY DISCHARGE INDICATOR

Explanation of the BDI algorithm for calculating battery state-of-charge (SOC) and its viewable parameters.

4 — PROGRAMMABLE PARAMETERS

PROGRAMMING MENUS

Overview of programmable parameters organized into nested menus for customization via CANbus connection.

PARAMETER CHANGE FAULTS [PCF]

Explanation of faults triggered when parameters are changed while the motor bridge is enabled.

MONITOR VARIABLES WITHIN PARAMETER MENUS

Information on specific monitor variables contained within parameter menus, which are read-only.

PROGRAMMING TOOLS

Details on PC-based Curtis Integrated Toolkit (CIT) and the Curtis 1313 handheld programmer.

5 — SYSTEM MONITOR MENU

MOTOR MENU

Displays real-time motor data including RPM, temperature, torque, power, and feedback signals.

VEHICLE MENU

Monitors vehicle speed, odometer, acceleration, and distance traveled, configurable in metric or English units.

FAULT HISTORY

Accesses and clears the controller's fault history file for diagnosing and verifying problem resolution.

6 — COMMISSIONING

INITIAL SETUP

Essential steps for setting up controller parameters and ensuring they are suited to the specific application.

TRACTION MOTOR SELECTION

Guidance on selecting and commissioning ACIM or PMAC motors, including compatibility and procedures.

AC Motor Characterization

Procedure for characterizing ACIM traction motors using a quadrature encoder or Sin/Cos sensor.

AC MOTOR TUNING GUIDE

Steps for tuning the AC traction motor performance by selecting control modes and adjusting parameters.

SETTING UP THE HYDRAULIC SYSTEM

Procedures for setting up hydraulic systems, including lift, lower, and load-hold valve controls.

7 — DIAGNOSTICS AND TROUBLESHOOTING

THE DIAGNOSTICS PROCESS

Methods for obtaining diagnostics information, including status indicators, programmer tool, and CAN emergency messages.

FAULT ACTIONS

Table detailing fault actions taken by the controller, including shutdown sequences and VCL references.

8 — MAINTENANCE

CLEANING

Procedure for routine cleaning of the controller exterior to protect against corrosion and electrical issues.

FAULT HISTORY

Accessing and clearing the controller's fault history file to diagnose and verify problem resolution.

APPENDIX A

CAN PDO MAP SETUP

Guidance on setting up PDO maps for F-Series controllers using the Curtis Integrated Toolkit™ for CAN communication.

APPENDIX B

ELECTROMAGNETIC COMPATIBILITY (EMC)

Information on emissions and immunity, and techniques to reduce EMC problems in products with Curtis controllers.

ELECTROSTATIC DISCHARGE (ESD) IMMUNITY

Necessary precautions to protect ESD-sensitive components from damage by providing sufficient distance or isolation.

DECOMMISSIONING AND RECYCLING THE CONTROLLER

Instructions for decommissioning and recycling the controller, following OEM and landfill directives.

APPENDIX C

EN 13849 COMPLIANCE

Overview of safety requirements and performance levels (PL) according to EN13849 for control systems.

APPENDIX D

CURTIS INTEGRATED TOOLKITTM

Description of CIT software for configuring and communicating with Curtis Instruments products via CAN network.

Choosing the CAN Interface Device Driver

Steps to select and install the appropriate CAN dongle driver for PC communication with the controller.

Creating a Project with a new F-Series controller

Step-by-step guide to opening the Project Explorer and creating a new project for F-Series controller configuration.

APPENDIX E

SPECIFICATIONS: CONTROLLER

Detailed specifications for AC F6-A, F4-A, and F2-A controllers, including electrical and mechanical data.