Kohler Curtis F Series User Manual

2 — INSTALLATION AND WIRING
pg. 23
Return to TOC Curtis AC F2-A, F4-A, F6-A Motor Controllers – FOS 4.5 – April 2022
Potentiometer Inputs with Dynamic Testing
In this manual, the term throttle is for the traction motors. If the vehicle uses a dual drive system,
the single throttle input controls both traction motors. Figures 12 and 13 illustrate the traction-drive
throttle as a traditional 3-wire potentiometer (pot) using Pot 1 Wiper, although Hall-eect voltage
throttles are more common today. e brake throttle in Figure 13 is via a 2-wire pot. Using CAN-
based throttles, as illustrated in Figures 14 and 15, frees the throttle (or brake) analog inputs for other
usages. For example, in a dual-drive system, a CAN-based throttle frees a potentiometer input for
use as the steer-angle input.
e three basic wired throttles use these analog input congurations:
0 = Voltage input (see Table 9 and Figure 39 {voltage throttle in commissioning chapter})
1 = 3-Wire Pot (see Table 10 and Figure 36 {3-wire throttle in commissioning chapter})
2 = 2-Wire Pot (see Table 10 and Figure 37 {2-wire throttle in commissioning chapter})
In Programmer, when selecting Analog 1 Type as a 3-wire pot, Analog 6 becomes unavailable. When
selecting Analog 18 as a 3-wire pot, Analog 19 becomes unavailable.
Note: e 3-wire potentiometer throttle provides complete throttle-fault protection that meets
the applicable EEC regulations. For voltage throttles, the congured-pins protect against out-
of-range input values, but do not detect external wiring faults; it is therefore the responsibility
of the OEM to provide full throttle fault protection in vehicles using voltage, current, or CAN-
based throttles.
e potentiometer inputs contain internal circuits, which dynamically test the wiper and pot high
connections to enable detection of the following faults:
• Pot wiper connected to B+ at any time.
• Pot wiper connected to B– at any time (if this could produce movement).
• Pot high connected to B+ at any time.
• Pot high connected to B– at any time.
• Pot wiper shorted to ground at any time (if this could produce movement).
• Pot wiper shorted to pot high at any time.
• Pot high shorted to ground at any time.
• Other internal tests ensure the potentiometer inputs remains valid.
erefore, when conguring an input as a potentiometer, always use the percent value for the reading,
not the voltage. e voltage value will vary based upon the dynamic test (it is not for control usage).
2-Wire potentiometers use the wiper as the supply voltage while “reading” the voltage at the pin.
The circuit is completed by the connection to the I/O ground. One end of the potentiometer
is left unconnected. The controllers can configure either or both Analog 1 and Analog 6 as
2-wire potentiometers.
Quick Links:
Fig 12 p.16
Fig 13 p.17
Fig 14 p.18
Fig15 p.19
Fig 36 p. 165
Fig 37 p. 166
Fig 39 p. 168
Analog Inputs p. 104

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.