MANUAL CURTIS PMC DUAL INTEGRATED MOTOR CONTROLLER

Transcription

1 MANUAL MODEL 1288 DUAL INTEGRATED MOTOR CONTROLLER 2002 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO CURTIS PMC 235 East Airway Boulevard Livermore, California USA Tel: Fax: Manual, p/n Rev. A: January 2002

2 1288 Manual p/n 36866, Rev. A: January CURTIS INSTRUMENTS, INC. CURTIS INSTRUMENTS, INC. 200 KISCO AVENUE MOUNT KISCO, NEW YORK U.S.A FAX CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE, CALIFORNIA U.S.A FAX ADDITIONAL OFFICES located in Bulgaria, China, England, France, Germany, India, Italy, Japan, Netherlands, Puerto Rico, Sweden, and Switzerland

3 CONTENTS CONTENTS 1. OVERVIEW INSTALLATION AND WIRING... 3 Mounting the Controller... 3 Main Harness... 4 Curtis connector... 5 Beau connectors... 6 Anderson connectors... 7 Charger/Programmer Port USER INTERFACE... 8 Joystick... 8 Control Pad... 8 Power on/off... 9 Mode... 9 Speed limit... 9 BDI display Faults Summary of LED display formats PROGRAMMABLE PARAMETERS Programming Menus General Drive Parameters Drive Current Limit Brake Current Limit Boost Current Limit Wheel Position Throttle Autocalibration Power Off Deceleration Brake Delay Sleep Timeout Save Parameters Restore Saved Parameters Joystick Parameters Perimeter Deadband Neutral Deadband Steer Sensitivity Tremor Suppression Start Delay Speed Parameters Maximum Forward Speed Minimum Forward Speed Curtis PMC 1288 Manual iii

4 CONTENTS Maximum Reverse Speed Minimum Reverse Speed Maximum Turn Speed Minimum Turn Speed Response Parameters Forward Acceleration High Speed Forward Acceleration Low Speed Forward Deceleration High Speed Forward Deceleration Low Speed Reverse Acceleration High Speed Reverse Acceleration Low Speed Reverse Deceleration High Speed Reverse Deceleration Low Speed Emergency Stop Emergency Stop Pause Turn Acceleration High Speed Turn Acceleration Low Speed Turn Deceleration High Speed Turn Deceleration Low Speed Turn Deceleration Neutral Turn Rate Softening Soft Start Gear Soften Motors and Wheels Parameters Motor Swap High Speed Compensation Low Speed Compensation Anti-Rollback Compensation Auto Trim Motor Trim Motor Current Rating Motor Energy Rating Motor Cooling Rate Motor Impedance Motor Test Mode Auxiliary Parameters Auxiliary Toggle Aux 1 Up Speed Aux 1 Down Speed Aux 2 Up Speed Aux 2 Down Speed Aux 1 Up Stop Current Aux 1 Down Stop Current Curtis PMC 1288 Manual iv

5 CONTENTS Aux 2 Up Stop Current Aux 2 Down Stop Current Battery Parameters Full Voltage Empty Voltage Reset Voltage Start Charge Voltage Discharge Rate Charge Rate Maximum Motor Volts Controller Cloning VEHICLE PERFORMANCE ADJUSTMENT Matching the Controller to the Motor Wiring Determining Motor Impedance Correcting the Motor Trim Basic Performance Emergency Stop Load Compensation Fine Tuning DIAGNOSTICS AND TROUBLESHOOTING MAINTENANCE Cleaning Diagnostic History APPENDIX A 1311 Programmer Operation... A-1 APPENDIX B Specifications: 1288 Controller... B-1 Curtis PMC 1288 Manual v

6 FIGURES / TABLES FIGURES FIG. 1: Curtis PMC 1288 electronic motor controller... 1 FIG. 2: Mounting dimensions, Curtis PMC 1288 controller... 3 FIG. 3: FIG. 4: FIG. 5: FIG. 6: FIG. 7: Wiring for Curtis PMC 1288 controller with Curtis Connector System (CCS)... 5 Wiring for Curtis PMC 1288 controller with Beau 9-pin connector... 6 Wiring for Curtis PMC 1288 controller with Beau 14-pin connector... 6 Wiring for Curtis PMC 1288 controller with Anderson connectors... 7 Wiring for Curtis PMC 1288 controller s charger/programmer port... 7 FIG. 8: Joystick configuration... 8 FIG. 9: Control pad... 8 FIG. 10: Physical range of speed limit knob... 9 FIG. 11: BDI display FIG. 12: Fault display TABLES TABLE 1: Wiring specifications... 4 TABLE 2: Types of LED display TABLE 3: LED fault codes TABLE 4: Troubleshooting chart TABLE B-1: Specifications: 1288 controller... B-1 Curtis PMC 1288 Manual vi

7 1 OVERVIEW 1 OVERVIEW The Curtis PMC 1288 controller combines an electronic motor speed controller with an ergonomic joystick in a single integrated unit. Designed for use with motorized wheelchairs and other mobility aids, the 1288 controls the two permanent magnet motors that power the vehicle s two drive wheels. This high performance programmable controller is simple to install, efficient, and cost effective. Fig. 1 Curtis PMC 1288 dual integrated permanent magnet motor controller. The 1288 controller offers smooth precise control of motor speed and torque. Two full-bridge MOSFET power sections provide solid state motor reversing and full regenerative braking. The 1288 controller is fully programmable through Curtis PMC s 1311 handheld programmer. In addition to configuration flexibility, the programmer provides diagnostic and test capability. Like all Curtis PMC motor controllers, the 1288 offers superior operator control of the vehicle s motor drive speed. Features include: Power and reliability industry-leading current handling capacity of 60 or 90 amps AutoTrim (patent pending) automatically corrects steering alignment to compensate for differences in motors, bearing/gear wear, tire inflation, lubrication, etc. smooth performance provided by vehicle-specific programming programmable for front, mid, or rear drive-wheel configurations More Features Curtis PMC 1288 Manual 1

8 1 OVERVIEW throttle tremor control delivers greater isolation for smooth performance programmable motor thermal protection Unique ergonomic design joystick designed with non-slip materials and hand-friendly indentations to deliver the maximum in user confidence and control integrated palm-rest provides greater comfort and allows for more stable throttle control mode switch, speed pot, and programmer/charger port easily accessible Energy efficiency automatic Power Saver power-off function Internal BDI monitors battery discharge rates opportunity charging provides interim battery charging in between full charges built-in protection against undervoltage and overvoltage fully compatible with Curtis PMC 1604/1608 high frequency chargers for simple and efficient battery recharging Safety emergency braking is programmable to individual vehicles to provide safe, confident stopping neutral release allows for gentle vehicle slowing when throttle is released maintains precise steering control even at current and voltage limits anti-roll control prevents forward or reverse motion on ramps, hills, etc. Diagnostics LED display indicates fault codes and battery charge status Optional 1311 handheld programmer provides detailed diagnostic and fault information Auxiliary seat lift function [optional] two channels available (8 amps), for seat lift plus back-rest or leg-rest tilt adjustment programmable up/down speed two modes of operation (up/down) Familiarity with your Curtis PMC 1288 controller will help you install and operate it properly. We encourage you to read this manual carefully. If you have questions, please contact the Curtis office nearest you. Curtis PMC 1288 Manual 2

9 2 INSTALLATION & WIRING 2 INSTALLATION AND WIRING MOUNTING THE CONTROLLER The outline and mounting hole dimensions for the 1288 controller are shown in Figure 2. Four untapped mounting holes in the base can be tapped for metric or English standard threads; another six mounting holes are pre-tapped for metric M4 fasteners. Fig. 2 Mounting dimensions, Curtis PMC 1288 controller. 149 (5.9) Palm rest lifts to expose port for charger/ programmer 188 (7.4) 211 (8.3) 120 M , 6 plcs ( ), 4 plcs 68 (2.7) 45.7 (1.80) 25.4 (1.00) 55.0 (2.17) (4.33) (5.50) Dimensions in millimeters (and inches) Curtis PMC 1288 Manual 3

10 2 INSTALLATION & WIRING CAUTION Working on electric vehicles is potentially dangerous. You should protect yourself against runaways, high current arcs, and outgassing from lead acid batteries: RUNAWAYS Some conditions could cause the vehicle 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 Electric vehicle batteries can supply very high power, and arcs can occur if they are short circuited. Always open the battery circuit before working on the motor control circuitry. 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. WIRING CONNECTIONS All the necessary signals for operating the vehicle are contained in the main harness cable, which exits the lower rear of the controller. This power cable terminates in a compact connector set. In addition, the 1288 has a charger/ programmer port, located under the palm rest. Main harness wiring On generic 1288 controllers, the power cable terminates in a Curtis Connector System (CCS). Other standard connectors are Beau (9-pin and 14-pin) and Anderson. If you would prefer the power cable to be terminated in some other type of connector, contact Curtis PMC applications engineers. In all cases, the wiring between the connector and the vehicle must be capable of meeting the same current ratings as the corresponding wire in the main harness, as listed in Table 1. Table 1 WIRING SPECIFICATIONS COMPONENT CURRENT RATING WIRE SIZE Battery +, - 40 A continuous; 140 A for 2 min. 10 AWG Motor +, - 20 A continuous; 75 A for 2 min. 14 AWG E-M brake +, - 1 A continuous 18 AWG Inhibit 100 ma continuous 18 AWG Auxiliary +, - 8 A continuous 18 AWG Curtis PMC 1288 Manual 4

11 2 INSTALLATION & WIRING Curtis Connector The Curtis Connector System (CCS) is a single molded unit containing a 2-pin battery connector and two 4-pin motor connectors. The mating connectors are available from Curtis. Signals for auxiliary motors, such as a seat lift motor, can be provided through an optional 5-pin Conexall connector. Alternatively, if the application has no auxiliary functions, a 6-pin Conexall connector can be substituted enabling the charger to be plugged into the cable overmold instead of into the body of the controller itself. The mating plug for this custom Conexall can be ordered directly from Curtis. Fig. 3 Wiring for Curtis PMC 1288 controller with Curtis Connector System (CCS). Conexall connector (see below) B+ BATTERIES B- MOTOR B E-M BRAKE MOTOR A E-M BRAKE M M MOTOR B MOTOR A 5-pin Conexall, for use with auxiliary motors 6-pin Conexall, for use with battery charger (inhibit) 1 5 inhibit 1 B+ B- - + M AUX MOTOR M AUX MOTOR 2 B+ B- BATTERY CHARGER Curtis PMC 1288 Manual 5

12 2 INSTALLATION & WIRING Beau 9-pin Connector When the power cable is terminated with a Beau 9-pin connector, the 1288 cannot control any auxiliary motors. Fig. 4 Wiring for Curtis PMC 1288 controller with Beau 9-pin connector Beau 9-pin connector B- BATTERIES B M M MOTOR B MOTOR B E-M BRAKE MOTOR A MOTOR A E-M BRAKE Beau 14-pin Connector When the power cable is terminated with a Beau 14-pin connector, the 1288 can control two auxiliary motors (e.g., for seat lift and back tilt). Fig. 5 Wiring for Curtis PMC 1288 controller with Beau 14-pin connector Beau 14-pin connector M AUX M AUX 2 B- B M M MOTOR B MOTOR A BATTERIES MOTOR B E-M BRAKE MOTOR A E-M BRAKE NOTE: Diagram shows wiring for 24V electromagnetic brakes. If 12V brakes are used, they can be wired in series. Curtis PMC 1288 Manual 6

13 2 INSTALLATION & WIRING Anderson Connectors The power cable can be terminated in a set of four Anderson connectors (or three, if the application has no auxiliary functions). J9 J10 (inhibit) J12 J M MOTOR A + - M MOTOR B B- BATTERIES B+ + - M AUX 2 AUX 1 + M - J9 J10 J11 J12 MOTOR A E-M BRAKE MOTOR B E-M BRAKE NOTE: Diagram shows wiring for 24V electromagnetic brakes. If 12V brakes are used, they can be wired in series. Fig. 6 Wiring for Anderson connectors. Charger/programmer port The charger/programmer port is a small 6-pin Conexall connector located under the controller s lift-up palm rest. It is used to connect a battery charger or a Curtis PMC 1311 handheld programmer. The Curtis PMC 1604 and 1608 chargers are fully compatible with the 1288 controller, and terminate in the appropriate mating 6-pin Conexall plug. Fig. 7 Wiring for Curtis PMC 1288 controller s charger/programmer port. For use with battery charger inhibit 1 B+ B- For use with programmer The 1311 programmer is designed to plug into this port. The 1311 programmer cable terminates in the mating 6-pin Conexall plug. B+ B- BATTERY CHARGER Charger/Programmer Port PINOUT Conexall pin 1 inhibit Conexall pin 2 battery positive (+) Conexall pin 3 controller transmit Conexall pin 4 controller receive Conexall pin 5 battery negative (+) Conexall pin 6 programmer power Curtis PMC 1288 Manual 7

14 3 USER INTERFACE 3 USER INTERFACE The 1288 controller s user interface has been designed to be both accessible and comfortable. The user has control over power up, throttle input, and speed limit adjustment. If the application has seat adjustment motors, the user also has control over those via the MODE button. In addition, the user is constantly notified of the battery state of charge and, should they occur, system faults. JOYSTICK The controller incorporates an XY analog joystick, ergonomically designed for enhanced comfort and control. The palm rest behind the joystick provides support and aids precise movement of the joystick. Fig. 8 Joystick configuration. CONTROL PAD The control pad, located in front of the joystick, is easy for the operator to use and to read. Fig. 9 Control pad. Speed Limit knob This growing bar is a graphic reminder of the directionality of the speed limit settings and the BDI display LED bar graph This row of 7 LEDs displays battery state of charge, mode, and fault information On/Off button Mode button [optional] The mode button is used to toggle between Drive mode and the two Auxiliary modes NOTE: in some models, this is the Horn button Curtis PMC 1288 Manual 8

15 3 USER INTERFACE Power on/off The power on/off button is a toggle switch marked with the I symbol. Pressing the I button causes the controller to turn on. Pressing the I button again causes the controller to turn off. If the power button is pressed while the vehicle is moving, the vehicle comes to a smooth stop governed by the setting of the Power Off Decel parameter. Mode The optional mode-select button is a 3-step toggle switch marked M. Pressing the M button causes the controller to exit Drive mode and enter Aux Driver 1 mode. Pressing the M button a second time causes the controller to enter Aux Driver 2 mode. Pressing the M button a third time causes the controller to go back to Drive mode. The controller defaults to Drive mode when it is first powered on. Pressing the mode-select button while the vehicle is moving has no effect until the vehicle has come to a stop and set the brake. When the vehicle is functioning in one of the auxiliary modes, the LEDs cycle continuously, in chaser-light fashion, thus indicating to the operator that the vehicle is in an auxiliary mode. For 1288 models that have both Horn and Auxiliary Drive features, the auxiliary modes are entered by pressing the I button and holding it for at least 3 seconds. Mode 1 and Mode 2 are cycled by repeatedly moving the joystick to the right. To exit the auxiliary mode, move the joystick to the left or press the I button. Speed limit The speed limit knob, located at the front of the controller, is protected by a slight rise in the housing. Adjustment of the speed limit knob determines maximum possible vehicle speed at full throttle and also influences accel/decel rates and turn rates. Smooth positive vehicle control is maintained at all speed limit settings. Fig. 10 Physical range of speed limit knob. Speed limit knob in minimum speed position Speed limit knob in maximum speed position Curtis PMC 1288 Manual 9

16 3 USER INTERFACE BDI display The controller indicates battery state-of-charge with the 7-LED bar graph. The battery discharge indicator (BDI) display is clearly visible to the operator from the standard driving position. All seven LEDs illuminated represent a fully charged battery. The LEDs will go out, one after another, as the open cell battery voltage drops. When the open cell battery voltage reaches the empty battery setpoint, the last red LED will flash. The flashing LED indicates a fault. The LEDs are lit steadily when they are indicating the battery state-ofcharge. This is the standard LED display during normal Drive operation. Fig. 11 BDI display. 2 red LEDs 5 green LEDs In this example, six of the seven LEDs are lit indicating that the battery is at a high state of charge. Faults The controller indicates system faults by flashing different numbers of LEDs to indicate various faults. The codes are presented in Section 6, Diagnostics and Troubleshooting. Fig. 12 Fault display. In this example, six of the seven LEDs are flashing indicating a vehicle wiring fault. Curtis PMC 1288 Manual 10

17 3 USER INTERFACE Summary of LED display formats The seven LEDs have four different display modes, indicating the type of information they are providing. Table 2 TYPES OF LED DISPLAY DISPLAY No lights illuminated Steadily illuminated lights Chaser light pattern Flashing lights VEHICLE STATUS Vehicle is not powered on, or is in battery charging mode, or has a dead battery. Vehicle is in Drive mode; number of illuminated lights indicates battery state of charge. Vehicle is in one of the Auxiliary modes; pattern of 4 LEDs indicates Aux 1, and pattern of all 7 LEDs indicates Aux 2. Vehicle is experiencing a system fault; flashed code identifies the specific fault. Curtis PMC 1288 Manual 11

18 4 PROGRAMMABLE PARAMETERS 4 PROGRAMMABLE PARAMETERS The 1288 controller has a number of parameters that can be programmed using a Curtis PMC 1311 programmer. These programmable parameters allow the vehicle s performance to be customized to fit the needs of individual vehicles or vehicle applications. For information on programmer operation, see Appendix A. PROGRAMMING MENUS (for setting the programmable parameters) The programmable parameters are grouped into seven categories, each with its own programming menu: General Drive Parameters Drive Current Limit Brake Current Limit Boost Current Limit Wheel Position Throttle Autocalibration Power Off Deceleration Brake Delay Sleep Timeout Save Parameters Restore Saved Parameters Joystick Parameters Perimeter Deadband Neutral Deadband Steer Sensitivity Tremor Suppression Start Delay Speed Parameters Maximum Forward Speed Minimum Forward Speed Maximum Reverse Speed Minimum Reverse Speed Maximum Turn Speed Minimum Turn Speed Response Parameters Forward Acceleration High Speed Forward Acceleration Low Speed Forward Deceleration High Speed Forward Deceleration Low Speed Reverse Acceleration High Speed Reverse Acceleration Low Speed Reverse Deceleration High Speed Reverse Deceleration Low Speed Emergency Stop Emergency Stop Pause Turn Acceleration High Speed Turn Acceleration Low Speed Turn Deceleration High Speed Turn Deceleration Low Speed Turn Deceleration Neutral Turn Rate Softening Soft Start Gear Soften Motors and Wheels Parameters Motor Swap High Speed Compensation Low Speed Compensation Anti-Rollback Compensation Auto Trim Motor Trim Motor Current Rating Motor Energy Rating Motor Cooling Rate Motor Impedance Motor Test Mode Auxiliary Parameters Auxiliary Toggle Aux 1 Up Speed Aux 1 Down Speed Aux 2 Up Speed Aux 2 Down Speed Aux 1 Up Stop Current Aux 1 Down Stop Current Aux 2 Up Stop Current Aux 2 Down Stop Current Battery Parameters Full Voltage Empty Voltage Reset Voltage Start Charge Voltage Discharge Rate Charge Rate Maximum Motor Volts Curtis PMC 1288 Manual 12

19 4 PROGRAMMABLE PARAMETERS The 1288 s programmable parameters are presented in the following charts. For each parameter, the charts provide: parameter name as it appears in the programmer s LCD display, allowable range, a description of the parameter s function and, where applicable, suggestions for setting it. We urge you to set the programmable parameters following the tuning sequence presented in Section 5, Vehicle Performance Adjustment. Even if you opt to leave most of the parameter values at their default settings, it is imperative that you follow the first two steps of the Section 5 tuning sequence, which match the controller to your motor wiring (1) and set the motor impedance value (2). Curtis PMC 1288 Manual 13

20 4 PROGRAMMABLE PARAMETERS: General Drive Parameters GENERAL DRIVE MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Drive Current Limit * -20XX: A Sets the maximum current the controller will supply to the motors during -21XX: A drive operation. The value is adjustable up to the 1-minute rating of the controller. Brake Current Limit * -20XX: A Sets the maximum current the controller will supply to the motors during -21XX: A regen braking operation. The value is adjustable up to the 1-minute rating of the controller. Boost Current Limit * -20XX: A Sets the maximum current the controller will supply to the motors during -21XX: A boost operation. The value must be set between the Drive C/L and the controller s full rated current. The boost feature provides a burst of extra torque by briefly applying a higher current. This can be useful for occasionally getting the vehicle out of a pothole or over an obstacle. The boost feature can be disabled by setting the Boost C/L to the same value as the Drive C/L. Wheel Position 0 2 This parameter matches the wheel configuration of the vehicle. 0 = rear wheel drive 1 = mid-wheel drive 2 = front wheel drive Note: The setting of the wheel position parameter affects several other parameters. It is important that this parameter be set correctly. Throttle Autocal 0 2 This parameter is used to calibrate the throttle. With the vehicle stopped, set Throttle AutoCal to 1. Rotate the joystick in a circle against the entire perimeter of the gate several times. Release the joystick, and set Throttle AutoCal to 2. The throttle is now calibrated. The 1288 s throttle has already been calibrated at the factory, so this procedure should not be necessary unless the throttle is replaced. Power Off Decel 1 100% Sets the decel rate when the vehicle is powered off while moving. The programmed Power Off Decel rate is independent of the normal programmed decel rate, the vehicle speed, and the direction of travel when power is turned off. Brake Delay sec. Sets the time delay before the brake is set, after the speed command reaches zero. The delay should be set low enough to minimize rolling downhill when stopping on ramps, yet long enough to allow for a smooth stop on flat surfaces. Sleep Timeout 0 60 min. Sets the time delay, after vehicle becomes inactive, before power is turned off. The sleep delay can be set from 1 to 60 minutes. Setting the parameter to zero disables the sleep delay. Save Parameters OFF / ON Replaces the previous set of saved values with the present values. Restore Saved Parameters OFF / ON Replaces all temporary (unsaved) values with the previously saved values. * Current limit depends on model ( XX or XX). Curtis PMC 1288 Manual 14

21 4 PROGRAMMABLE PARAMETERS: Joystick Parameters JOYSTICK MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Perimeter Deadband 0 50% Sets the threshold from the gate (perimeter) at which the electrical signal saturates; further joystick motion beyond this threshold has no additional effect. Neutral Deadband 5 20% Sets the throttle deadband threshold around the neutral position; this defines the amount the joystick can be moved before the controller will release the brake and send a speed request to the motors. Steer Sensitivity 1 80 This parameter adjusts the steering sensitivity for small turn requests; it is especially noticeable at full throttle. Higher settings increase the sensitivity. The best setting will depend on vehicle configuration, desired forward speed while turning, and preferred overall handling feel. The typical range is If the default setting does not seem sensitive enough, try increasing this parameter and make small to medium joystick turning movements while driving at full speed. If the steering is too sensitive, try a lower setting. Tremor Suppression 5 25 The tremor suppression feature filters the controller response to sharp joystick movements, such as might result from hand tremors. The settings are inverse: a setting of 25 provides the least compensation, and 5 the most. Smaller values provide steadier response, but they also result in more sluggish response to throttle requests. There is thus a trade-off between crispness of response (high settings) and steady speed in the presence of tremors (low settings). Although designed primarily to help operators with hand tremor problems, this parameter can be used more generally to smooth out overall vehicle responsiveness for steadier driving. Start Delay sec. The start delay inhibits acceleration for the programmed delay time. This delay can be useful for providing the operator a chance to release the throttle, after accidentally engaging it, before the vehicle starts to move. The start delay inhibits accelerating motor torque; it does not affect hill-holding torque. Curtis PMC 1288 Manual 15

22 4 PROGRAMMABLE PARAMETERS: Speed Parameters SPEED MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Max Forward Speed 1 100% Sets the vehicle forward speed at full throttle with the speed limit knob on the control pad set at maximum. This parameter is a percentage of the vehicle s maximum speed capability. Min Forward Speed 1 100% Sets the vehicle forward speed at full throttle with the speed limit knob on the control pad set at minimum. This parameter is a percentage of the vehicle s maximum speed capability. Forward speed at full throttle for other speed limit knob positions is interpolated between the max and min values. Max Reverse Speed 1 100% Sets the vehicle reverse speed at full throttle with the speed limit knob on the control pad set at maximum. This parameter is a percentage of the vehicle s maximum speed capability. Min Reverse Speed 1 100% Sets the vehicle reverse speed at full throttle with the speed limit knob on the control pad set at minimum. This parameter is a percentage of the vehicle s maximum speed capability. Reverse speed at full throttle for other speed limit knob positions is interpolated between the max and min values. Max Turn Speed 1 100% Sets the maximum turn speed at full turning throttle with the speed limit knob on the control pad set at maximum. Min Turn Speed 1 100% Sets the maximum turn speed at full turning throttle with the speed limit knob on the control pad set at minimum. Turn speed at full turning throttle for other speed limit knob positions is interpolated between the max and min values. Curtis PMC 1288 Manual 16

23 4 PROGRAMMABLE PARAMETERS: Response Parameters RESPONSE MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Forward Accel High Speed 1 100% Sets the forward acceleration rate with the speed limit knob on the control pad set at maximum. Forward Accel Low Speed 1 100% Sets the forward acceleration rate with the speed limit knob on the control pad set at minimum. Forward accel rates for other speed limit knob positions are interpolated between the high speed and low speed values. Forward Decel High Speed 1 100% Sets the forward deceleration rate when the vehicle is traveling at high speeds. Forward Decel Low Speed 1 100% Sets the forward deceleration rate when the vehicle is traveling at low speeds. Forward decel rates throughout the vehicle s speed range are interpolated between the high speed and low speed values. Reverse Accel High Speed 1 100% Sets the reverse acceleration rate with the speed limit knob on the control pad set at maximum. Reverse Accel Low Speed 1 100% Sets the reverse acceleration rate with the speed limit knob on the control pad set at minimum. Reverse accel rates for other speed limit knob positions are interpolated between the high speed and low speed values. Reverse Decel High Speed 1 100% Sets the reverse deceleration rate when the vehicle is traveling at high speeds. Reverse Decel Low Speed 1 100% Sets the reverse deceleration rate when the vehicle is traveling at low speeds. Reverse decel rates throughout the vehicle s speed range are interpolated between the high speed and low speed values. Emergency Stop % Emergency stopping ( E-stop ) is invoked when the vehicle is moving forward and the joystick is quickly pulled all the way back; this gives the operator a way to stop more quickly when unexpected conditions arise. The E-stop value is the percentage of the distance it would take the vehicle to come to a stop under the regular decel rate. Smaller settings thus provide faster response. A setting of 100% eliminates the E-stop feature. Emergency Stop Pause sec. Sets the length of time the vehicle will pause before going into reverse when E-stop is invoked. This delay can be useful for providing the operator a chance to release the throttle before the vehicle starts to move in reverse. A setting of 0.0 will eliminate the delay, if this feature is not desired. (Menu continues on next page.) Curtis PMC 1288 Manual 17

24 4 PROGRAMMABLE PARAMETERS: Response Parameters RESPONSE MENU, cont d ALLOWABLE PARAMETER RANGE DESCRIPTION Turn Accel High Speed 1 100% Sets the turn acceleration rate when the speed limit knob on the control pad is set at maximum. Turn Accel Low Speed 1 100% Sets the turn acceleration rate when the speed limit knob on the control pad is set at minimum. Turn accel rates for other speed limit knob positions are interpolated between the high speed and low speed values. Turn Decel High Speed 1 100% Sets the turn deceleration rate when the speed limit knob on the control pad is set at maximum. Turn Decel Low Speed 1 100% Sets the turn deceleration rate when the speed limit knob on the control pad is set at minimum. Turn decel rates for other speed limit knob positions are interpolated between the high speed and low speed values. Turn Decel Neutral 1 100% Sets the turn deceleration rate when the joystick is returned to neutral. This rate is independent of speed limit knob position. Turn Rate Softening 0 100% Desensitizes the low-speed turn responsiveness (turn accel/decel) when the speed limit knob is set to high speeds. This makes driving indoors, or in other tight or confined spaces, much easier at these speed limit positions. Set the speed limit knob to its high speed position and notice the difference when accelerating out of a full counter-rotation (90 joystick position) while varying the parameter from 0 to 100%. Typically this parameter is set in the 30 80% range. Higher values lead to gentler response. Soft Start 0 100% Soft start allows for softened torque endpoints for forward/reverse accelerations from a complete stop. Softening is useful for smoothly picking up the gear slop in the transmission before providing faster acceleration rates. When accelerating from a stop, some operators prefer the softened gear slack transitions this feature can provide, while others prefer the vehicle to respond instantly. A soft start value of 100% provides a great deal of softening, and a value of 0% eliminates the feature. The trade-off in increasing the value is that acceleration response may be slowed somewhat, especially at higher soft start values. Gear Soften 0 100% Gear softening allows smoother operation when the vehicle is tuned aggressively (i.e., with extremely fast accel/decel rates and max speeds), especially with regard to gear reversal. Its effect is most noticeable when turning at low speeds with the speed limit knob set high. Note: Gear softening is not in effect if the vehicle has been commanded to stop. A gear softening value of 100% provides a great deal of softening, and a value of 0% eliminates the feature. The trade-off in increasing the value is that acceleration response may be slowed somewhat, especially at higher gear soften values. Curtis PMC 1288 Manual 18

25 4 PROGRAMMABLE PARAMETERS: Motors and Wheels Parameters MOTORS AND WHEELS MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Motor Swap 0 7 Swaps motor sides and directions, to accommodate different wiring configurations. The parameter allows for all eight possible wiring combinations; changing it from 0 7 will cycle through all possible combinations. High Speed Comp 0 100% Sets motor load compensation at high speeds. Larger values provide stronger rejection of disturbances, while smaller values can provide smoother operation. Note: the motor impedance parameter (see below) must be set accurately before adjusting the high-speed compensation parameter. Low Speed Comp 0 100% Sets motor load compensation at low speeds. Larger values provide stronger rejection of disturbance, while smaller values can provide smoother operation. Note: the motor impedance parameter (see below) must be set accurately before adjusting the low-speed compensation parameter. Anti Rollback Comp 0 150% Anti-rollback compensation ensures that the vehicle comes to a complete stop on a hill before setting the brake. Larger values provide more hillholding force. Note: the motor impedance parameter (see below) must be set accurately before adjusting the anti-rollback parameter. Auto Trim OFF / ON When enabled (programmed On), the auto trim feature monitors vehicle characteristics and gradually corrects for motor variances, to keep the vehicle moving straight when the joystick is pointed straight. The motor trim parameter is not used when auto trim is enabled. Motor Trim -60 to +60 Sets motor trim. This allows for straight line tracking despite differences in motor characteristics. Setting this parameter to zero provides no steering correction. Positive numbers give the right motor more compensation for a vehicle drifting right with a straight joystick. Negative numbers provide compensation for a vehicle drifting left. Motor Current Rating -20XX: 8 50 A This parameter is part of the motor protection logic of the If the -21XX: 8 75 A power delivered exceeds the motor s continuous current ratings, the controller current will be cut back to the programmed value in an attempt to prevent motor damage. If this protection feature is not desired, the motor current rating can be set to the same value as the drive current limit. Motor Energy Rating kj This parameter is part of the motor protection logic of the The controller continuously calculates the energy flow in the motor, which influences motor temperature. The energy calculation includes both energy delivered and energy radiated. If the energy exceeds the value set for this parameter, the controller current will be reduced toward the motor s continuous current rating in an attempt to prevent motor damage. Motor Cooling Rate This parameter is part of the motor protection logic of the It represents the motors ability to dissipate heat. This value should be determined through experimental testing. (Menu continues on next page.) Curtis PMC 1288 Manual 19

26 4 PROGRAMMABLE PARAMETERS: Motors and Wheels Parameters MOTORS AND WHEELS MENU, cont d ALLOWABLE PARAMETER RANGE DESCRIPTION Motor Impedance mω Sets the motor impedance value used by the controller for load compensation and speed estimation. It is imperative that this value be set properly. It should be set to the actual impedance of the cold motors, as determined using the motor test mode parameter. The impedance value should not be reduced in an attempt to adjust compensation; compensation is determined by other parameters. Motor Test Mode OFF / ON When this parameter is enabled (programmed On), the motors impedance can be determined experimentally. This value is then entered as the motor impedance value. The test procedure is described in Section 5, Vehicle Performance Adjustment. Note: It is important to leave this parameter programmed Off except during motor impedance testing; when it is On, several parameters are set to values that prevent normal operation. Curtis PMC 1288 Manual 20

27 4 PROGRAMMABLE PARAMETERS: Auxiliary Parameters AUXILIARY MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Aux Toggle OFF / ON There are two types of auxiliary driver control. When this parameter is set OFF, pushing the joystick forward requests an Up movement, and pulling it back requests a Down movement. When this parameter is set ON, the joystick functions as a toggle switch. Moving the joystick out of the neutral deadband switches the output driver to the next state: UP, (joystick in neutral), DOWN, (joystick in neutral), UP, (joystick in neutral), etc. Aux 1 Up Speed % Sets the maximum controller output to the Aux 1 driver (as a percentage of maximum controller output) when an Up request is made. Aux 1 Down Speed % Sets the maximum controller output to the Aux 1 driver (as a percentage of maximum controller output) when a Down request is made. Aux 2 Up Speed % Sets the maximum controller output to the Aux 2 driver (as a percentage of maximum controller output) when an Up request is made. Aux 2 Down Speed % Sets the maximum controller output to the Aux 2 driver (as a percentage of maximum controller output) when a Down request is made. Aux 1 Up Stop Current A Sets the threshold current at which the Aux 1 driver will shut down, when it is in Up mode. Aux 1 Down Stop Current A Sets the threshold current at which the Aux 1 driver will shut down, when it is in Down mode. Aux 2 Up Stop Current A Sets the threshold current at which the Aux 2 driver will shut down, when it is in Up mode. Aux 2 Down Stop Current A Sets the threshold current at which the Aux 2 driver will shut down, when it is in Down mode. Curtis PMC 1288 Manual 21

28 4 PROGRAMMABLE PARAMETERS: Battery Parameters BATTERY MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Full Voltage V Sets the voltage at or above which 100% charge is indicated on the BDI display. The parameter value is the voltage per single battery cell. [ =24.48 V] Empty Voltage V Sets the voltage at or below which 0% charge is indicated on the BDI display. The parameter value is the voltage per single battery cell. [ =21.12 V] Reset Voltage V Sets the voltage at which the controller s battery-state-of-charge calculator will be reset to 100%. The parameter value is the voltage per single battery cell. [ =28.08 V] Start Charge Voltage V Sets the highest voltage at which charging begins. The parameter value is the voltage per single battery cell. [ =25.20 V] Discharge Rate 0 30 This parameter should be set to the battery discharge rate, so that the BDI display will be accurate as the battery discharges. Larger numbers are for smaller batteries that discharge more quickly. This value should be determined through experimental testing. Charge Rate 0 30 This parameter should be set to the battery charge rate, so that the BDI display will be accurate as the battery charges. Larger numbers are for smaller batteries that charge more quickly. This value should be determined through experimental testing. Max Motor Volts V Sets the maximum battery voltage that the controller can apply to the motors. This feature can be used to eliminate variations in maximum speed that would otherwise result when driving with a fully charged battery vs. a partially discharged battery. With the parameter set at 23 volts, for example, the vehicle s maximum speed will be the same whether the actual battery voltage is 28 volts or 23 volts or any value in between. Curtis PMC 1288 Manual 22

29 4 PROGRAMMABLE PARAMETERS: Cloning Controllers CLONING (for copying parameter settings to multiple controllers) Once a controller has been programmed to the desired settings, these settings can be transferred as a group to other controllers, thus creating a family of clone controllers with identical settings. Note: Cloning only works between controllers with the same model number and software version. For example, the programmer can read all the information from a controller and write it to other controllers; however, it cannot write that same information to controllers. To perform cloning, plug the 1311 programmer into the controller that has the desired settings. Scroll down to the Functions menu; clone is the only function included here. Select Get settings from controller to copy the settings into the programmer. Plug the programmer into the controller that you want to have these same settings, and select Write settings to controller. Curtis PMC 1288 Manual 23

30 5 VEHICLE PERFORMANCE ADJUSTMENT 5 VEHICLE PERFORMANCE ADJUSTMENT The 1288 controller s wide variety of adjustable parameters allow many aspects of vehicle performance to be optimized. This section explains what the major tuning parameters do and provides instructions on how to use these parameters to optimize the performance of your vehicle. Once a vehicle/motor/controller combination has been tuned, the parameter values can be made standard for that system or vehicle model. Any changes in the motor, the vehicle drive system, or the controller will require that the system be tuned again to provide optimum performance. The seven tuning procedures listed below should be conducted in the sequence given, because successive steps build upon the ones before. The tuning procedures instruct personnel how to adjust various programmable parameters to accomplish specific performance goals. It is important that the effect of these programmable parameters be understood in order to take full advantage of the 1288 controller s powerful features. Refer to the descriptions of the applicable parameters in Section 4 if there is any question about what any of them do. 1 Matching the controller to the motor wiring 2 Determining motor impedance 3 Correcting the motor trim 4 Basic performance 5 Emergency stop 6 Load compensation 7 Fine tuning Before starting the tuning exercise, make sure all the parameters are at or near their default values. The default parameter values are listed in the worksheet that came with the controller. Because much of the tuning must be done while driving the vehicle at high speed, it is important that you start with reasonable values or control may become difficult. The 1311 programmer can be used in two somewhat different ways to automatically reset any changed parameters. The Restore Saved Parameters parameter [Program > General Drive > Restore Saved Parameters] restores the most recently saved parameter values. The reset feature in the Functions menu restores the parameter values that were in place at the time the programmer was plugged in; each time the programmer powers up it reads and temporarily stores the existing parameter values. When the values are reset using either of these methods, the reset values will be in effect immediately but the programmer will not display them until it is unplugged and plugged in again. 1 Matching the controller to the motor wiring Each of the drive motors can be run forward or backwards and, to allow turning, they must each be controlled separately. There are eight possible combinations Curtis PMC 1288 Manual 24

31 5 VEHICLE PERFORMANCE ADJUSTMENT of motor and direction. The 1288 s Motor Swap parameter allows the controller to be programmed to match the vehicle s motor wiring configuration. After powering on the controller (by pressing the power on/off button), move the joystick slightly forward and from side to side. If the vehicle moves and turns in the correct directions, proceed to Step 2. If the vehicle is not moving as intended, there is no need to change the vehicle wiring, as this mismatch is readily fixed by the controller s Motor Swap parameter [Program > Motors&Wheels > Motor Swap]. Using small joystick movements, try different settings until you find the one that matches this particular vehicle. Note that this parameter cannot be changed while the vehicle is moving. Although a new value entered while moving appears on the 1311 programmer display, it does not take effect until the vehicle comes to a stop and the brake is set. 2 Determining the motor impedance Accurate setting of the motor impedance parameter is crucial to proper operation of the vehicle. Perform this test when the motors are not hot. Position the chair feet-forward flush against a wall, high curb, or other immovable object. Turn the speed limit knob to the high speed position. Set the Motor Test Mode parameter On [Program > Motors&Wheels > Motor Test Mode]. Go to the Motor Impedance monitor [Monitor > Motor Impedance], which is the last item on the Monitor menu. Drive the vehicle against the wall, while observing the impedance value displayed by the programmer. The displayed value is the average impedance of the two motors. Enter this observed value as the Motor Impedance setting [Program > Motors&Wheels > Motor Impedance]. Do not de-rate this value to a lower number. Enter the actual observed impedance value. Set the Motor Test Mode parameter Off [Program > Motors&Wheels > Motor Test Mode]. It is important that the Motor Test Mode be programmed Off except during testing; when it is On, several parameters are set to values that prevent normal operation. 3 Correcting the motor trim The motor trim capabilities of the 1288 controller can be used to correct for variances in motor and vehicle tolerances. Check both the left and right tire pressures to make sure they are inflated properly to their specs. If Auto Trim is enabled [Program > Motors&Wheels > Auto Trim], the controller will gradually adapt itself to differences in the motors. For the initial tuning of the vehicle, however, it may be useful to trim the motors manually. If you do choose to use Auto Trim, bear in mind that the trimming process can be Curtis PMC 1288 Manual 25

32 5 VEHICLE PERFORMANCE ADJUSTMENT accelerated by driving the vehicle straight for long distances, occasionally stopping and releasing the joystick for a moment. To tune the motor trim manually, use the Motor Trim parameter [Program > Motors&Wheels > Motor Trim]. Set the speed limit knob to the high speed position, and drive forward down a long, straight, flat surface. Note how the vehicle behaves with the throttle pushed full forward and centered against the gate. Adjust the values of the Motor Trim parameter incrementally until the vehicle drives straight. If the vehicle drifts to the right, increase the motor trim value to give the right motor more voltage; if it drifts to the left, decrease the motor trim value to give the left motor more voltage. The motor trim value can not be set larger than 60 in either direction, as that represents a large mismatch in motor characteristics. Note: You can verify that you are driving forward with the joystick centered by observing the X Throttle variable in the Monitor menu; it should show approximately 0. 4 Basic performance With the Motor Swap, Motor Impedance, and Motor Trim parameters set, go ahead and adjust the basic performance parameters as described in Section 4: General Drive parameters Drive, brake, and boost current limits Wheel position Power off decel Brake delay Sleep timeout Joystick parameters Perimeter and neutral deadbands Steer sensitivity Start delay Speed parameters (all) Response parameters Forward, reverse, and turn acceleration rates Forward, reverse, and turn deceleration rates Auxiliary driver parameters (all) When these parameters have been adjusted, proceed to tuning procedure 5. 5 Emergency stop (E-stop) When the vehicle is traveling forward, the operator can override the normal programmed deceleration rate by pulling back quickly on the joystick thus invoking the E-stop deceleration rate. The E-stop parameter [Program > Response > Emergency Stop] defines a percentage of the normal stopping distance. If the value is set at 33%, the vehicle will stop in one-third the distance it would otherwise have traveled while decelerating to a stop. Setting the value at 100% eliminates the E-stop feature. Curtis PMC 1288 Manual 26

33 5 VEHICLE PERFORMANCE ADJUSTMENT The Emergency Stop Pause feature holds the vehicle at a stop before accelerating in reverse; this delay gives the operator a chance to release the throttle before starting to move in reverse. The Emergency Stop Pause parameter [Program > Response > Emergency Stop Pause], sets the duration of the pause in seconds. The pause time is progressively reduced from the set value as the speed at which Emergency Stop is invoked is reduced. If no pause is desired, the parameter can be set to Load compensation The vehicle s response to increased loads can be mitigated through load compensation. The High Speed Comp and Low Speed Comp parameters [Program > Motors&Wheels > High/Low Speed Comp] set the compensation at high and low speeds, with compensation at mid-range speeds interpolated between these two values. There is a trade-off in load compensation, in that increased load compensation results in more consistent speed but less smoothness. Larger values provide stiffer, stronger response; the typical range for these parameters is between 40 and 80 percent. The Anti-Rollback feature can be used to ensure that the vehicle comes to a complete stop on a steep ramp before engaging the brake. Higher values [program > Motors&Wheels > Anti Rollback Comp] provide more hill-holding force and reduce low speed drifting before the brake is set. The Brake Delay parameter [Program > General Drive > Brake Delay] sets an interval after the throttle command has ramped to zero before setting the brake. The typical range for Anti-Rollback is between 70 and 100 percent, and for Brake Delay between 0.1 and 0.3 seconds. The Brake Delay parameter applies to all stops, not just those on hills, so its value should be a reasonable compromise between the desired delay on flat terrain and on hills. 7 Fine tuning The 1288 has a variety of additional features for softening and smoothing vehicle response. The effects of these parameters are subtle, and they are therefore best tuned at the end. Suggestions for tuning these parameters are included in Section 4: Joystick parameters Tremor suppression Response parameters Turn rate softening Soft start Gear softening. The ideal setting for these parameters is a matter of subjective preference. Curtis PMC 1288 Manual 27