WHB22220 - AC-Curtis-CAN - Eng - Rev.0.00 (CURTIS 1232-1236-1238 CAN)

file: WHB22220_AC-Motorsteuerung_Curtis-CAN_Eng.
doc
Page 1 of 34 Workshop manual

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AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
Overview
M
3~
U
W V
Control connections
file: WHB22220_AC-Motorsteuerung_Curtis-CAN_Eng.doc

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
1 General
1.1 Safety instructions
ATTENTION :
Installation and changes to the wiring may only be performed by specialized staff.
ATTENTION :
Never pull off the plug of the electronic systems under voltage!
During welding work, disconnect the electronic parts from the power supply (especially vehicle ground /
frame)!
1.2 Abbreviations
SLC  Safety steering computer
EEA  Electronic input/output terminal
HIT  HUBTEX Information Terminal
+Ub  Supply voltage +24V
0V-Last  Supply voltage, GND

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Curtis 1232 / 1236 / 1238 CAN
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Table of Contents
1 General......................................................................................................... 2
1.1 Safety instructions .................................................................................................. 2
1.2 Abbreviations ........................................................................................................... 2
1.3 Connections ............................................................................................................. 4
1.3.1 Power terminals ............................................................................................................................. 4
1.3.2 Control connections ..................................................................................................................... 5
1.4 Variants / versions which are used ....................................................................... 6
1.4.1 1232 series ..................................................................................................................................... 6
1.4.2 1236 series ..................................................................................................................................... 6
1.4.3 1238 series ..................................................................................................................................... 7
2 Installation instructions ............................................................................. 8

2.1 Installation below the battery in the case of standard ESTL sideloaders .......... 8
2.2 Console extension ................................................................................................... 9
2.3 CAN node number ................................................................................................. 10
2.4 Exchange of the control ........................................................................................ 10
2.5 Diagnosis regarding the control system SLC 019640 ........................................ 11
2.5.1 Status and diagnosis of the CAN AC traction controllers ...................................................... 11
2.5.2 Status and diagnosis of the CAN AC pump controls .............................................................. 12
2.5.3 Itemization of the individual diagnostic data ...........................................................................12
2.6 Diagnosis with the handheld console.................................................................. 15
2.6.1 Operation of the programming device ...................................................................................... 15
2.6.2 Programming menus .................................................................................................................. 16
3 Status messages ....................................................................................... 18

3.1 Display of the status messages in the terminal (FGT) ....................................... 18
3.2 Fault list .................................................................................................................. 19
3.1 Evaluation of the fault flash codes of the Curtis control systems .................... 34
3.2 Different display modes of the LEDs ................................................................... 34

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AC motor control
Curtis 1232 / 1236 / 1238 CAN
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1.3 Connections
There are 5 power terminals which are referred to as B+, B-, U, V. and W in the control.
Furthermore, a 35-pole AMPSEAL plug is available for the connection of all control
cables.
1.3.1 Power terminals
Terminal Function
B(+) Positive battery terminal to the control
B(-) Negative battery terminal to the control
U Motor phase U
V Motor phase V
W Motor phase W
1.3.1.1 Battery cables (B+, B-)
These two cables should be installed as closely as possible together. Pay attention to the
tightening torques when connecting them. For a better protection against stray radiation,
these cables should not be installed across the center of the control. In the case of several
controls, the connection to the B ( - ) terminal of the battery should be performed in a star-
shaped manner.
1.3.1.2 Motor cables (U, V, W)
These three cables of the motor phases should be of equal length and run together as a
bundle
from the control to the motor. The cable length should be as short as possible.
Here, too, please pay attention to the tightening torques. For a better protection against
stray radiation, these cables should not be installed across the center of the control. Signal
and control cables should not be installed together with the
motor cables.

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Curtis 1232 / 1236 / 1238 CAN
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1.3.2 Control connections

All control connections are implemented by means of the 35-pole AMPSEAL plug. The
mating connector has the Hubtex no. 4167780 for the housing and 4167784 for the
contacts. The plug is suitable for litz wires with a cross section from 0.75 to 1.5 mm2 (20 to
16 AWG) with thin insulation.
The 35 individual pins are described in table 2.
1.3.2.1 Motor encoder (pins 31, 32)
All 4 cables of the motor speed sensor should be bundled together on the route from the
motor to the control. They can be installed together with the other control cables. The
encoder cables should not be installed together with the motor cables.
1.3.2.2 CAN bus (pins 21, 23, 34, 35)
We recommend that you install the CAN cables in the form of twisted pairs.
The CAN cables should be installed separately from the motor cables, and they should
always intersect the motor cables at a right angle, if necessary.
1.3.2.3 All other control cables
The other control cables should be installed according to standard practice. Any joint
installation of control cables and power cables should always be avoided!
NOTE:
Please refer to the vehicle-specific electrical documentation (circuit diagram) for the connection of the AC motor
control in the HUBTEX vehicle.

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AC motor control
Curtis 1232 / 1236 / 1238 CAN
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1.4 Variants / versions which are used

1.4.1 1232 series
The series of “Curtis AC 1232“ is exclusively used for smaller and special series.
(“Boeing EPL“)
Items which are used:
4182207 – AC control 1232E-6221 / 48-80VDC/175A
4182208 – AC control 1232–2201 / 24V / 180A
Latest software status: V1.13
1.4.2 1236 series

The series of “Curtis AC 1236“ is installed in almost all ESTL device types for 48V and 80V
vehicles. The are used as drive and pump controls up to 450A.
4182202 – AC control 1236-6301 / 48-80VDC/300A
4182204 – AC control 1236-5301 / 36-48VDC/350A
4182205 – AC control 1236-5401 / 36-48VDC/450A


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Curtis 1232 / 1236 / 1238 CAN
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1.4.3 1238 series

The series of “Curtis AC 1238“ is used in standard and special-purpose vehicles for
drive and pump controls which require controls of > 450A, due to their
driving and/or pumping capacity.
The basic functions are identical to those of the 1236 series.
4182200 – AC control 1238-6501 / 48-80VDC/550A
NOTE:
 The software status must be identical in the case of double motor systems.
(e.g. drive unit 1 = V1.11  drive unit 2 = V1.11 )
 In the case of pump motor controls, different software statuses can be used.

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Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
2 Installation instructions
The drive and pump controls are installed below the battery as standard practice.
In the case of special-purpose vehicles and special versions, other places of installation
are also possible. Please refer to the Technical Documentation for the relevant
information!
2.1 Installation below the battery in the case of standard ESTL

sideloaders
Traction controllers Pump control
Installation situation of
the controls in the rear
frame

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2.2 Console extension

In order to make diagnostic operations regarding the AC motor control in the vehicle easier, the
HUBTEX vehicle is equipped with a so-called console extension.
This cable has been accessibly installed as extension of the plug-type connection of the handheld
console for Curtis controls in the installation space for the electrical components.
Installation space of the electrical components below the driver's seat
Safety steering computer

with interface to the
programming
Console extension for the

evaluation of the controls
The allocation to the motor control is ensured by means of the part name. Please refer to
the vehicle-specific electrical documentation for the part name.

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2.3 CAN node number

The inverters for activating the travel motors must be preset with the CAN node numbers.
This is performed by programming and/or the parameterization of the relevant control at
HUBTEX.
The addresses have been defined as follows:
Designation
“i/o-data display”
for Status
Designation CAN address SLC 019 640 display
Motor control unit, traction drive 1 ID 45 Drive AC 1 S-AC1-xxx
Motor control unit, pump drive 1 ID 60 Pump AC 5 S-AC5-xxx
Motor control unit, pump drive 2 ID 61 Pump AC 6 S-AC6-xxx
2.4 Exchange of the control

The AC motor control is programmed and parameterized at HUBTEX, stating the vehicle
data.
The following vehicle data should be known:
- machine number according to nameplate / e.g. 62545

- CAN ID according to electrical documentation / e.g. ID45
- voltage of battery / e.g. 80V
- designation of the drive unit / pump according to electrical documentation / e.g. 2M1
- output of the drive unit or the pump / e.g. 5kW
- software status of the control / e.g. V1.10
During the installation of the AC motor control, the instructions on the control housing for
the maximum tightening torque of the power terminals must be observed.
ATTENTION :
In case of exchanging an AC control, the installation instructions contained in the scope of delivery must be
observed.

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2.5 Diagnosis regarding the control system SLC 019640

Extensive diagnostic possibilities of the motor controls are available via CAN bus with regard to the control
system of SLC 019 640.
They can be retrieved via the service mode (i/o-data display) of the graphic display.
2.5.1 Status and diagnosis of the CAN AC traction controllers
Status and diagnosis of the CAN AC drives.

control: Control word to the traction controller
setpoint: Frequency setpoint value [0.01 Hz] to the traction controller
acc.ramp: Acceleration ramp (time for acceleration 0…100%)
dec.ramp: Braking ramp (time for braking 100%...standstill)
state: Status word from the traction controller
speed: Frequency actual value [0.01 Hz] from the traction controller
current: Present rms current [170A/controller max current]
mot.temp: Motor temperature [°C]
con.temp: Temperature of the traction controller [°C]
battery: Battery capacity measured by the traction controller [%]
fault cd: Alarm code/fault code of the traction controller
age: Age of the CAN message received from the SLC [0.02 s]
in.wh.rd: Value of inner wheel reduction.
 Speed ratio of the drive units in the case of driving along curves and in the case of using DUAL-
AC controls.
torque: Value of torque setpoint.
Maximum torque when the ZAPI traction controllers are operated in the torque mode.
- / - - - - Drive not present/parameterized

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2.5.2 Status and diagnosis of the CAN AC pump controls
control: control word to the traction controller

setpoint: Frequency setpoint value [0.01 Hz] to the traction controller
acc.ramp: acceleration ramp (time for acceleration 0…100%)
dec.ramp: braking ramp (time for braking 100%...standstill)
state: Status word from the traction controller
speed: Frequency actual value [0.01 Hz] from the traction controller
current: present rms current [unknown]
mot.temp: Motor temperature [°C]
con.temp: Temperature of the traction controller [°C]
battery: Battery capacity measured by the traction controller [%]
fault cd: Alarm code/fault code of the traction controller
age: Age of the CAN message received from the SLC [0.02 s]
-/---- Drive not present/parameterized
2.5.3 Itemization of the individual diagnostic data
control:
The relevant motor control is operated by means of a control word (control).
x0xx = master = ID45 and xxx0 = control OFF / emergency stop
both drive units in the same direction - no release of power unit
- main contactor OFF
x1xx = master = ID49 and - no release of electromagnetic brake
both drive units in the same direction
xxx3 = control ON / acknowledgement
x2xx = master = ID45 and
“emergency stop“
drive units in different directions
- release of power unit
x3xx = master = ID49 and - main contactor ON
drive units in different directions
(for future application) xxx7 = functional release / release for driving
- release of power unit
- main contactor ON
xx0x = no direction preselection - release of electromagnetic brake
xx4x = direction preselection “forwards“
xx8x = direction preselection “backwards“


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Curtis 1232 / 1236 / 1238 CAN
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setpoint:
The control receives the rpm setpoint (setpoint) via CAN.
The value range goes from 0 to 20000 and corresponds to a frequency of 0 … 200.00 Hz.
The direction of rotation of the motor is influenced by the control word (control).
Conversion: Display value [Hz] x 30 = setpoint rpm of motor [1/min]
acc. ramp:
This value indicates the active acceleration ramp in ms.
Motor control, traction drive:
Parameter 167 in case of control system SLC 019 667  max. acceleration ramp [0.01s]
Parameter 174 in case of control system SLC 019 667  actual rpm threshold for increased acceleration ramp [%]
Parameter 175 in case of control system SLC 019 667  factor for dynamic acceleration ramp
Motor control, pump drive:

Parameter 461 in case of control system SLC 019 667  general ramp [0.01s]
dec. ramp:
This value indicates the active ramp in ms. The static deceleration ramp or the dynamic deceleration ramp (deceleration ramp
reduction) can be indicated.
Motor control, traction drive:
Parameter 168 in case of control system SLC 019 667  static deceleration ramp [0.01s]
Parameter 185 in case of control system SLC 019 667  reduction of deceleration ramp [%]
Motor control, pump drive:

Parameter 461 in case of control system SLC 019 667  general ramp [0.01s]
state:
The relevant motor control gives a feedback by means of the status word (state).
0xxx = no signal active / emergency stop xxx0 = control OFF / emergency stop
- power unit locked
Yxxx = “signal 1“ and/or “signal 2“ active - main contactor OFF
(see type-specific workshop manual for details) - electromagnetic brake OFF
- drive status = braking
xxx3 = standstill
- power unit released
- main contactor ON
- electromagnetic brake OFF
x0xx = no signal active / emergency stop
xxx7 = function: deceleration
xYxx = “signal 1“ and/or “signal 2“ active - power unit released
(see type-specific workshop manual for details) - main contactor ON
- electromagnetic brake ON
xxxB = function: parking brake while driving

- main contactor ON
- electromagnetic brake OFF
xx0x = no release of direction preselection - drive status = driving
xxxF = function: driving

xx1x = release of direction selection
- main contactor ON
- electromagnetic brake ON
- drive status = driving

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speed:
The control gives a feedback on the motor RPM (speed) reached, via CAN bus.
The maximum values range from +20000 to –20000, corresponding to the direction, and they correspond to a rotation frequency of
+200.00 … -200.00 Hz.
Conversion: Display value [Hz] x 30 = actual rpm of motor [1/min]
current:
The motor current [A] is indicated here.
mot. temp:
The temperature [°C] of the AC motor is indicated here.
con. temp:
The temperature [°C] of the power unit of the AC motor control is indicated here.
battery:
The value indicates the remaining capacity [%] of the battery.
fault cd.:
The current fault of the AC motor control can be read from this entry.
The display value corresponds to the HIT message in the operator menu and can be coded in “Status messages“.
age:
With the help of the “age“ display, it is possible to check the CAN bus.
During the interruption of the CAN message reception, the value counts upwards by “1“.
If the value is “255“, a connection interruption of the CAN bus can be assumed.

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2.6 Diagnosis with the handheld console

During the commissioning of or the troubleshooting on the vehicle, the diagnosis of the
motor control system can be necessary.
Different functional sequences of the motor control components can be checked by means
of the handheld console.
Source: “Curtisinstruments.com“
If the handheld console is connected to the Curtis control, a

parameter list (block), including the corresponding parameter settings, is loaded into the
programming device. You can easily scroll through this list and change and/or check the
settings.
2.6.1 Operation of the programming device
The programming device can be easily operated due to its self-explanatory functions.
After plugging in the handheld console, wait a few seconds until the data are uploaded
from the control. For experimentation with the parameters, the programming device can
remain connected while driving the vehicle.

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2.6.2 Programming menus
There are 9 main menus with further submenus
The individual menus are described in detail in the following subsections!
Information:
If the device has been connected to a programming device,

information such as software, hardware and
parameter block versions are also read in.
Then the information menu provides a quick overview of
such information.
Parameters:
Components which have been externally connected can be set by means of the “Curtis
control“ in this menu, e.g. rpm and output of external fans for cooling. In the case of
Hubtex vehicles, the fans are not activated by the AC controls, but via the ON relays of the
electronic steering control.
Currently this menu is not relevant to Hubtex vehicles!
Monitoring:
Indicates all values in real time, also during the driving operation
. This menu is helpful for the troubleshooting and
provides information about several
conditions and functions of the “Curtis AC controls“.

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Faults:
Indicates diagnostic information of the relevant

control. Furthermore, the fault memory can be
deleted here.
Programming:
The programming menu can contain several submenus with parameters. In this menu, by
means of the programming device, the device (the pulse contact control, the charging
device, the display, etc.) is set to specific operating conditions. Parameters such as top
speed, current limitation, acceleration and deceleration are among the quantities which are
set in this menu.
Changes to the parameters may only be made after prior consultation with
HUBTEX Maschinenbau GmbH & Co.KG!
Favorites
The favorite menu is used for storing special functions and data which are frequently used.
The favorite list contributes to time saving and provides a better overview of the individual
menu items.
HHP options:
In this menu, settings of the

programming device
(brightness, contrast, language etc. )
can be made.
File manager:
New folders can be created, shifted, deleted or copied here. This menu ensures improved
management of large data volumes, e.g. machine-specific parameter sets.

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Plot & log:
This menu is exclusively used for fault diagnosis and fault finding. Individual control data
can be contemplated here over a longer period of time, and recorded as diagram.
ATTENTION :
 Please pay attention to the correct polarity of the plug.
 Do not insert by force.
3 Status messages
3.1 Display of the status messages in the terminal (FGT)

The pulse contact control recognizes a large number of faults or fault conditions.
The current status messages of the AC motor control are
shown in an encoded form in the terminal.
The marking “xx“ corresponds to the status message from the listing
(fault list) in this regard.
S-AC1-xx = AC motor control, traction drive 1
S-AC5-xx = AC motor control, pump drive 1
S-AC6-xx = AC motor control, pump drive 2
Likewise, the fault messages in the handheld console are indicated as text.
They can be retrieved in the menu “Diagnosis“.

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3.2 Fault list

The troubleshooting guide in the following table indicates the following information
regarding all faults:
- fault code
- fault name as indicated in the programming console
- the effects of this fault
- possible causes of this fault
- conditions for setting this fault
- conditions for resetting this fault
Whenever an error occurs and no fault can be found in the wiring or in the vehicle,
briefly disconnect the voltage supply
in order to see whether the error is deleted or not. If the error is not deleted, switch off
the device (remove the battery plug) and pull off the 35-pole control plug.
Check the plug for corrosion and damage, clean it, if necessary, and re-insert it.

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Curtis 1232 / 1236 / 1238 CAN
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Display of programmer Fault occurs if: Set Fault reset

Code Possible causes
Response to fault if: Clear
12 Controller overcurrent 1) External short circuit of the Set: Phase current exceeds
motor phases U, V, W limits of current measurement.
Overcurrent of control system
2) Motor parameters wrongly Clear: Deactivate and activate
Switches off the motor;
Switches off the main adjusted. the key‐operated switch.
contactor; 3) Control system defective.
Switches off the EM brake;
Switches off the drive sensor; 4) EMC problems in encoder
Full braking;
Switches off the pump.
13
Current sensor fault 1) Leakage current from phase U, Set: Current sensor in the
V or W to vehicle frame (short control system measures invalid
Fault in the current sensor
circuit in the motor). offset value.
Switches off the main 2) Control system defective. Clear: Deactivate/activate the
contactor; key‐operated switch.
Switches off the drive sensor;
Full braking;
14 Precharge failed 1) See menu Monitor > Battery: Set: It was impossible to charge
Capacitor voltage. the capacitor bank to KSI
Elkos precharge fault
voltage.
2) External load on the capacitors
Switches off the main (B+ terminal) prevents the Clear: Switch the release
contactor; capacitor bank from being (interlock) off/on. Or via VCL
Switches off the EM brake; charged. function Enable_Precharge().
Full braking;
15 Controller severe undertemp 1) See menu Monitor > Controller: Set: Cooling element
Temperature. temperature below – 40°C.
Extreme undertemperature of
the control system 2) Control system operates under Clear: Raise the cooling
extreme ambient conditions. temperature to a value above ‐
Switches off the main 40°C and perform release, or
contactor; deactivate/activate the key‐
Switches off the EM brake; operated switch.
Full braking;

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Code Display of programmer Possible causes Fault occurs if: Set Fault reset if:
Response to fault Clear
16 Controller severe overtemp 1) See menu Monitor > Controller: Set: Cooling element
Temperature. temperature above +95°C.
Extreme overtemperature of
the control system 2) Control system operates under Clear: Lower the cooling
extreme ambient conditions. temperature to a value below
Switches off the main +95°C and perform release, or
3) Vehicle is overloaded.
contactor; deactivate/activate the key‐
Switches off the EM brake; 3) The control system has been operated switch.
Switches off the drive sensor; wrongly assembled.
Full braking;
17 Severe undervoltage 1) Battery menu parameters Set: Voltage on the capacitor
wrongly adjusted bank drops below the extreme
Extreme undervoltage
undervoltage point, activated
2) Other electrical loads affect the
Reduction of the torque. with FET‐bridge (see page 58)
battery
Clear: Raise the voltage on the
3) Battery resistance too high
capacitor bank above the
4) Battery disconnected during extreme undervoltage point.
the driving operation.
4) See menu Monitor > Battery:
Capacitor voltage.
5) Fuse or main contactor open.
18
Severe overvoltage 1) See menu Monitor > Battery: Set: Voltage on the capacitor
Capacitor voltage. bank exceeds the extreme
Extreme overvoltage
overvoltage point, activated
2) Battery menu parameters
Switches off the motor; with FET‐bridge (see page 58)
Switches off the main wrongly adjusted.
contactor; Clear: Lower the voltage on the
3) Battery resistance is too high
Switches off the EM brake; capacitor bank to a value below
for the regenerative brake
Switches off the drive sensor; the extreme overvoltage point,
current.
Full braking; and deactivate/activate the key‐
Switches off the pump. 4) Battery disconnected during operated switch afterwards.
the braking operation.
22 Controller overtemp cutback 1) See menu Monitor > Controller: Set: Cooling element
Temperature temperature exceeds +85°C.
Overtemperature reduction
2) The control performance is Clear: Lower the cooling
Reduced driving and braking
torque limited at this temperature. temperature to a value below
+85°C.
3) Control system operates under
extreme ambient conditions.
4) Vehicle is overloaded.
5) The control system has been
wrongly assembled.

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Display of programmer Fault occurs if: Set Fault reset

Response to fault if: Clear
23 Undervoltage cutback 1) Normal operation: Fault indicates Set: Voltage on the capacitor
that the battery must be bank drops below the
Undervoltage reduction
charged. The control undervoltage point (see page
Reduced driving torque performance is limited at this 58), activated with FET‐bridge
voltage.
2) Battery parameters wrongly capacitor bank above the
adjusted. undervoltage point.
3) An electrical load other than the
control system affects the
battery.
4) Battery resistance too high
5) Battery was disconnected during
the driving operation.
Capacitor voltage.
7) Fuse is blown, or main contactor
is not closed.
24 Overvoltage cutback 1) Normal operation: Fault indicates Set: Voltage on the capacitor
that the regenerative brake bank exceeds the undervoltage
Overvoltage reduction
current raises the battery voltage point (see page 58), activated
Reduced braking torque too much during the braking with FET‐bridge
operation. The control
Clear: Lower the voltage on the
performance is limited at this
capacitor bank to a value below
voltage.
the undervoltage point.
2) Battery parameters wrongly
adjusted.
3) Battery resistance is too high for
this brake current.
4) Battery was disconnected during
the braking operation.
Capacitor voltage.
25 +5V supply failure 1) Impedance of the external load Set: +5V power supply (pin 26)
on the + 5V supply (pin 26) is too beyond the permissible value
Fault in the +5V power
low. range of +5V +‐ 10%.
supply
2) See menu Monitor> Outputs: 5 Clear: Adjust the voltage to a
None, unless a fault response
was programmed in VCL. volts and ext supply current. value in the permissible value
range.

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26 Digital out 6 overcurrent 1) Impedance of the external load Set: Current on the digital
on the digital output 6 (pin 19) is output 6 (pin 26) exceeds 15mA
Overcurrent in digital output low.
Clear: Eliminate the fault cause
6
and restart the driver output by
Digital output 6 does not means of the VCL function
switch on. Set_DigOut().
27 Digital out 7 overcurrent 1) Impedance of the external load Set: Current on the digital output
on the digital output 7 (pin 20) 7 (pin 20) exceeds 15mA
Overcurrent in digital output 7
is too low.
Clear: Eliminate the fault cause
Digital output 7 does not switch
on. and restart the driver output by
means of the VCL function
Set_DigOut().
28 Motor temp hot cutback 1) Motor temperature has Set: Motor temperature is higher
reached or exceeded the than the value adjusted for
Motor overtemperature
programmed temperature Temperature Hot.
reduction
value for HOT, and the required
Clear: Adjust the motor
Reduced driving torque current is reduced.
temperature to a value in the
2) Motor temperature values have permissible value range.
been wrongly adjusted in the
Control menu.
3) See menu Monitor> Motor:
Temperature and Monitor>
Inputs: Analog2
4) If no motor temperature sensor
is used in this application, the
parameters Temp
Compensation and Temp
Cutback should be set to Off.
29 Motor temp sensor fault 1) Motor temperature sensor has Set: Motor thermistor input (pin
been wrongly connected. 8) is connected to its power
Fault in the motor
supply (0 or 10V).
temperature sensor 2) If no motor temperature sensor
is used in this application, the Clear: Adjust the motor
Reduces the maximum speed
(emergency operation LOS, parameters Temp thermistor input to the
Limited Operating Strategy) and Compensation and Temp permissible value range.
deactivates the motor Cutback should be set to Off.
overtemperature reduction. 3) See menu Monitor> Motor:
Temperature and Monitor>
Inputs: Analog2.

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Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
31 Coil 1 driver open/short 1) Interruption or short circuit at Set: Driver output 1 (pin 6) is
the driver output. either open or short‐circuited.
Driver output, coil 1,
2) Dirty plug contact. Clear: Eliminate short circuit or
interruption/short circuit
interruption and switch driver
3) Poor crimp contact or defective
Deactivates driver 1. off/on.
wiring.
31 Main open/short 1) Interruption or short circuit at Set: Main contactor driver (pin 6)
the driver output. is either open or short‐circuited.
Main contactor driver
interruption/short circuit 2) Dirty plug contact. Clear: Eliminate short circuit or
Switches off the motor; 3) Poor crimp contact or defective
Switches off the main off/on.
wiring.
contactor;
Full braking;
Deactivates driver 2. 3) Poor crimp contact or defective
off/on.
wiring.
32 EM brake open/short 1) Interruption or short circuit at Set: EM brake driver(pin 5) is
EM brake driver
Switches off the drive sensor; 3) Poor crimp contact or defective
Switches off the EM brake; off/on.
wiring.
full braking.
wiring.
wiring.

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
35 PD open/short 1) Interruption or short circuit at Set: Proportional driver (pin 2) is

Proportional driver output
Deactivates the proportional off/on.
wiring.
driver.
36 Encoder fault 1) Fault in RPM sensor. Set: Fault detected in RPM

sensor.
Fault in encoder 2) Poor crimp contact or defective
wiring. Clear: Deactivate/activate the
Switches off the drive sensor; key‐operated switch.
3) See menu Monitor> Motor:
Motor RPM.
37 Motor open 1) Motor phase interrupted. Set: Interruption detected in
motor phase U, V or W.
Motor cable interrupted 2) Poor crimp contact or defective
wiring. Clear: Deactivate/activate the
Switches off the main key‐operated switch.
contactor;
Full braking;
38 Main contactor welded 1) Main contactor contacts are Set: Directly before the main
welded together contacts closed, the capacitor
Main contactor is welded
bank (B+ terminal) was charged
2) Motor phase U or V is
Switches off the motor; for a short period of time, and
Switches off the main interrupted or open.
the voltage was unable to
contactor; 3) Current flows to the capacitor discharge again.
Switches off the EM brake; bank (B+ terminal) via another
Switches off the drive sensor; Clear: Deactivate/activate the
current path (e.g. external
Full braking; key‐operated switch.
precharge resistor)
39 Main contactor did not close 1) The main contactor did not Set: When the main contactor is
close. supposed to close, the capacitor
Main contactor failed to close bank (B+ terminal) has not
2) Main contactor contacts are
Switches off the motor; charged at B+.
oxidized, burnt or have poor
Switches off the main contact. Clear: Deactivate/activate the
Switches off the EM brake; 3) External load on the capacitor
Switches off the drive sensor; bank (B+ terminal) prevents the
Full braking; capacitors from being charged.
Switches off the pump. 4) Blown fuse.

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
41 Throttle wiper high 1) See menu Monitor> Inputs: Set: Voltage in poti wiper (pin 16)
Throttle Pot. is higher than the upper fault
Drive sensor poti wiper high limit value. (Can be changed by
2) Voltage on poti wiper of drive
means of the VCL function
Switches off the drive sensor; sensor is too high.
Setup_Pot_Faults()).
poti wiper to a value below the
upper fault limit value.
42 Throttle wiper low 1) See menu Monitor> Inputs: Set: Voltage on poti wiper (pin
Throttle Pot. 16) is below the lower fault limit
Drive sensor poti wiper
value. (Can be changed by means
2) Voltage on poti wiper of drive
Switches off the drive sensor; of the VCL function
sensor is too low.
poti wiper to a value above the
lower fault limit value.
43 Pot2 wiper high 1) See menu Monitor> Inputs: Set: Voltage on Pot2 wiper (pin
Pot2 Raw. 17) is higher than the upper fault
Brake poti wiper high
limit value. (Can be changed by
2) Voltage on Pot2 wiper is too
Full braking; means of the VCL function
high.
Pot2 wiper to a value below the
upper fault limit value.
44 Pot2 wiper low 1) See menu Monitor> Inputs: Set: Voltage on Pot2 wiper (pin
Brake Pot. 17) is below the lower fault limit
Brake poti wiper low
value. (Can be changed by means
2) Voltage on Pot2 wiper is too
Full braking; of the VCL function
low.
Pot2 wiper to a value above the
lower fault limit value.
45 Pot low overcurrent 1) See menu Monitor> Outputs: Set: Current on poti ground(pin
Pot Low. 18) exceeds 10mA
Overcurrent on poti ground
2) The joint resistance of the potis Clear: Eliminate the cause of
Switches off the drive sensor; on poti ground is too low. overcurrent and
Full braking; deactivate/activate the key‐
operated switch.

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
46 EEPROM failure 1) Fault when writing into Set: The operating system tried
EEPROM. This can be caused by in vain to write into EEPROM.
Fault in EEPROM
EEPROM write commands by
Clear: Load the correct operating
Switches off the main VCL, CAN bus, parameter
system (OS) and the suitable
contactor; setting via the programmer or
parameter default values into
by loading new software into
Switches off the motor; the control, and
the control.
Switches off the main deactivate/activate the key‐
contactor; operated switch.
Switches off the release;
Switches off the drivers 1‐4;
Switches off PD;
Full braking;
47 HPD/sequencing fault 1) Key‐operated switch, release, Set: HPD (High Pedal Disable) or
direction switch and drive fault in switch‐on sequence due
Fault in switch‐on sequence
sensor were switched on in to wrong sequence of key‐
Switches off the drive sensor; wrong sequence. operated switch, release,
direction switch and drive sensor
2) Faulty wiring, crimp contact or
inputs.
switch on key‐operated switch,
release, direction switch and Clear: Re‐activate inputs in
drive sensor inputs. correct sequence.
3) See menu Monitor> Inputs.
47 Emer rev HPD 1) Although the emergency Set: A fault was reported
reverse function was finished, towards the end of the
Fault in switch‐on sequence
the drive sensor, direction emergency reverse function,
after actuating the
switch and interlock have not since some inputs have not yet
emergency reverse function
yet been reset to neutral been switched off again.
Switches off the drive sensor; position again.
Switches off the EM brake. Clear: If EMR_Interlock = On,
switch off the interlock, drive
sensor and the direction inputs.
If EMR_Interlock = Off, switch off
the drive sensor and the
direction inputs.

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
49 Parameter change fault 1) This is a safety shut‐off which is Set: Change of any parameter
caused by the change of certain which requires the deactivation
Fault caused by parameter
parameters (e.g. type of drive and re‐activation of the key‐
change
sensor), which means that the operated switch.
Switches off the motor; driving operation cannot be
Switches off the main Clear: Deactivate/activate the
restarted until you have
deactivated and re‐activated
Switches off the EM brake; the key‐operated switch.
Full braking;
51‐67 OEM faults 1) These faults can be specified by Set: See OEM documentation.
the OEM and are programmed
Clear: See OEM documentation.
OEM defined faults in the VCL code. See OEM
See documentation of OEM. documentation of the VCL
code.
68 VCL runtime error 1) VCL code encounters a VCL Set: VCL runtime error fault
runtime error. condition.
Runtime error of VCL
Switches off the motor; 2) See menu Monitor> Controller. Clear: Eliminate the fault in the
Switches off the main VCL Error Module and VCL VCL software; flashing of newly
contactor; Error. This error can be compiled software and
Switches off the EM brake; identified in the VCL module ID parameter settings;
Switches off the drive sensor; of the Sysinfo file for the Deactivate/activate the key‐
Switches off the release; relevant OS. operated switch.
Switches off PD;
Full braking;
69 External supply out of range 1) External load on 5V and 12V Set: The current of the external
supply either consumes too power supply (joint current of
External supply voltage is
much or too little electricity. the 5V (pin 26) and 12V supply
beyond the permissible
(pin 25)) is either larger than the
range 2) The review parameters Ext
upper or less than the lower limit
Supply Max and Ext Supply Min
None, unless a fault response value. The two limit values are
was programmed in VCL. have been wrongly adjusted.
defined by the parameters Ext
3) See menu Monitor> Outputs: Supply Max and Ext Supply Min
Ext Supply Current. (page 53).
Clear: Adjust the current of the
external power supply to a value
within the limit values.

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
71 OS general 1) Internal control fault. Set: Fault detected in the control.

Operating system in general Clear: Deactivate/activate the
key‐operated switch.
Switches off the main
contactor;
Switches off PD;
Full braking;
72 PDO timeout 1) The period of time between the Set: The period of time between
CAN PDO messages has the CAN PDO messages has
Switches off the drive
exceeded the PDO timeout exceeded the PDO timeout time.
sensor;
time.
Clear: Deactivate/activate the
CAN NMT status is set to key‐operated switch or obtain a
pre‐operational. CAN NMT.
73 Stall detect 1) Motor is blocked. Set: No motion of the RPM
sensor detected.
Motor is blocked 2) RPM sensor is defective.
Switches off the EM brake; Clear: Either deactivate/activate
Switches off the drive sensor; the key‐operated switch, or
wiring.
Operating mode changes to recognize valid RPM sensor
emergency operation LOS 4) Problems in the power supply signals while the motor is
(Limited Operating Strategy). of the RPM sensor. running in emergency operation
5) See menu Monitor> Motor: LOS and is outputting throttle
Motor RPM. command=0 and motor RPM=0.
74 Fault on other traction Dual drive fault: See dual drive

controller manual.
A fault occurred on the
other traction controller

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
Display of programmer Fault occurs if: Set Fault reset if:

75 Dual severe fault Dual drive fault: See dual drive
manual.
A severe dual drive fault
occurred
77 Supervisory fault 1) The supervisor processor has Set: Difference in case of

recognized a difference in the redundant measurements;
A supervisor fault occurred
redundant values. Motor is defective supervisor processor;
Switches off the motor; blocked. undefined switching inputs.
contactor; 2) The supervisor processor is Clear: Check for errors or
Switches off the EM brake; damaged. voltages drifts at the switching
Switches off the drive sensor; inputs; check connections;
3) Switching inputs are between
Switches off the release; Deactivate/activate the key‐
Switches off the drivers 1‐4; the lower and upper limit value
operated switch.
Switches off PD; for a period of more than
Full braking; 100ms .
78 Supervisory incompatible 1) The main OS is not compatible Set: Incompatible software.

with the supervisor OS.
Clear: Load suitable OS or update
Supervisor not compatible
supervisor code;
Switches off the motor; Deactivate/activate the key‐
Switches off the main operated switch.
contactor;
Switches off PD;
Full braking;

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00

87 Motor characterization fault 1) Fault during the motor Set: Motor characterization fault
characterization. See Monitor during the motor
A motor characterization
menu > Controller: Motor characterization.
fault occurred
Cause of the fault:
Switches off the motor; Clear: Eliminate the fault;
0= None
Switches off the main Deactivate/activate the key‐
1= Encoder signal has been
contactor; operated switch.
seen, but increment has not
Switches off the drive sensor; been recognized; Set the
Full braking; encoder steps manually
Switches off the pump. 2= Motor temperature sensor
fault
3= Motor overtemperature
reduction fault
4= Control overtemperature
reduction fault
5= Control undertemperature
reduction fault
6= Undervoltage reduction
fault
7= Extreme overvoltage fault
8= Encoder signal has not been
seen, or one or both tracks
have not been seen.
9= Motor parameters beyond
the characterization range
89 Motor type fault 1) The parameter Motor type is Set: The parameter Motor type
A motor type fault occurred beyond the valid range. has been set to an invalid value.
Switches off the motor; Clear: Set a valid motor type and
Switches off the main deactivate/activate the key‐
contactor;
operated switch.
Full braking;
91 VCL/OS mismatch 1) The VCL software in the control Set: VCL and OS are not
is not compatible with the OS in compatible. Upon activation of
A VCL/OS mismatch
the control. the KSI, it is checked whether the
occurred
two are compatible with each
Switches off the motor; other. If not, an error is reported.
contactor; Clear: Load suitable VCL and OS
Switches off the EM brake; into the control.
Switches off PD;
Full braking;

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00

92 EM brake failed to set 1) Vehicle motion recognized Set: A vehicle motion was
after application of the EM recognized after the EM brake
EM brake did not close
brake. received the command for
Switches off the EM brake; closing, and had sufficient time
Switches off the drive sensor; 2) EM brake does not prevent the
for closing completely.
motor from rotating.
Position Hold is activated when Clear: Actuate drive sensor.
interlock = On.
93 Encoder LOS (Limited 1) Encoder emergency operation Set: After detection of an

Operating Strateg) was activated in response to an encoder fault (fault 36) or a
Encoder emergency encoder fault (fault 36) or a blocked motor (fault 73) and
operation blocked motor (fault 73). subsequent activation of the
Switches to emergency brake or interlock, the control
2) RPM encoder defective.
operation LOS. changed over to emergency
3) Poor crimp contact or faulty operation LOS and merely
wiring. permitted a driving operation at
4) Motor or vehicle is blocked. reduced performance.
Clear: Deactivate/activate the
key‐operated switch or restore
the correct encoder operation if
the LOS mode was activated by a
blocked motor, motor RPM = 0
and drive sensor = 0.
94 Emer rev timeout 1) The emergency reverse Set: Emergency reverse function
function was started and was started and continued until
Emergency reverse function
finished after expiration of the the EMR timeout timer switched
timeout
EMR timer. off.
Switches off the drive sensor; 2) The emergency reverse input is Clear: Switch off the emergency
constantly ON. reverse input.
95 Encoder pulse error 1) The parameter Encoder Steps is Set: Motor can no longer be
not compatible with the controlled via IFO (vector
An encoder pulse error
encoder in the motor. control) and accelerates without
occurred
drive sensor signal.
Switches off the main Clear: Set the parameter Encoder
contactor; Steps to the correct value for the
Switches off the EM brake; encoder in the motor and
Switches off the drive sensor; deactivate/activate the key‐
Switches off the release; operated switch.
Switches off PD;
Full braking;

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00

98 Illegal model number 1) The variable Model_Number Set: Invalid value of the variable
contains an invalid value. In the Model_Number. Upon activation
Invalid model number
case of 1234E/36E/38E models, of KSI, the variable
Switches off the motor; values are invalid except for Model_Number is checked for a
1234, 1236, 1238 or 1298. valid value. A fault is reported if
contactor;
Regarding 1232E models, all no valid value is found.
Switches off the drive sensor; values are invalid, except for
Clear: Load the suitable software
Full braking; 1232.
for your controller model.
Switches off the pump. 2) Software and hardware are
incompatible with each other.
3) Control system defective.
99 Dual motor parameter Dual drive fault: See dual drive
mismatch manual.
A dual motor parameter
mismatch occurred.

25.02.2013 / KD
AC motor control
Curtis 1232 / 1236 / 1238 CAN
Rev. 0.00
3.3 Evaluation of the fault flash codes of the Curtis control systems
The evaluation of the fault codes can also be performed via the status diodes. The
following table shows a summary of the LED display formats.
Every code has two digits. The red LED flashes once and indicates in this way that
the yellow LED displays the figure of the first digit; if the red LED flashes
twice afterwards, it indicates in this way that the yellow LED displays the figure of the
second digit.
RED YELLOW RED YELLOW
First number of fault Second number of fault

First digit Second digit
code code
Example: Battery undervoltage (Code 23)
RED YELLOW RED YELLOW
First digit flashes Second digit flashes

once Flashes after the red twice Flashes after the red
for subsequent LED for subsequent LED
flashing of the yellow depending on the fault flashing of the yellow depending on the fault
LED code LED code
depending on the fault (acc. to example) depending on the fault (acc. to example)
(in the example, twice twice (in the example, three three times
afterwards ) times afterwards)
The two LEDs of the control system will display the following recurring pattern!
3.4 Different display modes of the LEDs
The two LEDs are provided with four different display modes with which they display the relevant type of
information!
Display Description
The control has not been activated; or the drive battery is empty;
No LED is lit up
or the control is defective.
Yellow LED flashes The control operates in a normal way.
No operating system was loaded into the control, or an internal

Red LED is continuously lit hardware error was detected by the supervisor or the primary
processor.
The control has detected an error. A two-digit flash code of the

LEDs points to the relevant error. When the red LED flashes
Red and yellow LED flash alternately
once or twice, it indicates in this way whether the first or second
digit of the flash code will follow by the yellow LED.

WHB22220 - AC-Curtis-CAN - Eng - Rev.0.00 (CURTIS 1232-1236-1238 CAN)

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Page 1 of 34 Workshop manual

Page 2 of 34 Workshop manual

Page 3 of 34 Workshop manual

2 Installation instructions ............................................................................. 8

3 Status messages ....................................................................................... 18

Page 4 of 34 Workshop manual

1.3.1 Power terminals

1.3.1.1 Battery cables (B+, B-)

1.3.1.2 Motor cables (U, V, W)

Page 5 of 34 Workshop manual

1.3.2 Control connections

1.3.2.1 Motor encoder (pins 31, 32)

1.3.2.2 CAN bus (pins 21, 23, 34, 35)

1.3.2.3 All other control cables

Page 6 of 34 Workshop manual

1.4 Variants / versions which are used

Items which are used:

4182207 – AC control 1232E-6221 / 48-80VDC/175A

4182208 – AC control 1232–2201 / 24V / 180A

Latest software status: V1.13

1.4.2 1236 series

Items which are used:

4182202 – AC control 1236-6301 / 48-80VDC/300A

4182204 – AC control 1236-5301 / 36-48VDC/350A

4182205 – AC control 1236-5401 / 36-48VDC/450A

Latest software status: V1.13

Page 7 of 34 Workshop manual

1.4.3 1238 series

Items which are used:

4182200 – AC control 1238-6501 / 48-80VDC/550A

Latest software status: V1.13

Page 8 of 34 Workshop manual

2.1 Installation below the battery in the case of standard ESTL

Traction controllers Pump control

Page 9 of 34 Workshop manual

2.2 Console extension

Installation space of the electrical components below the driver's seat

Safety steering computer

Console extension for the

Page 10 of 34 Workshop manual

2.3 CAN node number

The addresses have been defined as follows:

2.4 Exchange of the control

The following vehicle data should be known:

- machine number according to nameplate / e.g. 62545

Page 11 of 34 Workshop manual

2.5 Diagnosis regarding the control system SLC 019640

2.5.1 Status and diagnosis of the CAN AC traction controllers

Status and diagnosis of the CAN AC drives.

Page 12 of 34 Workshop manual

2.5.2 Status and diagnosis of the CAN AC pump controls

control: control word to the traction controller

2.5.3 Itemization of the individual diagnostic data

xx4x = direction preselection “forwards“

xx8x = direction preselection “backwards“

Page 13 of 34 Workshop manual

Conversion: Display value [Hz] x 30 = setpoint rpm of motor [1/min]

Motor control, pump drive:

Motor control, pump drive:

xxxB = function: parking brake while driving

xxxF = function: driving

Page 14 of 34 Workshop manual