lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car
Electric Club Car Electric DS, and Precedent golf cars



Post New Thread  Reply
Thread Tools Display Modes
Unread 02-09-2015, 10:52 AM   #31
Gone Wild
 
Sergio's Avatar
Club Car
 
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 4,574
Default Re: I2 Excel upgrade to Curtis 1268 Controller Problems

This is not directly related to your issue, but more as an FYI about the High Current Contactors (solenoids).

You often will see posts saying that the main contacts (big posts) of the solenoid have no polarity as they are just a big On/Off switch.

Anyone paying attention to these posts will notice that some contactors like the Albright industrial ones, have a polarity mark on one of the Big solenoid posts.

It is not really a polarity as there are no electronic devices inside the solenoid that can get damaged.

You have an option to get "magnetic blowout" protection in some high current contactors.

These are high power "rare earth" magnets mounted near the main contacts.

When a solenoid tries to break DC current passing through the main contacts, an arc is created that can possible melt or pit the contacts if it does not quickly gets extinguished.

Just like two magnets brought in close proximity, if the polarities are the same, they will repel each other, but if they have opposite polarity, they will attract each other.

The magnets near the contacts have their polarity positioned so that when the arc occurs, the magnet will blow the arc away from the contacts.

If the "Voltage Potential" across the main posts is different then how the solenoid was designed for, the arc will actually be attracted to the center of the contact (bad thing).

The post should really say: "side of the solenoid contact connected to the highest voltage potential", that it obviously very long, so they use the plus (+) symbol.

On a golf cart where the contactor is interrupting the 'Pack Positive', the highest potential is towards the pack positive, so that cable gets connected to the terminal with the + symbol.

If for some reason the contactor were to be installed in the 'Pack negative' side, then the + side would need to be connected to the Controller B- as it would be at a highest potential than the pack negative.

As long as the contactor is opening and closing without a load, the magnetic blowout does not make much difference, but if Your contactor has it, You might as well connect it properly.

I hope this helps more than confuses.
Sergio is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Unread 02-10-2015, 10:53 PM   #32
Not Yet Wild
Club Car
 
Join Date: Sep 2013
Location: Texas
Posts: 26
Default Re: I2 Excel upgrade to Curtis 1268 Controller Problems

Yesterday, I spoke with an engineer at FSIP. He informed me that the 161 ohms on the small post of this solenoid is actually fine for this particular solenoid. He then had me check resistance on the Walkaway relay, which apparently also tested as fine.

He said that he was concerned about the controller itself and noted that the diode is actually within this 1268 controller. I pulled the controller today and shipped it back to FSIP for a bench test.

I'll keep you guys updated for what comes back from them. Thanks for all of the education, input and help.
kuntryboy is offline   Reply With Quote
Unread 02-19-2015, 08:03 AM   #33
Gone Wild
 
Sergio's Avatar
Club Car
 
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 4,574
Default Re: I2 Excel upgrade to Curtis 1268 Controller Problems

I saw your question in the stickies and got me thinking, the last time someone had a really hard time installing a different controller in an Excel system, it was also a factory TPS that had been converted to MCOR.

The final solution was to replace the harness, which fixed the problem and also gave the Excel harness a bad reputation for upgrades.

Since then several folks have installed controller updates in Excel systems, and aside from having to make sure the Pot low (purple wire) is isolated from other negative devices, it works fine.

You are now having the same issues with a factory TPS, so I looked specifically to the Throttle wiring diagram for the factory TPS harness.

To my surprise, the pot low (purple wire) is not connected anywhere to the 16-pin controller connector.

That makes sense since the TPS is a 2 wire device that uses only positive and the wiper return signal.

I think the solution is to cut the purple wire anywhere between the sonic weld and the MCOR and tape the harness side to avoid shorts.

You will then need to run a new wire (18ga) from the MCOR side of the purple wire directly to the pin #3 on the 16 pin connector.

If You can, post a picture of the 16 pin controller harness adapter showing pins 1,2,3 on the controller and the corresponding 1268 harness, There is probably no wires on pin #3.

The 1268 controller has all sorts of safeties built in and provides return signal for solenoid/relay coil drivers, which by the way needs to be used as it is the only way the internal diode protection works, and also monitors the return signal (pot low) from the throttle.
Sergio is offline   Reply With Quote
Unread 02-19-2015, 08:32 AM   #34
Gone Wild
 
scooterman's Avatar
Club Car
 
Join Date: Jan 2014
Location: Lafayette, Louisiana
Posts: 1,641
Default Re: I2 Excel upgrade to Curtis 1268 Controller Problems

You would think when you buy the upgraded controller for the excel system they would convert it properly, that is why they have a bad rap. The only reason why I'm going to convert mine to IQ is I have to tear it all down anyways, so a new wiring harness won't be an issue to replace at that time. Otherwise I'm sure this is easy enough to fix as Sergio has discovered.
scooterman is offline   Reply With Quote
Unread 02-19-2015, 09:24 AM   #35
DS Drivers Club Founder
 
CCFanatic's Avatar
Club Car
 
Join Date: Jul 2013
Location: Upstate NY
Posts: 3,408
Default Re: I2 Excel upgrade to Curtis 1268 Controller Problems

kuntryboy, didn't want to plug up the Sticky, so here is the answer to your post

If you have an 09 Excel with a TPS and you want to convert it to an MCOR2, you need CCI# 103683101, which is the Excel TPS adapter
CCFanatic is offline   Reply With Quote
Unread 02-22-2015, 11:50 AM   #36
Not Yet Wild
Club Car
 
Join Date: Sep 2013
Location: Texas
Posts: 26
Default Re: I2 Excel upgrade to Curtis 1268 Controller Problems

WOOOO HOOOO! The cart is running well and goes 30MPH up a good size hill and 36 mph on flat land.

I received the controller back from FSIP and it turned out that the diode is inside the controller. It had blown and they replaced it under warranty. The people at FSIP were great and even did the whole thing under warranty, including free two shipping back to me in Texas.

I put the controller back into the cart and found I was only getting about 17mph out of the cart initially. I called PlumQuick just to see if it could be a motor issue. They were fantastic and gave me several things to check out.

I took the cart to my local dealer and we hooked up the handheld. The new Mcor2 I installed, with the adapter was only showing to have 44% with the pedal fully depressed. We called one of the Engineers at FSIP, Matt Roman, who was kind enough to walk us through all of the settings. With a couple of minor changes we were zooming along! TBH... I cannot remember the setting he had us change it went so quickly.

The cart has excellent acceleration and top speed now. To review here are the changes I made to the '09 Club Car I2 Excel to get these results.

1. Scottb's #2 AWG cable set
2. Changed my TPS throttle control out to MCOR2 with adapter
3. Curtis 1268 Controller upgrade kit from FSIP
4. Curtis heavy duty solenoid
5. Plum Quick Executioner motor

I thought might also be important to note that the cart has some regen braking still going. The cart is running great and I put about 12 miles on it around town yesterday.

I wanted to thank Sergio for all of his help. Also TahoeDawg sorry I didn't get back with you sooner. If anyone else is attempting this upgrade, I think I ran into every problem I could have. Hopefully I can help or point you in the right direction.
kuntryboy is offline   Reply With Quote
Unread 02-22-2015, 12:24 PM   #37
Gone Wild
 
Sergio's Avatar
Club Car
 
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 4,574
Default Re: I2 Excel upgrade to Curtis 1268 Controller Problems

Congratulations, another successful Excel conversion

Those are some pretty high speeds, what size tires are You running?

With 22" tires the motor would be running 6800rpm at 36mph, be carefull not to over rev that new motor.
Sergio is offline   Reply With Quote
Unread 02-22-2015, 03:21 PM   #38
Not Yet Wild
Club Car
 
Join Date: Sep 2013
Location: Texas
Posts: 26
Default Re: I2 Excel upgrade to Curtis 1268 Controller Problems

Quote:
Originally Posted by Sergio View Post
Congratulations, another successful Excel conversion

Those are some pretty high speeds, what size tires are You running?

With 22" tires the motor would be running 6800rpm at 36mph, be carefull not to over rev that new motor.
The tires are 23x10-14. I tend to keep the cart at around 30 to 31 most of the time. But it's nice to not be running it at top speed and being to keep the amps down. There is no heat showing on the cables seems to be running smoothly. I do have to be careful not to give too much throttle or it will shut down my solenoid. If it happens though, I only have to switch the tow run on/off and it resets. Only done that twice though and I was running it pretty hard.

The only problem I'm seeing that I could fine tune now would be the tires. I run them at 30psi to help eliminate some of the balance issues. But these off-road tires are way out of balance. Have considered using dynabeads but I'm not sold on the idea. Discount tire is hesitant because they haven't had much luck in balancing these tires.

Have been looking at more of a street tread with tires such as the Excel Street Fox radial tire http://www.buggiesunlimited.com/golf...x1000-14/41014.

I'm wondering if anyone has tried these and if they offer better balancing options.
kuntryboy is offline   Reply With Quote
Reply

Tags
curtis 1268, i2 excel, precedent, upgrade
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car


Thread Tools
Display Modes


Similar Threads
Thread Forum
Curtis 1268 Controller Electric Club Car
Curtis 1268 Controller Electric Club Car
Looking for Curtis Controller 1268-5403 Golf Carts and Parts
Anyone using a Curtis 1268 Sepex controller Extreme DC!
Curtis 1268 400 amp controller? Golf Carts and Parts


All times are GMT -5. The time now is 02:09 PM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.6
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.
Content Relevant URLs by vBSEO ©2011, Crawlability, Inc.