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Old 08-27-2013, 12:39 PM   #1
Storm S
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Default 1206 controller no plug breaking?

I am working on a friends cart now that they think I know what I am talking about because I fixed mine (lots of guessing and reading BGW). it is a EzGo 36volt. The ID tag is missing so I do not know the year. The controller is fried. I am looking up referb units and none of them seem to have the A2 plug breaking lug on them like the one I took out does. is this normal? why? What should I do?
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Old 08-27-2013, 12:44 PM   #2
Sir Nuke
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Default Re: 1206 controller no plug breaking?

first off, do yourself a favor and your friend, and do NOT buy a referbed controller.

but seeing as how you don't actually know the year of the cart.....lable every wire/cable on the controller and where they go to, then remove it. The controller itself has its model number. with that, you can determine what you have, or at least what will work.
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Old 08-27-2013, 01:12 PM   #3
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Default Re: 1206 controller no plug breaking?

Neither the 1206SX (DCS) nor the 1206MX (PDS) controllers had an A2 terminal, so he has a cart with a Series wound motor.

Series drive carts didn't change much, if any, over the years, so the attached schematic ought to be the right one, or at least close.

The OEM controller is only 275A and it burnt out, so it might be an idea to put something heavier in.
Perhaps an Alltrax AXE or SPM.
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File Type: jpg Wiring Diagram - Series.JPG (55.8 KB, 0 views)
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Old 08-27-2013, 01:52 PM   #4
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Default Re: 1206 controller no plug breaking?

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Originally Posted by JohnnieB View Post
Neither the 1206SX (DCS) nor the 1206MX (PDS) controllers had an A2 terminal, so he has a cart with a Series wound motor.

Series drive carts didn't change much, if any, over the years, so the attached schematic ought to be the right one, or at least close.

The OEM controller is only 275A and it burnt out, so it might be an idea to put something heavier in.
Perhaps an Alltrax AXE or SPM.
I have found a 400 that I want to put in thats easy. It is series I know that as well. My main issue that I have not been faced with in the past is the 275 that came out had plug breaking. I have yet to find a replacement that still has the plug breaking. It seems they all have been removed during referb?!?! They are tight on cash and I am just trying to help out so a $275 referb is easier for them then a $499 new. ya know? Why is there no plug breaking and it is good or bad to not have it? Could I "cap off" said wire and be okay?
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Old 08-27-2013, 02:03 PM   #5
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Default Re: 1206 controller no plug breaking?

My series cart had a wire from A2 on the motor to A2 on the controller. Another wire from A2 on the controller went to C on the F/R switch. C in my case was the 6 o'clock position.
Recently I installed an alltrax SPM. It did not have an A2 connection on it. I removed the wire from A2 on the controller to C on the F/R switch and ran a wire directly from A2 on the motor to C on the F/R switch. This is in accordance with the wiring diagram from Alltrax. Works as before. So one less wire with this set up.
I have owned this cart since new so it was wired IAW factory specs for it's year (2000). Note: This cart came with a curtis 400amp controller (1205 I believe) but wiring solution should be the same.

edit: Plug braking is not necessary for golf carts. Common on fork lifts I believe.
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Old 08-27-2013, 02:07 PM   #6
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Default Re: 1206 controller no plug breaking?

If you want to know what plug braking is: http://www.alltraxinc.com/files/Doc1...ug-Braking.pdf
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Old 08-27-2013, 02:09 PM   #7
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Default Re: 1206 controller no plug breaking?

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Originally Posted by kernal View Post
My series cart had a wire from A2 on the motor to A2 on the controller. Another wire from A2 on the controller went to C on the F/R switch. C in my case was the 6 o'clock position.
Recently I installed an alltrax SPM. It did not have an A2 connection on it. I removed the wire from A2 on the controller to C on the F/R switch and ran a wire directly from A2 on the motor to C on the F/R switch. This is in accordance with the wiring diagram from Alltrax. Works as before. So one less wire with this set up.
I have owned this cart since new so it was wired IAW factory specs for it's year (2000). Note: This cart came with a curtis 400amp controller (1205 I believe) but wiring solution should be the same.

edit: Plug braking is not necessary for golf carts. Common on fork lifts I believe.
So your good without it then. Did you notice any difference at all when you by passed it? THANK YOU for your input! It is very helpful!
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Old 08-27-2013, 02:13 PM   #8
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Default Re: 1206 controller no plug breaking?

Quote:
Originally Posted by Storm S View Post
I have found a 400 that I want to put in thats easy. It is series I know that as well. My main issue that I have not been faced with in the past is the 275 that came out had plug breaking. I have yet to find a replacement that still has the plug breaking. It seems they all have been removed during referb?!?! They are tight on cash and I am just trying to help out so a $275 referb is easier for them then a $499 new. ya know? Why is there no plug breaking and it is good or bad to not have it? Could I "cap off" said wire and be okay?
Plug Braking is to lessen the physical jolt when the F/R lever is switched to the other direction while moving, which is routinely done in forklifts but not often in golf carts, so it is for the most part not used.

Not shown by to the schematic, the A2 terminal has two high current cables attached to it. Basically, less cable is used that way, so if you get a controller without the A2 terminal and the existing controller's A2 terminal does have two heavy cables attached to it. just bolt the two together, insulate the connection, and tie it up so it doesn't touch anything, or replace the two cable with a single cable that is long enough to go from motor's A2 terminal to F/R switch's "C" terminal.

If there is only one cable on the controller's A2 terminal, trace it to the distal end and remove it completely.
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Old 08-27-2013, 02:14 PM   #9
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Default Re: 1206 controller no plug breaking?

Quote:
Originally Posted by JohnnieB View Post
Plug Braking is to lessen the physical jolt when the F/R lever is switched to the other direction while moving, which is routinely done in forklifts but not often in golf carts, so it is for the most part not used.

Not shown by to the schematic, the A2 terminal has two high current cables attached to it. Basically, less cable is used that way, so if you get a controller without the A2 terminal and the existing controller's A2 terminal does have two heavy cables attached to it. just bolt the two together, insulate the connection, and tie it up so it doesn't touch anything, or replace the two cable with a single cable that is long enough to go from motor's A2 terminal to F/RT switch's "C" terminal.
Got it. THANKS!
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Old 08-27-2013, 02:15 PM   #10
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Default Re: 1206 controller no plug breaking?

No change without it. I installed this controller in prep for 48v conversion and I expected no change in cart performance and that is what I got. Going to 48v is when I will get a change.
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