Curtis 1236 help needed

SiK

I bought brand new Curtis 1236-6406 controller from ebay to my ev project (70's Mini), but I can not get it running. Any help would be highly appreciated, I think this would be best forum to ask.

I have PC access to controller in OEM mode. There seem to be some kind of VCL software preprogrammed in controller. Attached are error codes, first one is constant and second comes when throttle is pressed.

Should motor run even if there are error codes present?

Would it be possible to remove VCL code from controller with 1309/1314 OEM connection?

Is there some information available how motor parameter recognizion should work?

Motor is 10kW (40kW peak) 4-pole AC motor from small chinese EV. Exact parameters are unknown.

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BGW

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cgtech

Charge interlock will prevent movement. (It thinks the charger is plugged in)
Incorrect throttle type will prevent movement. (Hpd = high pedal disable, throttle not at zero).

Some codes will allow operation at limited capability, some codes shut down the whole show..

What was this controller originally programmed to go in?

SiK

Thanks for reply. There is text FREEDOM in controller, so could it be programmed for Ez Go Freedom? I had no idea these might come with preprogrammed software when I bought this.

Could Charge interlock be simply one of the switch inputs of controller?

I will try different throttle pot settings to get rid of HPD code.

SiK

Charge interlock fault disappeared when I wired switch 5 "on" (pin 11).

VCL HPD fault comes still when throttle is pressed. It seem to appear also when some of the input switches is switched "on". Throttle is normal 5k potentiometer type, and I tried to change all throttle settings with no luck.

Does anyone have clue how throttle should be wired with this controller?

mjroman20

"VCL HPD" is not a native code in those controllers. On the system info screen there may be a VCL app number, if its not not 0 or blank there is defiantly something on there. There is not any way to 'remove' VCL technically, even so you need some other software to do so. It does sound as though it is indeed setup for an EZGO 72V freedom, that said unless you can overwrite that VCL you will have to conform to its programming if you want it to run as is.

Like most other Curtis controls the last 4 digits indicate voltage/current ratings and if its 'generic' or for a specific OEM. Ideally you will want a generic model, even with 'blank' VCL it's running conditions may not be ideal. There is a significant lack of safety features with the default software. No pedal switch for example. You will likely need to do some very basic programming to get the operation you want anyway.

http://www.fsip.biz/Documents/Curtis...2_34_36_38.pdf

This is an older version of the manual but it calls out some of the function designations for programming it if you manage to get your hands on the development tools needed to do so.

SiK

Thanks for reply and help so far.

I guess I need to find out EZGO 72V Freedom wiring and try to copy that. I have no access to any VCL programming tools. There seem to be v3.03 VCL SW version in controller.

I wired all the switch inputs to physical switches, and found out correct sequence to get rid of VCL HPD fault. When "interlock state" marked in attachment is changed to "1" with switch VCL throttle value works and VCL HPD error no longer comes. Also profile select (rapid/turtle) switch was found. Hopefully top speed would be more than 19,5mph with my drivetrain.

First motor spinning also achieved with motor parameter tuning sequence. Encoder is not yet correctly installed so error code from there.

Any help with EZGO Freedom 72V wiring and switches information would be appreciated.

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mjroman20

Been trying to get my hands on this wiring diagram as well. One other issue you may have however, is since I assume you are not using the same motor as the EZGO freedom system, you may have some minor performance 'issues' and I'm using that lightly. You just may not see the max possible speed or torque output since it wouldn't be properly characterized to that motor. The controller manual has a section on doing this but depending on what the EZGO VCL does it may simply overwrite any changes you make there.

SiK

I got motor encoder to work correctly, and surprisingly motor started to work pretty sophisticated right away. I did not run any motor tuning/recognizion sequences. I made testdrive with chinese vehicle where motor is still mounted. Acceleration was nice and wheels were spinning easily, in snow though. Battery voltage is now 48V so more power still expected with 72V.

I calculated top speed would be about 45mph with my drivetain. It could be more but I guess it is not possible without proper programming equipment.

mjroman20

Those controls have a hard limit of around 8k rpm, just due to the frequency. However since its setup as an EZGO it likely wont go over 25 (assuming you have a similar gearing and tire size) but ultimately its going off the RPM reading not MPH so larger tires and tighter gear ratio will increase speed for sure. You might notice some cogging when coming to a stop or reaching top speed if you do that however, so you may need to mess with the proportional and integral gains