Swapping Curtis Controller 1204 to 1205M

[Jimigoe]

Hi Guys,

I have a 1997 CC DS with 48V Serial motor that I am upgrading for speed and torque. I got a Stage II upgrade kit from Buggies Unlimited that includes an AMD 5.5 HP motor, Curtis 1205M-5605 500A controller, and new high AMP cable kit, Solenoid, F/R handle, Diode, and resistor. The catalog said it would come with instructions but it did not and I can’t get the new controller to work and I am wondering if I do not have it wired correctly. I have installed the new motor, Solenoid, F/R handle, Diode and resister using my old Curtis 1204-410 225A controller and the cart runs great, 27MPH vs the 14 with the old motor. But when I swap out the controller for the new one the cart will not move at all.

So a few questions if you can help.

1. My old controller is a 1204, not a 1204M and the new one is a 1205M not a 1205. What is the difference between the non “M” and the “M” models.

2. My 1204 only has busbars B+, B-, and M-, the new 1205 has B+, B-, M- and A2. From what I can tell from the Curtis manual is the A2 is a Plug diode to the motor armature for plug breaking feature. Do I need to use this busbar?

I wired up the 1205M just like my 1204 with the B+, B-, M- (did not use the A2) and the J1, J2, J3 but the controller will not work.

I called Buggies Unlimited support line to ask for the directions for my speed kit and they told me the “Engineer was still working on it”. I find that hard to believe since I have seen the speed kits in the Buggies Unlimited catalog for at least a couple of years. If anybody has a wiring diagram I should be using that would be great. Thanks for your help.

[sunoco]

Originally Posted by Jimigoe

Hi Guys,
I got a Stage II upgrade kit from Buggies Unlimited.

Problem #1.

That controller comes set 5k-0. Pretty sure your 410 is 0-5k
What's your cart serial number?

Can you post a link to the kit you got?

[Jimigoe]

Sorry, should have included that..

Ser # A9704-556860

The resistor they sent to go across the Solenoid is 250 OHM and the Diode that also goes across the Solenoid is 3 AMP.

[sunoco]

Your old controller works, so I think either the controller is bad or its set to the wrong throttle input. What does the new controller read on the label?

[Jimigoe]

There is no label on the back of the controller, just the busbars are marked with B+, B-, M-, and A2. No markings on the low current connections. The fort label has

Curtis D.C. Motor Controller
Part Number: 17721708
Voltage 36-48V Current: 500A
Serial Number 13106 000275
Made In China (ugh)

[sunoco]

I looked, but don't see any kits there with that controller. Can you let us know which kit you got? I still think the controller is set to the wrong input....

[stroob]

here is link to the Curtis manual for your controller. It should help you sort out the throttle wiring to ensure you have it correct.

http://curtisinstruments.com/?fuseac...egory&catID=11

Stroob

[Jimigoe]

I placed the order with Buggies Unlimited using the May 2013 Catalog on page 65.

Stage II Series Speed Kits

STQ CC12 SKA – CC 95-up Solid State Series System 48V $1,119.99

It is also in the summer 2013 catalog on page 33

30294 – CC 95-up Solid State Series System 48V $1,119.99

I can’t find either part numbers on the Buggies Unlimited web site but the entire kit was shipped from Nivel parts and the controller is part number 997 on their web site. Here is the URL

http://www.nivelparts.com/pages/product.aspx?sku=997

After looking at the nivelparts website you are correct that it is a 5K-0 series controller.

[Jimigoe]

I took a look at the manual for the 1204M/1205M at the web site Stroob provided at

http://curtisinstruments.com/?fuseac...egory&catID=11

looking at the “Throttle Wiring” on page 9 it states it supports both Type 0, 0-5K Ohms and Type 1, 5K- 0 Ohms and it makes no difference what wire is on J2 and J3, I guess it figures out what type you have.

So I think I am OK with the Throttle Wiring but an not sure if I need to connect the A2 on the controller for breaking feature, I did not have a A2 bussbar on my 1204 controller.

[Jimigoe]

Just got new instructions from tech support at BU. The old instructions had me cut the old 6 gauge wire going from B- on the controller thru the on board computer to the negative on the battery and replace it with the new 4 gauge wire still going thru the computer. I did that and the controller did not work with everything wired the same as my old 1204 controller (not using the A2 busbar on the controller).

The new instructions say to keep the old 6 gauge wire going thru the computer and connect to B- and the battery negative but now use the 4 gauge wire as a “By-Pass Cable” and connect it from B- on the 1205 directly to the battery negative. So I will have a 6 gauge and a 4 gauge wire running from the B- on the controller to negative on the battery, the 4 gauge will be direct and the 6 gauge will go thru the computer.

I will try that tonight and let you know how I make out.