Resistor burned when upgrading Curtis controller

Oberwan · 03-10-2021, 05:48 PM

I just replaced my ‘04 ClubCar DS controller (Curtis 250 amp) with a Curtis 350 amp. As soon as I attached the battery cables I smelled plastic. I’m confident that all the connections are correct. I looked under and saw the resistor casing on the solenoid smoking. I’ve ordered a new resistor for up to 400 amps. Could this solve the problem or am I kidding myself that it could be this easy?

scottyb · 03-10-2021, 05:52 PM

Welcome to BGW
Everything not connected correctly or the precharge resistor would still be okay.
Can you give more information ?
What cart?
Which drive system?
What controller .. such

Oberwan · 03-10-2021, 06:08 PM

‘04 Club car DS 48V. Took out a 250 Amp Curtis controller and replaced with a 350 Curtis controller. New solenoid, new Trojan batts., wires replaced exactly as taken off the 250.

scottyb · 03-11-2021, 08:29 AM

The resistor can get very hot when the controller is asking for power from the battery pack and the solenoid is not closed thus forcing the current to go around by way of the pre-charge resistor.
How can this happen if all the wires are correctly placed? The controller could be set for 5k-0 throttle when the cart throttle is actually 0-5k. In this case the controller would see a signal for WOT when the pedal was up and the solenoid was not closed

Oberwan · 03-11-2021, 01:08 PM

Thanks for the info. Any way to test the controller for this? Or what’s the fix?

scottyb · 03-11-2021, 02:18 PM

remove the throttle wires from the controller and plug your multimeter into the leads. It will read 0-5K or 5K to 0 as the pedal is depressed.

Not sure if it can be changed if it is incorrect for this cart. You will have to wait for a Curtis expert.

movin-on · 03-11-2021, 05:16 PM

What is the model # of the controller... Some are 0-5K or 5-0K and some are set up for ITS throttles..I beleive that they are set up at Curtis...I'm sure Sergio will know if he reads this thread...

biphase · 03-11-2021, 05:24 PM

It sounds like he may have the later DS cart with the shunt-wound motor and the IQ type Curtis controller (1510AS-5350)). If that is the case, he may have simply reversed the B- and M- cables on the controller.

Oberwan · 03-11-2021, 06:30 PM

1266R-5351 is the Curtis Model #.

movin-on · 03-11-2021, 06:47 PM

Looks like a 0-5K throttle....Go here to download the manual...

http://fsip.biz/CurtisManuals.html

03-10-2021, 05:48 PM	#1
Oberwan Not Yet Wild Join Date: Mar 2021 Posts: 10	Resistor burned when upgrading Curtis controller I just replaced my ‘04 ClubCar DS controller (Curtis 250 amp) with a Curtis 350 amp. As soon as I attached the battery cables I smelled plastic. I’m confident that all the connections are correct. I looked under and saw the resistor casing on the solenoid smoking. I’ve ordered a new resistor for up to 400 amps. Could this solve the problem or am I kidding myself that it could be this easy?
Oberwan Not Yet Wild Join Date: Mar 2021 Posts: 10

03-10-2021, 05:52 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Resistor burned when upgrading Curtis controller Welcome to BGW Everything not connected correctly or the precharge resistor would still be okay. Can you give more information ? What cart? Which drive system? What controller .. such

03-10-2021, 06:08 PM	#3
Oberwan Not Yet Wild Join Date: Mar 2021 Posts: 10	Re: Resistor burned when upgrading Curtis controller ‘04 Club car DS 48V. Took out a 250 Amp Curtis controller and replaced with a 350 Curtis controller. New solenoid, new Trojan batts., wires replaced exactly as taken off the 250.
Oberwan Not Yet Wild Join Date: Mar 2021 Posts: 10

03-11-2021, 08:29 AM	#4
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Resistor burned when upgrading Curtis controller The resistor can get very hot when the controller is asking for power from the battery pack and the solenoid is not closed thus forcing the current to go around by way of the pre-charge resistor. How can this happen if all the wires are correctly placed? The controller could be set for 5k-0 throttle when the cart throttle is actually 0-5k. In this case the controller would see a signal for WOT when the pedal was up and the solenoid was not closed

03-11-2021, 01:08 PM	#5
Oberwan Not Yet Wild Join Date: Mar 2021 Posts: 10	Re: Resistor burned when upgrading Curtis controller Thanks for the info. Any way to test the controller for this? Or what’s the fix?
Oberwan Not Yet Wild Join Date: Mar 2021 Posts: 10

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03-11-2021, 02:18 PM	#6
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Resistor burned when upgrading Curtis controller remove the throttle wires from the controller and plug your multimeter into the leads. It will read 0-5K or 5K to 0 as the pedal is depressed. Not sure if it can be changed if it is incorrect for this cart. You will have to wait for a Curtis expert.

03-11-2021, 05:16 PM	#7
movin-on Gone Wild Join Date: Sep 2016 Location: Titusville, FL...Space Coast Posts: 591	Re: Resistor burned when upgrading Curtis controller What is the model # of the controller... Some are 0-5K or 5-0K and some are set up for ITS throttles..I beleive that they are set up at Curtis...I'm sure Sergio will know if he reads this thread...

03-11-2021, 05:24 PM	#8
biphase Gone Wild Join Date: Jan 2009 Location: Ocala, FL Posts: 384	Re: Resistor burned when upgrading Curtis controller It sounds like he may have the later DS cart with the shunt-wound motor and the IQ type Curtis controller (1510AS-5350)). If that is the case, he may have simply reversed the B- and M- cables on the controller.

03-11-2021, 06:30 PM	#9
Oberwan Not Yet Wild Join Date: Mar 2021 Posts: 10	Re: Resistor burned when upgrading Curtis controller 1266R-5351 is the Curtis Model #.
Oberwan Not Yet Wild Join Date: Mar 2021 Posts: 10

03-11-2021, 06:47 PM	#10
movin-on Gone Wild Join Date: Sep 2016 Location: Titusville, FL...Space Coast Posts: 591	Re: Resistor burned when upgrading Curtis controller Looks like a 0-5K throttle....Go here to download the manual... http://fsip.biz/CurtisManuals.html

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