Error Code I can not clear - Curtis Controller 1236

[garolittle]

Hello. I am using the Curtis Controller 1236 on my electric go kart along with a 48V AC-9 from HPEVS.com. All was working will until a few days ago. There are 35 wire ("Pin") slots which connect to the curtis controller.

I have normally have Pin #25 (Red/Blue wire) connected to the “forward/reverse switch” on my go kart. It has been disconnected in the attached picture per the discussion below.

Until recently it was working fine with no error codes. I just received error code #69 and error code #25 on the Curtis Controller. When I remove Pin #25 (Red/Blue wire) from the forward/reverse switch, the error code goes away but the error code returns as soon as Pin #25 is connected again. From reading the manual it is clear to me that this is some type of over or under voltage issue regarding Pin #25 but I cannot figure out how to fix it. Per the attached photo, the manual states that I have to “bring the extra supply current within range”.

There in lies what must be a very simple problem. How do I bring the extra supply current within range? Any ideas? Thanks in advance for your help.

 

[Functional Artist]

Pokin' around a little, I found some info in http://www.hpevs.com/Site/images/pdf/troubleshooting/troubleshooting.pdf

Code #25
(+) 5V Supply Failure
Possible Cause
1) External load impedance on the +5V supply (pin 26) is too low 2) See Monitor menu >> outputs: 5 Volts and Ext Supply Current
Set/Clear Conditions
Set: +5V supply (pin 26) outside the +5V +/- 10% range Clear: Bring voltage within range


Code #69
External Supply Out of Range
Possible Cause
1) External load on the 5V and 12V supplies draws either too much or too little current 2) Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mis-tuned 3) See Monitor Menu >> Options: Ext Supply Current
Set/Clear Conditions
Set: The external supply current (combined current used by the 5V supply [pin 26] and the 12V supply [pin 25]) is either greater than the upper current threshold or lower than the lower current threshold. The two thresholds are defined by the External Supply Max and External Supply Min parameter settings. Clear: Bring the external supply current within range

I think they mean to bring the "current draw" with in range.
Do you have other stuff drawing power? (meters, brake lights etc.)
...either 5V or 12V?

 

[garolittle]

Hey Sir. Thanks for your response. I talked to the manufacturer and they been incredibly helpful. It appears to be a shorted wire leading from the throttle pot box to the controller. I will try a few more experiments tonight. I will let you know how it turns out. Thanks again for trying to help.

 

[garolittle]

I also noticed that the “Vehicle Controller Language” (VCL) was set to “on”. As soon as I moved J1-22 and J1-33 to 54V (pack voltage) and switched the VCL to “off” it worked. I really appreciate your responses as well as all of the others. You guys are great.

 

[garolittle]

Everything is working great now. Thanks to everyone for their help. Going for 70 mph this weekend. Hit 54 mph with a 4 to 1 gear ratio. Check it out.

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