Curtis 1205M-5603 Controller

Description

Curtis 1205M-5603 Main Features

1.36V/48V dual voltage application

1205M-5603 supports 36V and 48V battery systems. The NOCO EVCO page defaults to 48V/500A/0-5k Ω throttle, and users can also choose the 36V configuration based on the actual vehicle system.

Therefore, before purchasing, it is necessary to confirm the battery pack voltage of the vehicle and ensure that the controller parameters match the vehicle’s electrical system.

2.500A high current control capability

The maximum current limit of the controller is 500A, and the rated current given in the reference material is:

• 1 minute: 500A
• 5 minutes: 350A
• 1 hour: 200A

This high current design can meet the motor drive requirements under high load conditions and is suitable for applications such as industrial vehicles, traction equipment, and golf carts.

It should be noted that 500A is the current limit/rated capacity of the controller, which does not mean that the vehicle will continuously output 500A under all operating conditions.

3.MOSFET efficient mute control

1205M-5603 adopts high-frequency switch and low voltage drop design, which can improve power conversion efficiency and reduce noise during motor control process.

• High frequency switch
• Ultra low voltage drop
• High efficiency
• Smooth operation
• Low noise operation

4.Fully programmable design

1205M-5603 supports parameter adjustment and system diagnosis through Curtis programming equipment. Compatible programming devices include:

• Curtis 1313-4331 Handheld Programmer
• Curtis 1314 PC Programming Station

Through programming devices, controller parameters can be configured, diagnosed, and tested according to specific vehicle and application requirements.

5.Multiple throttle input methods

1205M-5603 supports multiple throttle types, including 10 throttle types:

• Type 0: Dual line potentiometer, 0-5k Ω
• Type 1: Dual line potentiometer, 5k Ω– 0
• Type 2: Single ended 0-5V input
• Type 3: Dual line potentiometer, 4.6k Ω– 0
• Type 4: Dual line potentiometer, 5.5k Ω– 0
• Type 5: Dual line potentiometer, 1k Ω– 0
• Type 6: ITS Input
• Type 7: Single ended 6.3-10.6V input
• Type 8: Single ended 6-12V input
• Type 9: Three wire potentiometer, 0-5k Ω

The default product setting is 0-5k Ω throttle. If the vehicle adopts other throttle forms such as 5k Ω -0 or 0-5V, the corresponding parameters should be confirmed before purchase and installation.

6.High Pedal Deactivation (HPD) Function

The controller has a High Pedal Disable function. If the accelerator is already in the applied state when the vehicle opens the key, the controller will prohibit the vehicle from running until the accelerator returns to neutral position.

This function can prevent the vehicle from suddenly moving at the moment of starting due to the throttle being applied, improving the safety of vehicle starting.

7.Throttle fault protection

The controller is equipped with a throttle fault detection circuit inside. When abnormal situations such as disconnection of the throttle circuit are detected, the controller can stop the corresponding control function, thereby reducing the risk of abnormal vehicle operation caused by throttle circuit faults.

8.Temperature protection and compensation

1205M-5603 is equipped with temperature protection and compensation circuits, which can perform corresponding current limitation and derating control according to the operating temperature of the controller. This function helps maintain stable current limitation under low and high temperature conditions, and protects the controller through temperature derating.

9.Undervoltage rating protection

The controller has Undervoltage Cutback function, which can reduce the control output in case of low battery voltage, thereby protecting the controller and vehicle electrical system. This function can also handle low voltage situations caused by external loads.

10.Insert brake function

1205M-5603 supports Plug Braking, and relevant information indicates that its braking function is achieved through A2 busbar, and corresponding diodes are set inside the controller. This function can be used for vehicle deceleration control, providing more comprehensive driving and braking control capabilities for electric vehicles.

Product Parameter

Product Size and Structure

The external dimensions of Curtis 1205M-5603 are:

• Length: 199 mm
• Width: 146 mm
• Height/Depth: 77 mm
• Weight: 2.7 kg

The controller adopts an aluminum shell structure and uses a coated solid copper busbar for high current connection. The reference indicates that the control signal adopts a plug-in connection method that is easy to install, while the power connection uses a coated solid copper busbar.

J5 Terminal and Wiring Instructions

The NOCO EVCO reference material specifically states that the J5 terminal of the new 1205M controller is not activated by default, and the default wiring method is the same as the old 1204M controller without the J5 terminal. If needed:

• Rev Input
• Main Driver

To activate the J5 terminal and set it according to the relevant instructions in the 1204M/1205M controller manual. Therefore, if the vehicle’s original system requires the use of J5 related functions, the controller version and parameter settings should be confirmed in advance before purchase.

Scope of Application

The Curtis 1205M series controller is primarily designed for electric vehicles that require DC Series Motor control. Applications include:

• Golf cart
• Industrial trucks
• Personnel transport vehicles
• Material handling vehicles
• Electric traction vehicles
• Pump equipment
• Hydraulic static drive system
• Other applications of DC series excited motors

Related Cross Reference Models

Cross reference number related to 1205M-5603:

• CL7011369R
• CT1205M-5603
• HU4130016
• YP550119911
• YP5501199-11
• 7011369R
• 1205M-5603
• 4130016
• 550119911
• 5501199-11

These numbers can be used as search and cross checking information during procurement, but it does not mean that all numbers can be directly exchanged on any vehicle. During actual replacement, it is still necessary to confirm the voltage, current, motor type, throttle type, terminals, and programming parameters.

Supporting Attachments

Curtis 906 Battery Level Gauge

Used to display the remaining battery level and provide vehicle battery status information.

Curtis Pot Box

By providing corresponding throttle resistors, vehicle speed control can be achieved.

Curtis 1313 programmer

Used for controller parameter adjustment, diagnosis, and system testing. In addition, the 1205M-5603 can also be parameterized using the Curtis 1314 PC programming station.

Product Selection and Installation Precautions

Before purchasing 1205M-5603, it is recommended to confirm the following information:

1. Is the vehicle battery voltage 36V or 48V;
2. Is the motor type a DC series excited motor;
3. Does the original controller model correspond to 1205M-5603;
4. Is the throttle type 0-5k Ω, 5k Ω -0, 0-5V, or other types;
5. Do you need HPD function;
6. Do you need Rev Input/Main Driver functionality;
7. Does the J5 terminal need to be activated;
8. Whether the wiring method of the original system matches;
9. Do you need to reprogram using 1313-4331 or 1314.

FAQ

Q1: What is Curtis 1205M-5603 Controller?

A: Curtis 1205M-5603 is a programmable speed controller for DC Series Motors, supporting a 36V/48V battery system with a maximum current limit of 500A. It is mainly used in golf carts, industrial vehicles, material handling vehicles, and other electric traction equipment.

Q2: Does 1205M-5603 support 36V or 48V?

A: Both are supported. This controller supports 36V and 48V. If used for 36V vehicles, it is necessary to confirm that the controller has been set to the corresponding voltage.

Q3: What is the maximum current of 1205M-5603?

A: The maximum current limit is 500A. According to the specifications, the rated current is 500A for 1 minute, 350A for 5 minutes, and 200A for 1 hour. The actual operating current may vary depending on the vehicle load, battery status, throttle input, and controller parameters.

Q4: What throttle can be used for 1205M-5603?

A: This controller supports multiple throttle types, including 0-5k Ω, 5k Ω -0, 0-5V, ITS, three wire 0-5k Ω potentiometer, and other voltage/resistance input types, with a total of 10 throttle types listed. The default setting is 0-5k Ω throttle.

Q5: Can 1205M-5603 be programmed?

A: Okay. The Curtis 1313-4331 handheld programmer or Curtis 1314 PC programming station can be used for parameter setting, diagnosis, and testing. Programming can help controllers adapt to the driving needs of different vehicles.

Q6:What is the relationship between 1205M-5603 and 1205M-5601?

A: 1205M-5603 is described as an upgraded version of 1205M-5601. The 1205M series controller has added programmable functions and more flexible application configurations on the basis of the original 1205 series. The specific replacement should still be confirmed based on the vehicle’s voltage, throttle, wiring, and parameters.

Q7: Is 1205M-5603 an original Curtis product?

A: Specific suppliers need to be distinguished.

Q8: What is the most important thing to confirm before purchasing 1205M-5603?

A: The most important thing is to confirm the battery voltage, motor type, throttle type, and controller wiring. Especially for throttle input, as the 1205M-5603 supports multiple throttle configurations, the default setting is 48V/500A/0-5k Ω. If the vehicle uses 36V or other throttle types, the corresponding parameters should be confirmed and set in advance.

Summary

Curtis 1205M-5603 is a high current programmable controller for DC Series Motor systems, featuring 36V/48V dual voltage, 500A current limit, multiple throttle inputs, 15.6kHz PWM, high pedal disable, undervoltage protection, temperature protection, insertion braking, and programmable diagnostics.

Its compact size of 199 × 146 × 77 mm and weight of 2.7kg make it suitable for electric vehicle applications with limited space, such as golf carts, industrial trucks, personnel transport vehicles, and material handling vehicles.

However, due to the coexistence of Curtis products, OEM remanufactured products, and third-party substitute products in the market, special confirmation of product source, complete model, voltage settings, throttle type, and J5 function configuration should be made during procurement to ensure that the controller is correctly matched with the original vehicle system.

DIMENSIONS

WIRING DIAGRAM

Wiring Diagram for Traction

Wiring Diagram for Pump