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For the last five years I've been running a pair of 1239-8501 Curtis controllers on a HPEVS AC35-2 at 144V's with no troubles. Now the primary controller is giving me an error 38 which is "Main Contactor Welded". Just to be thorough, i replaced both the secondary and the primary main contactor relays. Replaced both precharge relays too. Still same error. I even swapped the primary and secondary main relays with each other(you never know even with newly purchased stuff). Still only the primary gives the error and secondary boots without errors. I know the primary main contactor is not welded shut because simply measuring no DC voltage across the controller inputs proves that. I sent the controller to FSIP... an approved Curtis repair house and for a mere $500 they replaced all the FETs on one of the three AC legs as they said they were all blown. They did nothing else. OK fine, but when it's returned to me I get the same exact error.
The controller is designed to close the precharge relay(with 50ohm resister) for a moment before closing the main relay. This is good because we don't want the main relay to arc when it closes. Fine simple enough. However with my primary controller error state it won't keep the main contact closed. My question is, how crazy is it to bypass the controller? If I were to add switches to manually flip ON the precharge relay, manually flip ON the main contactor relay and then manually flip OFF the precharge. Too crazy? Should i sent the controller back again for another go with FSIP? Any other suggestions?
Couple pics of my setup...
today(rusty/dusty)
five years ago(shiny and new)
The controller is designed to close the precharge relay(with 50ohm resister) for a moment before closing the main relay. This is good because we don't want the main relay to arc when it closes. Fine simple enough. However with my primary controller error state it won't keep the main contact closed. My question is, how crazy is it to bypass the controller? If I were to add switches to manually flip ON the precharge relay, manually flip ON the main contactor relay and then manually flip OFF the precharge. Too crazy? Should i sent the controller back again for another go with FSIP? Any other suggestions?
Couple pics of my setup...
today(rusty/dusty)
five years ago(shiny and new)