System Components for Electric Vehicles
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ALLTRAX Motor Controllers:   
> EV Systems Components
Vehicles may or may not have the correct components for (and
others) used smaller OEM style low current solenoids, some did not use
Alltrax Controllers are compatible with these cars and other electric
vehicles by using the proper configuration wire adapters or in most cases  
plugs directly into the existing wire harness.

Alltrax Controllers are HIGH power, HIGH performance electric motor
controllers that require checking or replacing the
main solenoid, heavy
duty F&R switch, and adding the appropriate diode and resistor.  This is
true for ALL electric vehicles or conversions
.

This section describes the components offered by Alltrax for your
configuration.
  • SOLENOID - The main current solenoid (or called a contactor) that
    turns power on or off to the controller, the motor, and system
    using the Key Switch KSI.
  • COIL SUPPRESSION DIODE - The Solenoid coil stores lots of
    magnetic energy, when turned off, a flyback voltage spike can
    occur.  The diode absorbs this energy.
  • PRE-CHARGE RESISTOR - provides a small trickle charge to the
    main filter capacitors in the motor controller.  Having these "caps"
    charged prevents large surge currents when turning on the car.
  • FUSES - There are two varieties: 1) The MAIN 200-600amp battery
    LOGIC 5 to 10amps fuse for control power.
SOLENOIDS and DISCONNECTS (Contactors)                                                 
Return to PRODUCTS
SOLENOIDS:
Heavy duty 24, 36, 48, and 72 Volt solenoids Approved by ALLTRAX in 2008:
COIL SUPPRESSION DIODES:
The solenoid coil is a magnetic device.  When energized - the coil has allot of energy stored
in the magnetic field to close the contacts.  Turning "OFF" the Solenoid causes the magnetic
field to collapse and create an electrical voltage spike in the hundreds of volts.  The diode
"suppresses" this spike and protects the motor controller and any auxiliary equipment such
as DC-DC converters connected downstream.

All diodes have 400volt PIV or higher rating, terminated lead kits:
BLOCKING DIODE AND FUSE RETRO KIT:
When some conversions, (including older E-Z-Go Carts), a
blocking or reverse protection diode is required with in-line
protection fuse.

This kit requires some re-wiring with standard tools,
instructions are detailed and provide step-by-step to
upgrade the car.  
FUSE PROTECTION:
Fuses are rated for continuous duty.  For fuse ratings, please contact
customer service.  Note: Busman
(TM) CNN fuses are equivalent to ANN
Need help choosing the correct one?  Contact our Customer Service or
Explore
Document Depots: "Application & Cross Reference Guides"
Alternatively, send an email to: info@alltraxinc.com
Go To Document Depot
For more information, see Document Depot for drawings and installation guides.
Did you know?
> Between 1832 and
1839 (the exact year is
uncertain), Robert
Anderson of Scotland
invented the first crude
electric carriage.

Practical and more
successful electric road
vehicles were invented by
Davenport and Scotsmen
Robert Davidson around
1842.
>  The safety systems in
centuries worth of
development?  The
infancy regarding
As the fuel shutoff relay
protects the gas powered
cars during an incident,
the "electric solenoid"
does the same thing,
shuts off power to the
motor and controller.  

Make sure your solenoid
is sized for the current
rating and your foot
switch is operational!
Technical Note #010:
"
Lessons Learned" in using
the correct Solenoid
(Contactor), Fuse, Coil
Supression Diode, Battery
Fuse, and Pre-Charge
Resistor

MUST SEE THIS!
File Size: 429KB
Document Depot
36 VOLT 200AMP Specifications:
PART Number:  SOL-36V-200A
Voltage:          36 volt coil
Current:          200amps continuous
800amps surge (2 seconds)
Contacts:        Silver oxide
Terminals:      5/16" main lug, #10 coil term
Mounting:       2-up to 1/4" (6mm)
Voltage:          48 volt coil
Current:          200amps continuous
800amps surge (2 seconds)
Contacts:        Silver oxide
Terminals:      5/16" main lug, #10 coil term
Mounting:       2-up to 1/4" (6mm)
48 VOLT 400AMP Specifications:
PART Number:  SOL-48V-400A
Voltage:          48 volt coil
Current:          400amps continuous
1000amps surge (2 seconds)
Contacts:        Silver oxide
Terminals:      3/8" main lug, #10 coil term
Mounting:       2-up to 1/4" (6mm)
PRE-CHARGE RESISTORS:
All Resistors are Wire Wound +/-10% tol
24 Volt: 220 ohm, 5-10 Watt
36 volt: 220-250 ohm, 10 Watt
48 Volt: 470 ohm, 10 Watt
60-72 Volt: 1,000 ohm, 10 Watt
Note: The "WHITE BAND" on the diode MUST connect to the POSITIVE side of the coil, BLACK BODY
connected to negative.  Also see
Technical Note #10 on our Doc Depot for more details.
1AMP Coil Suppression Diode
Specifications:
PART NUMBER:  KIT-CSD-1
Description:      Diode Kit, 1Amp, 400 Volt,
Terminals:        #10 ring terminals
Leads:             RED heat shrink on POSITIVE
BLACK heat shrink on NEGATIVE
3AMP Coil Suppression Diode
Specifications:
PART NUMBER:   KIT-CSD-3
Description:         Diode Kit, 3Amp, 400 Volt,
Terminals:        #10 ring terminals
Leads:             RED heat shrink on POSITIVE
BLACK heat shrink on NEGATIVE
NOTE: Some resistors are round
enamel or square ceramic.  Both
resistors provide the same function.
220 ohm Pre-Charge Resitor Specifications:
PART NUMBER:   KIT-PCR-220
Description:         Resistor Kit, 220 ohm, 10 Watt,
Terminals:         5/16" ring terminals
Leads:               BLACK heat shrink
470 ohm Pre-Charge Resitor Specifications:
PART NUMBER:   KIT-PCR-470
Terminals:         5/16" ring terminals for SOL-xxV-200A
Leads:               BLACK heat shrink
24-36
Volt
48 Volt
60-72
Volt
1000 ohm Pre-Charge Resitor Specifications:
PART NUMBER:   KIT-PCR-1K
Description:         Resistor Kit, 1,000 ohm, 10 Watt,
Terminals:         5/16" ring terminals
Leads:               BLACK heat shrink
400 Amp Battery Fuse Specifications:
Manufacturer:    Busman(TM)  ANN/CNN series
Description:       Fuse, ANN400 Amp
Terminals:         5/16" Slot terminals
Use with:
200 to 400 Amp
controllers
Use with:
450 to 650 Amp
controllers
TOW RUN SWITCH - RETRO-KIT:
For Separately Excited (Re-Gen) cars
require a Tow/Run switch to disables the
FUSE HOLDERS:
Fuses Holders are rated for continuous duty.  For fuse holder required, please contact customer >
BATTERY FUSE: Protects the battery pack, wiring, and controller in the event of a short circuit
> LOGIC FUSE: Protects the control wires, key switch, foot-switch,     
and controller logic wiring
Note: When a fuse holder is not
available, the fuse is best installed
onto the battery post as shown.  

This protects the high current wires
from short circuits.
Alltrax PN# KIT-FUSE-HLDR-10A

Protects CONTROL circuits rated 5
to 10amp to protect the logic
wiring, Key Switch circuit, Controller
Logic Power, and main Solenoid
coil drive.
Alltrax PN# KIT-FUSE-HLDR-ANN

250 to 600amp ANN style main
battery fuse to protect the wiring
and batteries against short circuits.

Install as close to Battery post as
possible.
AVAILABLE UPON
REQUEST
COIL SUPPRESSION DIODES                                                                          
PRE-CHARGE RESISTORS                                                                             ___
FUSES                                                                                                                    
MISC COMPONENTS                                                                                   
THROTTLE PB-6 (Pot Box):
PN# PB-6

Linear potentiometer
Output: 0-5K
Interlock Switch: YES, Foot switch Activates
KSI
Special
Order
Use with:
200 Amp
24, 36, 48 Volt
SOLENOIDS
Use with:
400 Amp
24, 36, 48 Volt
SOLENOIDS
SOL-200Amp with
KIT-CSD-1A and
Pre-Charge Resistor
SOL-400AMP with
KIT-CSD-3A and
Pre-Charge Resistor
SOL-200Amp with
KIT-CSD-1A and
Pre-Charge Resistor
@2008 Alltrax Inc
FUSE HOLDERS                                                                                                          
Fairplay FYM 2006 Wire Diagram
Fairplay FYM 2006 Wire Diagram
PART Number:  SOL-72V-400A
Current:          400amps continuous
800amps surge (2 seconds)
Contacts:        Silver oxide
Terminals:      3/8" main lug, #10 coil term
Mounting:       2-up to 1/4" (6mm)
(Bracket Included)
Fairplay FYM 2006 Wire Diagram
Fairplay FYM 2006 Wire Diagram
24 VOLT 200AMP Specifications:
PART Number:  SOL-24V-200A
Voltage:          36 volt coil
Current:          200amps continuous
800amps surge (2 seconds)
Contacts:        Silver oxide
Terminals:      5/16" main lug, #10 coil term
Mounting:       2-up to 1/4" (6mm)
Fairplay FYM 2006 Wire Diagram
SOL-200-Spec.pdf
Rev A 4/29/2009
131Kb File Size
SOL-200-Spec.pdf
Rev A 4/29/2009
131Kb File Size
Rev A 4/29/2009
131Kb File Size
SOL-400-Spec.pdf
Rev A 4/29/2009
205Kb File Size
SOL-400-Spec.pdf
Rev A 4/29/2009
205Kb File Size
200AMP 5/16"
Terminals
PART NUMBER:   KIT-PCR-220T
Description:         Resistor Kit, 220 ohm, 10 Watt,
Terminals:         3/8" ring terminals
Leads:               BLACK heat shrink
470 ohm Pre-Charge Resitor Specifications:
PART NUMBER:   KIT-PCR-470T
Description:       Resistor Kit, 470 ohm, 10 Watt,
Terminals:        3/8" ring terminals for SOL-xxV-400A
Leads:               BLACK heat shrink
24-36
Volt
48 Volt
60-72
Volt
1000 ohm Pre-Charge Resitor Specifications:
PART NUMBER:   KIT-PCR-1KT
Description:         Resistor Kit, 1,000 ohm, 10 Watt,
Terminals:         3/8" ring terminals
Leads:               BLACK heat shrink
400AMP 3/8"
Terminals
SOL-400AMP with
KIT-CSD-3S (SPADE term)
and Pre-Charge Resistor
A separately derived relay for auxiliary
circuits such as DC-DC Converters, heaters,
stereos, lights, etc.  

Operates by KSI switch to turn on and off
these auxiliary loads - separate for the
controller KSI power. ALWAYS better to
separate Controller Power and Auxiliary
loads.
AUX Diagram
Doc100-053
E-Vehicle Accessory Wiring Suggestions
KIT-PCR-470T
3/8" Terminals
KIT-PCR-220T
3/8" Terminals
KIT-PCR-1KT
3/8" Terminals
KIT-PCR-470
5/16" Terminals
KIT-PCR-220
5/16" Terminals
KIT-PCR-1K
5/16" Terminals
-----------------------------------------------------------------------------------------------------------------
3AMP Coil Suppression Diode
Specifications used on 72V solenoids:
PART NUMBER:   KIT-CSD-3S ("S" as in SPADE)
Description:         Diode Kit, 3Amp, 400 Volt,
Terminals:        #0.250" SPADE FASTON
Leads:             RED heat shrink on POSITIVE
BLACK heat shrink on NEGATIVE
Use with:
200 or 400 Amp
72V SOLENOIDS
The motor controller has large internal filter capacitors.  When the vehicle is off, these capacitors
these capacitors.  This inrush can arc and damage the solenoid contacts and stress the controller.

Adding a Pre-Charge Resistor keeps the capacitors "topped-off" with a charge.  When the key
switch is turned on -
no surge current and no arcing on the contacts.  This not only increases the
life of the solenoid - but decreases the stress on the controllers electronics.
-----------------------------------------------------------------------------------------------------------------
BLF and BLN are fast acting
MIDGET fuses  rated at 250 volts,
10amps.
ANN or CNN fuses are rated for large
inrush currents used in DC Battery
applications.  Only BUSS (TM) fuses
are used by Alltrax.
PART NUMBER:   Alltrax #10AMP-FUSE-LOGIC
MFG PN#           BLN-10 or BLF-10
Description:       Fuse, 10 Amp
Terminals:         MIDGET (Use fuse holder shown below)
Controller Pro
The free download software shown on the
Controller Pro web page has a kit that can
be purchased which includes:
> USB to RS232 communications cable
> Transformer 18 Volt DC, 1Amp output
> Connector adapters for various
controller connections
> CD with Controller Pro Software
> Operators Manual, Controller Pro
Want to know
More? Go-To:
Controller Pro
Web Page
200 Amp solenoid with Alltrax Controller
Some electric vehicles including older golf cart may not be
equipped with a suitable heat sink.   The controller will provide
more power when cooler, and increase its reliability.

Alltrax now offers a heat sink assembly that mounts the
controller and all the support components in one convieniant
package!

> Fuse Holder Main Battery (250 & 400amp)
> Logic Fuse holder for Key Switch & Controller Logic Power
> Main Solenoid (contactor) disconnect switch
> Bus bar connecting solenoid to fuse source
> Coil Suppression Diode (for solenoid coil)
> Pre-Charge resistor (Across main terminals)
> Auxiliary Relay for DC-DC Converters (KSI Controlled)
> Mounting surface for Alltrax 300amp, 400, 450, 500, 600,
and the venerable 650 amp controller

Material: Aluminum plate approx 3/8" thick (9.5mm)
Size: 10.5" x 10.5" (267mm x 267mm)
Part Number:  Alltrax KIT-HEASTSINK-10x10

** Check with your dealer for pricing and lead times
400 Amp solenoid mounting with Alltrax Controller
200 AMP
Solenoid
Mounting
400 AMP
Solenoid
Mounting
Click on images for
larger close up view
250 Amp Battery Fuse Specifications:
PART NUMBER:  Alltrax# 250AMP-FUSE
Manufacturer:    Busman(TM)  ANN/CNN series
Description:       Fuse, ANN250 Amp
Terminals:         5/16" Slot terminals
Click on images for
larger view
UPDATE: 8-10-2010
Solenoids have been so popular - we have completely sold out!  
> Looking for solenoids?  Check stock at Nivel, Redhawk, EV Drives, or many of our Dealers.
 
                 >
Dealer-Distributor Locator  <
OUT OF
STOCK
8/10/2010
Special Order
Only
ALLTRAX stocked SOLENOIDS since 2008 to help the industry choose properly rated solenoids.  Since 2008,
safety equipment.  Make the right choice, when in doubt, change it out!
IN
STOCK
IN
STOCK
IN
STOCK
ALLTRAX TOOLKIT
The free download software shown on the
SPM web page has a kit that can be
purchased which includes:
> USB 2.0 communications cable (V1.1
compatible)
> Transformer NOT REQUIRED
> CD with ALLTRAX TOOLKIT Software
> Operators Manual, Alltrax Toolkit
SPM Programming - TOOLKIT
Want to know
More? Go-To:
SPM Web Page
Program
AXE
DCX
Program
SPM
IN
STOCK
Sales Inquiries?  See
"
CONTACT US" web page
SITE SEARCH
Updated 7/05/2016
OUT OF
8/10/2010
OUT OF
STOCK
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