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System Components for Electric Vehicles
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Alltrax Motor Controllers:
> EV Systems Components
> EV Systems Components
Various golf car, people movers, and small utility electric
vehicles may or may not have the correct components for
upgraded performance. For instance some Club Car, EZ-Go, Yamaha,
(and others) used smaller OEM style low current solenoids, some did not
use Coil Suppression Diodes, or may not have required Pre-Charge
Resistors.
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.
However, 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.
vehicles may or may not have the correct components for
upgraded performance. For instance some Club Car, EZ-Go, Yamaha,
(and others) used smaller OEM style low current solenoids, some did not
use Coil Suppression Diodes, or may not have required Pre-Charge
Resistors.
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.
However, 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
bus fuse that protects the wiring should a short circuit occur. 2) The
LOGIC 5 to 10amps fuse for control power.
| SOLENOIDS and DISCONNECTS (Contactors) |
SOLENOIDS:
The heavy duty 24, 36, 48, and 72 Volt solenoids offered by Alltrax in 200 to
400amp current ratings:
The heavy duty 24, 36, 48, and 72 Volt solenoids offered by Alltrax in 200 to
400amp current ratings:
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:
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.
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
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
Explore Document Depots: "Application & Cross Reference Guides"
Alternatively, send an email to: info@alltraxinc.com
For more information, please see Document Depot for drawings and
installation guides.
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
both American Thomas
Davenport and Scotsmen
Robert Davidson around
1842.
> 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
both American Thomas
Davenport and Scotsmen
Robert Davidson around
1842.
Did you know?
> The safety systems in
automobiles had a
centuries worth of
development? The
electric car is still in it's
infancy regarding
development.
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!
> The safety systems in
automobiles had a
centuries worth of
development? The
electric car is still in it's
infancy regarding
development.
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!
| Updated: 7/14-2011 |
| 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 |
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)
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)
48 VOLT 200AMP Specifications:
PART Number: SOL-48V-200A
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)
PART Number: SOL-48V-200A
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)
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
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
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
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
Description: Resistor Kit, 470 ohm, 10 Watt,
Terminals: 5/16" ring terminals for SOL-xxV-200A
Leads: BLACK heat shrink
PART NUMBER: KIT-PCR-470
Description: Resistor Kit, 470 ohm, 10 Watt,
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
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:
PART NUMBER: Alltrax# 400AMP-FUSE
Manufacturer: Busman(TM) ANN/CNN series
Description: Fuse, ANN400 Amp
Terminals: 5/16" Slot terminals
PART NUMBER: Alltrax# 400AMP-FUSE
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
controller when towing the car.
For Separately Excited (Re-Gen) cars
require a Tow/Run switch to disables the
controller when towing the car.
FUSE HOLDERS:
Fuses Holders are rated for continuous duty. For fuse holder required,
please contact customer service. The MAIN fuse holder and Logic Fuse
holder have different uses.
> 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
Fuses Holders are rated for continuous duty. For fuse holder required,
please contact customer service. The MAIN fuse holder and Logic Fuse
holder have different uses.
> 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. |
CONTROL (MIDGET) FUSE HOLDER:
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-10A
Protects CONTROL circuits rated 5
to 10amp to protect the logic
wiring, Key Switch circuit, Controller
Logic Power, and main Solenoid
coil drive.
MAIN BATTERY FUSE HOLDER:
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.
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 SOON |
| 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
PN# PB-6
Linear potentiometer
Output: 0-5K
Interlock Switch: YES, Foot switch Activates
KSI
| AVAILABLE SOON |
| 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 |
72 VOLT 400AMP Specifications:
PART Number: SOL-72V-400A
Voltage: 72 volt coil
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)
PART Number: SOL-72V-400A
Voltage: 72 volt coil
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)
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)
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)
| SOL-200-Spec.pdf Rev A 4/29/2009 131Kb File Size |
| SOL-200-Spec.pdf Rev A 4/29/2009 131Kb File Size |
| SOL-200-Spec.pdf 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 |
220 ohm Pre-Charge Resitor Specifications:
PART NUMBER: KIT-PCR-220T
Description: Resistor Kit, 220 ohm, 10 Watt,
Terminals: 3/8" ring terminals
Leads: BLACK heat shrink
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
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
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 |
AUX Relay - 10amp NO / 20Amp NC
A separately derived relay for auxiliary
circuits such as DC-DC Converters, heaters,
stereos, lights, etc.
Runs by KSI switch to turn on and off these
auxiliary loads - separate for the controller
KSI power. It is ALWAYS better to separate
Controller Power and Auxiliary loads.
A separately derived relay for auxiliary
circuits such as DC-DC Converters, heaters,
stereos, lights, etc.
Runs by KSI switch to turn on and off these
auxiliary loads - separate for the controller
KSI power. It is ALWAYS better to separate
Controller Power and Auxiliary loads.
| AUX Diagram Doc100-053 |
| 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
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
discharge. When the Key Switch (KSI) is turned on, a huge amount of current will flow charging
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.
discharge. When the Key Switch (KSI) is turned on, a huge amount of current will flow charging
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.
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.
inrush currents used in DC Battery
applications. Only BUSS (TM) fuses
are used by Alltrax.
10 Amp LOGIC control Fuse Specifications:
PART NUMBER: Alltrax #10AMP-FUSE-LOGIC
MFG PN# BLN-10 or BLF-10
Description: Fuse, 10 Amp
Terminals: MIDGET (Use fuse holder shown
below)
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 Communications Kit
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
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 |
HEAT-SINK ASSEMBLY - RETRO-KIT:
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
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
| 200 AMP Solenoid Mounting |
| 400 AMP Solenoid Mounting |
Click on images for
larger close up view
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
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 Forepar. > Dealer-Distributor Locator < |
| OUT OF STOCK 8/10/2010 |
| OUT OF STOCK 8/10/2010 |
| OUT OF STOCK 8/10/2010 |
| OUT OF STOCK 8/10/2010 |
| LIMITED STOCK 8/10/2010 |
| AVAILABLE |