System Components for Electric Vehicles
Alltrax Motor Controllers:
> EV Systems Components
Various golf car, people movers, and small utility electric vehicles may or
may not have the correct components for good system operation. 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)
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SOLENOIDS:
The heavy duty 36, 48 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. Turning off the Solenoid causes the magnetic field to collapse and
create electrical spike in the hundreds of volts. The diode "suppresses" this spike and
protects the controller and any 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.
MAIN BATTERY FUSE:
Fuses are rated for continuous duty. For fuse ratings, please contact
customer service. (CNN fuses are equivalent to ANN)
For more information, please 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
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!
Technical Note #010:
"Lessons Learned" in
using the correct
Contactor, Fuse, Coil
Diode, Fuse, and
Pre-Charge Resistor
MUST SEE THIS!
File Size: 429KB
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36 VOLT 200AMP Specifications:
PART Number: SOL-36V-200A
Voltage: 36 volt coil
Current: 200amps continuous
400amps surge (2 seconds)
Contacts: Silver oxide
Terminals: 5/16" main lug, #10 coil
Mounting: 2-up to 1/4"
48 VOLT 200AMP Specifications:
PART Number: SOL-48V-200A
Voltage: 48 volt coil
Current: 200amps continuous
400amps surge (2 seconds)
Contacts: Silver oxide
Terminals: 5/16" main lug, #10 coil
Mounting: 2-up to 1/4"
48 VOLT 400AMP Specifications:
PART Number: SOL-48V-400A
Voltage: 48 volt coil
Current: 400amps continuous
600amps surge (2 seconds)
Contacts: Silver oxide
Terminals: 3/8" main lug, #10 coil
Mounting: 2-up to 1/4"
PRE-CHARGE RESISTORS:
All Resistors are Wire Wound +/-10% tol
24 Volt: 220 ohm, 5-10 Watt
36 volt: 220 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.
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1AMP Coil Suppression Diode
Specifications:
PART NUMBER: KIT-CSR-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-CSR-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.
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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
Description: Resistor Kit, 470 ohm, 10 Watt,
Terminals: 5/16" ring terminals for SOL-xxV-200A
3/8 ring terminals for SOL-48V-400A
Leads: BLACK heat shrink
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
Drawing: PDF
download
Available
SOON
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250 Amp Battery Fuse Specifications:
PART NUMBER: ANN-250
Description: Fuse, 200 Amp
Terminals: 5/16" Slot terminals
400 Amp Battery Fuse Specifications:
PART NUMBER: ANN-400
Description: Fuse, 400 Amp
Terminals: 5/16" Slot terminals
Use with:
200 to 400 Amp
controllers
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Use with:
450 to 650 Amp
controllers
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TOW RUN SWITCH - RETRO-KIT:
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.
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.
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CONTROL FUSE HOLDER:
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 FUSE HOLDER:
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.
Drawing: PDF
download
Available
SOON
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Drawing: PDF
download
Available
SOON
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THROTTLE PB-6 (Pot Box):
PN# PB-6
Linear potentiometer
Output: 0-5K
Interlock Switch: YES, Foot switch Activates KSI
Use with:
200 Amp
SOLENOIDS
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Use with:
200-400 Amp
SOLENOIDS
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SOL-200Amp with
KIT-CSD-1A and
Pre-Charge Resistor
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SOL-400AMP with
KIT-CSD-3A and
Pre-Charge Resistor
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SOL-200Amp with
KIT-CSD-1A and
Pre-Charge Resistor
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@2008 Alltrax Inc
