Menu

EV Systems Components

Vehicles may or may not have the correct components! Golf carts and other electric vehicles come with parts rated for stock applications.

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.

Add to Cart

$15.00 – $31.00Select options

This section describes the components offered by Alltrax for your configuration.

 

  • 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 – These are two varieties: 1) The MAIN 200-600amp battery
  • LOGIC 5 to 10amps fuse for control power.

“Lessons Learned” in using the correct Solenoid (Contactor), Fuse, Coil Suppression Diode, Battery Fuse, and Pre-Charge Resistor:

DOWNLOAD TECHNICAL NOTE

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.

1AMP Coil Suppression Diode Specification

  • 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

Use with 200 AMP / 24, 36, 48 Volt Solenoids

3AMP Coil Suppression Diode Specification

  • PART NUMBER: KIT-CSD-3
  • Description: Diode Kit, 1Amp, 400 Volt,
  • Terminals: #10 ring terminals
  • Leads: RED heat shrink on POSITIVE
  • BLACK heat shrink on NEGATIVE

Use with 400 AMP / 24, 36, 48 Volt Solenoids

3AMP Coil Suppression Diode Specifications 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

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.

PRE-CHARGE RESISTORS

The motor controller has large internal filter capacitors.  When the vehicle is off, and there is no pre-charge resistor present, the capacitors will discharge and as soon as the solenoid is engaged there will be an inrush of current.  This inrush can cause arcing and damage the solenoid contacts and stress the controller.

Adding a pre-charge Resistor keeps the capacitors “topped-off” with a charge.  When the solenoid closes there is 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. This excludes the XCT and NCT models as the pre-charging is done through the tow-run circuit.

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: Some resistors are round enamel or square ceramic. Both resistors provide the same function.

220 ohm Pre-Charge Resistor
24-36 Volt

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-220T

  • Description: Resistor Kit, 200 ohm, 10 Watt,
  • Terminals: 3/8” ring terminals
  • Leads: BLACK heat shrink

470 ohm Pre-Charge Resistor
48 Volt

PART NUMBER: KIT-PCR-470

  • Terminals: 5/16” ring terminals for SOL-xxV-200A
  • 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

1000 ohm Pre-Charge Resistor
60-72 Volt

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-1KT

  • Description: Resistor Kit, 1,000 ohm, 10 Watt,
  • Terminals: 3/8” ring terminals
  • Leads: BLACK heat shrink