Alltrax AC1 Operator's Manual

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Operators Manual

AC1 Controller

DC Conversion

TXT48, PDS, DCS

Alltrax Inc

1111 Cheney Creek Road, Grants Pass, OR 97527 Ph: 541-476-3565 Fax: 541-476-3566

Web Site: http://www.alltraxinc.com

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Page 1 Operators Manual AC1 Controller DC Conversion TXT48, PDS, DCS Alltrax Inc 1111 Cheney Creek Road, Grants Pass, OR 97527 Ph: 541-476-3565 Fax: 541-476-3566 Web Site: http://www.alltraxinc.com ©ALLTRAX INC 2023 - All Rights Reserved...
Page 2 Contact Alltrax: Phone: 541-476-3565 EXT 3 Fax: 541-476-3566 Email: Tech Support: helpdesk@alltraxinc.com Orders: orders@alltraxinc.com Shipping: shipping@alltraxinc.com General Inquires: info@alltraxinc.com Website: http://www.alltraxinc.com Facebook: http://www.facebook.com/AlltraxInc Twitter: http://www.twitter.com/Alltraxinc EZ-TXT / TXT48 Conversion Install Manual DOC113-033 can be found on our website.
Page 3: Table Of Contents
TABLE OF CONTENTS WARNINGS AC TECHNICAL SPECIFICATIONS TERMS AND DEFINITIONS REQUIRED COMPONENT INFO SOLENOID/CONTACTORS MAIN FUSE WIRING HIGH CURRENT TEMP SENSOR SPEED SENSOR E-Z-GO DCS HARNESS PINOUTS SPEED AND TEMP SENSOR PINOUT TABLE 16 PIN MOLEX TXT48 PINOUT TABLE 1/2 E-Z-GO PDS PINOUT TABLE 1/2 CONTROLLER DIMENSIONS...
Page 4: Warnings
• Never connect a computer while the vehicle is being charged. • Disconnect batteries before installing or working on the Alltrax controller. • Wear safety glasses. • Because hydrogen can build up due to gassing from the batteries, work in a well ventilated area.
Page 5 WILL NOT be covered by warranty. Also, any requests for design assistance or technical support outside the scope of the product intended use may be denied. Alltrax assumes no liability for any damage or injury as a result of use of the motor controllers in a non-traction or process motor application.
Page 6 AC1 SPECIFICATIONS Model 2 Min 5 Min Continuous (Amps) (Amps) (Amps) AC1-48650 Type: 3 phase AC Operating Frequency: Controller Voltage, KSI & Reverse: 48v controllers = 16v - 60v 72v controllers = 16v - 92v Operating Temperature: -20c to 90c...
Page 7: Terms And Definitions
Terms and Definitions IPM: Internal Permanent Magnet SMPM: Surface Mount Permanent Magnet KI: Integral Gain for PI/PID controllers KP: Proportional Gain for PI/PID controllers KD: Derivative Gain for PI/PID controllers Quadrature: Most common type of Speed Sensor Signal used in AC Induction motor applications Sine/Cosine: Commonly used for speed sensors in IPM and SMPM motor applications.
Page 8 Unique Features Unique Features Low Voltage Protection - If battery voltage falls below your set Under Voltage limit the controller will shut off the power supply completely to prevent the batteries from getting drained to the point of damaging themselves. If you plug the controller into the toolkit software you will get a large SHUTDOWN warning to notify you of what happened.
Page 9: Main Fuse
COMPONENTS Heavy Duty Contactors Main Fuse Heavy Gauge Wires http://www.alltraxinc.com...
Page 10 Too small of a solenoid increases the likelihood that the contacts will weld together and not be able open. When installing a new controller, Alltrax recommends the OEM solenoids be replaced with a heavy duty version. See below for suggested sizing of solenoid replacements.
Page 11 Fuse Any application where there is a battery pack, a fuse must be installed. A fuse will open the battery circuit and prevent any serious damage from occurring. The fuse should be installed on or between the battery terminals. The main battery positive OR main battery negative OR in- between 2 batteries is an acceptable location for fuse installation.
Page 12: Wiring
Wiring Wiring and battery health in an electric vehicle are very important and overlooked during performance upgrades. Wiring size is important for safety and proper operation of the vehicle. Undersized wires will affect the performance of controllers and can overheat. Wires should be crimped with proper sized terminals and tools to provide a clean low resistance connection.
Page 13: High Current
High Current Connections TERMINAL FUNCTION Battery positive to Controller Battery negative to Controller Brake Resistor Motor phase U Motor phase V Motor phase W LUG ASSEMBLY The AC controller comes with 5-6 stainless steel 1/4-20 bolts for holding the high current terminals to the controller. http://www.alltraxinc.com...
Page 14: Temp Sensor
Low Power Wiring Signal Wiring Signal wires should be keep as short as practical. Care should be taken to protect the wires from sharp edges and rubbing. Consider the use of split loom or braided wire sheathing. Fasten bundles securely to framework. Do not route the signal wires together in the same bundle with power wires.
Page 15: Speed Sensor
Speed Sensor Information The speed sensor is a small group of wires attached to the side of the motor. Induction motors use a Quadrature signal that gives up to 64 readings per minute. Speed sensors are currently required. Carts that came stock with an AC motor will all be equipped to use the Quadrature sensor.
Page 16 Speed and Temp sensor cable All DC conversion systems will come with a new speed and temp sensor cable to match the new AC motor. We recommend not running this harness parallel to your high current wires. An example would be zip tying them to your large gauge motor wires. Even with shielded wires this can potentialy cause issues with the signal.
Page 17: E-Z-Go Dcs
E-Z-GO DCS INFORMATION ***ATTENTION*** E-Z-GO DCS OWNERS To run the AC1 conversion kit you will need to replace your factory wiring harness with an E-Z-GO TXT48 harness. The DCS harness only has 9 wires and would limit functionality of the AC1 conroller.
Page 18: Harness Pinouts
Wire Harness Pinouts Speed and Temp sensor harness connectors Used on all DC conversions - TE_Superseal 4P connector used for the speed sensor signal of the motor. Water resistant connector. C2 - TE_Superseal 2P connector used for the motor temp sensor harness. Water resistant connector.
Page 19 C1, C2, C3 pinouts for Alltrax harness NAME DESCRIPTION CONNECTOR Not Used Not Used Temp Sensor Lo Temp Sensor Hi CONNECTOR Temp Sensor Lo Temp Sensor Hi CONNECTOR http://www.alltraxinc.com...
Page 20 WIRE HARNESS PINOUT 16 pin MOLEX connector E-Z-G0 TXT48 Female side, top down view of controllers connector. For DC conversions this connector is used on the stock E-Z-GO TXT48 which came as a 48v. The cart side uses the 16 pin MOLEX ‘Mini-fit jr’ male housing (see below image) and the 18- 24awg crimps.
Page 21 16 PIN TABLE NAME DESCRIPTION Throttle High Hi side of throttle, white wire Throttle Wiper Lo side throttle signal, black wire Throttle Low Unused on E-Z-GO applications User 1 Signal voltage for User 1 control Charger Disable Charge interlock/disable Foot Switch Throttle activated microswitch Horn Neg Floating ground for horn...
Page 22 AC1 conversion are showed in the picture above. The missing connector is used for the speed sensor on the stock vehicle. With the Alltrax AC1 conversion you will be using a new speed sensor and temp sensor wire coming directly off the motor (in most cases). AC OPERATORS MANUAL...
Page 23: Pinout Table
PDS PINOUT TABLE NAME DESCRIPTION CONNECTOR FnR Feed Output from controller to FnR switch Reverse Reverse input from FnR switch Forward Forward input from the FnR switch Reedswitch Logic The reedswitch supplies logic power when the charger is disconnected. Logic Battery reference voltage Solenoid Neg Lo side logic for controlling solenoid...
Page 24: Controller Dimensions
CONTROLLER DIMENSIONS TOP DOWN VIEW AC OPERATORS MANUAL...
Page 25: Side View
CONTROLLER DIMENSIONS SIDE VIEW FRONT VIEW http://www.alltraxinc.com...
Page 26 E-Z-GO TXT48 CONVERSION J1 - For an indepth pinout of the harness see pages 20-21 of this manual B+ Positive from Solenoid J1 - B- Battery Negative Main wire harness connector J2 - R Not used for conversions Personality Switch J3 - U U of the Motor AC Motor case ground...
Page 27 E-Z-GO PDS CONVERSION J1 - For an indepth pinout of each connector see pages 22-23. Factory 3 pin speed sensor harness not used in AC conversions. B+ Positive from Solenoid J1 - Main wire harness connector B- Battery Negative J2 - Personality Switch R Large resistor connection J3 -...
Page 28 The USB A to B cable is used to connect your motor controller to your personal computer. Using the free Allrax Toolkit you can customize your performance to match your needs. The Alltrax Toolkit software can be downloaded from: https://alltraxinc.com/ac-toolkit-software/ No purchase necessary...
Page 29 BLINK CODES On power up, the controller will blink out a throttle code and then a Status or Error Code (see below) Throttle Type Codes: 1 Green LED Flash 2-wire 0-5k throttle 2 Green LED Flash 2-wire 5K-0 throttle 3 Green LED Flash 0-5V throttle 4 Green LED Flash EZGO ITS throttle...
Page 30 BLINK CODES Normal Display Status: Solid Green Light Controller Ready to Run Solid Red Light Controller in programming mode Solid Yellow Light Throttle is wide open and the controller is NOT in Current Limit Blinking Yellow Light Throttle is wide open, but the controller is in Current Limit Error Codes: AC alarm codes flash a sequence of green then red. All alarms are self clearing...
Page 31: Code Definitions
Check and/or replace throttle. Change throttle type to correct throttle installed on car. • Bad Variable Set Loaded: Alltrax loaded variable data is missing or corrupted. Contact Alltrax • Throttle/Brake Range: The RXV has a “throttle” built into the brake pedal to communicate with the motor brake.
Page 32 CODE DEFINITIONS Error Code Definitions: • Relay coil overcurrent: Relay coil has shorted, the wires were attached incorrectly or the suppression control diode is backwards. • Brake coil overcurrent: Short in the brake pedals resistor coil. Presently this can only trigger on EZGO RXV applications •...
Page 33: Warranty Statement
Alltrax reserves the right to repair or replace merchandise at its option at no cost to the customer, except for shipping costs of sending the defect item to Alltrax. Replacement shall mean furnishing the customer with a new equivalent product to the defective item.

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Alltrax AC1 Operator's Manual

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