Alltrax AC1 User manual

Alltrax Inc
1111 Cheney Creek Road, Grants Pass, OR 97527 Ph: 541-476-3565 Fax: [phone]
Web Site: http://www.alltraxinc.com
Operators Manual
AC1 Controller
DC Conversion
TXT48, PDS, DCS
©ALLTRAX INC 2023 - All Rights Reserved

Contact Alltrax:
Phone: [phone] EXT 3
Fax: [phone]
Email:
Tech Support: [email protected]
Orders: [email protected]
Shipping: [email protected]
General Inquires: [email protected]
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.

TABLE OF CONTENTS
WARNINGS 5
AC TECHNICAL SPECIFICATIONS 6
TERMS AND DEFINITIONS 7
REQUIRED COMPONENT INFO 9
SOLENOID/CONTACTORS 10
MAIN FUSE 11
WIRING 12
HIGH CURRENT 13
TEMP SENSOR 14
SPEED SENSOR 15
E-Z-GO DCS 17
HARNESS PINOUTS 18
SPEED AND TEMP SENSOR 18
PINOUT TABLE 19
16 PIN MOLEX TXT48 20
PINOUT TABLE 1/2 21
E-Z-GO PDS 22
PINOUT TABLE 1/2 23
CONTROLLER DIMENSIONS 24
TOP DOWN VIEW 24
SIDE VIEW 25
FRONT VIEW 25
LED BLINK CODES 29
THROTTLE AND BRAKE CODES 29
ALARM CODES 30
CODE DEFINITIONS 32
WARRANTY STATEMENT 33

4AC OPERATORS MANUAL
READ AND SAVE THESE
INSTRUCTIONS
Safety Notes:
When working on electric vehicles, sudden unexpected events can
occur, it’s recommended to:
 •Placethedriveaxleonjackstands—wheelsothe  
  oor.
• When working on wiring or batteries, always remove
rings, watches and secure dangling clothing/
hair/jewelry.
• Use the proper safety equipment, eye protection, and
insulated tools.
• 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.
• Make sure the battery pack is fused.
• Do not clean the controller with a high PSI pressure
washer.
•When cleaning batteries, take precautions to keep the
battery acid from splashing on the controller.
CAUTION:
It is the installer’s responsibility to ensure the correct equipment (i.e.
wire, motor, solenoid, fuse etc) is installed in the vehicle. Equipment
should be sized correctly for planned usage. Failure to do so could poses
asignicantriskofexplosion,re,propertydamageandseriousinjuryor
death.
GENERAL WARNINGS
WARNINGS

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WARNINGS
Alltrax Inc’s lines of AC Induction, IPM and SMPM Motor Controllers
are intended for use with brushless motors only. Any application or
usage that does not meet these criteria 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. See the
warranty at the end of this manual.
WARNING: Useofthisproductforotherthanthesespeciedusesmay
be highly dangerous and lead to serious injuries or death.
USABILITY STATEMENT

6AC OPERATORS MANUAL
AC1 SPECIFICATIONS
Model 2 Min
(Amps)
5 Min
(Amps)
Continuous
(Amps)
AC1-48650 650 500 400
Type: 3 phase AC
Operating Frequency:
Controller Voltage, KSI & Reverse: 48v controllers = 16v - 60v
72v controllers = 16v - 92v
Operating Temperature: -20c to 90c
Environmental Operating Temperature: -20c to 50c // 0F to 122F
Standby Current (Power up): 5mA
KSI & Rev Pin Input Current: 200mA max
Relay Drive Current: 4A max
Throttles Supported: 0-5k, 5k-0, E-Z-GO ITS,
5k-0 3 Wire, 0-5v, USB
Throttle, Absolute Mode
Terminal Bolt Torque: 60-80 in.lb (5-7ft.lb, 6.77-9.4nm)
Mounting Bolt Torque: 15-20 in.lb (1.25-1.75 ft.lb,
1.7-2.25nm)

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Terms and Denitions
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.
ITS: Inductive Throttle System, used in DC EZGOs
KSI: Key switch input, refers to signal voltage from the KEY
Roll Detect: Is a feature that uses the speed sensor to determine
whether or not the cart is moving with no active throttle.

8AC OPERATORS MANUAL
Unique FeaturesUnique Features
Low Voltage Protection -
If battery voltage falls below your set Under Voltage
limitthecontrollerwillshuto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. You can bring power back by cycling the TOW/RUN or
plugging your charger back into the cart.
Trigger Limts -
1v for one hour
5v under shutdown triggered in 5 minutes
10v under shutdown triggered in 1 minute

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COMPONENTS
Heavy Duty Contactors Main Fuse
Heavy Gauge Wires

10 AC OPERATORS MANUAL
Contactors (Solenoids)
The solenoid is the primary disconnect of the
battery pack in the case of the an emergency. In
  ordertobeeective,thesolenoidneedstobe
properly rated for the current that will be drawn
from the batteries. It is VERY important that the solenoid be rated
correctly. It is the only way to disconnect the batteries from the
motor/controller loop in case of a failure. 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.
As a regular part of a preventative maintenance plan, solenoids
should be replaced every 3-5 years.
Heavy Duty 400A
(800-1000A inrush)
A heavy duty solenoid is
required when using any of
the AC1 controllers. You
need a minimum of 400A
continuous and 800A inrush
rating.
Recommended Models
MZJ400 (Shown)
SW200 (Albright)
SOL600

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Fuse
Controller Amperage Fuse Style / Rating
650A ANN / 400A
750A
FUSE
NUT
LOCK WASHER
FLAT WASHER
BOLT
WIRE LUG
Diagram: Fuse terminal hardware
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.
The fuse must be rated for pack voltage and fault current.

12 AC OPERATORS MANUAL
Wiring
Controller Min. Wire AWG
Standard Duty
Min. Wire AWG
Heavy Duty
650A 2 AWG 1/0 AWG
Power Wiring
When running wiring for the vehicle care must be taken for proper
wire routing. Power wiring should be of proper sizing and ran as
low in the framework of the vehicle as practical. Lengths of power
wire runs need to be kept short and pairs of wires from common
circuits should be grouped together to reduce EMC emissions.
Secure all power wiring to the vehicle framework.
Motor Phase Wiring
The three phase wires should be kept close to the same length
and kept together as they run from the motor to the controller. For
optimum reliability don’t lay wire across other connections on
the controller. Low current wires should not be run alongside the
motor wiring or any high current wiring.
***Never swap motor phase wiring unless key is o and
vehicle is not moving***
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aecttheperformanceofcontrollersandcan
overheat. Wires should be crimped with proper sized terminals and
tools to provide a clean low resistance connection.

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High Current Connections
TERMINAL FUNCTION
B+ Battery positive to Controller
B- Battery negative to Controller
RBrake Resistor
UMotor phase U
VMotor phase V
WMotor 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.

14 AC OPERATORS MANUAL
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.
Temp Sensor
Induction motors come with a two wire temp sensor which
the controller uses to monitor internal temps during operation.
On DC conversions the temp sensor will run through the same
harness connector as your speed sensor.

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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. For AC Conversion applications a harness
adapter will be used to get the correct signal to the controller
without replacing the existing harness.
In the future a sensorless option will be available but
currently speed sensors are required for all ACT induction
applications.

16 AC OPERATORS MANUAL
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. Each connector can only be plugged into one location on
the cart/controller but there is a full break down of each connector
on the following page. TXT version is 48” long.
Encoder Pulses/Revolution Constraint (Quadrature Encoder)
The maximum encoder frequency the controller will accept is 10 kHz. To
determine how fast this constraint will allow the motor to spin, use the
equation:
Max Speed Encoder Limit = 600000 / Encoder Size
(e.g., a motor with 128-pulse encoder can run up to 4587 rpm).
Firmware Max Speed Constraint
The maximum motor speed the controller will allow is 10,000 rpm.
Max Sped RPM Limit = 10,000

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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.

18 AC OPERATORS MANUAL
Wire Harness Pinouts
Speed and Temp sensor harness connectors
Used on all DC conversions
C3 - 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.
C1 - JST-JWPF O8 connector used
for the controller side connection of
the Speed and Temp sensor harness.
Water resistant connector.

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C1, C2, C3 pinouts for Alltrax harness
PIN NAME DESCRIPTION
** C1 CONNECTOR
1
2
3
4
5
6Not Used Not Used
7Temp Sensor Lo
8Temp Sensor Hi
** C2 CONNECTOR
1Temp Sensor Lo
2Temp Sensor Hi
** C3 CONNECTOR
1
2
3
4

20 AC OPERATORS MANUAL
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-tjr’malehousing(seebelowimage)andthe18-
24awg crimps.