Alltrax SR48300 User manual

ALLTRAX
www.alltraxinc.com
Alltrax Inc
1111 Cheney Creek Road, Grants Pass, OR 97527 Ph: 541-476-3565 Fax: [phone]
Web Site: http://www.alltraxinc.com Twitter: @AlltraxInc
Operators Manual
SR
©ALLTRAX INC 2016 - All Rights Reserved

Contact Alltrax:
Phone: [phone]
Fax: [phone]
Email:
Tech Support: [email protected]
Orders: [email protected]
Shipping: [email protected]
General Inquires: [email protected]
Website:
http://www.alltraxinc.com
Facebook:
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Twitter:
http://www.twitter.com/Alltraxinc

TABLE OF CONTENTS
WARNINGS 4
SR LAYOUT 6
SR SPECIFICATIONS 7
INSTALLATION 8
INSTALLATION DRAWINGS 14
PRE-1994 EZGO 15
1994 AND NEWER EZGO 16
1994 AND NEWER CLUB CAR 17
YAMAHA - G8, G9, G14, G16 18
GENERIC, SERIES WITH REVERSE 19
GENERIC, SERIES W/O REVERSE 20
CONTROLLER DIMENSIONS 21
FAN COVER (OPTIONAL) 22
USER (PERSONALITY) TAB 23
PROGRAMMING THE CONTROLLER 24
BLINK CODES 25
WARRANTY STATEMENT 27

4SR OPERATORS MANUAL
Safety Notes:
When working on electric vehicles, sudden unexpected events can
occur, it’s recommended to:
• Place the drive axle on jack stands—wheels off the
  oor.
• When working on wiring or batteries, always remove
rings and watches.
• 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 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.
Note:
It is the installer’s responsibility to ensure the correct equipment
(ie. wire, motor, solenoid, fuse etc) is installed in the car.
READ AND SAVE THESE
INSTRUCTIONS
WARNINGS

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Alltrax Inc’s lines of Series and Shunt Motor Controllers are
intended for use with 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.
WARNING:Useofthisproductforotherthanthesespecieduses
may be highly dangerous and lead to serious injuries or death.
WARNING: The use of this product for the production of
Plasma Assisted Hydrogen, Brown’s Gas, HHO (H20 Hydrogen
Electrolysis) or any other type of gas is prohibited. Generation
and storage of these gasses is extremely dangerous and poses a
signicantriskofexplosion,re,propertydamageandserious
injury or death.
USABILITY STATEMENT

6SR OPERATORS MANUAL
SR LAYOUT
M-
USB
Port
STATUS
LED
B-
B+
SOL -
(Blk)
REVERSE
(Blue) THROT 1
USER
(Green)
KSI
(Red) THROT 2

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SR SPECIFICATIONS
Note1:The larger number represents the value when the “Peak Amp Mode” is enabled in the Alltrax Toolkit
program.
All ratings are at 25°C with nominal rated voltages at 50% PWM. Actual currents are
±5% listed rating
Model Peak (Amps) 2 Min
(Amps)
5 Min
(Amps)
Continuous
(Amps)
SR48300 300/3501300 (1.5min) 230 125
SR48400 400/4601400 300 140
SR48500 500/5751500 350 175
SR48600 600/6901600 425 210
SR72300 300/3501300 275 130
SR72400 400/4601400 (1.5min) 300 150
SR72500 500/5751500 400 210
Type: Series Motor Controller
Operating Frequency: 18kHz
Controller Voltage, KSI & Reverse:
SR48XXX 12-48V nom, 62V max
SR72XXX 12-72V nom, 90V max
Controller Operating Temp: -20°C to 75°C, shutdown @ 85°C
Environmental Operating Temp: -20°C to 50°C
Stand by Power (Power up): <1W nom, <8W Fan on
Stand by Current: <20mA
Relay Drive Current: 5A peak, 1A Cont.
KSI Peak In Rush: 60V = 9A, 30V = 4A, 9.5V = 2A
Throttles Supported: 0-5k, 5k-0, E-Z-GO ITS, Club Cart 5k-0 3
Wire (MCOR), 0-5v, Taylor Dunn 6v-10.5v,
USB Throttle, Absolute Mode
Terminal Torque: Torque to 60-80 in.lb (5-7 ft/lb, 6.77-9.4Nm)
Mounting Bolt Torque: Torque bolts to 15-20 in.lb (1.25-
1.75 ft.lb, 1.7-2.25nm)

8SR OPERATORS MANUAL
The resistor typically seen across the contactors big terminals
pre-chargestheltercapacitorsinthecontroller.Thisminimizes
arcing across the
contactor terminals
when closing.
INSTALLATION
Battery Voltage Resistor
12-36V 220-250 Ohm 10W
48V 470 Ohm 10W
72V 1000 Ohm 10W
Diode
Resistor
Resistor & Diode
Mounting
Contactor Size Diode Diode Current
70A-200A Solenoid 1N4004 1A
400A-550A Solenoid 1N5408 3A
600A or larger Solenoid MR754 6A
The diode across the coil terminals safely dissipates the energy
when the coil is turned off. Installation Dependant, refer to
applicable drawing.

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Controller Amperage F/R Size
400A or less Stock/HD
450A to 650A Heavy Duty/Change-Over
Contactor
650A or more Change-Over Contactor
The forward/reverse switch is an often overlooked part of the
upgrade process. In a series motor, all of the motor current will
pass through the F/R switch. An undersized F/R Switch is as bad as
an undersized solenoid or small wire gauge.
For higher amperage controllers (>600A), it is suggested that a
change-over contactor set up be used. These are large enough to
handle the higher currents without over heating the contacts and
theyprovidetheusertheabilitytochangedirectionbyippinga
switch.
F/R Switch
Change-over contactors are multiple contactors bound together
that allow the user to change the polarity of the voltage going to
the motor thus reversing direction. It works exactly the same as the
manual F/R switch, except that it uses coil drive contactors. See the
installation drawings for how to wire up a change-over contactor.

10 SR OPERATORS MANUAL
Flat lands with moderate speed and torque performance
expectations.
Contactors (Solenoids)
Stock 100 AMP
Use with 300A controllers.
Stock 70 AMP
Used with older ClubCars
vehicles
DO NOT Use with
Alltrax Controller
The solenoid is the primary disconnect of the
battery pack in the case of the an emergency. In
order to be effective, 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.
UNACCEPTABLE
STANDARD DUTY

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High performance, high speed, maximum torque, pulling loads,
hilly terrain or Hunting Buggies.
Performance 200 AMP
(600amp Inrush) Use with 300
and 400 AMP Controllers
Heavy Duty 200 AMP
(800A surge) Use with 300 to
500 AMP Controllers
Heavy Duty 400 AMP
(1000A surge) Use with 500 and
600 AMP Controllers
Suggested types:
SW200
MZJ400 (Shown)
HEAVY DUTY
EXTREME DUTY
Extreme Duty 600A+ AMP
(1000A + surge) Use with 600
AMP or bigger Controllers.

12 SR OPERATORS MANUAL
Fuse
Controller Amperage Fuse Rating
400A or less 250A
450A to 650A 400A
650A or more 600A
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 B+, B- or in-between 2 batteries is an acceptable
location. The fuse must be rated for pack voltage and fault current.

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Wiring
Controller Min. Wire AWG
Standard Duty
Min. Wire AWG
Heavy Duty
300A OEM -6 AWG 4 AWG
400A 4 AWG 4 AWG
500A 2 AWG 1/0 AWG
600A 1/0 AWG 2/0 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.
Signal Wiring
Signal wires should be keep as short as practical. Care should
be taken to protect the wires 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. All safety interlocks
(KSI, Footswitch, etc) need to be mechanical switches or
electromechanical relay.
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.

14 SR OPERATORS MANUAL
INSTALLATION
DRAWINGS
See our Website more drawings:
Full Sized & Updated
Other OEM Drawings
More Generic Wire Diagrams
Non Standard Throttle Wiring

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PRE-1994 EZGO

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1994 AND NEWER EZGO

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1994 AND NEWER CLUB CAR

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YAMAHA - G8, G9, G14, G16

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TAYLOR DUNN GENERIC WIRING

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GENERIC, SERIES WITH REVERSE