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Alltrax AC1 - User Manual

Alltrax AC1
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Alltrax Inc
1111 Cheney Creek Road, Grants Pass, OR 97527 Ph: 541-476-3565 Fax: 541-476-3566
Web Site: http://www.alltraxinc.com
Operators Manual
AC1 Controller
DC Conversion
TXT48, PDS, DCS
©ALLTRAX INC 2023 - All Rights Reserved
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Alltrax AC1 Specifications

General IconGeneral
Input Voltage12-48V
Voltage12-48V
TypeAC Motor Controller
Operating Frequency16 kHz
Throttle Type0-5V
Operating Temperature50°C
ProtectionOvercurrent, Overvoltage, Undervoltage, Overtemperature

Summary

General Warnings

Safety Notes

Essential safety precautions for working on electric vehicles and the Alltrax controller.

Usability Statement

Product Use and Warranty Limitations

Defines the intended use of Alltrax AC controllers and warranty limitations.

AC1 Specifications

Technical Data

Details electrical and physical specifications including model, voltage, temperature, and torque.

Terms and Definitions

Glossary of Terms

Explanation of technical terms and acronyms used in the manual.

Unique Features

Low Voltage Protection

Explains the controller's feature to prevent battery damage from low voltage.

Components

Heavy Gauge Wires

Information on the importance and sizing of heavy gauge wires.

Contactors (Solenoids)

Heavy Duty 400 A Requirement

Details the required heavy-duty solenoid rating for AC1 controllers.

Fuse

Fuse Installation and Rating

Explains fuse installation locations and provides a table for controller amperage to fuse rating.

Wiring

Wire Gauge and Routing

Guidance on proper wire sizing, routing, and connections for performance and safety.

High Current Connections

Terminal Functions

Describes the function of high current terminals like B+, B-, R, U, V, W.

Lug Assembly

Details the lug assembly and bolts used for high current terminals.

Low Power Wiring

Signal Wiring Best Practices

Recommendations for routing and protecting signal wires.

Temp Sensor

Information on the two-wire temperature sensor and its connection.

Speed Sensor Information

Quadrature Signal Use

Explains the speed sensor, its quadrature signal, and its requirement for AC applications.

Speed and Temp sensor cable

Harness Routing and Encoder Limits

Guidance on harness routing and details on encoder pulses and max speed constraints.

E-Z-GO DCS Information

Harness Replacement Requirement

Instructs E-Z-GO DCS owners to replace the factory harness for AC1 conversion.

Wire Harness Pinouts

Speed and Temp Sensor Connectors

Details the TE_Superseal 4P (C3) and 2P (C2) connectors for speed and temp sensors.

Controller Side Connector

Describes the JST-JWPF O8 connector (C1) for speed and temp sensor harness.

C1, C2, C3 pinouts for Alltrax harness

Connector Pin Assignments

Provides detailed pinout information for C1, C2, and C3 connectors.

Wire Harness Pinout

16 pin MOLEX connector E-Z-GO TXT48

Illustrates the female side, top-down view of the 16-pin Molex connector for TXT48.

16 Pin Table

TXT48 Connector Pinout Details

Lists pin numbers, names, and descriptions for the 16-pin TXT48 Molex connector.

Wire Harness Pinout

PDS MOLEX connectors

Shows the PDS Molex connectors (Flat 4-pin, Square 4-pin, Rectangle 10-pin).

PDS Pinout Table

PDS Connector Pin Details

Provides pinout information for PDS C1, C3, and C4 connectors.

Controller Dimensions

Top Down View

Diagram showing the top view of the controller with dimensions.

Controller Dimensions

Side View

Diagram illustrating the side view of the controller with dimensions.

Front View

Diagram showing the front view of the controller with dimensions.

E-Z-GO TXT48 Conversion

TXT48 Controller and Pinout Overview

Overview of the AC1 controller for TXT48 conversion with B+, B-, U, V, W connections.

E-Z-GO PDS Conversion

PDS Controller and Pinout Overview

Overview of the AC1 controller for PDS conversion with B+, B-, U, V, W connections.

Programming the Controller

Alltrax Toolkit Software

Information on downloading and using the Alltrax Toolkit software for customization.

Blink Codes

Throttle Type Codes

Lists blink codes corresponding to different throttle types.

Brake Type Codes

Lists blink codes corresponding to different brake types.

Blink Codes

Normal Display Status

Describes normal operating indicators like solid green, red, or yellow lights.

Error Codes

Details error codes indicated by sequences of green and red LED flashes.

Code Definitions

Error Code Explanations

Provides detailed explanations for various error codes, including circuit faults and voltage issues.

Code Definitions

More Error Code Explanations

Continues explanations for error codes like relay coil overcurrent and horn overcurrent.

Warranty Statement

Limited Warranty Terms

Outlines the 2-year warranty, exclusions, and procedures for warranty service.

Disclaimer of Implied Warranties

States limitations on implied warranties and liability for damages.

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