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-   -   Alltrax SR controller install (https://www.buggiesgonewild.com/showthread.php?t=117069)

scottyb 04-14-2016 09:47 AM

Alltrax SR controller install
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I will walk you through install and upgrade of a 99 Ezgo TXT. Stock ranch cart with a cargo box and SW182 shift kit installed 2 years ago.

I choose SR48500, so we could upgrade the motor later. Cart has 2.5 yr old Crown CR225 batteries. I may add one for more speed and torque at 42v.
Here is the users manual. This is as much printed material as you will find on this new control.

scottyb 04-14-2016 09:48 AM

Re: Alltrax SR controller install
2 Attachment(s)
And here is what we started with.

scottyb 04-14-2016 10:09 AM

Re: Alltrax SR controller install
5 Attachment(s)
First thing i notice is the molex plug with the control wires needs to get cut off and spade terminals put on each of the 4 wires. Note there are 2 short wires here in the harness. The black and red ones, strip the harness jacket back and you will find these 2 wires are only 4-5 inches long. This may work for the smaller solenoid but the 400 super duty solenoid requires more reach. Make new ones about 8-10 inches with 1/4 spade on one end and #10 stud ring terminal on the other.

How is a good time to refresh all the ring terminals on Battery plus and minus. the charger connection is 17 yrs old. Not to mention the stock cable set needs replacing. I was kind of surprised how bad they looked when I pulled them out. Looks like some damage was done to one cable. That's a breakdown waiting to happen.

scottyb 04-14-2016 10:14 AM

Re: Alltrax SR controller install
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I was pleased to see the control bolt in with 4 fasteners onto the OEM heat sink. The SR control has an integrated heat sink and fan so it can be mounted any where there is a supply of fresh air without heat problems.
It's a nice fit with lots of room to work, I like that. I was disappointed I have to source my own 4 bolts to mount it. I used 1.5 inch 1/4-20 bolts. Careful tightening these up, the controller base is plastic. Good & Snug is my suggestion. I got all 4 bolts started for alignment, then snugged the top 2 and removed the bottom 2 for the solenoid bracket.

scottyb 04-14-2016 10:19 AM

Re: Alltrax SR controller install
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The OEM solenoid bracket will work for the SR400 and 200 solenoid.
For the SR500 and 400 solenoid I'm using the Alltrax solenoid bracket designed specifically for the 400 solenoid and taller profile SR500. The fan adds a little height.

For controller set up I plugged it into the laptop with usb1 to usb2 cable below. Update software version 2.1.8 is needed if you have the original version, available at Alltraxinc.com
My control came set for 0-5k throttle, this is the default setting. My cart is Ezgo ITS. I had to go into tools and enable throttle selections. Once that was done throttle selection was simple from a drop down menu.

I will be programming each control before they ship.
I can set throttle selection for you is you let me know what you need.

Volt_Ampere 04-14-2016 10:24 AM

Re: Alltrax SR controller install
What is the difference with this new control? I thought they were adding Lithium support.

scottyb 04-14-2016 10:33 AM

Re: Alltrax SR controller install

Originally Posted by Volt_Ampere (Post 1263708)
What is the difference with this new control? I thought they were adding Lithium support.

They are working on Lithium support. Both the XCT and SR have a battery management option in the program for lithium but I'm not sure it is active just yet. One big new thing is the personality selection, soon this control will have an external control for mode selection. Great for street to hill operation or adult to kiddie operation.
Additionally the soon to follow SRX will offer regen braking in series motors and AX drive compatibility. I won't hold my breath for this release. We have been given no dates.

scottyb 04-14-2016 01:30 PM

Re: Alltrax SR controller install
5 Attachment(s)
Since we are upgrading the original 275 amp control with a 500a control (570 amp peak output)
It's a good time to upgrade the SW182 to the larger SW202 for 500 amp and up controls.
First on the bench we tighten up the hard to reach bolts on the sides and mount the SW202 to the Carts Unlimited custom mount bracket shown. And install the suppression diodes, making sure the red end is on the terminal marked with the + sign.
Then we mount the whole unit in the cart using the new bolts supplied with the SW202 kit in the 2 holes originally used for the F&R switch.
For more information and kit pricing go here > http://www.cartsunlimited.net/reversing-contactors.html

scottyb 04-14-2016 01:33 PM

Re: Alltrax SR controller install
Now we need to make some cables 8)

Revolution 04-14-2016 01:46 PM

Re: Alltrax SR controller install
I am aware of series re-gen braking but what is AX drive?

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