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Old 01-22-2019, 12:59 PM   #1
KRAZYMATT
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Default Adding Alltrax SR48500 To 2000 DS 36V Series Cart

Well i picked up an electric cart, its a 2000 ds 36v series v-glide cart with the resistor bank, no controller or on-board computer. it needs the batteries replaced so i will be converting to 48v. I already have most the components to install alltrax 500 amp controller as well. Its been awhile since ive looked at the things i have for it so i will list the items and if there is anything im missing maybe you guys could lead me in the right direction. I plan on leaving the stock 36v motor to get a little extra speed with the 48v pack. Also have some wiring questions regarding the controller and also addition of an on-board charger.

Here is what i have so far:

Alltrax 500 AMP SR controller - SR-48500
Heavy duty 48v 400a solenoid - MJZ-400A
Diode # IN5408 3A
Also have the larger diode
Diode # MR574
Resistor 48v 470ohm 10watt
Bussman ANN-400 Fuse
Approx 40' #2 AWG high voltage wire -tinned and about 3/8 thick insulation.
Have assorted 5/16" lugs and hydraulic crimper for making the battery cables.

Have not purchased the f-n-r switch yet.
On the fence on weather to use the heavy duty one or go for the reversing contactor setup.

Need to know weather 18AWG wire will be sufficiant for all the control wiring throughout the cart (going to completly rewire it) or does it need to be 16awg? I can get 18 in many different colors is why i am asking.

I have picked up an assortment of suggested resistors to modify the v-glide assembly for throttle control. Cant remember if this makes it a 2 or 3 wire setup? I know the controller will work with either. May eventually convert to mcor setup.

Couple questions regarding the micro switch wiring for the alltrax controller, the print shows what I'm guessing is 4 different micro switches. The "foot switch" is obviously the one in the vglide assembly. Is the "half speed reverse" switch coming from the f-n-r switch micro switch? Also what is the "anti-arcing" switch? Guessing it is the other one on the f-n-r switch that drops the power to the contactor when switching from forward to reverse? Then "ms4" reverse switch which controls the buzzer and I will be removing.

There is no on-board computer in this cart. The wiring diagram for the alltrax shows a couple wires going to the on-board computer. Are these Necessary or can those be left out or reconfigured to work without the computer? Going to delete the reverse buzzer. It shows a yellow wire coming from the main solenoid going to the obc. Also wire going from the battery warning light to the obc, don't care for that indicator light either.

Also on the topic of the on-board computer, think I am going to go for on-board charger. Can these be hooked up/used without the computer? Looking at the Lester summit ii on-board charger. Where does the 3rd wire connect to?
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Old 01-22-2019, 01:29 PM   #2
Sergio
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

You don't need any of the wires from the OBC.

The yellow wire from the solenoid small post that used to go to the OBC should now go to the Controller "BLK - SOL-".

What are you going to do for a throttle?
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Old 01-22-2019, 01:31 PM   #3
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

Quote:
Originally Posted by Sergio View Post
What are you going to do for a throttle?
He's going to convert the Vglide into a multi-step potentiometer.
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Old 01-22-2019, 01:38 PM   #4
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

wow, I need new glasses as I never saw that sentence

Definitely wire the Vglide for a 3-wire as it will provide more steps than a 2-wire rheostat setup
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Old 01-22-2019, 03:09 PM   #5
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

Quote:
Originally Posted by scottyb View Post
He's going to convert the Vglide into a multi-step potentiometer.
thats the plan for now. will do the 3 wire setup as suggested by sergio, i think the resistors i got are from a post with the listed values from sergio awhile back...

Quote:
Originally Posted by Sergio View Post
All resistors start counting from the post #3 (Post #1 is wiper connection and #2 is open)

3 wire Multi-Step Resistor Values:
910Ω
750Ω
910Ω
1000Ω
1000Ω
1000Ω
from this post http://www.buggiesgonewild.com/elect...ml#post1187456
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Old 01-22-2019, 03:14 PM   #6
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

So, I can remove that bundle of wires from the current v-glide to the resistor bank, the old coil resistors, wires to the motor and the wires on the F-N-R switch?
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Old 01-22-2019, 03:15 PM   #7
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

Any input on the F-N-R switch? Heavy Duty switch or the reversing contactor style? The alltrax manual says either are sufficient with the 500 amp controller...
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Old 01-22-2019, 03:20 PM   #8
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

Quote:
Originally Posted by KRAZYMATT View Post
So, I can remove that bundle of wires from the current v-glide to the resistor bank, the old coil resistors, wires to the motor and the wires on the F-N-R switch?
Yep, that all goes away.

Quote:
Originally Posted by KRAZYMATT View Post
Any input on the F-N-R switch? Heavy Duty switch or the reversing contactor style? The alltrax manual says either are sufficient with the 500 amp controller...
I like the Reversing contactor setup ScottyB sells, and you don't need to deal with micro-switches since the reverse reduced speed from the Alltrax can be wired directly to the reverse side of the contactor.
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Old 01-22-2019, 04:01 PM   #9
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

Use the 400a SW202 reversing contactor kit with the SR500 control. Use 2 more 3a 1000v diodes on the coils. And yeah, reverse activation is real easy
The rotary HD F&R version is cheaper but it has no provision for reduced reverse activation unless it's fitted with an additional reverse micro switch.
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Old 01-22-2019, 04:33 PM   #10
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Default Re: Adding Alltrax SR48500 To 2000 DS 36V Series Cart

Quote:
Originally Posted by KRAZYMATT View Post
-snip-

Here is what i have so far:

Bussman ANN-400 Fuse - You may want a fuse holder to mount this in...
Approx 40' #2 AWG high voltage wire -tinned and about 3/8 thick insulation.
Have assorted 5/16" lugs and hydraulic crimper for making the battery cables. You will need a couple of 3/8" lugs for your solenoid

Also on the topic of the on-board computer, think I am going to go for on-board charger. Can these be hooked up/used without the computer? Looking at the Lester summit ii on-board charger. Yes they can and that is an excellent charger....
A couple of comments.
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