........................................................ 3

2.

REQUIRED ACCESSORIES ..................................................................................................................... 4

2.1

B
ATTERY
C
ONTACTOR
(S
OLENOID OR
R
ELAY
)....................................................................................... 4

2.2

M
AIN
F
USE
(P
ROVIDED WITH
C
ONTROLLER
).......................................................................................... 4

2.3

S
AFETY
D
ISCONNECT
............................................................................................................................ 5

2.4

D
RIVE
M
OTORS
.................................................................................................................................... 5

3.

CONTROLLER INSTALLATION ............................................................................................................ 5

3.1

C
ONTACTOR
C
OIL
D
IODE
: ..................................................................................................................... 5

3.2

P
RE
-
CHARGE
R
ESISTOR
:........................................................................................................................ 5

4.

LED STATUS INDICATOR....................................................................................................................... 6

5.

SOFTWARE USE AND CALIBRATION.................................................................................................. 7

6.

PROGRAMMING THE CONTROLLER: ................................................................................................ 8

6.1

C
ONTROL
P
ANEL
T
AB
........................................................................................................................... 9

6.1.1

SWITCHES: .................................................................................................................................... 9

6.1.2

SETTINGS: ................................................................................................................................... 10

6.2

T
HROTTLE
R
ESPONSE
T
AB
.................................................................................................................. 11

6.2.1

Throttle Sensor Type...................................................................................................................... 11

6.3

M
ONITOR
T
AB
.................................................................................................................................... 12

6.3.1

Monitor Section:............................................................................................................................ 12

6.3.2

Interval Section: ............................................................................................................................ 12

6.3.3

Gauges Section:............................................................................................................................. 13

7.

LIMITED WARRANTY........................................................................................................................... 14



Keep this manual
AllTrax Inc.
Doc100-003-A_OP-AXE-Operators-Manual
Page: 3 of 14

1. AXE Motor Control Product Overview

Thank You for purchasing the Alltrax motor controller. We design and manufacture products for
a variety of electric vehicles and markets. This motor controller employs modern power
MOSFETs to provide extremely low on resistance, in both the main switch function and
freewheel diode.

Synchronous freewheel rectification permits extended high power operation
over similar sized controllers due to increased efficiency. A microprocessor
based control system monitors numerous functions, and a windows interface
allows the user to change numerous operating parameters and perform status
monitoring.


































Replaces Curtis
1204 (6.5 long)
Replaces Curtis
1205 (8.5 long) AllTrax Inc.
Doc100-003-A_OP-AXE-Operators-Manual
Page: 4 of 14

2. Required Accessories

These components are not supplied with the controller, except the main fuse. For your safety
and that of others, some basic precautionary measures must be employed when designing,
working on, and driving electric vehicles.



Use a contactor in the battery circuit, rated for the amperage and voltage of the system.
Use a fuse rated for the voltage and available fault current of the battery, such as the one
provided.
Safety interlocks must be employed to prevent enabling the controller while the vehicle is
unoccupied or charging.

Controllers have failure modes which can result in runaway (stuck throttle) conditions. This
controller has been designed to prevent and preclude as many of those from ever occurring as
possible. Please follow the Recommended Controller Wiring System document in this manual.
Failure to do so could result in damage to the controller, and serious injury or death to vehicle
occupants or bystanders
2.1

Battery Contactor (Solenoid or Relay)
The main battery contactor needs to be rated correctly in terms of amps and volts, in order to
safely carry the intended continuous battery current, and to interrupt the pack DC voltage. Its
coil voltage should also be rated for the pack voltage.







2.2

Main Fuse (Provided with Controller)
The main fuse needs to be sized to protect the wiring in
the drive system.
Fuse DC voltage rating must be greater than the peak
battery voltage.
Fuse current rating equal to or less than amperage
rating of controller.

Most high current fuses have very long tolerance (2 minutes or more) up to 50 - 100% overloads.
Thus a 300A fuse likely wont open in a 500A vehicle application. Most Golf OEM vehicles
may not have a fuse and must be added with these performance controller upgrades. When carts
are equipped with large controllers, the wire gauge must be made larger. This in turn permits
higher fault currents, due to the reduced wiring resistance. Under these conditions, we strongly
recommend the addition of a fuse to prevent catastrophic battery failure or fire in the event of an
electrical system failure. AllTrax Inc.
Doc100-003-A_OP-AXE-Operators-Manual
Page: 5 of 14

2.3

Safety Disconnect
The safety disconnect provides a way to disconnect the battery pack from the controller and
contactor. It may be a circuit breaker, a mechanical switch, or a large removable connector.
Make sure it is rated for the current capacity and DC Voltage of your system. Some
installations disconnect both the positive and negative leg of the battery pack. Most Golf type
vehicles do not have a battery disconnect.

2.4

Drive Motors
The motor controller is designed to operate with series wound brush commutated and permanent
magnet motors rated for operation from 12-72 VDC. Operation with compound motors is
possible. Contact Alltrax, Inc. for information on using compound motors.

3. Controller Installation
Choose a location outside the drivers compartment to mount the controller. Any mounting
position is acceptable. It is recommended that you protect the controller from direct contact with
water, as the electrical connections can corrode. In high moisture environments, seal the
electrical connections with silicone or grease.

Mount the controller as close to the motor as is reasonably possible. Ideally, your motor leads
should be less than 4 feet long. Making a twisted pair out of the motor leads will reduce RF
emissions.
Most car employ small (6AWG) battery interconnect wiring.
For 400A controllers, a minimum of 4AWG wire should be used in light weight carts.
2AWG to 1/0 is appropriate for higher amperage controllers and heavier vehicles.

High current wiring to the motor controller should use 5/16 mounting hole ring terminals of
tinned copper. Bolt them to the controller using 5/16 hardware.

3.1 Contactor Coil Diode:
CAUTION: A Diode (1A, 100V) MUST BE USED across the solenoid/contactor coil (and any
other relays that may be installed to control lights or accessories). The Cathode or banded end
faces the positive terminal. These diodes are required to prevent the speed sensor from
producing erroneous signals.


3.2 Pre-charge Resistor:
The controller has a fair amount of DC filter capacitance. When the contactor closes to apply
power to the controller, the capacitors can arc the contactor. The pre-charge resistor wil apply a
low current to the capacitors to prevent any arcing and keep the capacitors at bus voltages. It
also acts as a discharge snubber that helps dissipate the arc when the contactor disengages. (see
schematics for proper value).
AllTrax Inc.
Doc100-003-A_OP-AXE-Operators-Manual
Page: 6 of 14

4. LED Status Indicator
The AXE controller has a bicolor front panel LED. This LED displays a variety of
information each time the controller is powered up, by series of blinks. Count the
number of green blinks to identify the type of throttle the controller is configured for.
After the blink code indicating throttle type, the LED will stay green if there are no errors.













LED Blink Codes:

At power up the number of green blinks indic