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Unread 07-27-2015, 10:03 AM   #1
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Default Solenoid resistor question two/too

Reading some advice from Scottyb, I noticed that the 1999 Power drive plus car doesn't have a resistor on the main solenoid. in stock form there is a coil in the power supply to the controller on the dynamic braking solenoid

My cart has the dynamic braking solenoid bypassed, now it is from A2 on cotroller to A2 on motor
My question is do I need a resistor on my solenoid?

taken from Solenoid resister question? thread

and a 470Ω resistor to save the controller from taking a hit each time you press the pedal and the solenoid contacts from arching each time you let off the gas

Solenoid resister question?


also no diodes either,
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Unread 07-27-2015, 10:31 AM   #2
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Default Re: Solenoid resistor question two/too

Looks like you have Regen 1 system....
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Unread 07-27-2015, 10:58 AM   #3
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Default Re: Solenoid resistor question two/too

No - that's Regen 2; I think, Scotty according to the diagrams. Regen 1 has a frame mount for the DB solenoid coil and cables lead-to it, whereas Regen 2, the coil just "hangs-in-the-breeze" off the solenoid (just like in the picture). Also, the controller for Regen 1 has a different type Z-Plug than the one shown.
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Unread 07-27-2015, 11:10 AM   #4
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Default Re: Solenoid resistor question two/too

The main purpose of the pre-charge resistor is to keep the capacitors inside the Controller charged so there is less stress in both the capacitors and the main solenoid contacts when they close.

Not every controller does it that way, the Regen2 Controller capacitors are kept charged by the voltage on Controller pin #1 (red wire).

The fly-back diodes are mandatory in my opinion, and in fact they are present on the early 2001 models of the Regen2 (without DB solenoid).

I know some controllers like the Curtis 1268, when wired using both the positive and negative controller pins for solenoid activation, don't require an external diode since one is present between those 2 pins inside the controller.
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Unread 07-27-2015, 11:19 AM   #5
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Default Re: Solenoid resistor question two/too

Sergio - that leads to a related question. One day no doubt, I'll have to rewire my Regen 1 cart to IQ using a (yet to be developed) harness/kit from Revolution (plus add my own IQ compatible controller). So the rewire kit from Tahoe SHOULD contain a resistor for the main solenoid to be "a complete kit"....yes?
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Unread 07-27-2015, 11:56 AM   #6
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Default Re: Solenoid resistor question two/too

Not necessarily, if You use an Alltrax XCT controller, they don't use a pre-charge resistor.

The current capacity of the fly-back diode will also depend on the strength of the Solenoid coil, some of the HD solenoids will require a 6amp diode (3amps usually for 200 amps or less solenoids).
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Unread 07-27-2015, 12:09 PM   #7
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Default Re: Solenoid resistor question two/too

What also keeps the solenoid from taking a "hit" is the solenoid drop out delay once you remove your foot from the throttle. Curtis literature says it can be as much as 30 sec. The Alltrax is about 3 sec.before the solenoid drops out. This gives enough time for the current to be at or near zero.
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Unread 07-27-2015, 12:36 PM   #8
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Default Re: Solenoid resistor question two/too

Thanks guys (will need this info one day) - good to be aware.
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Unread 07-27-2015, 05:04 PM   #9
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Default Re: Solenoid resistor question two/too

Think i'll add a fly back diode, has tow/run switch, motor is 3.2 HP 101854501 , has the multi step potentiometer , GE controller IC3645SH4D222C2, speed sensor works for braking and roll away, works pretty well for a stock cart, great information on this site,
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