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Unread 06-09-2017, 06:46 AM   #11
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Default Re: Diode and Resistor Size

If I'm not mistaken Dave @ Revolution has also stated that the controller has a resistor internally.
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Unread 06-09-2017, 06:50 AM   #12
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Default Re: Diode and Resistor Size

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Originally Posted by movin-on View Post
The service manual for my 2005 IQ states that if the diode fails clip it off the solenoid and replacement is not needed because a diode that serves the same purpose is located within the controller...
That was my gut feeling, but hey I've been wrong plenty of times.
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Unread 06-09-2017, 07:43 AM   #13
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Default Re: Diode and Resistor Size

David would know....
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Unread 06-09-2017, 10:15 AM   #14
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Default Re: Diode and Resistor Size

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Originally Posted by movin-on View Post
The service manual for my 2005 IQ states that if the diode fails clip it off the solenoid and replacement is not needed because a diode that serves the same purpose is located within the controller...
I'm not Dave but I did stay at a holiday inn express once. Alltrax has incorporated the pre-charge resistor and the suppression diode in the XCT control. This was not the case in the first generation and we do not have a manufacture date when last year this practice began so for safety purposes I am saying any XCT manufactured in 2017 does not need (should not have) the external resistor and diode installed on the solenoid.

This excludes the SR controls for series carts which still does need the external resistor and diode installed.

And Yes, Cruiser. You need both of these items in your system. The resistor to prevent excessive controller strain and wear and the diode to protect the whole cart from voltage spikes. These things are so important that the SR control will not start up if it detects no precharge resistor resulting in the LED flash code 1 green and 6 red
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Unread 06-09-2017, 10:42 AM   #15
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Default Re: Diode and Resistor Size

There is definitely no generic answer to the question about resistor and diode being needed.

As Scottyb stated, unless the manufacturer explicitly states either one of those devices is not needed externally, they should be included.

It is also important to understand that even if the controller has an internal diode on the Solenoid activation circuit, it is only effectively as long as the Controller is on the "cold" side of the activation.

If someone does a custom wiring instead of using the wiring diagram provided, it is possible to render the Controller diode ineffective at protecting the switching circuit.
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Unread 06-09-2017, 10:45 AM   #16
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Default Re: Diode and Resistor Size

Thanks to you both for taking the time and effort to explain it.
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Unread 06-09-2017, 10:56 AM   #17
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Default Re: Diode and Resistor Size

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Originally Posted by Sergio View Post
There is definitely no generic answer to the question about resistor and diode being needed.

As Scottyb stated, unless the manufacturer explicitly states either one of those devices is not needed externally, they should be included.

It is also important to understand that even if the controller has an internal diode on the Solenoid activation circuit, it is only effectively as long as the Controller is on the "cold" side of the activation.

If someone does a custom wiring instead of using the wiring diagram provided, it is possible to render the Controller diode ineffective at protecting the switching circuit.

True true. There as so many ways to skin this cat ~ The (-) side of the activation circuit can be connected to B- (a constant source)or control J1 blk. If connected to J1 blk the program option for relay off at zero throttle exists.
This is the recommended solenoid control. In all SR diagrams the (+) side of the solenoid activation comes from the key switch (battery source) through a foot pedal switch to the solenoid
Sepex is a little more complicated

Notice the title of the now aged Alltrax document I posted is "lessons learned" about solenoid size, pre charge resistors, and voltage spike suppression
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Unread 06-10-2017, 11:32 AM   #18
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Default Re: Diode and Resistor Size

That's some good information. Makes me feel even better about installing your 400A solenoid and reversing contactor.

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Originally Posted by scottyb View Post
I could not consolidate or rephrase this information any better - short read = see the Alltrax document

http://www.alltraxinc.com/files/Doc1...ns-Learned.pdf
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Unread 06-10-2017, 12:31 PM   #19
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Default Re: Diode and Resistor Size

Guys this is all great info I'm sure, but I really don't see how it has anything to do with my post.
I was simply asking if the resistor and diode I cited can be used on HD solenoids.
If somebody could tell me yes or no, that they will or will not work ,I would appreciate it.
Thanks,Muddog
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Unread 06-10-2017, 12:46 PM   #20
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Default Re: Diode and Resistor Size

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Originally Posted by movin-on View Post
The service manual for my 2005 IQ states that if the diode fails clip it off the solenoid and replacement is not needed because a diode that serves the same purpose is located within the controller...
As long as they are good for your 48 volt cart, Yes, you can use them. But all the rest of the knowledge you read explained it too and a lot more. CTD's picture also showed it.

Pre-Charge resistor needs to be 470 ohnm 10W
Diode needs to be 3 amps (Usually they are 1 amp on 200's and 3 amp on 400's)
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