4qd Pro-150 Instruction Manual

Digital motor controller
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Cambridgeshire, CB25 0AH
"We're in Control"
See us via the Internet:
Pro-150 Digital Motor Controller
Keep this manual safe after installation in case a fault develops in your
system and you need to refer to the manual's fault finding information. The
latest version of this manual is always available from 4QD's www site.

1 Introduction

The PRO 150 (PROgrammable 150 amp controller)
is the first of a new range of 4QD motor controllers
to benefit from digital technology.
The PRO 150 is a digital, four-quadrant motor
controller for battery operation of permanent magnet
DC motors. 4 Quadrant means that it controls speed
and direction, drive and braking.
The standard controller is suitable for 24v to 36v
batteries (14v through 42v operation). The 48v
version is suitable for battery voltages between 16V
and 48V.
The controller will not operate from 12v.
The Pro-150 can deliver a motor current of up to
150A for short periods and up to 60A continuously.
Office
30 Reach Road
Burwell
Fax: 01638 744 080
http://www.4QD.co.uk
Instruction Manual
Mark 2
Software version 2.0
Date printed: 8th July 2014
Stores
Unit 6A
Heath Road Industrial Estate
Burwell
Cambridgeshire, CB25 0AP
Email to: esupport@4QD.co.uk
The Pro-150 is digital: it uses computer technology.
This gives two advantages:
1
controllers with the identical programming will
behave identically and reproducibly.
2
The controller is 'intelligent' and, at power-up
checks itself and its environment for faults: if it finds
a fault, it will not operate but will display a fault
code.
If all is correct, it then starts to operate and the
display (if fitted) will read the battery voltage.
When a display is not fitted, a sounder is present
which will give a coded series of pulses to indicate
the fault found. This can be particularly useful in, for
instance, diagnosing a problem over a telephone
The Pro-150 is probably the easiest controller to
program that exists.
"We're in Control"

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Summary of Contents for 4qd Pro-150

  • Page 1: Introduction

    Keep this manual safe after installation in case a fault develops in your system and you need to refer to the manual's fault finding information. The latest version of this manual is always available from 4QD's www site. 1 Introduction The PRO 150 (PROgrammable 150 amp controller) The Pro-150 is digital: it uses computer technology.
  • Page 2: Table Of Contents

    Parking Brake Serial number Operation Specifications More information and wiring Our web site www.4qd.co.uk contains more This includes such details as: information on this and other controllers. Anything radio control that is beyond the scope of these instructions is likely...
  • Page 3: Safety

    In a controller with regenerative braking, mechanical brakes are hardly used. However, it is the battery that The capacitors in the Pro-150 can retain charge for a is doing the actual braking, not the controller. Faults long while after the battery is disconnected so...
  • Page 4: Dimensions And Mounting

    If water does splash onto the controller, it will run down the heatsink and away harmlessly. Otherwise mount with the heatsink at the bottom so water cannot get onto the circuit board. 1.80" (46mm) tag end of circuit board 121mm Page 4 Pro-150 controller instructions...
  • Page 5: Internal Features, Dimensions And Mounting Of Board Version

    0.50" (12.7mm) Brake (B) Connector M4 Tapped Display (D) Connector Battery Positive (B+) Terminal Reverse Motor Positive Aux/Program (A) (M+) Terminal Connector 1234 3.1 (78mm) Serial number 5.53" (140.3mm) View of board from component side Pro-150 controller instructions Page 5...
  • Page 6: Mounting: Display

    During power up, the controller makes system checks and shows progress on the display. Many of these checks are too fast for a human to see! Page 6 Pro-150 controller instructions...
  • Page 7: Wiring

    The diagram shows the simplest wiring for the Pro- 150. Wiring is covered in more detail in section 5.1. 4QD's BCM-524 or 748 can be used, connected between white and green wires. However the voltage Use of a reversing switch is optional: the controller...
  • Page 8: Motor And Battery Connections

    The controller's power contacts are designed for use Motor wires should also be kept as short as possible. with fast-on receptacles. (4QD can supply these pre- Excessively long motor wires waste power and crimped to leads). Each motor contact can accept two reduce performance, but do no damage.
  • Page 9: Control Wiring

    D red: Max speed closed in a vice or with suitable parallel E blue: Wiper +Vb is about 0,6v less than battery F green: 0v (Min speed) action pliers. As you do so, the tines of Pro-150 controller instructions Page 9...
  • Page 10: Input Mode

    Voltage following Single ended is the default mode. The Pro-150 can be used as a voltage follower. A You can easily change to wig-wag either by 10k resistor must be fitted between pins D and F so switching to a different mode (if a suitable one pot fault is not triggered.
  • Page 11: Auxiliary Connector

    A 3rd pin (C) is present: this is internally connected to battery -ve and may be used to wire a 3 position switch as show inset. Release Brake Normal To brake Pro-150 controller instructions Page 11...
  • Page 12: Operation

    You will usually do this after the motor has stopped. 8.1. However, if the ignition switch is turned off while the motor is running, the display flashes and the controller will reduce the motor speed smoothly down to zero before it shut itself down. Page 12 Pro-150 controller instructions...
  • Page 13: Altering The Performance

    The number displayed now is the number of the Neither the controller nor 4QD can be responsible for parameter you wish to alter. You can increase and you instructing it to do something which may not be decrease it with + and - buttons.
  • Page 14: Programmable Parameters

    = + or Inhibit yellow = - or Slow Display green = 0v blue yellow blue yellow green green spare spare spare blue + – spare Programmer yellow green blue yellow green View of board from component side Page 14 Pro-150 controller instructions...
  • Page 15: Altering A Parameter

    Remember you can always reset the controller to the factory default by turning on the ignition with + held If you do want to change the mode, skip step down. go to step Pro-150 controller instructions Page 15...
  • Page 16: Programmable Parameters

    Parameter number) from 00. to 15. and beyond to PG. Press SEL That's it! New mode. Controller ready for action. Use and enjoy! Wasn't it easy! Now you can tell your friends you are computer programmer! Page 16 Pro-150 controller instructions...
  • Page 17 - don't Too low a value will allow the machine to roll back blame the controller (or 4QD!). on a hill start, too high a value and the motor will start with a jerk.
  • Page 18 Adjust the pot (the display will change to show where the pot is) and the direction switch (if you are using one) to the position and state you require as full Page 18 Pro-150 controller instructions...
  • Page 19: Service And Fault Finding

    8 Service and Fault finding The Pro-150 has sophisticated self and environment 8.1 Detected faults testing so will find most faults that are likely. If such a fault if detected, the controller will shuts down the Note: the display is powered from its own internal...
  • Page 20: Fault Numbers And Codes

    (below about 15v). Otherwise there is an internal controller fault. Over-voltage usually occurs during regeneration if the wiring is bad, or the battery is being excessively Check you have not connected the battery + to a overcharged. motor connection. Page 20 Pro-150 controller instructions...
  • Page 21 Overheat! The thermal; sensor has detected over-temperature. This happens if the internal heatsink block temperature rises above about 90°C. Switch off and allow the controller to cool down! Pro-150 controller instructions Page 21...
  • Page 22: Fault Sound Codes

    8.3 Fault sound codes The Pro-150 is fitted with a sounder which HL HPLO (p.12) Continuous tone emits a pattern of sounds to indicate there is Pot fault Continuous tone a fault and where this may be. It is Current limit —...
  • Page 23: Service

    (preferably by email) before returning! Serial number Controllers are serial numbered with a 4 digit number, written on the circuit board near the sounder. The controller in the diagram on page 5 is numbered 1234. Pro-150 controller instructions Page 23...
  • Page 24: Specifications

    Motor Current/Time, Throttle Fault, Heatsink Temperature. Protective Mechanisms Reverse Polarity Protection -60V Max Motor Current Limiting 150A to 60A, time profiled Over Voltage Limiting Under Voltage Limiting Weight Unboxed 320g Boxed 630g Power down Motor state Short circuit Page 24 Pro-150 controller instructions...

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