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4qd pro-150 Instruction Manual

Digital controller
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PRO-150 Digital controller
Section
1. Introduction ...................................... 2
2. Do's and Don'ts................................ 2
3. Safety ................................................ 3
4. Mounting........................................... 4
5. Power Connections ......................... 7
6. Control Connections ....................... 9
7. Inputs .............................................. 11
PRO-150 V1.0 11/18
Instruction Manual
Mark 2, Software Version 2.3
Contents
Page
Page 1
Section
8. Braking ........................................... 13
9. Operation ........................................ 14
10. Programming ................................. 16
11. Fault Finding .................................. 22
12. Fuse tracks ..................................... 26
13. Service ............................................ 27
14. Specifications ................................ 28
www.4qd.co.uk
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  • Page 1: Table Of Contents

    Instruction Manual PRO-150 Digital controller Mark 2, Software Version 2.3 Contents Section Page Section Page 1. Introduction ........2 8. Braking ........... 13 2. Do's and Don’ts........ 2 9. Operation ........14 3. Safety ..........3 10. Programming ......... 16 4.

  • Page 2: Introduction

    (if fitted) will either show the battery voltage if the motor is turning, or Pd if the Pro-150 is idle. When a display is not fitted, a sounder is present which will give a coded series of pulses to indicate any fault found.

  • Page 3: Safety

    Suggestions for wiring etc are given in good faith and will suit most customers, but 4QD Ltd accept no liability for the design of your particular machine. It is up to the machine manufacturer to make sure that the machine is safe under all fault conditions, and meets all relevant regulations.

  • Page 4: Mounting

    Mounting The dimensions of the Pro-150's base plate are shown below. It has two M5 tapped screw holes for mounting: ideally it should be in thermal contact with the machine's chassis which will then act as additional heatsinking. The Pro-150 may be mounted in any orientation. However you should consider whether it is likely to be subject to dust, dirt, oil or water during use and mount it appropriately.
  • Page 5 For best results, heatsink compound should be used between block and heatsink. The Pro-150 should be mounted by means of the two M4 tapped holes in the metal block heatsink, onto the chosen metal (preferably aluminium) plate.
  • Page 6 The Pro-150 will work without the display. The display is used for four purposes: you should consider all of these when deciding where to mount the display: 1. In normal use, to show either the battery voltage, or Pd if the Pro-150 is idle.

  • Page 7: Power Connections

    Colours shown below are recommended. We recommend that you use different colours for battery and motor to minimise the risk of connecting a battery wire to a motor terminal. Warning: Connecting a battery lead to any motor terminal may damage the Pro-150. PRO-150 V1.0 11/18 Page 7 www.4qd.co.uk...
  • Page 8 The actual supply voltage can be between 16V and 55V. This allows room for droops or peaks in battery voltage under hard acceleration or braking. Be aware that the Pro-150 feeds current back to the battery during braking, so if the battery is sensitive to over-charging (such as Li-ion) consider what will happen if regen braking occurs when the battery is fully charged.

  • Page 9: Control Connections

    Simple Wiring Diagram The diagram shows the simplest wiring for the Pro- 150. Use of a reversing switch is optional, the Pro-150 can be programmed to accept a joystick or wig-wag [centre zero] pot. See the programming section or our website knowledgebase.
  • Page 10 There are two control connectors, the positions of these are shown in the internal features diagram (page 5). Most uses will only connect to the main 6 way connector which is accessible without removing the Pro-150's cover. The auxiliary connector allows some less common controls to be fitted.

  • Page 11: Inputs

    Throttle Pot The Pro-150 is optimised for a 10K pot, although any pot from 1K to 15K can be used. The pot can take many forms; a simple rotary pot, a twist grip, a plunger pot, a joystick, or any other resistance based throttle device.
  • Page 12 Voltage following The Pro-150 can be used as a voltage follower. A 10k resistor must be fitted between pins D and F so pot fault is not triggered. The pot wiper must not be open-circuit: if the source impedance is too high this will be registered as a PO fault (input is internally pulled up with 330K to 5v rail).

  • Page 13: Braking

    Such a brake can be connected to the brake connector as shown in diagram below. The brake must not draw more than 1A, or the Pro-150 will shut down. Be careful to check the brake wiring - especially at 48v since a shorted brake coil could damage the Pro-150.

  • Page 14: Operation

    If all is well, the display will show a steady Pd [power down]. The Pro-150 is now ready to work, as the speed is ramped up the display will show the battery voltage. Standby If Pro-150 is not used for 30 seconds it will turn off the display and go into a standby mode. Fault display...
  • Page 15 You can easily alter any of these rates and speeds, see section 10. Dual Ramp reversing If the Pro-150 is operating at full speed and you change direction by using the direction switch the Pro-150 will: 1. decelerate to zero speed, (controlled by the deceleration ramp time) 2.

  • Page 16: Programming

    10. Programming Overview The Pro-150 has 10 separate 'profiles' built in, each one can be tailored to a different application such as a golf buggy or a model locomotive. Each profile has a number of parameters that can be adjusted such as top speed and acceleration.
  • Page 17 PG. 7. Press SEL The relays should click and the Pro-150 is now ready for action. Note: When displaying a parameter number, the decimal point will flash slowly. When displaying a parameter value the decimal point will either not be present or will not flash.
  • Page 18 Factory default profiles and parameters PRO-150 V1.0 11/18 Page 18 www.4qd.co.uk...
  • Page 19 Parameter 10 sets the pot level which is considered high. Zero means the level is the same as the dead-band. 99 is full pot deflection and effectively turns HPLO off. If the pot is above the HPLO level at switch on the Pro-150 will not operate until the pot is turned low.
  • Page 20 Using joystick operation a direction switch is not needed. Note: The Pro-150 is set as standard for a 10K pot but will accept 5K to 15K, however, changing the pot value may affect slightly the speed range. Parameters 12 and 13 allow you to fine tune this.
  • Page 21 Releasing + while Fd is displayed will cause the factory default parameters to be restored. Keeping + held down will show fault 11 (Inhibit activated). Software version Pressing - while turning on the ignition will cause the software version number to be displayed. PRO-150 V1.0 11/18 Page 21 www.4qd.co.uk...

  • Page 22: Fault Finding

    The Pro-150 has sophisticated self and environment testing so will find most faults that are likely. If a fault if detected, the Pro-150 will shut down, will sound a pattern of beeps, and display letters or numbers to indicate the nature of the fault found [see table].
  • Page 23 The display shows this when the ignition is on but the speed pot is at zero. This is not a fault condition. Fault codes with numbers: These are permanent faults that cause the Pro-150 to shut down and show a number on the display. To reset these the ignition must be switched off then on again.
  • Page 24 During regen braking, power is fed back to the battery: it is the batteries that do the braking - not the Pro-150. This fault may occur if the battery voltage rises too high during braking. Usually caused by a dud battery or a bad battery connection.
  • Page 25 Fault sound codes The Pro-150 is fitted with a sounder which emits a pattern of sounds to indicate the fault. It is particularly useful for remote diagnosis by telephone. The list shows the beep pattern corresponding with each possible fault code.

  • Page 26: Fuse Tracks

    F2: in the ignition feed (pin A) and power to the parking brake. It can be blown by a wiring short to chassis (battery -ve). If this track is blown then the Pro-150 will be completely dead. If a fuse track gets blown, a self-resetting fuse (FSR- 090) may be fitted in the holes provided.

  • Page 27: Service

    Details of service charges are on the website. Warranty All our controllers have a warranty against defective manufacturing for 12 months from the date of shipment. The warranty doesn’t cover damage caused by incorrect installation. PRO-150 V1.0 11/18 Page 27 www.4qd.co.uk...

  • Page 28: Specifications

    Acc and decel programmable between 0.1S and 15S Parking brake Y [1A max] Delay and threshold programmable Inhibit function Powerdown state (motor) shorted Heatsink Integral with boxed version Double heading Switching frequency 20 kHz Quadrants PRO-150 V1.0 11/18 Page 28 www.4qd.co.uk...

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