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Page 10

Pro-120 controller instructions

11 Adjustments

Do not 

use excessive force when adjusting the

presets: these are quite small and are easily damaged.

11.01

Gain

This is marked ‘Gain’ on the diagram ‘Features’. Set
this so that, at maximum required pot range, the
controller just reaches full speed: this is easiest to do
with the motor unloaded. Set the speed pot to your
required maximum point (e.g. full up) then, listening
to the motor, adjust the preset. It it usually quite easy
to tell when the motor stops accelerating. Too low a
setting and the motor will not reach full speed (this
can be useful to restrict top speed). 
Too high a setting and there will be a ‘flat’ spot at
maximum speed where the control has no effect.
This will also confuse the special ‘power down’
circuitry so you will get a bumpy ride if you switch
off at speed.

Maximum setting of the gain preset will give full
output for about 3v input. The sensitivity can be
increased by fitting a resistor: contact the factory for
details.

11.02

Full speed

Where user adjustment of the top speed is required
the ’gain control’ is not satisfactory. In this case the
arrangement below can be used.

Both pots should be the same value (10K). The
resistor shown in the green lead to the top speed
adjust pot is optional: if left out (open-circuit) the top
speed will adjust between 50% and 100%

resistor
none 50% - 100%
10K   33% - 100%
4K7   25% - 100%
3K3   20% - 100%
2K2   15% - 100%
1K2   10% - 100%
linked: 0% - 100%

Alternatively, you can simply fit a resistor in the top
of the pot (red wire) but the value of this resistor plus
the pot should not exceed 20K.

11.03

Ramps

The Pro series controllers incorporate very
sophisticated ramps to control the acceleration and
deceleration rates. These are user adjustable and, to
get best performance from your machine, you should
adjust them!

Acceleration ramp

This is shown as ‘Accel’ on the ‘Features’ diagram.
It is present to make the vehicle accelerate smoothly
when the speed pot is increased suddenly so as to
avoid sudden surges and shocks to the mechanics. As
supplied it is at half setting so that the motor takes
about 3 seconds to accelerate.Adjust it as you require
to give smooth acceleration. Clockwise increases the
time (reduces the acceleration) anticlockwise
decreases the time (increases the acceleration) If the
time is set too short (anticlockwise) the vehicle’s
acceleration will be limited by the current limit
which does no harm (except that repeated accel/decel
will cause over heating) but it means that
acceleration is not being controlled properly, so will
vary depending on the gradient.

Deceleration ramp

This is shown as ‘Decel’ on the Features diagram: it
is present to make the vehicle decelerate smoothly
when the speed pot is reduced suddenly. As supplied
it is at half setting (about 3 seconds). Adjust it as you
require to give smooth deceleration. You will usually
find you require a lower setting (more anticlockwise)
for Decel than for Accel. If the Decel time is set too
low (anticlockwise) then the relays will drop out and

short out the motor before regenerative braking has
finished. This may give a jerk before the vehicle
stops completely and may also shorten the life of the
relays.

11.04

RAT and MST

Two other presets exist: we advise against altering
these. 
Normal setting is centre scale. 
Another sensible setting is with both fully
clockwise.

RAT. As the throttle is moved from zero, at a low
setting one or other direction relay engages
(depending on the selected direction). This is the
RAT (Relay Acceptance Threshold). At the same

Blue

Green

Top speed adjust

Speed control pot

Red

Summary of Contents for Mark 2 Series

Page 1: ...available either for 24v operation or for 12v operation Models can also be supplied for 36v and 48v The voltage is marked on the relays Make sure this are correct as 24v relays will not operate from 12v and 12v relays will soon burn out if used on 24v The standard model is suitable for permanent magnet or shunt wound motors Applications 4QD s Pro range of 4 quadrant controllers are well suited to ...

Page 2: ...n and electromagnetic brake driver Many of these features can be disabled if so required The simplest configuration is shown in section 7 However because of the features and versatility of our controllers we give a lot of extra information in this manual which may make it seem to be more complicated than it is so we ve marked the more technical sections so you may ignore them Please don t be put o...

Page 3: ...braking may have difficulty in operating as it has to overcharge the battery A similar problem exists if the battery is disconnected or the wiring faulty There are several options as to how the controller should react under such fault conditions so if in doubt ask In any case all passenger carrying vehicles should be fitted with mechanical brakes it is unwise to rely on the battery as an emergency...

Page 4: ... Reverse Gain Accel MST RAT Decel Expansion connector HPLO Thermal sensor Trickle resistor UVP Brake drive transistor Battery Controls Parking brake Motor Motor Battery A B C D F E A B C RB1 RB2 Reverse Forward 3 Features The Pro 120 has double 9 5mm motor tabs for one or two motors and single 9 5mm battery tabs Also fitted on the battery terminals is a set of 6 3mm blades to connect a charger or ...

Page 5: ...ter won t cause damage unless the unit is connected to the battery when electrolytic corrosion will occur See also section 15 Supply voltage 12v or 24v or 36v or 48v different models Supply current 30mA at zero speed plus power relay current Motor speed forward 0 to 100 full speed adjustable in reverse 0 to 50 full Or as forward speed On board option Output current typical Current limit 125 amps m...

Page 6: ...ttery connectors the controller feeds current back the battery during braking and if a battery connector falls off when braking this regenerated current can pump up the voltage on the dud battery connection Although the controller is protected against damage this is not advised since control is lost The same will happen if a fuse or circuit breaker opens during braking Wire size Use heavy duty wir...

Page 7: ...ickly disconnect the motor in an emergency Also with the motor disconnected freewheeling becomes possible It is also possible to get a battery isolator switch these are normally fitted to lorries buses and boats to isolate the battery in an emergency but this is not required as the Pro 120 has a power relay which effectively disconnects the battery except for a small bleed resistor 8 04 Battery co...

Page 8: ...internal capacitor charging through a bleed resistor before the ignition switch is closed Beware of opening the switch when the motor is running the motor will brake to a halt more or less quickly depending on the deceleration ramp setting With the ignition off or even with the battery disconnected the relays short out the motor so free wheeling is not possible To freewheel properly the motor shou...

Page 9: ...Connections diagram page 7 For variable cutback you could fit a variable resistor Or you could use a switch to enable disable the feature The level at which it works is controlled by the value of the external resistor The controller cannot know the difference between a flat battery and losses caused by very high battery current in wiring that is too thin so in some applications it may have undesir...

Page 10: ... deceleration rates These are user adjustable and to get best performance from your machine you should adjust them Acceleration ramp This is shown as Accel on the Features diagram It is present to make the vehicle accelerate smoothly when the speed pot is increased suddenly so as to avoid sudden surges and shocks to the mechanics As supplied it is at half setting so that the motor takes about 3 se...

Page 11: ...link disconnected they will be independent The two motors will perform identically but with independent current limits If two motors are used off one single 200 amp controller then the full 200 amps current is available to drive either motor in stall conditions With the Pro 120 each motor may only draw up to 120 amps limited by its own controller The system therefore offers more protection to the ...

Page 12: ... extra holes in the base swarf could get into the controller and this will invalidate any warranty 13 Heat Heatsinking The long time current the controller can give is limited by the build up of heat in the heatsink The controller will give over 110 amps for one minute this is limited by the heatsink and by heating in the printed wiring relays and other components For periods of more than a minute...

Page 13: ...Page 13 Pro 120 controller instructions 113 9 181 166 121 118 0 0 3 15 47 8 73 2 A A B B B B 50 60 5 C 126 C ...

Page 14: ...ession capacitor a ceramic type of 10n value is ideal If the motor does not include this you are advised to fit one across the brushes as close as possible to the motor body The controller will work without this capacitor but fitting it can lengthen the life of the system A word of warning many car type motors have the chassis connected to one terminal Take great care with these as you could easil...

Page 15: ...damage to the controller is there is an external wiring fault There are three special sections of track which should blow if a major fault occurs in the controls or the brake connected to the 6 pin and 3 pin input connectors They are situated beneath the input connectors on the back of the board They are thin waists in the track and are is as shown arrowed in the diagram above If one fuses solder ...

Page 16: ... the drive MOSFETs cause their drive resistors to burn up a sure sign the MOSFET has failed Relay drop out A flat battery or wiring which is too thin can cause excessive voltage drop If the supply voltage gets to low then on the 24v controllers the battery discharge protection operates and reduces controller performance On the 12v controllers discharge protection is not fitted as standard so the i...

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