4qd Mark 2 Series Instruction Manual Download

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Page 4

Pro-120 controller instructions

30-3B-2-04

CB5 0AH U K

4 Q D

www.4qd.co.uk

1 2 3 4 5 6 7 8 9

100K

10K

3K3

3M3

100K

9V1

1µ0

100n

4µ7

1µ0

4µ7

1µ0

10n

N N

P P

1µ0

1K5

1K0

3V9

10K

33K

4K7

330K

33K

330K

3K3

180K

10K

9V1

10K

47K

10K

100K

22K

100K

10K

1N400?

4K7

100K

10K

330K

100K

33K

6R8

3K3

33K

47K

4µ7

10R

10R 10R

HPLO

DRR

RB1

10K

330K

10n

10K

1µ0

47K

10R

C9B

C9A

C10

C11

C11b

C12

C13

C14

C15

C16

C17

47µ

1µ0

C19

C21C22

C20

C23

C24

10p

22K

100K

180K

RB2

120K

47v

1K0

100n

10K

180K

100n

1M0

100p

330p

100R

100K

10K

47K

18R

10K

Z‡

33K ‡

10K

1K5

100K

1K0

1µ0

1K0

6V2

4K7

10K

BDP

100K

22K

10K

470R

18R

10K

8V2

10K

330p

1K0

Full speed

Half speed

Dual Ramp

Reverse

Gain

Accel

MST

RAT

Decel

Expansion connector

HPLO

Thermal sensor Trickle resistor

UVP

Brake drive transistor

Controls

Parking brake

Motor −

Motor +

Battery −

B
C
D

B
C

RB1

RB2

Reverse

Forward

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 for similar purpose.

These are illustrated below.

Also available is an expansion connector option as

shown above, see section 12.
There are several on board options which can be
altered by removable jumpers:

Feature

Section Page

High Pot Lockout

9.04

UVP (Battery Discharge Protection) 9.05

Reverse speed

9.07

Dual ramp/Preselect reversing

9.08

Regenerative Braking

There are also several user adjustments:
Gain

11.01

Acceleration

11.03

Deceleration

11.03

RAT

11.04

MST

11.04

For shipping, the mating parts of the 'Controls' and 'Parking brake' connectors are inserted into the sockets
on the board. See page 7.

Single 9.5mm

Double 9.5mm

Cover (optional)

Heatsink (optional)

Relays

Battery & Motor connections

Pot & direction switch via IDC

Splashplate (with cover)

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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4qd Mark 2 Series, Instruction Manual

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