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“We're in Control”

“We're in Control”

Office

30 Reach Road

Burwell

Cambridgeshire,  CB25 0AH

Fax: 01638 744 080

Stores

Unit 6A
Heath Road Industrial Estate
Burwell
Cambridgeshire, CB25 0AP

Instruction Manual

Pro-120 series controllers

Mark 2 series

Foreword

4QD try to write a manual which is readable. Please
read the manual through before starting installation.

To help you, we have marked the more technical
sections ¶ so that you may ignore them.

This manual covers installation and wiring of 4QD's
Pro series controller in the usual applications. There
are finer points of installation which are outside the
scope of such a printed manual and you should refer
to our www site for more information.

Models

The Pro-120 is 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 general purpose speed control 
applications where reversing is required. They 
are used extensively by hobbyists and industry. 

Amongst other applications our controllers have
been successfully used in the following:

Camera dollies

Caravan shifters

Carnival floats

Conveyors

Factory stores vehicles

Floor cleaning machines

Golf buggies

Invalid scooters

Kiddie cars

Miniature railways, 3”, 5” and 7¼ gauge

Mobile targets

Mountain rescue vehicles

Remote controlled vehicles (Robots)

Ride on golf buggies

Winches

In fact wherever battery motor speed control is
required

Date  printed:   30th April 2014

Содержание Mark 2 Series

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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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