Using the Pro-100 / 160 in a Greenpower car

The Pro-100 / 160 have some features that are becoming increasingly popular in Greenpower cars; this article will look at each of these and give some outlines as to how they can be used.

1. Remote display.
   1. The Pro-100 / 160 can both have a remote display mounted where the driver can see it. This allows for various information to be made available such as voltage, temperature, speed, remaining battery capacity, and warning messages. There are several options available.
2. Data logging.
   • This feature allows all the operating data to be recorded on a uSD card. Anything that appears on the display will be recorded, e.g. voltage, current, temperature, speed, error messages etc. This data can be examined post race to evaluate the performance of the car and make adjustments as required. There is a data logging supplement that describes the operation of data logging in more detail.
   • Getting the uSD in and out of the Pro-100 is quite fiddly – an extension cable can be used, we’ve found that this type works quite well.
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3. Coulomb* counting.
   • The Pro-100 / 160 have accurate current measurement, so it is possible to integrate the current used over time to calculate how many coulombs have been used. This gives the basis for a very accurate “fuel gauge” that can be displayed to the driver, or logged for later analysis. There is a section in the data logging supplement that covers the set-up and use of coulomb counting [* 1 coulomb = 1 amp for 1 second].
4. RPM measurement and limiting.
   • For optimal performance of a Greenpower car it is important to keep the motor as close as possible to its maximum efficiency RPM. The Pro-100 / 160 have an input for an optional rpm sensor which allows for the accurate measurement of the motor RPM. The RPM can be displayed on an external display as is, or converted to a speed reading in MPH or KPH.
   • The limiting feature allows the team to set a maximum RPM to assist with keeping the motor to the required speed.
5. Current limiting.
   • This feature allows a precise limit on the motor current to be set. This can be used to prevent excess currents being drawn during starts, uphill sections, or over-enthusiastic driving. Note that motor current can be very different from the battery current, we have this article that explains the difference.
6. Regenerative braking current limiting.
   • Limiting the regen current affects the way that the car will respond to the throttle being closed. Reducing the regen current limit can reduce the braking force that the motor applies when the throttle is closed. The regen current limit can be set in the forward / reverse settings sections of the menu. Alternatively it is possible to have it adjustable on the go by using the “variable regen” feature [described in the manual]. The correct setting is really down to team / driver preference. The particular demands of the circuit may also be a factor – if there is a lot of heavy braking required, then having higher regen currents will help with energy recovery.
7.  Motor and controller temperature measurement.
   • The Pro-100 / 160 have an onboard temperature sensor, and inputs for two external temperature sensors. This data can be logged and also shown on an external display. The external temperatures have adjustable alert levels.
   • Motor temperature; It is important to make sure that the motor temperature is not allowed to get too high as the magnets can be permanently weakened, and the torque reduced by overheating. The safe values depend on the type of magnets being used in the motor and can be as low as 80 – 120’C. If anyone can find out what type is used in the Greenpower motor please let us know. Also, cooler motors are more efficient.
   • The controllers have a safe upper temperature limit of 75’C. Above this they will start to reduce the motor current in order to keep the temperature below 80’C. If values above 75’C are regularly seen on a Greenpower car it is likely an indication that the motor gearing is incorrect and that the motor is not reaching its correct operating RPM. We have this page that discusses heat dissipation in more detail.
8. Battery voltage alerts.
   • The Pro-100 / 160 have adjustable low voltage alert and cut-off settings. The first can be used to alert the driver that they are getting to the end of the battery capacity, the second can be used to protect the batteries from damage due to over-discharge.
   • Version 2.5.5 software now includes IR compensation, this adjusts the points at which the alert and cut-off settings are applied depending on the current being drawn. There is an IR compensation supplement that describes this in more detail.
9. Multiple profiles.
   • The Pro-100 / 160 both have 15 separate “profiles”, 14 of which can be edited. A profile stores all the individual settings that can be configured in the menu. This makes it possible to store different settings that may be required for different tracks.
   • There is also an “Alternative profile” input, this makes it easy to switch between any two profiles by operating a simple switch. This can be used to set different settings for different sections of the race, or to switch between fast and slow modes.