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Pro-100: 12V – 48V, 100A, programmable.

£216.00 inc VAT

Our new Pro-100 has been designed specifically with industrial applications in mind. It’s a little brother to the Pro-160, just as clever but not quite as strong. About as strong as the DNO-10 but much smarter.

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Please scroll down for full controller specification

Motor noise suppression

We strongly recommend fitting motor noise suppression components to each motor in your system to protect the controller. See this quick explanation of what EMC is and why it matters. We have interference suppression packs  and a page of advice on how to fit them, and other steps to take to reduce RFI.

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Description

Our new Pro-100 has been designed specifically with industrial applications in mind. It’s a little brother to the Pro-160, just as clever but not quite as strong.

Its headline features are:

  • 120A peak current rating.
  • 12V – 48V operation without adjustment.
  • Full H-bridge design – does away with relays for long term reliability.
  • Same full feature set as the Pro-160 and 360, easy adjustment of many features, including:
    • Acceleration and deceleration ramps.
    • Maximum speed.
    • Current limiting for drive and regeneration [plays nicely with lithium battery BMSs].
    • Over / under voltage protection [with “limp home mode”].
  • Controller and motor temperature protection.
  • Radio control.
  • 15 profiles for storing different configurations.
  • Top speed limiting [requires external sensor].
  • Suitable for motors up to around 1kW.
  • Safety contactor driver.
  • Parking brake driver.
  • Limit switch operation.
  • Push button mode.
  • Emergency stop.

One big difference is that the Pro-100 does not come with a display or keypad mounted on the case. The ports are still there, but all the data and software adjustments now require a separate [low cost] programmer unit. This is ideal for those applications where an on-board display is not needed, and end-users are not permitted to make adjustments to the settings. If programming is required there is the low cost display adaptor board [intended for one-offs], a robust display programmer where multiple units will be programmed, or the remote display box if an external display / keypad is required.

The Pro-100 is ideal for use in industrial applications up to 100A max. It is highly configurable, but provides the basic control functions right out of the box. In terms of our existing products, it is only slightly larger than the DNO-10 but with a greater current and voltage rating, and with the comprehensive feature set and protections of the Pro-160 / 360.

Simple to fit

The Pro-100 has all the essential control inputs on one 6-way connector. Here’s a video showing how this is arranged.

Safety

The microprocessor monitors the controller and parts of the external system. Should a fault be detected, the processor will shut down the controller and sound an indication of the fault. If a safety contactor is incorporated, the power stage can be disconnected to protect against run away failures.

Linear actuator software

We have now developed software that allows the Pro-100 to respond to a feedback voltage from a position sensor, the aim being to create a really powerful servo mechanism, see video on this page. Contact us for details.

Adobe_PDF_file_icon_32x32   Read manual

Specification

Model PRO-100
Nominal voltage range 12 – 48
Minimum / maximum voltage 10.5 – 65
Motor current A [max] 120
Motor current A [1 minute] 100
Motor current A [continuous] Depends on cooling
Programmable parameters  See full list in manual
Dimensions [mm] 191 x 85 x 55
Weight [g] 476g
Power connections M5 studs
Input 5k – 25k pot, RC [PWM], 0 – 4.7V
Reverse polarity protection N
Over voltage protection Y [65V]
Pot fault protection Y
Thermal protection Warn @ 75’C [also for 2 external sensors]. Cut-off @ 85’C
Joystick/Wig-wag input Y
Radio Control Y
Parking brake Y [1A max] Delay and threshold programmable
Inhibit function Emergency stop input, ramp adjustable.
Other inputs Deadman, alt profile, speed, 2 x thermistor, 2 x limit switch, 2 x spare
Idle state Mosfet short across motor
Powerdown state (motor) Diode bridge across motor
RPM Limiting Y via optional speed sensor
Safety contactor circuit Y
Heatsink Aluminium plate
Double heading Y
Switching frequency 20 kHz
Quadrants 4

Pictures

Pro-100 motor controller

Support

The manual provides full instructions on setting up and operating the controller. The manual is available in PDF  format:

Adobe_PDF_file_icon_32x32   Read manual

The manual is designed to be printed double-sided in A4 booklet format. To print the booklet from the PDF on a double-sided printer, select Booklet in the Page Size & Handling section of the print window, and set Orientation to Portrait.

Software versions

A full list of the software versions is maintained on this page.

Speed sensor

The speed sensor input looks for a 5V pulse proportional to the RPM of the motor. Our SEN-SPD kit uses a hall effect sensor and a magnet to provide this. Once the kit has been installed set the “Speed sensor active” setting to yes, there are then two ways to set an upper speed limit.

a] Calculate the actual RPM you want based on gearing and wheel size, and enter this into the “Max RPM” setting.

b] Set the “learn” function to on, operate the vehicle [or machine] at the required maximum speed, note the RPM displayed, then enter this value into the “Max RPM” setting. Note; while “learn” is on, the display will show RPM, when “learn” is off the display reverts to normal but will display “speed limit” whenever the upper speed limit is hit.

Troubleshooting

  1. As well as the fuse tracks F1 and F2, there is this small, zero ohm resistor [R112] that can blow if the control wiring is short circuited. It can be repaired by bridging with a small wire link.
  2. To use only radio control of the Pro-100 it is still necessary to connect the ignition switch terminals of the main control input.
  3. The Pro-100 has sophisticated on board diagnostics and will display a fault code whenever it is not happy with something. A list of all the fault codes is here.

Accessories

Programmer box

If you will be programming multiple controllers or need a more robust floating display, then our rugged display / programmer is the most suitable unit.

Rugged display and programmer box for the Pro series

Display adaptor board

The display adaptor board allows a display to be mounted together with an optional remote keypad to make adjustments easy without having to dive under the bonnet. Ideal if you only need to program a few controllers. The adaptor board is supplied with a 1m LCD display lead, and a 1m keypad lead. It is possible to have longer leads, but we recommend using screened cable for any display leads greater than 2m.

Temperature sensor.

These temperature sensors are specially selected and calibrated to work with our Pro-100 / 160 / 360 controllers. One or two of these sensors can be plugged directly into the thermistor port on the control board, and the software set to show the temperatures on the display. The controller can also provide warnings at user selectable temperatures.

Temperature sensor

[Needs software at version 2.3 or above]

Speed sensor

This speed sensor works with our Pro-100 / 160 / 360 controllers. It can be plugged into the speed port on the control board, and the software can then be set to show and limit the RPM on the display. The sensor detects a North magnetic field which can be from the 1cm disc magnet included, or any other suitable magnet capable of giving a field of 7mT. Supplied with a 1.5m screened lead and 5 way IDC connector.

speed sensor

You may also need some or all of the following: