Pro-160: 12V – 84V, 200A, programmable.

£240.00£265.00

The Pro-160 is the new kid on our block. A full H-bridge controller without relays it can operate from 12V – 84V and up to 200A. It has a built in radio control input, a detachable LCD display, and a high degree of configurability.

 

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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. This is because electric motors are electrically noisy machines, the sparks commonly seen at the brushes are a source of radio frequency interference [RFI] that can interfere with, and even cause terminal damage to a controller. We have interference suppression packs suitable for 24V and 48V systems, 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-160 has been designed from the ground up to give a wide range of features and capabilities. It has a unique detachable display that allows you to really understand what your motor and battery are doing.  We’ve kept it the same size and shape as the Pro-150 but have pushed the current and voltage ratings way up. The design brief was for a full H-bridge controller so we could do away with reversing relays for long term reliability, we  wanted full control over the motor current in both drive and regen modes, and we also wanted lots of inputs for radio control, temperature and speed sensors, dead mans handles, limit switches etc. Think it’s safe to say mission accomplished!

We’ve kept the 4QD trademark of super smooth and progressive power, and the built-in keypad means it’s easy to adjust between steady or very dynamic operation.

The standard version is ideally suited for motors up to around 2kW and the high current version up to 3kW.

The key features are:

  • Built in radio control input with battery eliminator circuit [BEC].
  • Easily adjustable control over many features including:
    • Acceleration and deceleration.
    • Maximum speed.
    • Maximum drive current.
    • Regenerative braking current.
    • Low voltage alert and “limp home mode” to protect batteries.
  • 2 line display showing:
    • Battery voltage
    • Motor and battery current [bet you’ve never seen how different they can be!]
    • Controller temperature, [motor and battery temperature available soon with extra sensors] .
    • Throttle position.
    • Can be mounted conveniently to provide information to the driver.
  • Deadmans handle input.
  • Emergency stop input.
  • 15 profiles for storing different configurations, 1st 9 pre-programmed for the most common applications.
  • Alternate profile input can quickly switch between any 2 profiles e.g. RC and pot, or fast and slow. Ideal for training new drivers.
  • Software updates via uSD card [coming soon are mapped throttle curves, current control mode, closed loop RPM control, and others].
  • Thermal overload protection.
  • 12V to 84V without adjustment, * depends on version.
  • Peak current 200A, * depends on version and heatsink.
  • Input learning feature allows:
    • Single ended or joystick [wig-wag] operation.
    • Fine tuning of pot or RC stick positions.
    • Voltage control.
  • Based on a specialised Infineon microprocessor with deadtime control to prevent shoot through mosfet failures.
  • Safety contactor driver.
  • Parking brake driver for vehicle applications.
  • Other inputs:
    • 2 x limit switches.
    • 2 x  thermistor inputs for monitoring battery and motor temperature.
    • Speed sensor.
    • 2 x spare.
  • Optional communications board to support daisy chaining / double heading of multiple units [coming soon].

Options

The Pro-160 can be built in a variety of specifications to give exactly what you want;

  • Voltage – the standard specification is 12V – 48V, but by fitting uprated mosfets and capacitors the upper voltage can be raised to 84V.
  • Current – the standard versions can handle up to 140A, but the high current versions will support up to 200A. As with all controllers the time these ratings can be supported depends on the cooling provided.
  • Display / keypad – the standard Pro-160 has a 2 line backlit LCD display and a keypad built into the front of the case. The display can be detached and mounted remotely, either on its own or on an optional adaptor board that has its own keypad.
  • Case – the standard case is black HIPS [high impact polystyrene] with a built in keypad and display window. There are also transparent perspex versions without the keypad in different colours.
  • Heatsink – the standard heatsink is suitable for many applications, for higher loads we will have enhanced air cooled heatsinks available soon.

Simple to fit

The Pro-160 follows the same basic wiring scheme as the Pro-150 with all the essential inputs on one 6-way connector. See the support tab for the instruction manual and wiring diagrams.

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 display an indication of the fault. If a safety contactor is incorporated, the power stage can be disconnected to protect against run away failures.

Versatile

With a range of voltage, current, display, case, and cooling options the Pro-160 is ideal for use in model locos, golf buggies, and industrial applications. It has a high degree of configurability but can still be used as a simple controller right out of the box. In terms of our existing products it has a feature set that is much greater than the Pro-150, a current rating near that of the 4QD-200, and a voltage range way beyond anything else.

 

 

Specification

Pro-160
160-S 160-HC 160-HV 160-HCV
Nominal voltage range 12 – 48 12 – 84
Minimum / maximum voltage 10.5 – 65 10.5 – 96
Motor current A [max] 140 200 140 200
Motor current A [1 minute] 140 200 140 200
Motor current A [continuous] Depends on cooling
Programmable parameters Forward & reverse top speed
Forward and reverse acceleration and deceleration ramps [0.1 – 30S]
Drive and regen current
Reverse beep
Low battery alert and limp home
Parking brake behaviour
High pot lockout
Deadband
Input values for zero, full forward & reverse
Dimensions [mm] 181 x 121 x 50
Weight [g] ~700g
Power connections M6 studs
Input 5k – 15k pot, RC [PWM],  0 – 4.7V
Reverse polarity protection N
Overvoltage protection Y [65V] Y [95V]
Pot fault protection Y
Thermal protection Y [also for motor & battery]
Joystick/Wig-wag input Y
Radio Control Y
Parking brake 1A max, delay and threshold programmable
Inhibit function Emergency stop input
Other inputs Deadman, alt profile, speed, 2 x thermistor, 2 x limit, 2 x spare
Powerdown state (motor) Diode bridge
Closed loop RPM control Via software update
Ignition, Electronic Y
Safety contactor circuit Y
Heatsink Standard plus advanced air cooled
Double heading Y [also comms board coming soon]
Switching frequency 20 kHz
Quadrants 4

 

Pictures

Inside the Pro-160
Inside the Pro-160
Pro-160 with split display adaptor
Pro-160 with split display adaptor
Pro-160 with display adaptor
Pro-160 with combined display adaptor
Pro-160 end view
End view

 

 

Support

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

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.

Troubleshooting

Accessories

The Pro-160 display can be removed from its normal position and mounted anywhere convenient for the operator. The display adaptor board allows the display to be mounted together with a remote keypad to make adjustments easy without having to dive under the bonnet.

Coloured covers: As refugees from the mobile phone industry it was inevitable that we had to offer these. The display can be seen through the 3mm perspex [smoke gives the best contrast].

Red cover

Smoke cover
Smoke
Green cover
Green
Blue cover
Blue

You may also need some or all of the following: