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

Description

Packed with advanced features yet simple to set up and operate, the Pro-160 delivers professional-grade motor control without the complexity. All settings can be adjusted directly from its built-in keypad and display—no programmer or PC software required—giving you all the performance and flexibility you need without a steep learning curve.

The LCD display lets you keep an eye on voltage, current, temperature, and more at a glance. Multiple input options make it easy to connect radio control, temperature and speed sensors, dead-man’s handles, and limit switches etc.

With its full H-bridge programmable PWM design, the Pro-160 eliminates the need for reversing relays—ensuring long-term reliability.

The standard version is ideally suited for motors up to around 2kW and the high current version up to 3kW. The standard maximum voltage is a nominal 48V, but we also have high voltage variants that can go to 84V.

The key features are:

• 2 line LCD display makes this not just a controller, it’s a full information system for your installation, it can show:
  • Battery voltage [now with battery “fuel tank” via coulomb counting in 2.5.3 software].
  • Motor and battery current [you’ll be surprised how different they can be!]
  • Controller temperature, [+2 external temperatures with optional extra sensors] .
  • Throttle position.
  • RPM & speed [with optional speed sensor]
  • Can be mounted conveniently to provide information to the driver.
• Built in radio control input.
• Easily adjustable control over many features including:
  • Acceleration and deceleration.
  • Maximum speed.
  • Maximum drive current.
  • Regenerative braking current [variable “on the fly” in 2.3.4].
  • Dynamic braking in joystick mode – pull back to brake [in 2.3.3].
  • Low voltage alert and “limp home mode” to protect expensive lithium batteries.
• Dead-mans handle input.
• 15 profiles for storing different configurations, 1st 9 pre-programmed for the most common applications.
• A single switch to toggle between any 2 profiles e.g. RC and hand control, or fast and slow. Ideal for training new drivers.
• Top speed limiting [with optional speed sensor]
• Overheat warning and cut-out , also overheat warning for 2 motors with extra sensors.
• 12V to 84V without adjustment, * depends on version.
• Peak current 200A, * depends on version and heatsink [not enough? our Pro-360 can handle 360A].
• Datalogging to uSD card [needs 2.5.3 or later software].
• Coulomb counting, provides an accurate measure of battery life remaining [needs 2.5.3 or later software].
• Input learning feature allows:
  • Single ended or joystick [wig-wag] operation.
  • Fine tuning of pot or RC stick positions.
  • Voltage control.
• Safety contactor driver.
• Parking brake driver for vehicle applications.
• Push button mode.
• Other inputs:
  • Emergency stop.
  • 2 x limit switches.
  • Speed sensor.
• Software updates via uSD card
• Based on a specialised Infineon microprocessor with deadtime control to prevent shoot through mosfet failures.

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. This page has details on how best to keep things cool.
• 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 has all the essential control inputs on one 6-way connector. Here’s a video showing how to install one.

The full instruction manual is on the support tab.

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 is highly configurable, but provides the basic control functions 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. The Pro-160 can be used as an alternative to many Curtis controllers, and has the advantage of not requiring a separate programmer.

Linear actuator software

We have now developed software that allows the Pro-160 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.

The manual provides full instructions on setting up and operating the controller.