4qd PRO-160 Series User manual

PRO-160 V2.0 10/19 Page 1 www.4qd.co.uk
Instruction Manual
PRO-160 Series Controllers
PRO-160-S/HC/HV/HCV
Rev 3, Firmware Version 2.2
Contents
Section Page Section Page
1. Introduction.................................2
2. Do's and Don’ts ..........................2
3. Getting Started............................2
4. Control Connections..................3
5. Auxiliary Input 1..........................4
6. Auxiliary Input 2..........................4
7. Thermistor Input.........................5
8. Radio Control Input and BEC....5
9. Power Connections....................6
10. Display.........................................7
11. Programming..............................7
12. Forward / Reverse Settings .......9
13. General Settings.........................9
14. Input configuration...................10
15. Using the “learn” function .......10
16. Power-up options .....................11
17. Firmware update.......................11
18. Mounting ...................................12
19. Display mounting......................13
20. Default profile settings.............14
21. Specifications ...........................15
22. Service.......................................16

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1. Introduction
The Pro-160 is an advanced digital PWM motor controller for currents up to 200A.
It uses a specialist microprocessor to control a full H-bridge design that does not
require relays for reversing. The display provides key information to the operator,
and can be mounted separately to the controller if required. It has a full range of
features and is very easy to configure if required.
2. Do's and Don’ts
Warning –the Pro-160 does not have reverse polarity protection.
Connecting the battery wires incorrectly WILL destroy the controller.
Do
Do read the instructions fully
before installing.
Do take care to connect the
battery wires with the correct
polarity
Do fit a motor suppression
capacitor, and ferrite rings.
Do twist the motor wires
together if possible.
Do call 4QD if you are
uncertain about something
Do not
Do not allow water to enter
the box.
3. Getting Started
First remove the four screws that hold the cover to the end plates and lift off
the cover.
The Pro-160 is supplied with the keymat ribbon cable not connected to its
socket. We recommend only plugging this in once the Pro-160 has been
fixed in position, the control and power connections made, and you are
ready to start operation.

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4. Control Connections
The control input sockets are shown below.
The main control input and brake should be wired as shown below [they are
compatible with Pro-120/150 and DNO/VTX installations].

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5. Auxiliary Input 1
Has the following functions.
A -Deadman’s handle. If this pin is connected to Gnd then the Pro-160 will
follow the active profile ramp down to zero, it will ramp up again when the
signal is removed.
B -Alternate profile. If this pin is connected to Gnd the Pro-160 will start up in
the alternate profile defined in the profile that was operating without the signal
present. This allows easy switching between any two profiles.
C -Limit 1. If this pin is connected to Gnd then the Pro-160 will invoke the
behavior defined for this limit. This will be available in version 2.3.
D -Emergency stop. If this pin is connected to Gnd then the Pro-160 will stop
immediately. It will not start up again until the signal is removed, and the
ignition has been turned off / on.
6. Auxiliary Input 2
Has the following functions.
C - Speed
Looks for a 5V pulse for
speed sensing application.
These inputs will be live in
version 2.3.
See website for more details

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7. Thermistor Input
Can be used to connect external thermistors to monitor external temperatures.
8. Radio Control Input and BEC
The Pro-160 will accept a standard hobbyist radio control servo signal directly
from a receiver. The receiver should be connected to pins B, C, and D. Pin D is
linked to pin A by Lk1, this can be removed if a 4 wire radio connection is
required.
The Pro-160 is pre-programmed to work with the majority of radio receivers.
Profiles 7 and 8 are pre-configured for RC single ended and joystick use. But to
get the best results you may need to use the RC learn function to properly match
the Pro-160 to your radio system.
The RDO port can act as a BEC for currents up to 1A. Pin B of the adjacent BEC
port can be used in parallel to increase this to 2A if required.
B & D -Thermistors 2 and 3 should be 4QD
part number 39-B0.
If the Pro-160 detects thermistor[s] it will show
the approximate temperature readings on the
display.

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9. Power Connections
The power connections are M6 diameter threaded posts. The wire used should
be of a diameter appropriate for the load envisaged.
Battery Wiring
Keep the battery wiring as short as possible to reduce the load on the main
capacitors.
Motor Wiring
To reduce electrical noise the motor wires should be kept close to each other and
twisted together if possible. A 10nF 100V disc ceramic motor suppression
capacitor should be fitted across the brushes of the motor. Ferrite rings should be
fitted on the motor wires. See the knowledgebase on our website for more
information on noise suppression.
If the motor rotates in the wrong direction, swap over the M+ and M- wires.
Battery Circuit Breaker
A circuit breaker or fuse should be fitted in the battery wiring. The rating should
be above that of the motors normal operating current.
A battery isolator switch should also be fitted to provide an emergency
disconnection capability. In some applications such an isolator is a legal
requirement.
Failsafe
The Pro-160 has provision to drive a failsafe contactor which can provide an
emergency disconnection in the event of a controller failure. Details of how to
implement this feature are on our website.

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10. Display
The Pro-160 has a 2 line display to display useful information during operation
and programming. A display adaptor board is available that allows the display
and / or keypad to be mounted remotely from the Pro-160.
During operation the display will show information in this format
Volts = battery voltage.
Volts = battery voltage.
Duty cycle = % of battery voltage being applied to the motor [- = reverse].
Motor current in amps.
Profile = profile currently selected [suffix R indicates reverse].
Temp = temperature in ‘C. Prefix c denotes controller temp, b denotes battery
temp, m denotes motor temp.*b and m only displayed if additional thermistors are
fitted.
Battery current in amps. Please note the difference between this and motor
current.
The display will also show any alert or fault information.
11. Programming
The Pro-160 has 15 profiles, 14 of which can be edited to suit the user. Each
profile has a number of settings which control various aspects of the controller’s
behavior. We have configured the first 9 profiles with values that are a good
starting point for the most popular applications, full details are in the table at the
end of the manual.
It is not possible to make changes to profile 01, to save changes you must first
select another profile.
To edit the settings the SEL button should be held down while turning on the
ignition, you can then navigate through the options and settings as shown in the
menu structure below. Remember to use the menu option to save changes.

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12. Forward / Reverse Settings
12.1 “Accel ramp”. Sets the time taken to reach Max PWM. 1 - 300 corresponds to 0.1
- 30 seconds.
12.2 “Decel ramp”. Sets the time taken to slow down to zero. 1 - 300 corresponds to
0.1 - 30 seconds.
12.3 “Max PWM”. Sets the percentage of maximum power that can be applied.
12.4 “Regen limit”. Sets the upper limit of the regen braking current. This works in
conjunction with “Decel ramp” to control the braking effect.
A slow “Decel ramp” [high number] will generate low regen currents. A low
“Regen limit” will allow the motor to coast more.
13. General Settings
13.1 “Current limit”. Sets the maximum motor current that the Pro-160 will allow. If the
motor / load tries to exceed this value the PWM duty cycle stops increasing.This
can be used to provide a torque limiting function.
13.2 “Reverse beep”. Switches the reversing beeper on or off.
13.3 “Low battery”. Allows the alert and cut-off voltages to be set. When the low
battery alert activates, the Pro-160 will reduce its maximum speed by 50%.
13.4 “Parking brake”. Sets the time delay before the parking brake is applied, and the
power threshold that must be reached before the parking brake is released.
13.5 “Alternate profile”. Sets the profile to be selected if the Alt-P input is activated,
and the Pro-160 re-started.
Note; There is also a “System current limit” which is not user adjustable. If the
load tries to exceed this value a message is shown, and the controller will shut
down to protect itself.

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14. Input configuration
14.1 “Input mode”. Selects the input to be used. Pot will use the signal applied to pin B
of the control port. RC will use the RDO port.
14.2 “Joystick”. Selects either single ended or joystick [center-off / wig-wag] mode.
14.3 “Deadband”. Sets the amount of input required before the output starts.
14.4 “Pot learn”. See Using the “learn” function.
14.5 “RC learn.” See Using the “learn” function.
14.6 “High pot lockout”. Prevents the motor starting if the Pro-160 is switched on with
the throttle not at zero. This setting defines the throttle setting above which this
occurs.
15. Using the “learn” function
The “learn”function allow you to match zero speed, full forward, and full reverse
from the Pro-160 to specific input signals from your pot, radio control receiver, or
other input source.
15.1 Set either “Pot learn” or “RC learn”active [only one per profile].
15.2 Select “Learn zero”and press SEL, the Pro-160 will show a number related to the
value detected from the pot [or other input].
15.3 Set the pot, transmitter stick, or other input to the point you want to have as zero,
and press SEL to capture the associated number.
15.4 Repeat steps 15.2 –15.3 for “Learn max forward” and “Learn max reverse”
15.5 Use BACK to return to the main menu and then save changes.
Note: If you are not using “Joystick” mode, you should set “Learn max reverse” to
the same value as “Learn max forward”. Reverse is then selected by the reverse
switch.

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16. Power-up options
Power on with SEL pressed enters set-up mode.
Power on with BACK pressed displays the software version.
Power on with UP pressed will provide the option to reset to factory defaults.
Power on with DOWN pressed will start up with profile 1 but not reading
EEPROM.
17. Firmware update
17.1 Insert a uSD card containing the new software into the card holder.
17.2 Navigate through the advanced menu to “Update” and then follow instructions.

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18. Mounting
The Pro-160 has 4 M5 threaded mounting holes in the baseplate, shown in green
in the diagram below.
If the operating temperature of the Pro-160 regularly gets above 50’C we
recommend fitting either additional heatsinking and / or cooling. A cooling fan can
be driven from the parking brake socket. Uprated heatsinks will be available from
our website.

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19. Display mounting
The LCD display can be detached from its normal place on the control board and
mounted in a more convenient location for the operator. There is an optional
display / adaptor board which combines a display mounting place with an
alternative keypad.
The display
adaptor board and
cables can be
found on our
website.

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20. Default profile settings
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10-15
Parameter Range Default
Small
loco
Large
loco
Golf
buggy
Go kart Joystick
RC single
end
RC
joystick
12 V Custom
Forward accelerationramp time 0.1 -30 sec 50 50 70 50 20 50 50 50 50 50
Forward decelerationramp time 0.1 - 30 sec 30 30 30 20 10 30 30 30 30 30
Maximum forward speed 1 - 100 % 100 100 100 100 100 100 100 100 100 100
Maximum forward regencurrent 0 - 200A
Reverse accelerationramp time 0.1 - 30 sec 50 70 100 50 20 50 50 50 50 50
Reverse decelerationramp time 0.1 -30 sec 30 30 30 20 10 30 30 30 30 30
Maximum reverse speed 1 - 100 % 100 50 50 50 100 100 100 100 100 100
Maximum reverse regen current 0 - 200A
Current limit [fwd and rev] 0 - 140A / 200A
Reverse beeper on / off On/ off on off off on off off off off on on
Low voltage cut-off 11 - 72 Volts 210 210 210 210 210 210 210 210 105 210
Low voltage alert [50% maxspeed] 11 - 72 Volts 220 220 220 220 220 220 220 220 110 220
Parking brake delay 0.1 -9.9 sec 10 10 10 10 10 10 10 10 10 10
Parking brake threshold 0- 10% 1 1 1 1 1 1 1 1 1 1
Alternative profile 0 - 20 0 3 2 0 0 0 0 0 0 0
Input method Pot / RC / Volt pot pot pot pot pot pot rc rc pot pot
Joystick mode On/ off off off off off off on off on off off
Joystick throttle dead band % 0 -50% 10 10 10 10 10 10 10 10 10 10
Pot learnactive Yes / no no no no no no no no no no no
RC learnactive Yes / no no no no no no no no no no no
Volt learn active Yes / no no no no no no no no no no no
High pot / RC lockout level 0 - 99% 5 5 5 5 5 5 5 5 5 5
140A / 200A depending onmodel
Profile
140A / 200A depending onmodel
120A / 175A depending onmodel

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21. Specifications
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

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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
22. Service
The Pro-160 has a 12 month warranty. Please see the service section of our
website for full details.