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4qd VTX Series User manual

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“We're in Control”“We're in Control”
Office
30 Reach Road
Burwell
Cambridgeshire, CB25 0AH
Fax: 01638 744 080
Stores
Unit 6A
Heath Road Industrial Estate
Burwell
Cambridgeshire, CB25 0AP
Instruction Manual
VTX series controllers
VTX-40 and VTX-75
4QD try to write a manual which is readable. If we
succeed and you don’t read it there is not a lot more
we can do. However if you try to read it and don’t
understand it (or even don’t like our style) - then we
have failed so please tell us. Only by means of your
criticisms and suggestions can we improve our
publications! To help you, we have marked the more
technical sections ¶ so that you may ignore them.
If you have any problems or queries, 4QD pride
ourselves on our level of technical advice and if we
put as much information into this manual as we could
many would find it too long.
If you require more information, 4QD have a very
full WWW site which has a large section giving
answers to commonly asked technical questions.
Even if you do not have easy Internet access, you will
find this well worth reading, so ask a friend who is
connected or go to your local Internet Cafe or public
library.
4QD’s VTX range of economy 4 quadrant controllers
have been engineered to replace the NCC series. As
well as improved circuitry, they benefit from surface
mount technology, which offers superior reliability
and is better suited to higher volume production.
The VTX controllers are very suitable for general
purpose speed control applications where reversing is
required. Amongst other applications our controllers
have been successfully used in the following:
Camera dollies
Caravan shifters
Carnival floats
Conveyors
Factory stores vehicles
Floor cleaning machines
Golf buggies
Invalid scooters
Kiddie cars
Miniature railways, 3”, 5” and 7¼ gauge
Mobile targets
Mountain rescue vehicles
Remote controlled vehicles
Ride on golf buggies
Winches
In fact wherever battery motor speed control - and
good value - is required.
Date printed: 13th May 2014
Foreword
Page 2 VTX series instructions
Contents
1 . . Introduction . . . . . . . . . . p. 2
2 . . Handling . . . . . . . . . . . . p. 2
3 . . Models . . . . . . . . . . . . . p. 3
4 . . Safety . . . . . . . . . . . . . p. 3
. . . . . . Reversing . . . . . . . . p. 3
5 . . Features . . . . . . . . . . . . p. 4
6 . . ¶ Specifications . . . . . . . . p. 4
7 . . Mounting . . . . . . . . . . . p. 5
8 . . Connections . . . . . . . . . . p. 6
. . . . . . Simple wiring . . . . . . p. 6
. . . . . . Control Fuse . . . . . . p. 6
. . . Battery Fuse . . . . . . . . . . p. 6
. . . . . . Push buttons . . . . . . . p. 6
. . . . . . Power Connections . . . p. 7
. . . . . . Battery wiring . . . . . . p. 7
. . . . . . Motor wiring . . . . . . p. 8
. . . . . . Fuse or Circuit breaker . p. 8
. . . . . . Battery condition meter. p. 8
9 . . Controls . . . . . . . . . . . . p. 8
. . . . . . Speed pot . . . . . . . . p. 9
. . . . . . Use as voltage follower . p. 9
. . . . . . On/Off switch . . . . . p. 9
. . . . . . Reversing . . . . . . . . p.9
. . . . . . Braking . . . . . . . . . p. 10
10 . Boxed version . . . . . . . . . p. 11
11 . Adjustments . . . . . . . . . . p. 11
. . . . . . Gain . . . . . . . . . . . p. 11
. . . . . . Ramps . . . . . . . . . . p. 11
. . . . . . RAT and MST . . . . . p. 12
12 . Expansion connector . . . . . p. 12
13 . Heat & Heatsinking . . . . . . p. 13
14 . Choice of motor . . . . . . . . p. 13
15 . Common faults . . . . . . . . p. 14
16 . Dos and Don'ts . . . . . . . . p. 16
. . . Other products . . . . . . . . . p. 16
. . . More information . . . . . . . p. 16
. . . Service & Guarantee . . . . . p. 16
The VTX series are open-card controllers. A very
high proportion of controllers returned for repair have
been damaged by mishandling!
Do not let any foreign body contact the board. That
includes water, dirt, screwdrivers, nuts and bolts.
Use only fully-insulated power connectors.
The controller can be damaged by foreign body
contact if the main capacitor is still charged.
Before handling the controller or unplugging the
power or motor connections, disconnect the battery,
then leave the ignition turned on for at least one
minute before handling the controller, to discharge
the main capacitor.
Otherwise, short out the battery inputs to the
controller, to discharge the capacitor to make the
controller safe to handle.
See also back page for dos and don’ts
2: Handling
Page 3VTX series instructions
It is normal practise, on passenger carrying vehicles,
to include some means of disconnecting the battery or
motor in an emergency. This could be a "kill switch",
or perhaps a removable link in the battery wire. This
is to guard against a failure in the controller or
wiring which, although very unlikely, could cause the
motor to run at an uncontrollable top speed. You
must not operate this switch with the motors moving
as (on rare occasions) this could damage the
controller.
Even without such additional safety features, the
VTX range controllers are designed so that failure,
and particularly dangerous failure is very unlikely.
Experience also shows that, in the improbable event
of a power device failing, the device normally acts as
its own fuse, removing drive from the motors.
Furthermore, notwithstanding a very unusual fault,
the motor can be stopped quickly by turning off the
ignition, or turning the speed down to 0. Either action
operates the relays to give full emergency braking.
Most dangerous faults have been due to water
splashes on the board - which is outside of our
control. No manufacturer, however careful, can
always guarantee what will happen in the event of a
failure.
It is important for the last word here be that the
constructor should fit a means of quickly
disconnecting the battery in the event of abnormal
control system operation.
All passenger carrying vehicles should, in any case,
be fitted with a mechanical braking system to
complement regenerative braking.
Reversing
On the VTX controller series, reversing is normally
‘dual ramp’. This means that, when the reversing
switch is operated at speed, the controller slows down
under control of the deceleration ramp, automatically
reverses and accelerates again under control of the
acceleration ramp. If the ramp controls are set for
quick response this process can be quite violent.
Also, reversing is done by monitoring the demand
speed, after the ramp circuit and not by measuring the
motor voltage so that, if the vehicle is reversed when
going down a hill, the motor will still be rotating and
the vehicle will be travelling when reversing occurs.
Reversing can therefore be accomplished on any hill
but it will be more or less violent if the gradient is
steep depending on the setting of the ramp controls.
The user is best advised therefore not to change
direction on steep hills!
Dual Ramp reversing can be deactivated, when the
reversing becomes pre-select. To disengage dual
ramp, alter the header shown in the diagram opposite.
4: Safety
Two models are available, for different current
ratings and with different options.
Each is available as 12v or 24v, but the 24v can be
supplied with resistors in the relays for 36v operation.
VTX-40 40 Amps nominal 55A max typical
VTX-75 75 Amps nominal 110A max typical
The nominal current is available for around 1 minute
(depends on mounting).
For some applications, e.g. double heading loco, two
standard units can be interconnected in tandem (if the
optional expansion connector is fitted).
The voltage is marked on the relays. Make sure these
are correct as 24v relays will not operate from 12v
and 12v relays will soon burn out their coils if used
on 24v.
The 36 version uses the 24v relays but with a resistor
in series with the relay coils and other components
changed as appropriate.
A boxed option is also available.
3: Models
Page 4 VTX series instructions
5: Features
The diagram above shows the VTX-75 which has
four MOSFETs and capacitors. The VTX-40 has two
only. Otherwise, the VTX-40 is largely the same as
the VTX-75.
Speed pot and reversing switch input is via a 6 pin
connector, supplied.
Power & Motor connections are by 6.3mm blade
connectors on top of the board. Spare power
connections are provided and can be used for control
wires or for extra motor wires as you wish.
Also available is an expansion connector option, see
page 12.
Regen brake defeat option, RAT and MST presets are
not normally fitted but are replaced by fixed resistors.
Parking brake and Thermal Sensor are standard on
VTX-75 but optional on VTX-40.
A version of the controller is supplied with fixed
acceleration, deceleration and gain: in this the presets
are replaced by fixed resistors.
Dual Ramp Reverse
Half Speed Reverse
MST Preset
ACC Preset
DEC Preset
Gain Preset
RAT Preset
B- Connection
B+ Connection
M- Connection
Parking
Brake
Controls
Expansion Connector
FETs
Heatsink
Forward
Relay
Relay
Reverse
Thermal Sensor
Capacitors
A
B
C
D
E
F
A
B
C
D
E
F
159mm
88mm
89mm
25.4
Supply voltage 12v, 24v, 36v or 48v different models.
Supply current 25mA at zero speed
Motor speed forward 0 to 100% full speed adjustable
reverse 0 to 50%/100% full speed selectable
Output current VTX-40 40A approx 1 minute 55A limit, typical
(typical) VTX-75 75A approx 1 minute 110A limit, typical
6: Specifications
Page 5VTX series instructions
The VTX series are designed for mounting via the
heatsink as in the diagram below. In most
applications, full current is only drawn for short
periods so little heating will be experienced.
However, the VTX’s heatsink is a thick block of
aluminium which won’t cool down quickly to the air.
In more demanding applications, good heatsinking is
important, such as a suitable metal plate which will
usually be the vehicle’s chassis. If heatsinking is
inadequate, the controller will give reduced
performance, and if allowed to overheat for too long,
may be damaged. The heatsink is completely
electrically insulated.
Mounting holes in the heatsink are tapped M4. Do
not drill these out larger. It is unnecessary and you
will contaminate the board with swarf, invalidating
any guarantees.
We recommend mounting only by the heatsink.
However if you want to use the corner mounting
holes as well, you must use insulating mountings.
Whatever you do, make sure the controller can’t get
wet and, if it does, don’t connect the battery until you
have dried the controller thoroughly. The water won’t
cause damage unless the unit is connected to the
battery, when electrolytic corrosion will occur.
Overheat temperature 95°C on heatsink
Overheat current 20 amps typical
Switching frequency 20kHz approximately
Size 153mm x 78mm x 45m Board version
198mm x 88mm x 43mm Boxed version
Weight 260g
Input 2k to 20k pot.
Pot fault detect greater than 25K
Input voltage 3v to 20v for full speed adjustable
Acceleration time 100mSec to 5 Sec adjustable
Deceleration time 100mSec to 5 Sec adjustable
Ignition input threshold 8v into 50k approximately
Reverse input threshold 5v into 10k approximately
Parking brake 1 amp max.
Thermal Sensor
Pot and direction switch via IDC connector.
Customer's heatsink
Main capacitors
Relays
6.3mm tags for battery and motor
Heatsink
7: Mounting
Page 6 VTX series instructions
Simple wiring
On the 6 way multicore control wire, yellow is
internally connected to battery +ve. White and black
may also be battery +ve (depending on the control
switches). Green is battery -ve and blue and red are
the control pot. A short circuit in the wiring between
these two groups will cause problems!
Boxed version: Wire colours are as shown in the
diagram above.
Control Fuse
Note the 1A fuse in the yellow wire. If this is omitted,
a mistake in the wiring can blow fuse tracks on the
controller. Controllers returned for repair with the
fuse tracks blown will be subject to a handling
charge. See page 15.
Battery Fuse
Note the fuse in the battery line: this is partially to
give a useful measure of protection against a reversed
battery. It will also protect against some other wiring
faults. The boxed VTX-75 has a 40 amp fuse (25A
for VTX-40) fitted but the controller may draw more
than this depending on the application. A larger fuse
can be fitted, but will give less protection. Use the
smallest value fuse which does not cause nuisance
blowing: if the controller is giving more current than
it can readily handle it will simply get hot. See also
pages 7 and 8.
Motor Capacitor
See page 13.
Push buttons
Instead of two switches (ignition and
forward / reverse) you may use two
push-and hold buttons. Wiring is
shown left: note the extra diode (any
small signal diode, e.g. 1N4148).
Without this, reverse will not work.
The diode's Cathode (the end with the
band) should be connected to White.
8: Connections.
Blue
Red or Brown
Permanent
magnet
motor
Black
6 core cable
Speed control pot
Reverse switch
Ignition switch
Cables anchored
to chassis.
Yellow
Yellow
White
White
Black
Black
Green
Green
Blue
Blue
Red
Red
1amp fuse
Fuse
A
B
C
D
E
F
Yellow
motor
capacitor
6 core cable
Speed control pot
Reverse
Forward
Black
Green
Blue
Red
Yellow
Yellow
Diode
White
Fuse, see text
Yellow
WhiteBlack
Green
Blue
Red F
E
D
C
B
A
The diagram shows the simplest
connections needed to use the
controller.
Fused yellow wire may be fed
from B+ if preferred.
green wire must not
connect to machine
chassis.
Page 7
VTX series instructions
Battery connections to the controller are shown in the
diagram opposite. Use only good quality battery
connectors: the controller feeds current back into the
battery during braking and if a battery connector falls
off when braking this regenerated current can pump
up the voltage on the dud battery connection.
Although the controller is protected against damage
from this, it is not advised. The same will happen if a
fuse or circuit breaker opens during braking.
Note that, if the battery is disconnected for a minute
of more, when the battery is re-connected, it is
normal for there to be a noticeable spark as the main
capacitors charge.
Polarity
Take great care: THE CONTROLLER IS NOT
POLARITY PROTECTED: BATTERY
REVERSAL WILL INSTANTLY DESTROY THE
CONTROLLER!
This will not be covered by the guarantee!
In practise a suitable fuse (opposite page) gives quite
effective protection. However a more positive
protection against reversed battery can be done by
wiring a suitable relay (one normally open contact) in
the positive battery lead. One end of the coil connects
to battery -ve and the other to pin B of the input
connector which is also connected to the ignition
switch. A resistor must be connected across the
contacts as shown. When the ignition is off, there is
no voltage on the relay coil and the relay contacts are
open. The VTX’s main capacitor charges through the
470 ohm resistor.
If the battery is reversed the VTX's MOSFETs short
out the capacitor, so no voltage is present and the 470
ohm resistor limits the current to a safe value. When
the ignition switch is closed the relay coil is
connected across the capacitor: if there is voltage
(battery correct) the relay operates and applies full
power.
Wire size. Use heavy duty wire for the battery and
make them as short as possible. This also applies to
the battery linking wire on 24v systems. 4mm
(12awg) wire is ‘officially’ rated to handle 41 amps
continuously. At 100 amps it gets too hot to touch
within about 60 seconds, so it is fairly well matched
to the controller. You may prefer to use 6.0mm²
(10awg) wire for the 75 amp version. Thicker wire
will cause no problems, so use the thickest you have.
Use of wire that is too long (and/or too thin) will
cause loss of power, but more importantly the
decoupling capacitor (see ‘features’ diagram above)
will heat up. Heat will shorten the operating life of
capacitors.
Crimp Contacts
It is VERY IMPORTANT that you use fully insulated
crimps: the power connections are close to the board.
Uninsulated crimps may short out and destroy the
controller. Best of all use ‘F type’ crimps with vinyl
covers shown in the drawing.
4QD can supply these pre-
crimped - they require a special
crimp tool.
Also be aware that the main
capacitor can store charge for a
long time (several minutes) so
the potential for damage is there
after the battery has been
connected.
Power Connections
Battery wiring
Relay 470 ohm
2 watt
Battery +
+ to controllerBattery -
+24v switched by ign switch
Page 8 VTX series instructions
Motor wiring
This is not so critical as battery wiring: too long
and/or too thin wire will cause a loss of maximum
current, will get hot and will waste battery power but
will not damage the controller. However, wire which
is too thick will do no harm either so we recommend
the same wire for the motor as for the battery.
Circuit breaker, fuse, isolator.
A circuit breaker or fuse may be fitted if required.
The main advantage is that it will enable the battery
or motor to be disconnected in the event of an
emergency or for security and it will give a measure
of protection should the battery be reversed.
Suggested fuse/breaker value:
50 amp max for VTX-75
25 amp max for VTX-40
Alternatively, you could fit a breaker in the battery
lead: take care not to increase the wiring length too
much. Also, certain types of breaker can have the
same effect as increased battery lead length.
A breaker in the motor may also be useful: it will
enable you to quickly disconnect the motor in an
emergency. If correctly rated, this can also protect the
motor against overheating due to mechanical
faults.Also with the motor disconnected, free-
wheeling becomes possible.
It is also possible to get a battery isolator switch.
These are normally fitted to lorries, buses and boats
to isolate the battery in an emergency.
Battery condition meter.
Pins A and F (yellow and green on the diagram) are
directly connected to the battery so that you may use
them to connect a battery condition meter.
The drawing shows 4QD's LED battery indicators.
6 way connector.
The mating connector supplied is suitable only for
the correct size of wire.
Acceptable wire sizes are:
. . . 7 stranded 0.22-0.25mm²
. . . Equivalent 24 AWG (7/32 AWG)
It is an Insulation Displacement Connector (IDC)
which 4QD have chosen because it is so very easy to
use and very dependable. - but only with the correct
wire!
Do not strip the insulation from the wires, simply
push them into the top part of the open connector and
squeeze it closed in a vice or with suitable parallel
action pliers. As you do this the tines of the contacts
bite through the insulation to make contact with the
conductors.
Wire which is too thin will not make contact. Wire
which is too thick will damage the tines.
Do not use single strand (telephone) wire: it will
make unreliable contact and easily breaks.
You can re-open a closed connector by gently
moving the tabs at the sides of the top cover outwards
to disengage the latches while lifting the cover
slightly, one side at a time.
11
Open Closed
1 1
1
D red: Max speed (7.8v approx)
E blue: Wiper
F green: 0v (Min speed)
C black: Reverse
A yellow: +24v to Ignition
B white: Ignition and reverse common.
A B C D E F A B C D E F
9: Controls
Page 9VTX series instructions
Speed pot.
We suggest a 10K linear pot, although other values
from 4K7 to 20K, linear or log, can be used.
The gain adjustment on the controller alters the
amount of rotation required before full speed is
reached: this enables a simple lever operated control
by means of a lever arm screwed onto a standard
rotary pot.
The simplest speed control is an ordinary rotary pot:
this won’t give any ‘dead man’ control as the pot
won’t return to zero when it is released. 4QD can
supply a spring return to zero hand control.
Alternatively 4QD can supply a plunger operated pot
(linear position sensor), suitable for incorporating
into a foot pedal.
The drawing shows the pot supplied by 4QD
With this pot you should only solder to the tips of the
tags: the holes shown are not for soldering but as
heat barriers to stop heat travelling up the tag and
melting the plastic body.
¶ Use as voltage follower
Instead of a pot, the input may be fed from a variable
voltage. 0v (common) to pin F, signal input (+ve) to
pin E. A resistor (10k) should be connected from pin
D to pin F to over-ride the internal pot fault detector
circuit.
Zero speed will be for zero voltage input and full
speed voltage may be adjusted (by the pre-set) to be
from 3v to above 20v. Input impedance is 100K.
If pin D is shorted to pin E (and the 10K present) the
gain control may be used as a pre-set speed control.
Ignition and reverse inputs are both high impedance
(voltage controlled). High activates. Thresholds are
around 5v and 7v.
On/Off switch
Circuitry in the controller switches it off (zero
current consumption) unless there is a voltage on pin
B or pin C.
The wiring is shown on page 6.
Beware of changing any switch when the motor is
running: the motor will brake to a halt more or less
quickly, depending on the deceleration ramp setting.
If the switch changed is the reverse, it will then
accelerate up to speed in the other direction. This
process is quite safe (for the controller).
With the ignition off, or even with the battery
disconnected, the relays short out the motor so free-
wheeling is not possible. To freewheel properly the
motor should be disconnected.
Reversing
Reversing switch
Reversing switch connections are shown in the
diagram above. Reversing is ‘dual ramp’ which
means that, if the vehicle is reversed at speed, it
automatically slows down under control of the
deceleration ramp then reverses and speeds up under
control of the acceleration ramp.
Whenever the vehicle is in reverse, a speed reduction
circuit operates, so that (if the gain adjustment has
been set up sensibly) full reverse speed is half of full
forward speed.
Reverse Speed reduction
¶ If half speed reverse is not required it can be
disabled by moving the header marked ‘HSR’ on the
board (and shown in the ‘features’ diagram). This is
a pinstrip with a shorting link which simply unplugs.
As shown (bottom pin free) reverse is at half speed.
Reverse threshold
If you are reversing the controller from, for instance,
a microcontroller, the threshold is around 5v. A
voltage above this selects reverse, below the
threshold selects forward.
front side back
Page 10 VTX series instructions
Dual Ramp Reversing
‘Dual ramp’ reversing can be disengaged by
removing the header marked Dual Ramp Reverse on
the diagram, page 4 (DRR on the board). Reversing
then becomes ‘pre-select’ so that, if the reverse
switch is operated at speed, nothing will happen until
the demand speed is reduced to zero.
Reversing will now occur when the demand speed is
turned up again. In this mode a push switch can be
used for reversing: push the switch as you move the
speed control from zero to engage reverse and release
it when the vehicle is moving. Then, when the speed
control is again reduced to zero, the controller will
drop back into forward.
Pre-Select reversing must be used for series-wound
motors or if regen braking is disabled.
Regenerative Braking
Regenerative motor braking is integral to the VTX
controllers. When the demand speed is reduced
below the actual motor speed, the controller starts
braking, returning as much of the braking energy as
possible back into the battery. The speed at which the
braking acts is adjusted by means of the deceleration
adjustment.
Regenerative braking does not work well at very slow
speeds, simply because it relies on the motor turning
to provide braking energy. If the motor is only
turning slowly then it cannot give a lot of braking, so
a vehicle will creep if parked on a hill. To stop this
you can get motors fitted with an electromagnetically
operated parking brake. When power is applied to
this, the brake is removed and when power is
removed the brake is applied by a spring.
There are few applications where regenerative
braking is deleterious and it should normally be left
engaged.
The ability to disable regen braking can be included
as an optional extra if requested at point of purchase.
When regen braking is disengaged :
1: the controller must be also switched to pre-select
reversing (see above).
2: Chose the longest deceleration ramp setting, as the
motor will brake only under friction.
Failure to do this will cause jerky performance and
may burn out the relays
Parking Brake
Some motors are fitted with a separate solenoid
released parking brake.
The VTX controller has a circuit to drive such a
parking brake brake: battery power is applied to the
solenoid as demand speed is increased above zero
and when the demand speed returns to zero, power is
removed.
Parking brake is via the 3 pin connector, shown on
the diagram ‘Features’. Wiring is as the diagram
below.
This feature is standard on VTX-75 but is an
optional extra on the VTX-40.
Pin A is battery +ve.
Pin C is 0v which can be used as you wish or can be
used for an off - auto - on switch as below.
Braking
1
A B C
Release
Brake
Normal
To brake
1
A
B
C