Download 4QD Controllers - Selection guide

Publications
Manuals
Each controller is supplied with a detailed instruction
manual, typically a small booklet similar to this
selection guide. These are available separately for a
small charge - see Accessories Catalogue.
4QD
Office
Stores
30 Reach Road
Unit 6A
Burwell
Heath Road Industrial Estate
Cambridgeshire, CB5 0AH
Burwell
“We're in Control”
“We're in Control”
Fax: 01638 744 080
Cambridgeshire, CB5 0AP
See us via the Internet:
http://www.4QD.co.uk
Email to: [email protected]
Accessories
A separate catalogue is available which details pots,
switches, connectors, boxes, wires and a lot more
bits and pieces you may find useful.
Speed controllers for battery powered electric motors.
Selection Guide
Price List and Order form
Internet.
If you have Internet access you will find a lot of
useful information on our www site. This is now the
worlds main internet resource on the subject of
battery motor control.
Information there includes details of our controllers,
a huge sheet of answers to frequently asked
questions on battery motor control, names and
addresses of motor manufacturers and others, and
details of various electric vehicles.
motor - but we will try not to get too technical – if
you want more reading we have a large internet site
with lots of technical information and assistance..
This pamphlet is intended to introduce our range and
to help you make an appropriate choice: this means
we need to introduce some of the concepts and terms
we use, and to give you a little understanding of the
Our controllers are mainly used with permanent
magnet motors (though other types can be used) so
we will confine the discussion to these PM motors.
Permanent Magnet Motors
4QD
Office
We have a wide range of speed controllers available some would say too large - and this can make the
choice a little difficult.
Stores
30 Reach Road
Unit 6A
Burwell
Heath Road Industrial Estate
Cambridgeshire, CB5 0AH
Burwell
“We're in Control”
“We're in Control”
Fax: 01638 744 080
Cambridgeshire, CB5 0AP
See us via the Internet:
http://www.4QD.co.uk
Email to: [email protected]
In a PM motor, a coil of wire (called the armature) is
arranged in the magnetic field of a permanent magnet
in such a way that it rotates when a current is passed
through it. Now, when a coil of wire is moving in a
magnetic field a voltage is induced in the coil - so the
current (which is caused by applying a voltage to the
coil) causes it to rotate and generate a voltage. It is
the nature of cause and effect in physics that the
effect tends to cancel the cause, so the induced
voltage tends to cancel out the applied voltage.
It is this difference that causes the current in the
armature to flow - so the current will increase as you
increase the mechanical loading. It should therefore
be apparent that an unloaded motor will take little
current. It should also be clear that if you apply more
voltage the motor will speed up, apply less and it will
slow. This is what the speed controller does: it varies
the voltage applied to the motor.
Voltage is electrical pressure. Current is electrical
flow. Pressure tends to cause movement, or flow so
an electrical pressure is a force which moves
electricity - or an ‘electromotive force' (EMF). The
induced voltage caused by the armature's movement
is a ‘back EMF’ – it cancels out the applied voltage
so that the actual voltage (pressure) across the
armature is the difference between the applied
voltage and the back EMF.
Nameplate ratings
The nameplate quotes a voltage, a rotation speed and
a current. But, as we have seen, the current is
dependant on the mechanical loading and its rotation
speed is proportional to the applied voltage and the
load. So what about the figures on the motor
nameplate?
Now if you apply a load to the armature it will slow
down. The back emf will decrease so the difference
between applied voltage and back emf will increase.
The nameplate current is in fact a safe working
continuous load. If you load a motor so that it draws
more than this current then, eventually, it may
overheat.
1st May 2002
The voltage and speed are simply the speed you can
expect from a motor run from the nameplate voltage
and loaded so that it draws the rated current.
The motor, unloaded, will run a little faster and will
draw very little current. If you lock the rotor, a
typical motor may draw as much as 20 times the
nameplate current - but it will quickly heat. However
most motors will safely take a 300-400% overload for
about one minute - if your mechanical loading is
enough to cause that much to be drawn.
Battery Condition Meters
As a battery gets discharged, its no-load voltage
drops. A voltmeter connected across the terminals
will then tell you how much charge is left.
Furthermore it can permanently damage a battery to
discharge a battery too far: most manufacturers
recommend no more than 80% discharge, to a no load
voltage of around 10.5v (for a 12v battery).
We offer a range of LED battery condition meters:
these are attractive when fitted into an instrument
panel and are accurately calibrated so the orange
LED goes out at the 80% level. Moreover, they give a
dynamic indication, responding to dips in voltage
under load. Changes in this indication can give early
warning of a battery's failure.
Battery discharge protection
Discharging a lead-acid battery too far can
permanently damage it. This is why some sort of
Battery Condition Monitor is useful. Also, if you are
selling your machines a controller which prevents
over discharge may stop your customers claiming
replacement batteries under guarantee, so some
controllers are fitted with discharge protection (which
reduces the controller's performance when the battery
Page: 2
Some sort of ‘fuel gauge’ is probably even more
necessary on a battery vehicle than on a petrol one.
The illustration below shows the meters we offer.
They use rectangular LEDs (Light Emitting Diodes)
to form a 'Line of light'. Not only are they very
functional but they add instant appeal to any panel.
The controller
The controller varies the voltage applied to the motor
- but it has to do much more than that: if the motor
ever took 20 times its rated current (even for an
instant during starting) it would instantly blow the
controller, so the controller needs to be protected
against this. Then you may want the controller to
reverse the motor: to do this safely it first has to stop
the motor - for it is hardly desirable to simply reverse
it at full speed. Then there is reverse polarity
protection, protection against operator misuse,
regenerative braking, safe response in case of broken
wires etc. Some applications require some features,
some do not, so the centrefold of this pamphlet has a
check list of features and the first section is an
explanation the technical features of our controllers.
Battery Condition meters
is low to avoid over discharge. However, if discharge
protection is fitted, it will cause other problems later
in the battery life as the battery capacity falls off with
use, so 4QD do not recommend the feature.
Nevertheless it is available on most controllers.
Box/cover
Some controllers have an integral box or cover, some
do not. Some have a box or cover available as an
option.
Current limit - drive
Protection fitted to all controllers so that the initial
starting surge (or the current that would flow if the
armature were locked) cannot exceed that which the
MOSFETs can handle. The standard current limit is
fitted only to protect the MOSFETs and you should
not rely on it to protect other components in the
controller, or to protect the wiring or motor. These
are all application dependant so if you want these
also to be protected (and your expected quantity
warrants the effort) - contact the office for advice.
At full charge all the LEDs are on. As the voltage
falls, first the top green goes out, then the second then
the yellow. If the yellow stays out when the controller
is not working the battery is fully discharged (further
discharge can damage the battery).
Connections are by flying wires.
5 LED has 2 green, one yellow and 2 red.
7 LED has 4 green, one yellow, 2 red.
The drawing above shows how the meters mount
behind a panel.
The top drawing, left. is the 3 LED meter, for 12v.
The centre one has 5 LEDs and is for 24v but is also
available for 36v.
The bottom one (7 LEDs) is available for 36v, 48v
or 60v.
The drawing below shows the 3 LED circuit built
into a hand control box for the Eagle or Egret series
(12v only).
Order codes
BCM-312
BCM-524
BCM-536
BCM-736
BCM-748
BCM-760
EHC-123
4QD controllers: selection Guide
The meters are highly stable and very accurate.
The 3 LED meter (for 12v only) has one each green,
yellow and red.
All 4QD controllers use extremely fast current
limiting which even protects the MOSFETs against
short circuits in the wiring (though this is not
guaranteed), so there is no minimum motor resistance
or inductance.
The current limit automatically compensates for the
internal temperature of the MOSFETs - since this
affects the current they can handle - so the available
current decreases as the MOSFETs get hot. See also
'Thermal shutdown'.
The reading is 'dynamic' in that the lights respond
quickly - so will flicker and dim as heavy current is
drawn, for instance, ascending a steep slope. This
enables the user to monitor the battery state from day
to day: if this hill normally causes 3 LEDs to go out
and today 4 are going off the battery is showing its
age.
4QD controllers: selection Guide
EHC-123
Page: 23
Egret series speed controllers
Features
Economy controller
Accel ramp only
Preset gain.
2 or 4 MOSFETs 1 Quadrant
(beneath board) Hand control box
available.
The Egret (our simplest controller) is essentially a card version of the Eagle.
The Egret board is a available with Insulated (EaI) MOSFETs for simple installation or with standard,
uninsulated ones (EaS series) for full performance.
The insulated MOSFETS (EgI) version is very easy to install, but is protected so that it is safe even without
any additional heatsinking.
The Egret has battery discharge protection, set at 10.5v on the standard version. May be factory set for bulk
orders to suit 24v, 36v or 48v battery.
Current limit - regeneration
If the vehicle is driven down too steep a hill (or the
demand speed is suddenly reduced so that hard
braking results) the current generated by the motor
could exceed that which the MOSFETs can safely
handle.
Since such current would blow the MOSFETs it must
be protected against. Therefore all controllers that
give regenerative braking are also fitted with a
current limit to stop such failure.
Again: this limit is set to protect the MOSFETs only.
It is not intended to control the vehicle's handling or
to protect the mechanisms or motor. Contact 4QD for
advice if you require this.
Double heading
This feature is an (optional) extra connector on some
controllers. It is mainly used in miniature locos where
two engines are coupled to one train. It enables the
controllers to be interconnected to work as one.
It can also be used on twin motor machines to work
both motors as one - see 'Master-Slave'.
Standard board works from 12v to 48v with only one adjustment (except for battery discharge protection).
Battery is available on 3 pin connector to feed battery condition meter.
Pot fault protection can be engaged by cutting an on-board link (which removes battery voltage from pin 1 of
the connector).
Order codes: EgS-40-12
EgI-20-12
EgS-40-24
EgI-20-24
EgS-40-36
Voltages
12v , 24v or 36v
48v to order
EgI-20-36
EgS-40-48
Undervoltage
10.5v
standard
EgI-20-48
Supply current
20mA
with no motor load.
EgS-80-12
Input
10k pot or Hand Control Box
EgI-40-12
EgS-80-24
Input voltage:
0.6v
power up.
EgI-40-24
EgS-80-36
(adjustable)
4v
full speed
EgI-40-36
EgS-80-48
6.5v
over voltage cutoff
EgI-40-48
Ramp time
2.3 sec
approx (may be altered)
Egr-Box
Size (board)
93mm x 48mm x 20mm
10K for use with 10K pot
Weight
100g
-EHC for use with EHC-123
Size (boxed)
111mm x 60mm x 31mm (without wiring)
-GTH for Twist-grip throttle
Weight
30g
board only
(choice on 12v versions only,
Output current (typical) 20A 10 minute
EgI-20 amp version
-EHC not available on other
15A continuous ¶ EgI-20 amp version
voltages).
¶with no heatsink. Figure will be more with proper mounting. or for other pot (please
specify).
Page: 22
4QD controllers: selection Guide
Half bridge
All of our controllers use state-of-the art MOSFET
circuitry switching at around 20kHz - that is 20,000
times per second. In the half bridge, two sets of
MOSFETS are connected across the battery, as
shown in the diagram below.
Dual ramp reversing
If the operator reverses the controller at speed, the
controller must behave safely. With dual ramp
reversing, the controller realises it has been asked to
change direction - so it immediately slows down
(under control of the deceleration ramp) then, when
speed if zero, reverses the motor and accelerates
again (under control of the acceleration ramp).
So the automatic reversing cycle is controlled by two
ramps, hence 'dual ramp' reversing.
See also 'Pre-select reversing'.
Gain adjustment
This enables the top speed to be reduced, e.g. in a
child's car where the child is too young to use the full
speed range. It also allows the controller to be
matched to various throttle devices (e.g. foot-pedal,
Bell throttle, twist-grip throttle) and supply voltages.
Flywheel
MOSFET
Motor
B
Main
Capacitor
Drive
MOSFET
Battery
A
The drive MOSFET switches rapidly on and off in a
series of pulses (the 20kHz). When it is on, current
flows from the battery, through the motor, through
the drive MOSFET and back to the battery (path ‘A’).
The Drive MOSFET switches off - but the motor has
inductance (inductance is, to electricity the same as
mass is in mechanics) so the motor current cannot
stop suddenly. Most other controllers use a power
diode (where the diagram shows the ‘flywheel’
MOSFET) connected across the motor so the motor
current can circulate when the drive MOSFET is off a sort of ‘flywheel’ to smooth out what would
otherwise be electrical surges caused by the sudden
changes in electrical flow. However, power diodes
get hot and waste a lot of heat. For this reason 4QD
use MOSFETs which are much better devices since
they don’t get so hot. Moreover, depending on the
method used to switch the MOSFET, the controller
can give regenerative braking. To get regen braking,
the top MOSFET is switched on when the bottom one
is off. Our ‘Eagle’ and 1QD series don’t give regen
braking because they switch the MOSFET
synchronously with the motor current. This is a
system invented by 4QD and causes our ‘standard’
golf caddy controller (the Eagle) to safely give 40
amps when other caddy controllers are limited to
about 25!
Half speed reverse
In many vehicles (kiddie cars, mobility aids, golf
buggies) it is dangerous to allow reversing at full
4QD controllers: selection Guide
Page: 3
speed - so all reversing controllers are supplied with
half-speed reversing.
This feature can easily be disabled for applications
such as locos which require symmetrical speeds in
forward and reverse.
The 'half speed' value also could be changed if
required but in practise half seems the best value.
Hand controls
The speed controller is simply the 'electronics': it
does not include any of the knobs and switches for
the user since no two applications seem to want the
same set of knobs: these are listed in a separate
pamphlet.
All controllers require a 'throttle' device which may
be as simple as a 10K rotary pot or may be a foot
pedal, a twist-grip or a finger operated lever.
All controllers have the option of an ignition switch often key operated. Reversing controllers need a
direction switch so the rider can select this.
Heatsink
Any electronic component, motor, wire or connection
that handles a lot of current gets hot. In fact heating is
the factor which limits the ultimate performance of
the motor and the controller so they can give a small
current continuously or a high current for a short
time. Most (but not all) of the heating is in the
MOSFETs (q.v.) which are fitted on a piece of
aluminium. In most controllers this will take quite a
lot of heat before the MOSFETs get too hot (which
would limit the short time, peak current) - but it is not
good at losing this heat to the air so a secondary
heatsink will increase the continuous current. Most
applications require high current only in short bursts
so often the internal aluminium block is sufficient.
See also 'thermal shutdown'.
High pedal lockout (HPLO)
If the controller's ignition is turned on while the
throttle pedal is depressed, the vehicle could
accelerate to full speed. HPLO prevents this by
disabling the vehicle until the throttle pedal is
released. When this is done, the controller resets itself
automatically.
Page: 4
Ignition - Electronic
When the controller is not in use it needs to be
deactivated. The electronic ignition circuitry (fitted to
all controllers) does this, so the controller draws no
current and the throttle input will have no effect.
Note that 'electronic ignition' does not disconnect the
battery, so should not be relied upon for long periods
of storage. You may also like to fit a battery isolator
switch for emergencies - although modern MOSFETs
are very reliable!
In the simpler controllers the ignition is switched by
connecting or disconnecting the potentiometer (pot)
or else automatically as the pot zeroes (auto). Others
have a separate ignition switch (€). On some
controllers the ignition is 'active' - when switched off
the controller will ramp down to zero and only then
will it switch itself off ('act' on the check list).
Inhibit
An input to disable the controller: could be used by a
switch on the (mechanical) hand brake or on the
charging point.
Instruction manuals
All controllers are supplied with a detailed instruction
manual - typically 10 A4 pages long - which details
the wiring and other useful information. Manuals can
be supplied separately, but a small charge is made.
Alternatively, you can pick them up via our internet
site.
Eagle series Speed Controllers
As you may guess from its name, the Eagle is aimed at powered golf caddies and similar machines. It and the
Egret are designed for small, slow machines such as golf caddies and are not suitable for passenger carrying
machines or for fast machines.
The basic version is -40. The standard controller need only a minor (internal) change to operate from 12v, 24v
or 36v. For volume orders, a 48v version can be supplied, as can higher current versions.
The -40 version will give 35 amps for one minute, thanks to 4QD's innovative high efficiency (low
dissipation) circuitry. The MOSFETs are mounted (beneath the circuit board) on aluminium 'heat spreaders'
which makes the thermal design very efficient.
For ‘bare board applications, use the Egret series.
Supply voltage:
Supply current:
Output current (typical):
Voltage drop:
Input:
Input voltage:
Ramp time (to full speed):
Size:
(boxed)
Weight:
12v, 24v or 36v
48v versions to order
20mA
with no motor load.
40 amps
cold
40 amp version
35A
1 minute rating 40 amp version
280mV
at 20 amps, typical 40 amp version
10k pot or Hand Control Box
0.6v
power up.
4v
full speed
6.5v
overvoltage cutoff
2.3 sec
approx (may be altered)
111mm x 60mm x 31mm (without wiring)
100g
Joystick
Usually a two-axis device as used with machines
having two motors, each driving one wheel. Moving
the stick front to back causes both motors to speed or
slow and to reverse as necessary. Moving to the side
speeds one motor and slows (or reverses) the other
for steering.
Full joystick control requires two controllers (or a
double controller) and can be done with two
controllers (e.g. NCC series) and a Dual Channel
Interface
board (DCI-111) which gives the
differential steering action.
For single axis use, the throttle device will simply
give zero speed in the centre. Push the device forward
for one direction and back for the reverse direction.
4QD controllers: selection Guide
Order codes (Eagle series):
EAJ-40
EAL-40
4QD controllers: selection Guide
EHC-123
Page: 21
Eagle series Speed Controllers
Motor leads (30cm with 9.5mm push-on connectors)
31
111
Orange
Yellow
60
1.5 m 4 core cable
red
Yellow
Red
Blue
Green/Black
black
5cm Battery Tail
‘Powerpole’ connectors
50cm Battery lead
¶ Controller includes box, motor leads and battery
leads, as illustrated above. Order Code EAL-40
¶ Standard controller include 3 core control cable as
shown above.
¶ EAJ-40 (below) has a flying jack socket with
mating Jack lead.
Features
Accel ramp only
Preset gain
1 Quadrant
Boxed
Reverse polarity protected by power plug only
Motor leads supplied.
Jack connector option.
¶ Both series: pot or hand control is required - order
separately.
EHC-123
¶ Pots, Hand controls (EHC-123) etc. are listed in
the Accessories Catalogue.
Motor leads (30cm with 9.5mm push-on connectors)
31
111
Orange
60
Yellow
1.5 m 4 core cable
red
black
5cm Battery Tail
50cm Battery lead
Page: 20
‘Powerpole’ connectors
4QD controllers: selection Guide
Main capacitor
Referring to the earlier section ‘Half-Bridge’ you will
see that the battery current is being switched on and
off 20,000 times per second. Now electricity in wires
has the equivalent of ‘mass’ - it does not like
stopping and starting this rapidly! So most controllers
have a capacitor (a bit like a local battery) to
compensate for some of the ‘inductance’ (as the
effect is called). Controllers without this (Eagle and
Egret) must be used with very short power
connections: they are intended for small machines,
e.g. golf caddies!
Master-Slave
The expansion connector can be used for coupling
together two NCC or Pro series controllers so they
work as one, each driving a separate motor, for
applications where a single motor is either not
powerful enough or is mechanically inconvenient.
Used like this one is the 'Master', the other controller
the 'Slave'.
MOSFET
MOSFETs are the power chip devices used to control
the current.
Overheat protection
See 'Thermal shutdown'
Over-voltage protection
If the controller has regen braking there is a potential
problem if a battery connection fails during braking:
the controller will automatically increase the
regenerated voltage in the braking attempt until
something fails. This feature limits the regenerated
over-voltage and is fitted on all controllers having
regenerative braking.
Parking brake
Regen braking relies on the voltage generated by the
rotating armature so it is speed dependent. If the
speed is slow enough there is no effective braking, so
the machine will creep down hill. A parking brake is
a mechanical brake which can be fitted to some
motors and which is released by a voltage supplied
by the controller. This feature is the electronic switch
to activate this parking brake.
The circuit applies power to the brake as the motor
starts up and removes the power about a second after
the motor stops.
4QD controllers: selection Guide
Alternatively, the driver can be used to switch the
field of a shunt wound motor, or to switch an air
solenoid to release brakes.
Potentiometer (Pot)
The input device which allows the operator to interact
with the controller. It may be as simple as a rotary
knob or may be a plunger device operated by a foot
pedal. Other styles are twist-grip, finger-tip lever
operated and joystick.
Pot fault protection
If a wire to the pot breaks it is desirable (in some
applications) that the controller does not go to full
speed. This feature ensures this.
Power-down state
When the ignition is switched off, the controller may
be in one of 3 states:
1 Shorted out. This is the state with controllers that
use relays for reversing. Shorting the motor gives
maximum braking, but makes free-wheeling
difficult.
2 Open-circuit. This is the state with the 4QD
series. There is no braking, but free-wheeling is
possible with no battery connected.
3 Diode. (➤❙) The 'Flywheel' MOSFET works as a
diode when the controller is turned off - the
machine can be free-wheeled forward, but not in
reverse.
In practise, there is little to chose - each has pros and
cons.
Pre-Select reversing
In pre-select reversing, changing direction at full
speed has no immediate effect but when the throttle is
released the controller will start up again in the new
direction. This is 'pre-select' reversing.
See also Dual-ramp reversing.
PWM
Stands for pulse width modulation and refers to the
fact that the controller is switching power to the
motor in a series of pulses whose width is modulated
- see ‘Half Bridge’.
Page: 5
Quadrants
If you draw a graph of motor current against drive
voltage for a reversing controller, you have to cater
for positive and negative currents and voltages:
positive voltage and current is normal forward drive.
+ voltage
Both
negative
is
normal reverse drive.
Forward brake Forward drive
For forward braking,
voltage is positive but − current
+ current
current has reversed
and vice versa for
Reverse drive Reverse brake
reverse braking.
The '4 quadrants' are
− voltage
shown in the graph.
Ramping
Even if the throttle is applied sharply, the motor must
accelerate smoothly so an 'acceleration ramp' is built
into the controller. Similarly, when the throttle is
released sharply, a controller with regenerative
braking must decelerate the machine smoothly - this
is controlled by the deceleration ramp. In 4QD's
controllers, the ramps are very smooth and very
linear.
The rate at which the machine needs to accelerate (or
decelerate) will depend upon the machine and how
fast it is, so the reversing controllers have adjustable
ramps.
So the checklist shows 'A&D' where both ramps are
fitted (and independently adjustable) or 'A' for
controllers where there is no regen: these have
ramped acceleration only (which is not adjustable but
could be altered by changing a component) - decel is
limited by the mechanics.
The 2QD series do not have a linear ramp but a
simple system controlled by a fixed resistor and
capacitor (hence 'CR').
Reverse polarity protection
If you inadvertently connect the battery up the wrong
way round, the controller will be destroyed.
Protection is fitted internally to some controllers or
may easily be added externally to others. However, it
is always possible to fit an external relay to any
controller to do this.
Reversing
A permanent magnet motor is reversed simply by
interchanging its two armature wires. However, this
should never be done while the motor is rotating: not
only will that cause a mechanical jolt but large
currents could flow which could damage controller
and/or motor. If the controller is a reversing one, it
will do the reversing safely - even if the switch is
operated at full speed (see Dual-ramp and Pre-select)
- so these controllers are better where the
inexperienced may operate the machine!
Robots
4QD’s controllers get used a lot for Robot Wars. Two
speed controllers are normally used, one for each
motor so that motor speed can be varied
independently to steer the machine.
A ‘Dual Channel Interface’ (DCI) card (listed in the
Accessories Catalogue) is used to interface between
two potentiometers (which are operated by the radio
controlled servos) and the controllers. The DCI
translates the potentiometers to a speed and direction
signal suitable for two NCC or Pro series controllers
so that the pot centre is zero speed. The DCI has two
modes
Independent (or 'Tank Style') so that one pot operates
left controller and the other, the right.
Uni series Speed Controllers
A series of Universal, Unidirectional, Unique controllers of unimpeachable reliability suitable for all the usual
applications as as well as some unusual ones.
This is our simplest general purpose speed controller which gives regenerative braking.
Regenerative braking which may be disabled (factory option)
Reverse polarity protection
Pot fault protection
Auto power up
Auto power down
Thermal shutdown (90°)
Adjustable gain
Accel and decel ramps, adjustable
Current limit: fast, on drive and regeneration
Level automatically reduces as MOSFETs heat to keep current to a level that is safe for the MOSFETs
6.3mm push-on connectors for battery and motor
Supply voltage:
Supply current :
Output current:
Size:
Size:
Weight:
Input:
Pot fault detect:
12v or 24v or 36v
depends on model.
48v on request.
electronics
30mA
relay (12v)
relay (24v)
typical when cold: current reduces with heating.
Uni-4
55A (45A braking)
Uni-8
110A (90A braking)
board only
71mm x 71mm x 35mm
base/heatsink
80mm x 100mm x 4mm
board version
110 gm
Cased version
210 gm
1k to 25k pot.
or
3v to 20v
greater than
30K
adjustable
Differential (or ‘Speed and Steer') where one pot
controls the speed of both motors equally and the
other controls the difference between left and right.
Regen braking
Some controllers can not only supply (source) current
to the motors but can also sink current which is
generated by the motor. Thus causes regenerative
braking (regenerative since the braking energy is fed
back - regenerated - to the battery). The process is
entirely automatic and occurs when the motor overruns (or the demand speed is reduced) so that the
motor's back EMF is greater than the output voltage
from the controller.
Page: 6
mV drop at 20 amp
260mV
130mV
Section of controller in case.
4QD controllers: selection Guide
4QD controllers: selection Guide
Page: 19
Uni series Speed Controllers
Board version
Cased version
(with Base and cover)
Battery +
Motor +
Motor Battery -
It is therefore up to the vehicle designer to ensure that
there is adequate provision for emergencies.
Series wound motors
These work differently from PM motors, but can be
used with our controllers: sometimes as a factory
option ('Opt'). Contact 4QD for advice.
Reverse polarity protection relay
Gain adjust
Battery +
Input connector
Motor +
Acceleration
Deceleration
©
Battery -
0002
Heatsink/mounting block
Uni-4-12
Uni-4-24
Uni-4-36
Uni-4-48
Uni-8-12
Uni-8-24
Uni-8-36
Uni-8-48
-RG regen braking
-NB no regen braking
Note: if not specified
RG model is supplied.
Page: 18
Speed controller
All series are 'speed controllers' but you should be
aware of the difference between these and a 'vehicle
controller'. Vehicle controllers are normally intended
for passenger-carrying vehicles so have more safety
features and more provision against rider abuse.
Speed range
All controllers in our range give fine speed control
over the full range 0% to 100%.
Motor -
Order codes:
Safety
In practice, regenerative braking
is extremely
reliable, but there are circumstances where it cannot
operate, therefore it should not be relied on as a
safety feature. Similarly, the parking brake often
fitted to the motors is not designed to cope with
emergency stopping at full speed and the controller
cannot safely call on this for emergency use.
Uni-Bas (base only)
Uni-BCL (base, cover and leads)
For housed version, add suffix
--BCL
Base and cover may be ordered
separately
4QD controllers: selection Guide
Switching frequency
All 4QDs controllers switch at high frequency
(typically around 20 thousand times per second 20kHz). This is high enough to give no whistle or
whine from the motor but, more importantly, it means
that as far as the motor is concerned the voltage to it
is pure d.c., so the current it draws is continuous - not
pulsed as it used to be in older thyristor or similar
controllers.
Tachogenerator feedback
A simple controller feeds a varying voltage to the
motor: this is normally completely adequate since, if
the operator wants to go faster they will simply
increase speed. This is an 'open loop' system where
the controller does not compensate for varying loads.
A tachogenerator is a small generator (a small PM
motor can be used) which is attached to the motor
shaft and which generates a voltage which tells the
controller the true shaft speed: in this way the
controller can compensate for varying loads. There
are other methods of 'closing the loop': contact 4QD
for advice.
4QD controllers: selection Guide
Thermal shutdown
On some controllers a thermal sensor is fitted (or can
be fitted as an option) to detect the temperature and
reduce the available current if the controller
overheats. Some models have a switch action which
turns off the controller ('trip' on the check list).
This sensor clearly must measure the temperature at
one place (normally the internal heatsink) but, at high
current, several components can get hot (copper
track, relays, connections and main capacitor). The
distribution of heating depends on the application, the
motor and wiring so is outside our control. You
should therefore contact 4QD for advice if you think
overheating may be a problem.
Sensors fitted operate typically at 95°C - so the units
can get quite hot before the sensor operates.
Do not confuse thermal shutdown with the automatic
temperature-compensating 'Current limit'.
Vehicle controller
This is a controller intended for passenger carrying
vehicles. It has more safety features than a straight
speed controller.
Voltage input.
Instead of a speed pot, all controllers can be driven
from a voltage input, typically 0.5v for zero speed, 4v
for full speed.
Waterproofing
Controllers vary in their target markets, so in the
degree of protection afforded. All controllers are
varnished and do not suffer problems with normal
humidity. However water splashes on the circuit
board are likely to cause malfunction - or can even
kill the board.
Cased controllers such as the 4QD series and the Pro120 can (when mounted as we instruct) have very
good splashproofing. The covers are completely
waterproof and the most likely entry for water is by it
running down power leads - which is easily stopped!
On the other hand, if you mount the controller
upside-down so the cover collects water there's not
much we can do to stop you!
Page: 7
4QD series Vehicle Controllers
Features
Wig-wag
US term for 'Joystick' (q.v.)
NCC series, Budget Vehicle Controllers
The NCC series are budget (yet full-featured) reversing controllers intended for such things as miniature locos,
kiddie cars and mobility aids.
Accel/decel ramps - adjustable
Other Features
Many other features can be Battery discharge protection
incorporated either by modification (to special order only).
to the controller or in the external
wiring so if you don't see what you Box/Cover - included
require, please enquire.
Gain adjustment
Ordering
The controllers are laid out one Current limit adjustment
'family' per page, with a drawing.
The centre page is a check list of High pedal lockout
available features showing the
features that each controller range Inhibit input
offers.
Joystick/Wig-wag input
Against each family of controllers is
a box listing the available model Parking brake driver
with an order code thus: Pro-120-24
Please use these codes to order: see 4 Quadrants
separate price list for details and
prices.
Regen braking
There are two basic boards: the NCC-35 and the NCC-60 / NCC-70.
Both are available in 12v, 24v, 36v and 48v versions.
The controller is also popular as a component in large systems as it is economical and has fast response.
Supply voltage:
Supply current:
Output current:
(typical when cold)
Output current:
(typical when hot)
mV drop at 20 amps:
Overheat current:
NCC-35
NCC-60 & 70
NCC-35
NCC-60 & 70
NCC-35
NCC-60 & 70
typical,
NCC-60 & 70
Size:
Weight:
Input (adjustable):
Pot fault detect:
Ramp times (adjustable):
12v or 24v (36 & 48 to order)
30mA (At zero speed)
55A (50 amps regen)
current limit, typical
110A (100 amps regen)
current limit, typical
40A
90A
240mV
120mV
20 amps
172mm x 81mm x 40mm
260g
2k to 20k pot or 0-3v
greater than 25K
1/3 Sec to 7 Sec
Reversing
Thermal shutdown (90°C)
Features
Reverse polarity protection by
external relay or contactor.
Options
Parking brake may be replaced by
'Braking' light output.
4 Quadrants
Accel/decel ramps
Box/Cover order separately
Gain adjustment
Ignition: active
Joystick/Wig-wag input: by external board
Parking brake driver on -70, optional on others
Regen braking
Reverse polarity protection by external relay
Thermal shutdown (90°C) (on -70, option OHS-095 on others)
Expansion Connector option
Dual Channel Interface
Some machines, such as robots, have two motors, one to each drive wheel, and are steered by speeding up one
motor and slowing the other. The DCI-111 is an interface between two pots (which can be mechanically
operated by the radio control servos) and two controllers such an NCC Series or Pro Series.
The interface is described in the ‘Accessories Catalogue’.
Page: 8
4QD controllers: selection Guide
4QD controllers: selection Guide
Page: 17
The drawings below shows the construction which is
NCC series, Budget Vehicle Controllers
Battery +
Brake MOSFETs
Motor +
Brake solenoid
driver (option)
Our 'flagship' range of controllers, available for 24v, 36v and 48v in 3 current ranges - 150a, 200a and 300a.
The -250a is a higher voltage version of the -300, slightly de-rated because of the higher voltage.
NCC-70/100
4QD © 1996
Brake
solenoid
Burwell
Cambridgeshire
CB5 0AH
+44 1638 741 930
(Phone & Fax)
Ignition
Dir'n switch
Speed pot
They are all-semiconductor full-bridge designs giving full 4 quadrant control. Having no relays, the higher
voltage versions will all work properly down to below 24v so the 36v version is in fact normally identical to
the 24v version!
The controller is built on to a substantial aluminium base and has a waterproof cover which is shown cutaway in the lower diagram to view the two-board construction with the MOSFETs mounted on substantial
thermal/electrical busbars. Power connection are 6mm (8mm on -300 models) studs at the mouth of the
controller. Splash barriers are present behind the terminals to resist water.
Gain
Input connectors : 6 way for pot, reversing switch & inhibit, 4 way for ignition and main contactor (reverse
polarity protection relay) and 3 way for parking brake.
Heatsink
Accel Decel
Expansion connector
Order codes:
NCC-35-12
NCC-35-24
NCC-35-36
NCC-35-48
NCC-70-12
NCC-70-24
NCC-70-36
NCC-70-48
Power relays Motor –
Drive MOSFETs
Thermal sensor (option)
Battery –
NCC-Box-Wir
NCC-Box-Bul
HCB-600
BUS-006
Overheat sensor option: OHS-095
Expansion socket option: XCN-006
Bulgin 6 way
chassis plug
(option)
118
55
1.0m cables
red & black: battery
blue & yellow: motor
187
Boxed version of NCC (shown above) is available
with Bulgin 6 way connector set (NCC-Cas-Bul), as
shown or with a 6 core flying lead (NCC-Cas-Wir).
The Bulgin connector is illustrated in the Accessories
Catalogue. Don’t forget to order a hand control or
plug or lead for this!
Page: 16
modular so that elements of it are suitable for
The boxed option includes an internal fuse which
gives a good measure of reverse battery protection.
Order controller plus box as two separate codes but it
will be supplied assembled.
The range is intended for heavier one-man golf buggies, larger locos, go-karts and similar machines. The
4QD-300-48 and 4QD-250-60 are a good match to the Lynch motor for larger golf cars, go-karts etc.
Battery discharge protection can be fitted, to special order only. Clearly when fitted, the 36v, 48v and 60v
controllers will not function on lower voltages.
Order Codes
Supply current, quiescent:
70mA
Supply voltage:
24v version
18v to 42v
4QD-150-24/36
36v version
18v to 42v
4QD-150-48
48v version
18v to 56v
60v version
18v to 70v
4QD-200-24/36
Battery discharge protection threshold (when fitted):
4QD-200-48
21v
24v version
31.5v / 42v
36v / 48v versions
4QD-300-24/36
Output current, limit:
150a version
160A
4QD-300-48
(typical)
200a version
210A
300a version
320A
4QD-250-60
250a version
250
4 minute rating:
150a version
120A minimum
Current adjustment:
50% to 100% full current
Reverse current limit:
150a and 200a
75% of forward current
250a
80% of forward current
300a version
85% of forward current
Ramps (accel & decel):
0.3s to 12 sec, linear, adjustable
Pot Value:
10K preferred
1K to 22K acceptable
Input voltage for full speed:
adjustable, 3v min, 20v max (can be altered).
Size:
-150 & -200
250mm x 103mm x 60mm
-250 & -300
280mm x 103mm x 60mm
Weight:
-150 & -200
1300g (of which heatsink is 650gm)
-300
1685g (of which heatsink is 725gm)
Mode switch:
(optional)
Single ended or joystick
Parking brake output:
1A
(overcurrent operates at about 1.2A)
These are assembled as required so may take a few
days.
4QD controllers: selection Guide
4QD controllers: selection Guide
Page: 9
Excel range Controllers
'Scoota' Non Reversing Vehicle Controllers
Virtually all modern controllers are getting more and
more sophisticated and we need to keep our position
in this high tech market. However, there are lots of
applications which need a simple yet powerful
controller with no ‘frills’. It seems impossible to
satisfy both markets - yet this is exactly what our
new Excel range will do.
the 4QD series) 220mm long by 100mm wide.
The 'Scoota' is based on our very successful Pro-120, but without the reversing facility.
Current limit (drive): fast, thermally sensitive,
monitors MOSFETs to keep them within safe limits.
Approx 600A limit when cold.
It also has a unique 'refresh' ignition circuit where the throttle must be engaged and the refresh button pressed
momentarily to start. The controller will switch itself off automatically several seconds after the speed has
returned to zero.
Current limit (regen): approx 500A when cold.
The regen current also can be reduced (or disabled completely) to decrease braking torque, for instance, in
high-ratio belt drives that can slip when the motor is driven in regen braking.
It uses MXM technology (standing for MiX and
Match): the first unit to be available will be the XL500 ‘Power Brick’. This is the power amplifier only:
it is a two quadrant controller (drive and regen
braking) using 4QD’s well established powerhandling circuitry - this has fast current limiting in
both drive and regen mode, to protect the MOSFETs
against abuse.
Overheat sensor: cuts back current limit when
controller temperature reaches 95°C.
Available as an 80 or a 120 amp version.
The ‘Power Brick’ will be available separately for
those customers who wish to use their own control
software. It will also be available with a very simple
analogue front end for simple ‘brute force’
applications which require no sophistication.
Specifications of the Scoota-120 are virtually identical to those or the Pro-120, and Sc-80 is similar but with
2/3 the current output.
Power connections are by 9.5mm tabs. For quantity orders, 6.3mm tabs can be fitted.
Specifications of the Sco-120 generally as for the Pro-120 except:
The XL-500 will give a peak current of around 600
amps but of course, like all controllers, at this current
it will get hot and cut out. The intention is that it
should give 200 amps continuous with not too much
additional airflow or heatsinking.
Output current, continuous:
50 amps typically, heatsink and wiring dependant.
Base and cover available (as for Pro series).
The current limit is present only to protect the
MOSFETs: at this level of current the motor can get
hot and this also needs monitoring. The idea is to use
a microprocessor to monitor and control motor and
vehicle operation (and battery charging), leaving the
‘Power Brick’ to look after itself. The micro will
control ramping, operator interface, reversing and
any additional features that are required.
Of course, it is possible to produce a whole family of
microprocessor front-ends, from simple ones up to
sophisticated systems, such as a proposed one for
go-karts which have sound generation, remote
monitoring, remote fault analysis and diagnosis by
modem and whatever else is required.
Other modules in the system might be a simple
analogue ramp board where no sophistication is
required. Other modules can be designed as required.
The whole MiX and Match technology means that to
make a new controller will not require re-designing
the whole board, but maybe modifying a single
module - or perhaps designing a new module, but not
a complete controller.
The XL PB-500 is on an aluminium base (similar to
Page: 10
4QD controllers: selection Guide
4QD controllers: selection Guide
Page: 15
'Scoota' Non Reversing Vehicle Controllers
Regen brake current control (opt)
Excel range Controllers
Trickle resistor
22R
Battery +
Gain
1
2
3
4
5
6
Controls
Motor +
4QD
Burwell
Cambridgeshire
100K
CB5 0AH
UK
+44 1638 741930
100K
Accel
☎
Motor −
10K
Decel
1
2
3
©
Parking brake
Battery −
100K
1997
MOSFETs
Brake drive transistor
Thermal sensor
The Scoota is available only to OEMs, i.e. against quantity orders only.
Features
Accel/decel ramps
Auto power-down optional
Battery discharge protection
Box/Cover order separately
Gain adjustment
High pedal lockout
Ignition: active
Joystick/Wig-wag input by external board.
Parking brake driver
2 Quadrants
Regen braking
Reverse polarity protection
Thermal shutdown (90°C)
Outer cover
Cavity for microprocessor or other control board.
Inner cover
Main capacitors
Regen braking may be reduced or deactivated (factory option)
Modulator board
MOSFETs
Order codes
Sco-80-12
Sco-80-24
Sco-80-36
Sco-80-48
Page: 14
Pro-Bas
Pro-Cov
Sco-120-12
Sco-120-24
MOSFET drive board
Sco-120-36
Sco-120-48
busbar
aluminium baseplate
4QD controllers: selection Guide
4QD controllers: selection Guide
Page: 11
Pro series Professional Vehicle Controllers
UVP
2
3 123456789
4
1
Thermal sensor Trickle resistor
Rhplo
Expansion connector
Pro series Professional vehicle controllers
6
7
The Pro-120 design was based on our long established and well proven NCC series controllers and versions
are available for operation on 12v, 24v, 36v and 48v
8
5
Battery +
9
12
10
1
2
3
4
5
6
13
Gain
14
1
2
3
18
19
15
20
Accel
16
Controls
It is particularly valuable for OEM purposes as it has all the 'industry' standard features built in - but at a
distinctly non-standard value for money.
Parking brake
Optional extras include a
tacho feedback board
base and cover (shown opposite).
17
Motor −
21
Motor +
22
Decel
23
24
25
S
28
26
Half speed
Full speed
Reverse
27
29
Battery −
MOSFETs
30
4QD
Burwell
Cambridgeshire
CB5 0AH
UK
+44 1638 741 930
31
It is aimed at small to medium one-man golf buggies, 7¼" locos and similar heavy duty applications
applications.
Brake drive transistor
Features
Accel/decel ramps
Auto power-down (optional)
¶ Battery discharge protection
Box/Cover - order separately
Gain adjustment
¶ Half speed reverse
¶ High pedal lockout
¶ Ignition: active
Joystick/Wig-wag input by external board.
¶ Parking brake driver OR ‘Decelerating’ light driver
4 Quadrants
Regen braking
Reverse polarity protection
Reversing
Thermal shutdown (90°C)
Standard power connections are by 9.5mm tabs. Two sets of 9.5 motor tabs are fitted (to accommodate two
motors). A second set of battery terminals (for 9.5 or for 6.3 push-ons) is fitted to accommodate a charger or
other battery connection.
6.3mm tabs or M4 studs can be fitted to order at extra charge.
Supply current
(no load)
Output current limit, drive (typical)
regen
1 minute rating
2 minute
continuous
Voltage drop
at 20 amps
Overheat current
25a
Pot
Ramp times
Size
Board only
with base & cover
with large base and cover #
Weight
board only
with base & cover
30mA
145 amps
100 amps
110 amps ¶
60 amps
30 amps ‡
90mV
typical
5K-10K 30K = fault
1/3 sec to 7 sec
adjustable
160mm x 100mm x 40mm
181mm x 121mm x 48mm
245mm x 144mm x 48mm
325g
625g complete
¶ without additional heatsink!
‡ Heatsink dependant
# Large base suits some golf buggies for replacement of older controllers.
¶ Features may be disabled
Order codes
Pro-120-12
Pro-120-24
Pro-120-36
Pro-120-48
Page: 12
Optional Tacho feedback board for Pro-120.
Plugs into optional expansion connector on Pro-120
and enables it to be used with a tacho generator in
closed loop (velocity control) systems. Contact
factory for availability.
Pro-Bas
Pro-Cov
Pro-Bas-Lg
Expansion connector option
XCP-009
4QD controllers: selection Guide
Pro Tacho board . . . . . . . . . . . . . TFB-120
4QD controllers: selection Guide
Page: 13