1. Introduction
This manual provides essential information for the safe and effective installation, operation, and maintenance of the BM24C10-CAN (24V/100A) Walking Controller. This controller is designed for use in forklift control systems, managing the operation of DC permanent magnet motors. Please read this manual thoroughly before attempting any installation or operation.
2. Safety Information
Always observe the following safety precautions to prevent injury and damage to the equipment:
- Professional Installation: Installation should only be performed by qualified personnel with experience in electrical systems and forklift maintenance.
- Power Disconnection: Always disconnect the battery power before performing any installation, maintenance, or troubleshooting.
- Correct Voltage: Ensure the power supply voltage matches the controller's specifications (24VDC). Incorrect voltage can cause severe damage.
- Proper Wiring: Verify all wiring connections are secure and correctly polarized (positive to positive, negative to negative). Loose connections can lead to overheating or malfunction.
- Environmental Conditions: Avoid exposing the controller to excessive moisture, dust, or extreme temperatures.
- Component Integrity: Do not use the controller if it shows signs of physical damage.
3. Product Overview
The BM24C10-CAN is a robust DC permanent magnet motor controller. It features a compact design suitable for integration into various forklift models. The controller includes clearly labeled terminals for motor and battery connections.
3.1. Dimensions and Physical Features
3.2. Key Components
- Motor Terminals: M1, M2 (for connecting to the DC permanent magnet motor).
- Battery Terminals: B+, B- (for connecting to the 24VDC power source).
- Control Interface: Additional connectors for control signals (e.g., throttle, direction, safety interlocks).
- Product Label: Contains model number, voltage, current, torque, and serial number.
4. Installation
Proper installation is crucial for the controller's performance and safety. Refer to the forklift's specific wiring diagrams and consult a qualified technician.
4.1. Mounting
- Mount the controller in a location that is protected from direct moisture, excessive heat, and vibration.
- Ensure adequate airflow around the controller for cooling.
- Use appropriate fasteners to secure the controller firmly to the forklift chassis.
4.2. Wiring Connections
- Disconnect Power: Before making any connections, ensure the forklift's battery is completely disconnected.
- Battery Connections: Connect the main positive (+) terminal of the 24VDC battery to the B+ terminal on the controller. Connect the main negative (-) terminal of the battery to the B- terminal on the controller. Use heavy-gauge wires suitable for 100A current.
- Motor Connections: Connect the motor leads to the M1 and M2 terminals. The polarity of these connections will determine the motor's direction. If the motor rotates in the wrong direction, reverse these connections.
- Control Signal Connections: Connect the throttle, direction switch, and any safety interlock signals to the appropriate control terminals as per the forklift's wiring diagram.
- Verify Connections: Double-check all connections for tightness and correct polarity.
- Reconnect Power: Once all connections are verified, carefully reconnect the battery power.
5. Operation
The BM24C10-CAN controller manages the speed and direction of the forklift's DC permanent magnet motor based on input from the throttle and direction controls.
- Power On: Turn on the forklift's main power switch. The controller should initialize.
- Throttle Control: Gradually apply the throttle to increase motor speed. The controller will regulate power to the motor.
- Direction Control: Use the direction switch (forward/reverse) to change the motor's rotation direction. Ensure the vehicle is stationary or moving slowly before changing direction to prevent mechanical stress.
- Braking: The controller may support regenerative braking or other braking mechanisms depending on the forklift's system. Refer to the forklift's specific operational manual.
6. Maintenance
Regular maintenance ensures optimal performance and longevity of the controller.
- Visual Inspection: Periodically inspect the controller for any signs of physical damage, corrosion, or loose connections.
- Cleaning: Keep the controller clean and free from dust, dirt, and debris. Use a dry, soft cloth for cleaning. Do not use solvents or abrasive cleaners.
- Connection Checks: Ensure all wiring terminals (M1, M2, B+, B-) are tight and free from oxidation.
- Heat Dissipation: Verify that the mounting area allows for proper heat dissipation and that cooling fins (if present) are not obstructed.
- Firmware Updates: If applicable, consult the manufacturer for information on firmware updates.
7. Troubleshooting
Before troubleshooting, always disconnect power. If issues persist after basic checks, consult a qualified technician.
| Problem | Possible Cause | Solution |
|---|---|---|
| Controller has no power/indicator lights off | No battery power; Loose battery connections; Blown fuse | Check battery charge; Inspect and tighten B+, B- connections; Check and replace fuse if necessary. |
| Motor does not respond | Loose motor connections; Faulty throttle; Faulty motor; Safety interlock engaged | Inspect and tighten M1, M2 connections; Test throttle functionality; Check motor for faults; Ensure all safety interlocks are disengaged. |
| Motor runs in wrong direction | Incorrect motor wiring polarity | Reverse the M1 and M2 motor connections. |
| Overheating | Excessive load; Insufficient ventilation; Short circuit | Reduce load; Ensure proper airflow around controller; Check for short circuits in wiring. |
8. Specifications
The following table outlines the general specifications for the BM24C10 series walking controllers. Specific models may have slight variations.
| Feature | Specification |
|---|---|
| Model | BM24C10-CAN, BM24C10, BM24C10-CAN-N (and variants) |
| Type | DC Permanent Magnet Motor Controller |
| Voltage | 24VDC |
| Current | 100A |
| Torque | 1.6-2.0 N.m |
| Dimensions (approx.) | Height: 43mm, Width: 72-73mm, Depth: 35mm |
| DIY Supplies | Electrical |
| Origin | Mainland China |
| Certification | NONE (as per product data) |
| Customization | Yes (Can be customized) |
8.1. Available Variants
- Walking controller (Lida program) BM24C10-CAN (24V/100A)
- Walking controller (Lida program) BM24C10 (24V/100A)
- Walking Controller (Hangcha Program 1) BM24C10 AMBJ157-720000-00
- Walking Controller (Hangcha Program 2) BM24C10 AIMBJ150-72000-000
- BM24C10 (Noli Program/EPT15) BM24C10 (24V/100A) 921400100126
- BM24C10 (Nori Program/PSE15-C)
- BM24C10-CAN-N (Nori Program/PTE15Q)
9. User Tips
No specific user tips were available from the provided reviews or Q&A data. Always refer to the forklift's specific operational guidelines and consult with a qualified technician for any complex issues.
10. Warranty and Support
For warranty information and technical support, please refer to the terms provided by your supplier or the forklift manufacturer. Ensure you retain your purchase records for any warranty claims.
