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ZB48400
ZHIBI
High current big power 24V 48V 400A 600A 800A DC motor speed controller 48v brushed dc motor controller
Product model | Rated voltage | Rated current | 1 hour current | Minimum voltage | Highest voltage | Referenced motor power |
DC24DP400BL-R01 | 24V | 400A | 150A | 19V | 36V | 4KW |
DC36DP400BL-R01 | 36V | 400A | 160A | 28V | 44V | 4KW |
DC48DP400BL-R01 | 48V | 400A | 170A | 36V | 60V | 4KW |
DC72DP400BL-R01 | 72V | 400A | 180A | 54V | 90V | 4KW |
| DC48DP600BL-R01 | 48V | 600A | 200A | 36V | 60V | 5KW |
| DC48DP800BL-R01 | 48V | 800A | 266A | 36V | 60V | 8KW |
1. PWM pulse width modulation
2. Speed regulation ratio: 1:60
3. Speed regulation mode:
Model suffix with R01 means speed regulation mode of:
Potentiometer (10KΩ/2W)/signal isolator (0-5V,0-10V,4-20mA)
4. Input impedance: ≥10KΩ
5. Working voltage range: ±25% of nominal voltage
6. Soft start time: 1-5 S
7. Ambient temperature: -10℃~+60℃
8. Ambient humidity: relative humidity ≤80RH.(non condensing)
9. Current restriction protection
10. Remote start-stop can be realized
11. Applied for permanent magnet, separate excitation and series-excited motor
12. Thermal protection for controller cutting off output in case of overheating for controller to effectively protect controller and traveling crane safety.
13. Able to directly judge source of fault through luminous diode under working condition.
14. Stepless speed regulating and anti-phase braking control
15. Built-in precharging resistor and polarity protection diode provide convenience for installation and use
16. Under voltage and over voltage protection effectively protects storage battery and all components of controller assembly
17. 90 seconds no acceleration signal input can automatically cut off the power of contactor magnet coil to save the energy of storage battery.
LED Code | Definition | Potential fault cause and solution |
LED is off | No power | 1.Power is off, and check if main power correctly and reliably connects with controller system or not; main fuse and control circuit protection is open circuit or not; voltage is present at control wiring terminal of controller "P12" or not. 2.If still not work in case of all wires and power supply under normal condition, controller is broken |
LED is on normally | Controller fault | 1．Controller is broken |
Single flashing of LED | Normal running | 1．Spacing interval of single flashing is 4 seconds |
Quick single flashing of LED | Normal running | 1．Spacing interval of single flashing is 0.13 seconds, and controller is on the position of reverse gear |
1, 2 | Overheating of the controller | 1．Temperature within controller is higher than 85 Celsius Degree. 2．Vehicle continues be under overload operation. 3．Installation position of controller assembly is not suitable with bad ventilation. 4．Be in used under hot environment. 5．Selection for controller assembly power is not suitable, and please select suitable controller assembly power. |
1, 4 | Operation sequence error | In case of sequence error, only reset and re-speed up the footstep of accelerator to remove fault. In case of fault for accelerator, the output voltage signal voltage is higher than 1.5V under reset state for accelerator. (normal value < 0.8V). |
2, 1 | Accelerator micro switch fault | In case of reset for accelerator, there is high potential for controlling terminal P3 of controller (same as power voltage). Contact adhesion of micro switch. |
2, 2 | M-output fault | B- Short circuit of M-output. 2．Open circuit of testing line for accelerator position. In case of stepping footstep of accelerator, there will be high potential for controlling terminal P3 of controller. 3．Motor short circuit |
2, 3 | Contact adhesion of main contactor | Measure the resistance of two ends of main contactors prior to un-closing electric lock switch, and resistance of 0Ω means contactors adhesion. Dismantle the top cover of contactor points, reinstall it after grinding burned-out contactor point with fine sand paper, and replace the contactor with serious damage. In case of fault, controller assembly will cut off output current and last alarm for 15 seconds. It is not safe if continue to use vehicle. |
2, 4 | Power supply overpressure protection | Voltage of storage battery exceeds voltage application range of controller assembly Voltage of storage battery should not exceed 125% of the voltage of controller assembly. |
3, 1 | Contactor driving circuit fault | For overcurrent of driving circuit, maximum current of allowed long time of working for contactor's driving circuit is 2A, and overcurrent protection is 3A. Short circuit for contactor magnet coils. Reversed connection for diode in parallel of contactor magnet coils. Excessive working current of contactor magnet coils. |
3, 2 | Main contactor fault | Voltage drop of contactor points is greater than 0.7V. Poor connection for contactor points. The sucking sound from main contactor can be heard in case of stepping footstep of accelerator, the voltage of two ends of measuring points is zero when controller assembly working, and there must be poor connection for contactor if voltage not equal to zero; Dismantle the top cover of contactor points, and reinstall it after grinding burned-out contactor point with fine sand paper. If dust exists, clear it. And replace the contactor with serious damage. If contactor coils do not work and the sucking sound from main contactor can not be heard in case of stepping footstep of accelerator, the reason generally is that contactor magnet coils is open circuit. |
3, 3 | Reversing contactor fault | This fault is used for testing motor. For reversing contactor circuit, it can display results after 60 seconds since stepping the footstep of accelerator. If there is poor contact for reversing contactor points, the sucking sound of forward/back from contactor can be heard. If the sucking sound from contactor can not be heard in case of switching for change-over switch, the reason generally is that contactor magnet coils is open circuit. For forward/back of vehicle, normal operation for one side and abnormal operation for the other side shows that there is fault for the contactor with abnormal operation. Dismantle the top cover of contactor points, and reinstall it after grinding burned-out contactor point with fine sand paper. If dust exists, clear it. And replace the contactor with serious damage. In case of open circuit for electromotor, if the sucking sound from contactor can not be heard in case of switching for change-over switch and vehicle do not work forward and back, check if the wires of motor is correct and stable, and if there is good contact for carbon brush of motor. |
4, 1 | Acceleration signal input fault | Accelerator output signal exceeds the voltage of signal input range of chopper. Error of acceleration wiring Acceleration is broken Poor contact or open circuit of negative wires of acceleration power |
4, 2 | Precharge fails | Short circuit of M-output to B- 2．Short circuit of motor outlet to B- 3．Interior short circuit of controller |
4, 3 | Controller fault | 1．Controller fault |
High current big power 24V 48V 400A 600A 800A DC motor speed controller 48v brushed dc motor controller
Product model | Rated voltage | Rated current | 1 hour current | Minimum voltage | Highest voltage | Referenced motor power |
DC24DP400BL-R01 | 24V | 400A | 150A | 19V | 36V | 4KW |
DC36DP400BL-R01 | 36V | 400A | 160A | 28V | 44V | 4KW |
DC48DP400BL-R01 | 48V | 400A | 170A | 36V | 60V | 4KW |
DC72DP400BL-R01 | 72V | 400A | 180A | 54V | 90V | 4KW |
| DC48DP600BL-R01 | 48V | 600A | 200A | 36V | 60V | 5KW |
| DC48DP800BL-R01 | 48V | 800A | 266A | 36V | 60V | 8KW |
1. PWM pulse width modulation
2. Speed regulation ratio: 1:60
3. Speed regulation mode:
Model suffix with R01 means speed regulation mode of:
Potentiometer (10KΩ/2W)/signal isolator (0-5V,0-10V,4-20mA)
4. Input impedance: ≥10KΩ
5. Working voltage range: ±25% of nominal voltage
6. Soft start time: 1-5 S
7. Ambient temperature: -10℃~+60℃
8. Ambient humidity: relative humidity ≤80RH.(non condensing)
9. Current restriction protection
10. Remote start-stop can be realized
11. Applied for permanent magnet, separate excitation and series-excited motor
12. Thermal protection for controller cutting off output in case of overheating for controller to effectively protect controller and traveling crane safety.
13. Able to directly judge source of fault through luminous diode under working condition.
14. Stepless speed regulating and anti-phase braking control
15. Built-in precharging resistor and polarity protection diode provide convenience for installation and use
16. Under voltage and over voltage protection effectively protects storage battery and all components of controller assembly
17. 90 seconds no acceleration signal input can automatically cut off the power of contactor magnet coil to save the energy of storage battery.
LED Code | Definition | Potential fault cause and solution |
LED is off | No power | 1.Power is off, and check if main power correctly and reliably connects with controller system or not; main fuse and control circuit protection is open circuit or not; voltage is present at control wiring terminal of controller "P12" or not. 2.If still not work in case of all wires and power supply under normal condition, controller is broken |
LED is on normally | Controller fault | 1．Controller is broken |
Single flashing of LED | Normal running | 1．Spacing interval of single flashing is 4 seconds |
Quick single flashing of LED | Normal running | 1．Spacing interval of single flashing is 0.13 seconds, and controller is on the position of reverse gear |
1, 2 | Overheating of the controller | 1．Temperature within controller is higher than 85 Celsius Degree. 2．Vehicle continues be under overload operation. 3．Installation position of controller assembly is not suitable with bad ventilation. 4．Be in used under hot environment. 5．Selection for controller assembly power is not suitable, and please select suitable controller assembly power. |
1, 4 | Operation sequence error | In case of sequence error, only reset and re-speed up the footstep of accelerator to remove fault. In case of fault for accelerator, the output voltage signal voltage is higher than 1.5V under reset state for accelerator. (normal value < 0.8V). |
2, 1 | Accelerator micro switch fault | In case of reset for accelerator, there is high potential for controlling terminal P3 of controller (same as power voltage). Contact adhesion of micro switch. |
2, 2 | M-output fault | B- Short circuit of M-output. 2．Open circuit of testing line for accelerator position. In case of stepping footstep of accelerator, there will be high potential for controlling terminal P3 of controller. 3．Motor short circuit |
2, 3 | Contact adhesion of main contactor | Measure the resistance of two ends of main contactors prior to un-closing electric lock switch, and resistance of 0Ω means contactors adhesion. Dismantle the top cover of contactor points, reinstall it after grinding burned-out contactor point with fine sand paper, and replace the contactor with serious damage. In case of fault, controller assembly will cut off output current and last alarm for 15 seconds. It is not safe if continue to use vehicle. |
2, 4 | Power supply overpressure protection | Voltage of storage battery exceeds voltage application range of controller assembly Voltage of storage battery should not exceed 125% of the voltage of controller assembly. |
3, 1 | Contactor driving circuit fault | For overcurrent of driving circuit, maximum current of allowed long time of working for contactor's driving circuit is 2A, and overcurrent protection is 3A. Short circuit for contactor magnet coils. Reversed connection for diode in parallel of contactor magnet coils. Excessive working current of contactor magnet coils. |
3, 2 | Main contactor fault | Voltage drop of contactor points is greater than 0.7V. Poor connection for contactor points. The sucking sound from main contactor can be heard in case of stepping footstep of accelerator, the voltage of two ends of measuring points is zero when controller assembly working, and there must be poor connection for contactor if voltage not equal to zero; Dismantle the top cover of contactor points, and reinstall it after grinding burned-out contactor point with fine sand paper. If dust exists, clear it. And replace the contactor with serious damage. If contactor coils do not work and the sucking sound from main contactor can not be heard in case of stepping footstep of accelerator, the reason generally is that contactor magnet coils is open circuit. |
3, 3 | Reversing contactor fault | This fault is used for testing motor. For reversing contactor circuit, it can display results after 60 seconds since stepping the footstep of accelerator. If there is poor contact for reversing contactor points, the sucking sound of forward/back from contactor can be heard. If the sucking sound from contactor can not be heard in case of switching for change-over switch, the reason generally is that contactor magnet coils is open circuit. For forward/back of vehicle, normal operation for one side and abnormal operation for the other side shows that there is fault for the contactor with abnormal operation. Dismantle the top cover of contactor points, and reinstall it after grinding burned-out contactor point with fine sand paper. If dust exists, clear it. And replace the contactor with serious damage. In case of open circuit for electromotor, if the sucking sound from contactor can not be heard in case of switching for change-over switch and vehicle do not work forward and back, check if the wires of motor is correct and stable, and if there is good contact for carbon brush of motor. |
4, 1 | Acceleration signal input fault | Accelerator output signal exceeds the voltage of signal input range of chopper. Error of acceleration wiring Acceleration is broken Poor contact or open circuit of negative wires of acceleration power |
4, 2 | Precharge fails | Short circuit of M-output to B- 2．Short circuit of motor outlet to B- 3．Interior short circuit of controller |
4, 3 | Controller fault | 1．Controller fault |
