ZXD2400 modification guild 3Kw 0-60V 0-50A

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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 02 Apr 2019, 08:45

I will do mine shortly. I don't feel safe using bananas because I'm so stupid that i can easily put red in black and vis-versa. hanged

I like Anderson's and XTs cos they're idiot proof. Except when you pop out the pins to slide cable through hole etc and have forgotten to disconnect cable from battery :oops:

I don't quite understand what you've done there Shirley :problem: But I'm sure the penny will drop eventually... Probably when i have a look in my psu case :thumbup:
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby shirley_hkg » 02 Apr 2019, 09:34

I did the modification myself last month, with thick wires and ring terminals.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 03 Apr 2019, 09:16

Nice job Shirley, very professional :thumbup:
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 04 Apr 2019, 09:49

shirley_hkg wrote:I did the modification myself last month, with thick wires and ring terminals.

So you fitted banana terminals to rear of psu case? Hmmm i never thought of that. I will have a look at mine.
It looks like you've drilled or notched the side of the case for the red & black cable entry?
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 04 Apr 2019, 10:18

No...

His is the stock unit. Yours has the fancy case. He has fitted an ANDERSON at the front, powered by the stock banana connectors on the rear shown here!
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 04 Apr 2019, 10:23

Burgerman wrote:No...

His is the stock unit. Yours has the fancy case. He has fitted an ANDERSON at the front, powered by the stock banana connectors on the rear shown here!

Ah! Thank you :thumbup:
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 06 Apr 2019, 09:54

I had a look in the back of the PSU yesterday. Fitting an anderson connector isn't a problem but the space is a bit tight for the cabling, there's a big heat sink in the way?

When you guys did your's did you remove the side panel or just the rear panel? It could be done by just removing the side panel but the terminal screws are the wrong orientation for a screwdriver so would have to be removed and tightened side on with a pair of pliers... :problem:

I put the rear cover back on and left it for now. It would be nice to do but I don't want to mess it up and am fearful of stripping it down to get better access.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 06 Apr 2019, 10:32

As I said, use the cables it ALREADY HAS that go to the front, to feed the Anderson. Then ad 2 extra wires from anderson to the front... You dont need to touch the screws. You can get a screwdriver on if you disassemble it all.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 06 Apr 2019, 10:34

I put the rear cover back on and left it for now. It would be nice to do but I don't want to mess it up and am fearful of stripping it down to get better access.


Why?
You cant make an omelett without breaking a few eggs.
Its like meccano. You cant get it wrong. BUT YOU DONT NEED ACCESS TO THOSE SCREWS!!! Read above.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 06 Apr 2019, 10:38

Burgerman wrote:
I think BM means bi-wires at each Anderson pin ; as a Y-spliter.


Yes. Strip 1.25 inch of insulation in the middle of a wire. Easy on silicone as its soft. Fold wire in half. Insert into Anderson connector pin and crimp/solder.

Supply >>>>>>>>. Anderson >>>>>>>>front connectors

Makes the fight for space etc easier.

Ah! I didn't see this, I will have another look.

Cheers cheers
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby shirley_hkg » 08 Apr 2019, 03:18

Another two ZXD2400 were out , for Australia .
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 08 Apr 2019, 16:52

I managed to fit an Anderson connector. :dance

It will be better for connecting the PL8 seeing as PL8 is rear entry.

I wouldn't even have thought of fitting an Anderson inside the case if you hadn't done it BM :worship

The main thing is everything still works when I switched back on, and polarity is correct, no loud BANG!!! hanged

Just gotta clear up the mess now...

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Image
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 08 Apr 2019, 16:58

Neater than mine other than the horrid screws! Order some M4 countersunk stainless x 20mm long. And a countersink bit.

M4 self taps into the connector.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Gnomatic » 08 Apr 2019, 17:07

Nice job Scooterman. Neater than mine as well!

These are real handy chargers/PSU's.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 08 Apr 2019, 17:29

Thank you guys I appreciate that cheers

And good thinking BM, countersunk screws would look better. I shall have a rummage in my nuts & bolts drawer to see if I can rustle up a couple.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 08 Apr 2019, 17:45

.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 08 Apr 2019, 18:41

Your's is really neat BM :thumbup:

And you mounted the Anderson nearer the fan screw which was more sensible than me. After I'd cut the hole I was worried that the hexagonal pcb post wouldn't clear the Anderson, but it did just so I was lucky. That's typical of the sort of thing I overlook when doing a job.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby sin85 » 14 Apr 2019, 02:41

shirley_hkg wrote: Another two ZXD2400 were out , for Australia .


and it is here.

thanks shirley.

sorry for late response , just got back home
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 19 Apr 2019, 08:36

I cut the perforated metal grill out of my old psu that I repaired (used to smoke). It's not pretty, but it's only a backup. I bought a piece of mesh to cover the exposed end, but on hindsight I could probably leave open. I dunno, I might fit the mesh now I've bought it? I test charge lithium at 28A and supply said 35A, so psu holding up, fingers crossed.

Image

Image

Image

PS there's a couple of fans at the suck end.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby steves1977uk » 13 May 2019, 21:06

Got my 3rd ZXD2400 PSU already modded in a fancy case today, thanks Shirley! cheers drunk2

Now to fit a SB50 Anderson connector to use it at high power. BM, which dremel and metal cutting discs do I need to buy?

Thanks,

Steve
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 13 May 2019, 23:01

My dremmel is a 240v unbranded one from the local market.

The disks are those fancy twist lock ones. I used what I had. Like these https://www.amazon.co.uk/Dremel-2615S45 ... YCZME7XRPH
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby martin007 » 21 May 2019, 23:58

Has anyone modified the charger to make the fan quieter?
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Gnomatic » 22 May 2019, 00:28

martin007 wrote:Has anyone modified the charger to make the fan quieter?


I swapped the stock fans for quiet ones when I installed it in the fancy case. I believe BM removed the stock front fan on his.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby LROBBINS » 22 May 2019, 08:22

I replaced both fans with super quiet ones with their own temp sensors. Very quiet, but cooling may be marginal for large LiFePO4 packs (those that sit at 50A for a long time). Details are in an earlier post of mine in this thread.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Scooterman » 22 May 2019, 08:46

steves1977uk wrote:BM, which dremel and metal cutting discs do I need to buy?

Thanks,

Steve

If/when you get a dremel (or similar) Steve, can you post which one you got. I've always wanted a multitool but never have bought on cos I don't know which one to buy.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 22 May 2019, 09:05

I replaced both fans with super quiet ones with their own temp sensors. Very quiet, but cooling may be marginal for large LiFePO4 packs (those that sit at 50A for a long time). Details are in an earlier post of mine in this thread.


Stock fans, and that resrtrictive grill material removed, and the thing doesent even get warm at 50A. The fan sped up once slightly, for a few secs only, maybe 15 to 20? Over a 1 hour period.

So stock setup in the alloy case is huge overkill.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby LROBBINS » 22 May 2019, 11:42

Yes, the stock fans are overkill, and the ones I put in are on the low-flow side. The crazy thing about the programming of the stock fans is that using the 3-stage charging regime, the fans are always at full speed when in float even though there's almost no current flowing. With the self-controlled fans I set the internal fan speed temp sensor to never slow down.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby steves1977uk » 24 May 2019, 17:02

Scooterman wrote:
steves1977uk wrote:BM, which dremel and metal cutting discs do I need to buy?

Thanks,

Steve

If/when you get a dremel (or similar) Steve, can you post which one you got. I've always wanted a multitool but never have bought on cos I don't know which one to buy.


I've just won this dremel kit... https://www.ebay.co.uk/itm/173905800673 Might have to buy the cutting discs that BM recommended above, but will see which accessories I get with it.

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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Gnomatic » 25 May 2019, 19:06

BM I believe you said you used countersunk M4 screws to mount your Anderson to the fancy case. Do you remember what length you used?
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 25 May 2019, 19:51

16mm from memory.
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