PINNED ZXD2400 Old + New 0-60V 0-50A Power Supply & Charger

[Burgerman]

Other voltages, with -0.01% voltage calibration. its perfect spot on and my 3 month freshly factory calibrated and certified fluke 289 agrees across the board. At least to 2 decimal places. It did read 1 (sometimes to 2) hundredths of a volt high.

Below 10V its around 0.06 to 0.01V higher that what is displayed. Which is completely insignificant. If I correct that then its reading wrong at the high end where I use it most. So this is what we are settled on! Tested hot, cold, and under load and not under load. Pretty much spot on. You should not need to calibrate yours, its likely more accurate than most cheap multimeters.

Fluke set to 2 decimals for clarity.

[Burgerman]

About the WATTS setting.
Just like the PL8 the watts limit, doesent allow both volts out, and amps out to exceed whatever you set for maximum watts.

So lets say you actually want to use all 50A and 60V. Well 50x60= 3000 (watts).
So as long as your AC in the wall can give you 3000 watts + 10% (its 90% efficient) then that will be fine. It will draw 3300 watts from the AC. Here in britain that works fine.

If you go into the factory menu you can set 3500 watts. Thats more than the originally intended 3000. But not by much. So its shouldnt be an issue. Because if you want both the newly freed 70V, AND the full 50A capability then thats what you need to do.

If you dont increase this in the factory menu, and leave it set to a nice safe 3000W in the max figure allowed and same on the colour main start/control/set screen, then you will only get the full 50A as your battery charges as far as 60V. Above this voltage the current will taper away slightly. So the ZXD will reduce Amps as it reaches the 70V point automatically.

I can tell you with simple mathemtics what this new 70V reduced current (Max amps) will be. Its simple. 3000 watts, div by 70V = 42A Max.

[shirley_hkg]

You are squeezing every little bit of juice out of it, BM.

Not seen anyone on the internet done this before.

[Burgerman]

Theres plenty on aliexpress that say 65V ?

Well it certainly does it. And no issues, but yes. I will likely never use this. But just in case I ever want to do so... I know it can.
Maybe I will build a 16Shobby LiPo pack one day. 67.2V is 4.20V X 16...
Or Set for only 65V max, as 64.8V is an 18S LFP pack. That leaves a large 8V of unused headroom.

Wonder if its because my AC is never less than 244V usually 245-253V? No that cannot be as it runs from 90-130V too.

[Burgerman]

Accurate power draw from wall for those that count watts!

Dark, turned off, plugged in doing nothing = 4.2 watts.
Turned on, screen at 65% brightness (I turned it up a little) and its the unit with a larger screen, is = 11.6 watts.
At float, delivering very low current intermittently Jumps between 13.2W and 28.4W as it turns on off. So depends on float current.
At high power its basically whatever you choose, (for e.g 28.8V x 10A = 280W), + 10% (So now 308W) plus that initial 11.6W. So total is 319.6W.

Obviously this holds true to its max at 60V x 50A (3000W x 10% (efficiency) + 11.6W so 3311.6W maxed out from the wall.

Because it wastes (unsurprisingly) between 13 and 28 watts at float, its not really a good tool for continual long term float use. But then I never expected a 3kw output device to be efficient at 1 or 2 watts output!

So set timer the end float at say 5 to 20 hours depending on termination point and float voltage chosen. And state of charge.

[emilevirus]

I tried setting fans to not be always on in the menu but now fans will just turn off and go full blast every few seconds.

[Burgerman]

Yes. They dont ram up or run all the time. But if charging at a low rate, or on float they dont come on.
The other way is to set the percentage to a figure (percentage) for each fan by trial and error instead where they dont make any sound when charging at a low rate. 1 or 2 % either way when you find this point makes all the difference.

Both ways allow it to be silent most of the time when charging next to your bed.

[emilevirus]

Well, I set fans at 20%. But after charging at 50A for a few hours the unit gets HOT. Is it normal?

[Burgerman]

If set to 20% probably.

Mine are set VERY carefully! 20 way too low.

Turrn it on.
Set fans to 0.
Gradually increase one fan at a time until it JUST starts to spin. By spin I mean so it can turn slowly. Silently.
In this way each fan does not operate at very low currents or does so silently. I used a torch (flashlight?) to see. They will ramp up as needed later as it warms up.

Mine currently set to 29 and rear at 31.

And at 12A its very quiet. Not tested at 50 but that is a 3000W output capability device! If 90% efficient as claimed thats 300 watts of power to lose. So I would expect it to warm a bit. The older ones do. And those have a larger front fan. So it all depends on your idea of hot. It has overheat protection. So too hot will shut it down.

When hot do fans run at speed?

[emilevirus]

They do spin but I'd expect them to ramp up as it gets warmer.

[Burgerman]

So would I.

Once hot, the fans should be at max speed. Again it does depend on your definition of hot. So hard to tell from a distance. Its all metal so tends to feel a bit warm when worked hard. The casing is bolted to the heat sinks and extends them. So it too forms a heat sink.

[shirley_hkg]

He has a stock case version.

[Burgerman]

Then I dont know. Probably both will want to be at around 31%?

[shirley_hkg]

I wouldn't run at max amp.
Leave it room for long service life.

[Burgerman]

Well you say that, but I always have. Nothing failed in years of doing it. Yes gets a bit warm. So far its never been a problem.

[emilevirus]

I wouldn't run at max amp.
Leave it room for long service life.

But will the fans ramp up if it gets hot?

[emilevirus]

Well you say that, but I always have. Nothing failed in years of doing it. Yes gets a bit warm. So far its never been a problem.

But you charge lead acid at 50A so it must stay at 50A for a few minutes only. I charge my 230ah at 50A so it pushes 50A for over 4 hours.

[Burgerman]

With Odyssey, very low impedance, it stays at 50A for maybe 15 mins bfore dropping away slowly. I doubt it would continue heating up. Will soon know as will be charging the 230Ah pack soon enough. If I charge with the 40A PL8 at 24V at the ZXD then it will draw around 45 to 48 Amps. Because battery voltage is higher than input volts, and efficiency of charger.

It should be fine though. And I expect fans to ramp up as it needs due to temp.

Do your fans speed up as it gets warmer?

[shirley_hkg]

But will the fans ramp up if it gets hot?

Yes. They are thermal controlled.

What you set is the threshold speed.

[Burgerman]

Yes I know. Mine do as they should as far as I can tell. I was asking if his did the same or he has set the threshold too low.

If fan is at high speed, then thats as much cooling as it has.
Efficiency is around 90% and so at 50A and at 28.8V thats 1444 watts out. With 140.4Watts of heat to lose. So it will get warm!

I know that my older ones do get quite warm, at 50A. Yes I am not doing that for 4 hours. But they should get about as hot as they are going to do in the first 5 mins or so.
But it wont actually overheat as theres a thermal cut out that protects it. Not sure how it works as I never reached that point. It may switch charge off, or lower the Amps. But it wont hurt the supply/charger.

[shirley_hkg]

As you've said, that they ALL are the same internally. Nothing to do with what case they have.

And yes to the thermal cutoff.

It will stop, if it were too hot.

[Burgerman]

Electrically yes.
Case type and fan size both also change cooling though.

Smaller fan on my new one should need to rev faster at any given temp/output power. Although it doesent seem louder.
And fancy case is much better heat sink as those thick alloy sides are bolted to (and extend) the heat sink area with good thermal conductivity and are actively cooled by airflow inside.
But I doubt either makes a huge difference.

Can a fancy large screen case be fitted to my original older zxd?
Or is different firmware etc needed?
And how much would it cost?

[shirley_hkg]

Smaller fan on my new one should need to rev faster at any given temp/output power.

Again, same 8015 fans inside, no matter what case it has.

Your ZXD with smaller intake front opening. However, the maker open 2 intake slots on the sides, to ensure sufficient air flow.

Only the newest compact case, with 3.2" display, has these 2 additional openings.

[shirley_hkg]

Can a fancy large screen case be fitted to my original older zxd?
Or is different firmware etc needed?
And how much would it cost?

You need a new modification kits. (£28)

Whole set of aluminum case with 3.2" display. (£40)

Or only the front plate(£6), if you could settle with 2.4" display, so that you can reuse most of the existing case.

[shirley_hkg]

Throw away the stock control board, and remove the halogen lamp.

Modification involves 4 steps as follows.

[Burgerman]

OK. Thanks. Will have a think!

[shirley_hkg]

Plug in the new control board, and place the temp sensor as indicated.

Hook up the fans. Power up and run the self calibration as usual.

[Burgerman]

I would want all the bits to make a third one, same as the one I just recieved, same as the one on order. So I end up with 3 the same...

Is my 2nd one ready?

[shirley_hkg]

Not finished yet.
Hope it could catch the last flight before Chinese New Year, or will be put after till mid February.

[emilevirus]

With Odyssey, very low impedance, it stays at 50A for maybe 15 mins bfore dropping away slowly. I doubt it would continue heating up. Will soon know as will be charging the 230Ah pack soon enough. If I charge with the 40A PL8 at 24V at the ZXD then it will draw around 45 to 48 Amps. Because battery voltage is higher than input volts, and efficiency of charger.

It should be fine though. And I expect fans to ramp up as it needs due to temp.

Do your fans speed up as it gets warmer?

I wouldn't know. Govt provided batteries are so crappy they won't even charge at 12A even if they're flat. They instantly drop to 8A.