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

[shirley_hkg]

Thanks Shirley

Ordering tools etc now, need soldering iron ， crimper be back at it couple days..

Crimper will be too luxurious, if used for once just.

Alternatively, hammer the barrel flat and solder.

[Burgerman]

Should be soldered anyway. Those are too thin and flimsy to crimp alone.

[ex-Gooserider]

I have a Rapid 0-30V 30A power supply powering my PL8. It gets turned off and on once a day at least. Could this kill the power supply or shorten its life appreciably? Or indeed harm the PL8 itself? My 0-30V 10A power supply which I don't use much has a warning in its user manual not to turn it on with sensitive equipment connected, lest the equipment be damaged. So I was a bit concerned about the PL8, but decided it would have to not count as sensitive equipment because I do just leave it plugged into whichever power supply I'm using. But I'm mostly concerned about the Rapid as I have no idea how sturdy that brand is, I now use it daily and I got it already well used in its previous life (not sat in a warehouse used.)

Power cycles are the most challenging thing to do to any electronics, but should not be a problem if the device is well designed...

One of the big concerns is that when power is applied, there will be some potential for random spikes and surges as the various components charge up and go from zero to operating voltages - some of this is due to component variation, some from just where in the AC cycle you were when you hit the power switch and so on - the phase of the moon probably matters... In some cases there will be an effort to keep the supply from powering anything until it is fully up and operating stably (it can take a few AC cycles as capacitors need to charge, etc) but in other cases the supply specs simply make no guarantees of stability during power cycles....

If a device manufacturer is good they will have some conditioning circuitry on the inputs to handle this sort of thing, but that costs a bit for components board real estate and even designer time, so cheap stuff doesn't bother....

Since the power supply manufacturer has no way to know what you are connecting to their supply, they do a 'CYA' of telling you not to have things connected during a power cycle - that way if you blow up the attached device, they can just say "We told you not to do that - not our problem...."

One of the many challenges in electronics is understanding the difference between the "Ideal World" as taught in the text books and the actual stuff that happens in the REAL world - and how to design / work around those differences....

ex-Gooserider

ex-Gooserider

[shirley_hkg]

I have my ZXD output suspended during power up. Confirm the right volt/amp, and press to go.

Would that be useful ?

[Burgerman]

Yes.

But I have tested and measured on powerup, and see no significant spikes or problems that would be any cause for concern anyway. At least on the two I have here. Certainly nothing that would hurt a hobby charger. Those are built to run of a noisy car battery, or generator on a flying site. It takes a lot to upset one!

If you really worry, fit a couple of big 30V zenners and a large electrolytic capacitor, and a few small ceramic caps to remove any ringing or noise across the output. And a big power diode in series just in case... That would make any supply way safer if you are concerned. For about £5.

[terry2]

Just had my power supply come.

It's got a whole bunch electronics bolted on to the front it...

It's ok. It's his own board for safety and other things

[Burgerman]

Test it no load. Loaded. And at switch on and off. For stability. noise. Spikes. Ripple. AC component. Thats the way to know. Everything else is guesswork.

[steves1977uk]

Does Terry have a Fluke 289 to do all that?

Steve

[LROBBINS]

Decent PC oscilloscopes are available for a lot less than that Fluke - but, of course, there's a learning curve to using one.

[Burgerman]

Theres hundreds of ways to test things. Noise for e.g can be heard on headphones. Use high impedance ones and use a resistor or pot to listen. And a capacitor in series to lose the DC component. A simple sound card can see ac, noise, etc on screen in the same way. Some sound cards can be used as a basic occiloscope with free software and a little electronoics knowledge.

But yes sillyscopes are cheap. But unless you know what to buy, and what to do, i.e. user knowledge are still ultimately useless.

This is one of those things where knowledge is power. As per usual. And those with more knowledge have much more "luck" with everything in life. That fancy meter just makes doing these kind of basic tests before use and in use quick and easy. An occiloscope will tell you more ultimtely but beyond what we need for this.

For e.g. Last year my neibor had electrical issues with his BMW car. Radio noise, eratic instruments. His cheap multimeter showed it at 13.5V with engine running. Thats a little bit low. But it didnt show the massive regular engine speed related ac spikes on the dc charge voltage and other noise peaks. It had a bad diode in the alternator. That took 5 seconds to diagnose.

[terry2]

Does Terry have a Fluke 289 to do all that?

Steve

No steve. But thanks for asking.

Fluke is a funny name that

I am to busy helping a guy install fibre optic cable in his new build.
Then I will help him setup the racks\10-40GB SFP+\SFP and switches ect.

[daunjan]

Hey there currently soldering the front plugs to the board, red green black with 25amp 10awg

Can you please show me where the earth goes to on the board, and how to connect solder to the front plugs.

Thnxxx..

[shirley_hkg]

You see the earth sign that the top arrow points to ?

Thin wire will do.

[Burgerman]

Its only used as a reference when testing or measuring or to ground yourself when working on electronics, or to ground things you may be working on that require it. For your purposes it will be unlikely to ever be used. So no need to connect at all really. The power supply is floating in reference to ground. As it should be.

[daunjan]

Can I get the settings for gel batteries for the charger, going to charge via xlr on chair.

Setting up one from Aliexpress, is this same as Shirley's version.
https://www.aliexpress.com/item/4000385493813.html?spm=a2g0s.9042311.0.0.52494c4dXpjTnR

Once pl8 is here hopefully next week, then can balance lifepo4. Last piece of the puzzle.

[Burgerman]

PL8: Gel batteries want to be charged at 12A via XLR or 25A via Anderson, at a CV voltage of 28.2V max at 20C or reduce that slightly if its warmer. Set an 8 hour CV stage time limit and terminate at 500thC in milliamps. No float needed.

Via Shirley charger set to 3 stage charge: at 12A via XLR or 25A via Anderson, at a CV voltage of 28.2V max at 20C or reduce that slightly if its warmer. Set it to move to a lower voltage 27V float, as soon as CV charge current falls to .2A or .3A if that takes longer than 8 hours. Adjust this termination current untll it spends 6 to 8 hours at CV before going to float stage. Every battery is different.

[daunjan]

Thanks Burgerman, can you please help to input the settings to the ZXD2400 for XLR.

[Burgerman]

Theres a thread page near the beginning viewtopic.php?f=2&t=7670 where steve did a translation link somewhere here. And it tells you this, and 101 other things with images.

And I cant write a book to repeat everything. Not even sure I could explain it. But you are going to have to learn how to input the settings. Its a case of how long you press the button, which way to turn it, and what you see on screen. Its not very intuitive. At first. Then it clicks...

[daunjan]

Think I got it for the float settings 27.2v and float amps 0.2ah do I set that in 3 stage settings?

Also for Auto off do I need that on? not sure settings here? When I select it got weird letter under voltage and can change amps?

[Burgerman]

Dunno what the second sentence means. Auto off no.

You set it to charge at 14.1V per battery. (28.2) at whatever Amps you wish. If its warmer than room temp 20C and you live in australia so it may be, lower this a little. Remember the battery will likely be even warmer than the room after a days use. See chart below.

You then set the point where it falls to a lower (float) voltage of 27.0V FOR UP TO A WEEK MAX. If storing a chair LONGER set this to a lower voltage like 26.6V. The reason we set it to 13.5V per battery is so that it will complete the charge to 100%.

You set the point where the battery drops to float in Amps. As you charge this naturally drops lower and lower. (if it doesent or it rises again then stop! And lower the charge voltage). Set this to a safe for most healthy batteries of .3A (300mA). -- Less if charge ends inside 5 or 6 hours. More if charge ends (goes to float) later like longer than 8 hours. Thats how to fine tune.

That will make the MK last as long as it can.

These relate to GEL batteries.

[shirley_hkg]

No need to enable AUTO OFF.

[LROBBINS]

I also don't use auto off, but I do use AUTO ON when plugged in. The reason for that is that we often have momentary power outages here (a thunderstorm within 100 km at 2 AM is a typical scenario), but with AUTO ON the ZXD restarts itself.

[biscuit]

in Amps. As you charge this naturally drops lower and lower. (if it doesent or it rises again then stop! And lower the charge voltage). Set this to a safe for most healthy batteries of .3A (300mA). -- Less if charge ends inside 5 or 6 hours. More if charge ends (goes to float) later like longer than 8 hours. Thats how to fine tune.

Is it best to fine tune charging of other lead batteries with the PL8 in the same way, that is adjusting the termination current until it's charging for about 6-8 hours, or is it better to just stick with 1000thC?
I am asking because my own bad quality 20Ah lead batteries usually reach 20mA within less than 4 hours. I charge them with the PL8 because my mobility chargers were all rotten and I don't have a ZXD2400. I think the PL8 only goes down to 10mA anyway, so my options are limited.

[Burgerman]

Is it best to fine tune charging of other lead batteries with the PL8 in the same way, that is adjusting the termination current until it's charging for about 6-8 hours, or is it better to just stick with 1000thC?

With AGMs that are healthy and always have been correctly charged you should have no trouble with getting to 14.4V, 1000thC (20Ah = 20mA). As long as you remember to drop the volts a touch if its warmer than 20 Centigrade. Some batteries will take 3 hours. Some take 8. Some never get there. And it depends on the way they have been treated in the ast as well as the actual manufacturer and even the batch. (Old or mistreated batteries may start to rise in current as they near the end instead of drop. So an 8 hour limit is for safety against thermal runaway too.)

So... If on a deep discharge/recharge they may take roughly 8 hours to 10 hours to reach this point, (gel take longest) thats about perfect. Lower impedance (odyssey / optima etc) may take a little less. The point to watch is that they stop dropping current at all over a full hour. Or that they reach an 8 hour at CV time limit. In both cases they are done even if they never reach 1000thC.

Remember the shirley power supply has float, and isnt charging to 1000thC, because it cant, and has no CV timer safety limit. So we must let that end sooner, at around .3A or 300mA on a grp24 battery. So it is ending before the battery is fully saturated and at say 99% charged. It then NEEDS another good few hours at the lower float voltage, to complete the saturation/desulfation/charge. So 3 stage takes longer.

The PL8 doesent need a float stage as it fully charges the battery at CV at around 8 hours/1000th C. 2 stage. So thats faster. Better suited to overnight charging in the time we have available whilst fully charging for best battery life.

But... if charging a slightly discharged battery, with the PL8 (say only 5% used?) or as a top up while in storage, its best to set charge timer to 4 hours CV. Since the battery is already charged "internally" and so almost no lag, due to peukert. Meaning inside all the lead paste particles in the plate/grids are already charged. No need to wait 8 hours if its almost or already full.

[shirley_hkg]

https://translate.googleusercontent.com/translate_c?act=url&depth=1&hl=en&ie=UTF8&prev=_t&rurl=translate.google.com&sl=auto&sp=nmt4&tl=en&u=http://diy.lgm3361.com/zxd2400/3/&xid=25657,15700023,15700124,15700149,15700168,15700186,15700189,15700190,15700201,15700205&usg=ALkJrhiEpGE3pPSx2zOTsvypO_2h0w8c8w

Still can't believe it's compact size!

Steve

Hi Steve , the link has expired. Would you please bring it back again ?

[daunjan]

Hi Shirley,

Your link still works, reading it mo. Using Firefox to view. got this one pinned.

https://translate.google.com/translate?act=url&depth=4&hl=en&ie=UTF8&prev=_t&pto=aue&rurl=translate.google.com&sl=auto&sp=nmt4&tl=en&u=http://diy.lgm3361.com/zxd2400/3/&xid=25657,15700023,15700124,15700149,15700168,15700186,15700189,15700190,15700201,15700205

[optical10]

This diagram might make the connections clearer....I have removed the confusing + and - signs from the SB50 plugs at the connection point.

The yellow is the middle connection between the 2 off 12v batteries...wired like this in SERIES you get 24v.

The attachment wiring bats3.jpg is no longer available

Can somebody kindly connect these eight 3.2v 200ah LiFePO4 Cells in the image below in series for 24 V on this charger please?

future 3.2v 200ah LiFePO4 Cells for series 24v

current gel Cells in series for 24v

[woodygb]

.NOTE :- THAT YOU WILL NEED A PL8 AND ADDITIONAL BALANCE WIRES.

[optical10]

.NOTE :- THAT YOU WILL NEED A PL8 AND ADDITIONAL BALANCE WIRES.

series.png

Cheers Woody I owe you more than one .

Got PL8, spare on back order, Cellpro (JST PA) PowerLab 36" Extension Cable x 2 (spare for reasons) ordered from REVO USA, out of stock from Singapore.

[steves1977uk]

https://translate.googleusercontent.com/translate_c?act=url&depth=1&hl=en&ie=UTF8&prev=_t&rurl=translate.google.com&sl=auto&sp=nmt4&tl=en&u=http://diy.lgm3361.com/zxd2400/3/&xid=25657,15700023,15700124,15700149,15700168,15700186,15700189,15700190,15700201,15700205&usg=ALkJrhiEpGE3pPSx2zOTsvypO_2h0w8c8w

Still can't believe it's compact size!

Steve

Hi Steve , the link has expired. Would you please bring it back again ?

That link still works for me Shirley in Waterfox (Based on Firefox). Which browser are you using?

Steve