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

[shirley_hkg]

ADDED BY BURGERMAN:
NEWEST VERSION, READY BUILT (TO ORDER) VIA SHIRLEY. PM him for details. Or to order.

This is mine below, I added this top section on 3rd January 2025 (burgerman) Details near the end of this 67 page mega thread...
Few pages around here - some before, some later... https://www.wheelchairdriver.com/board/ ... start=1920

3Kw 0-60V 0-50A Power Supply & user configurable 3 stage charger.
Complete with AC "kette" type connector.
DC outputs: Anderson 50 connector, 4mm banana plug and binding post connectors, and front mounted XT90 connector.
These work out at approx £200 UK or $260 US Dollars or around a million HK dollars! Inc delivery by air (9 days?) approx.

This is the best high power bench supply or battery charger you will ever buy. Custom made for shirley in HK.

It can be configured as plug and play PROPERLY like a dumb mobility charger with all settings locked and auto start.
Or can be as configurable as you want. This will allow CORRECT battery charging on lead, lithium, or a massively powerful bench power supply to a huge 50A and 60V capability. (reduced to 25A max on 110/120V AC systems) And its very very quiet.
There are THREE or more CURRENT versions.
This is the smaller case, larger screen more compact 2025 one. These things keep evolving and improving!

EDITED Shirleys post, by Burgerman. ADDED NEW DATA JANUARY 2025


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ORIGINAL SHIRLEY POST BEGINS HERE FROM JANUARY 2018
It’s all about this 3Kw ZXD2400 PSU modification :

http://www.wheelchairdriver.com/board/v ... &start=100

[shirley_hkg]

With and w/o a fency outfit :

[shirley_hkg]

It has quite some playful features apart from just a 0-60V / 0-50A CC/CV power supply .

Hold the encoder 3 sec on power up will enter this mode :
http://diy.lgm3361.com/zxd2400/3/annex2/
1, manual calibration of 3V
2, manual calibration of 19-60V
3, manual calibration of 1A
4, manual calibration of 9-50A
5, SAVE adjustment and leave
6, LEAVE without saving
7, Reset to factory setting
8, OVER Volt & Amp output protection ; with user adjustable criteria
9, explained below
A, 0.1 or 0.01 display of the V&A
B, EMPTY
C, Version of kit
D, reserved for examination
E, EEPRM decimal
F, EEPRM hexadecimal

[shirley_hkg]

No 9 for the Hide / ON of the features below . 7 zeros for 7 features ; ZERO on top is ON , bottom is hide .

1, nine preset profiles allowed
2, lock menu
3, auto output at power up
4, auto power up at MAIN on


5, a 3-stage charger; with adjustable residual current that trickles to float , and float voltage as well
http://diy.lgm3361.com/zxd2400/3/annex1/1/
default settings of residual current and float volt are 30% and 93% respectively (with MAX cap at bulk charge values).



6, display of present & last session Ah delivered
7, auto shunt down ; when output is lower than user prescribed ampere

[shirley_hkg]

Your PSUs are a bit different . Factory manu locked .
To enter : Press "3 seconds" during power up , and enter code "00088" .

Operation tips :
On "short press" to select volt / amp adjustment , new value will become active when press encoder again.
If press/hold 1 second instead of just a short press , adjustment will be INSTANT .

[Burgerman]

ALL very good. And useful. I have a very accurate calibrated Fluke test meter so will calibrate when here. Also those front terminals are not adequate for high currents or very safe if the other end is connected to a battery. So will be fitting andersons as well, to rear. Probably 2 in parallel to allow multiple connections.S
And CC/CV/CV FLOAT is useful.

Will make a good high power bedside charger too for lead. Via anderson.

Can it be configured for volts current (CC/CV) as well a choose a low termination/residual current like say 100mA? Before going to float?
If so its the perfect battery charger for gel or AGM.

[shirley_hkg]

I hide the 3-stage-charger and auto-stop features of your PSUs.

Will work with you if you can't find it how .

[Burgerman]

How do I find it?

5, a 3-stage charger; with adjustable residual current that trickles to float , and float voltage as well
http://diy.lgm3361.com/zxd2400/3/annex1/1/
default settings of residual current and float volt are 30% and 93% respectively (with MAX cap at bulk charge values).



6, display of present & last session Ah delivered
7, auto shunt down ; when output is lower than user prescribed ampere

Useful!!!

[shirley_hkg]

If 3-stage-charger is ON , the no load voltage will be displayed as the float voltage being set ; not the bulk volt .

They are all under the sub-manu #9 .

[shirley_hkg]

Can it be configured for volts current (CC/CV) as well a choose a low termination/residual current like say 100mA? Before going to float?
If so its the perfect battery charger for gel or AGM.

It should be, as it can display 0.1A .

P.S. Whenever the bulk current setting is altered , this trickle-to-float current will be reset to 30% of bulk . Need to manually set again if you want other rate .

3rd item @ --- http://diy.lgm3361.com/zxd2400/3/annex1/1/

[Burgerman]

P.S. Whenever the bulk current setting is altered , this trickle-to-float current will be reset to 30% of bulk

Thats rediculous! It should be set to 100thC for a top up, (say .7A) on a 70Ah battery then float, and to 1/500th to 1/1000th for deep cycle use or 8 hours max.

So setting to say 500thC or (140mA), and then float at 13.5 is about right for an average wheelchair use.

[shirley_hkg]

Shirley supplied them.
I suggest you be nice to shirley!

My pleasure .

[Burgerman]

You know shirley is a girls name right?

[Burgerman]

Is there a way to get an english translated version of the full menu inc hidden bits... In one place?

[shirley_hkg]

Select item you want to adjust by TURNING it.

Selected item will blink .

Short PRESS will make the blinking field goes DIM.
Now you adjust the value .
Short press again , adjustment is set.

[shirley_hkg]

..

This one is small and quiet, so will run a PL8 next to my bed. USB'd to my laptop...
!

Fency outfit allows more room for thicker fan , if you really want it deadly quiet .

[Burgerman]

OK...

[Burgerman]

pICS AS ARRIVED
Sorry keyboard is stup[id and types caps!

This thing is 3000 watts, and not much bigger than a coke can!

Front with optional case (not built yet)
Rear with high power terminals. The new case adds some up to 20A termiunals, and a earth/ground to the front as well.

[Burgerman]

Within 18mV worst case, from 5V to 60V so pretty accurate, Once warmed up. (20 mins) and over 10 min monitoring, varies by just 2mv lower/higher unloaded. And theres no measurable ripple or AC at any frequency on the output I can detect. So far pretty good. But all measured without load.

[shirley_hkg]

I like your FLUKE . It's cool.

[Burgerman]

Me too. A unused but not new tool. Bought from a rich american for a silly price on ebay. And calibrated 4 months ago by fluke with certificate.

My fancy case is now fitted. But 3 questions.

The blue LED? No clue how its wired...
The display, held at one end by the nut on the switch/dial. And nothing at the other?
And my 3 pin mains connector was in 4 bits . So looking on ebay for a spare.

Otherwise it a really well made case/kit. Looks complicated, and gets much simpler as you go. No instructions? No problem. Just take it apart and it all just falls into place.

Hardly any wiring to do. Just basic stuff. However the provided 4mm banana connectors cant do 50A. They struggle at half that. I know this because my other two bench supplies use identical ones on the front. But they melt is you overdo things! I replaced them previously. So I will be fitting an anderson on the rear. Easy to do. It also has 2 fans that are not thermostatic as far as I know. They just start up with the power. So will be adding a heat switch to those. So they start up if the heat sinks exceed 40C. And 50C. Rear one first. Then the noisier front one if required.

[shirley_hkg]

The CL on the front will lit when in CV mode , so is treated as CC / CV indicator . Its orange in colour . You may change it with the blue led provided .

The encoding knot is held only with a thin nut in front . Just unscrew it and push the knot back in .

The fans are thermally controlled by the PSU , so any fan will do.

Yes , I'd like a better pair of power poles too.

[shirley_hkg]

Thermal couple is embedded already with the modification kits .

However , I find it enters full throttle a bit too soon , ie the heat sink was only warm at touch . Will it help by just to increase the insulation layers ?

[Burgerman]

OK.

The encoding knot is held only with a thin nut in front . Just unscrew it and push the knot back in .

Thats done. But the digital display can move about easily, as its held only at one end, and doesent sit flat. Maybe a glue gun...

[Burgerman]

If this can really run at 60v and 50A at this tiny size it is remarkable!

[shirley_hkg]

However , I find it enters full throttle a bit too soon , ie the heat sink was only slightly warm at touch .

Will it help by just to wrap a few more layers of tape around the thermal sensor ?

Will you consider doing it while changing the outfit . .

[shirley_hkg]

If this can really run at 60v and 50A at this tiny size it is remarkable!

I've tried . Ok .

Not for long .

However , I find it enters full throttle a bit too soon , ie the heat sink was only slightly warm at touch .

Will it help by just to wrap a few more layers of tape around the thermal sensor ?

Will you consider doing it while changing the outfit . .

[Burgerman]

Done.

[Gnomatic]

How much more disassembly?

[shirley_hkg]

Loose all screws , and remove the case completely .