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

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

Postby shirley_hkg » 17 Sep 2018, 02:55

Burgerman wrote:You were not swept away then? :clap

Barely survived ! drunk2

No death toll .


https://youtu.be/NCNqVi9naog
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby shirley_hkg » 17 Sep 2018, 03:32

Monday morning going to office is a nightmare in subway . Buses suspended .
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 17 Sep 2018, 07:41

Hmmm. HK seems a bit busy. You need more space. You should invade china. cheers

US. https://abcnews.go.com/US/major-river-f ... d=57857204
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby mickeymonk » 18 Sep 2018, 17:10

That storm's a bit breezy. If I went out in that my mum would make me put my big coat on.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 19 Sep 2018, 10:53

I havent got a big coat. Or a mum. :fencing
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby martin007 » 20 Sep 2018, 00:27

martin007 wrote:Hello again.
I have been busy for a few days and I haven´t been able to connect.


I have a question for you.
What is the correct order to connect the batteries to the PSU and the electrical network?

Connect.

1º- Powerchair to PSU.

2º- PSU to electrical network.
:P

shirley_hkg wrote:
Burgerman wrote:Normally power up first. Connect to chair last.


Yes, and power off last . drunk2 :dirtbike




01.jpg


02.jpg


03.jpg


OK.


4- Disconnect the powerchair from the power supply.

5- Disconnect the power supply from the electric current.

Am I doing it right?
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 20 Sep 2018, 00:35

Yep. Its always bad to connect a battery to the OUTPUT of a charger, or power supply as general practice as there may be unbiased mosfets etc that will short out the output and then go bang. If unlucky.

Same applies to hobby chargers. You should not really connect the battery first. With the PL8 you should get away with this, but even with the generic chargers you should power up the charger first.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby martin007 » 20 Sep 2018, 00:46

I asked why with the (generic) mobility loaders it is done the other way around.

charge.jpg


1- Connect batteries to charger.
2- Connect charger to electrical network.
3- Batteries charged 100%.
4- Disconnect charger from the electrical network.
5- Disconnect the batteries from the charger.

I have always done it in this order.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 20 Sep 2018, 01:07

With that charger it likely makes no difference.

If a charger is designed for a simple purpose, limited voltage range, etc it is posible to easily design it so its safe even when the battery is connected first.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Gnomatic » 20 Sep 2018, 20:02

Iam trying to run the autocalibration but not having much luck. The translated instructions say the following

Power on the power supply, and enter the power-off state, do not short-circuit the output end, hold the knob for 15 seconds , turn on the power, wait for the white 0 word to appear and then let go , it has entered the automatic calibration mode.

Tip: Each time you enter Auto Calibration, the factory settings will be restored first, and all settings and calibration parameters will be cleared.


I hold the button for 15 seconds after it turns off. I let go and nothing happens. I turn the unit back on and it just powers up like normal, can't get the white 0 to appear
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby steves1977uk » 20 Sep 2018, 22:07

Hmm, it should work as I've done exactly the same routine. When you power it up, hold the button in until it shuts off completely. Now hold the button in for 15-20 secs and it should power up in auto-calibration mode.

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

Postby LROBBINS » 20 Sep 2018, 22:10

Don't let go after 15 seconds, but wait as long as it takes to enter calibration mode.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby shirley_hkg » 21 Sep 2018, 00:36

Plug in A/C & it powers up.
Press 3 sec to power off.
Don't remove A/C.
Press again & hold 15 sec into calibration .


BTW , have you removed password yet ?
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Gnomatic » 22 Sep 2018, 01:54

shirley_hkg wrote:

BTW , have you removed password yet ?


No, I haven't.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby shirley_hkg » 22 Sep 2018, 06:48

LROBBINS wrote:I think that I now have this supply mostly set up as I want it, so I thought I'd share my settings in case they're of use to others. Aside from use as a bench supply, the main use will be for charging series-paired Odyssey P1500 batteries. So my first step was to go to Figure 5 of the Odyssey technical manual to see what voltages they recommend:

temp. -- Vcv -- Vfloat
20oC -- 29.7 -- 27.5
25oC -- 29.4 -- 27.3
30oC -- 29.2 -- 27.1 (for typical summer days here, this is what I've set)
40oC -- 28.8 -- 26.8

With out a Vcv timer, Odyssey recommends switching to float at 0.1C10, which is 0.63A which seemed to me excessive. Burgerman suggests a more reasonable 0.2A, but I found that with a pair of old, almost fully-charged batteries current didn't fall to 0.2A after 8 hours, but fell to 0.3A in about two hours with Vcv = 29.2 at a room temp of ca. 28oC, so that's what I've set.


So, now on to setting up the supply:
The Eprom values (factory menu E) were set for my situation. I foresee rarely if ever needing more than 30V output, nor more than 30A so I set:
Eprom address --- Value
52 --- 3000 (= 30 V maximum allowed setting)
53 --- 3000 (= 30 A maximum allowed setting)
3-stage charger float voltage and transition current are set as thousandths of the base voltage and current settings:
Eprom address --- Value
73 --- left at default 930 which is 93% of CV voltage and very close to Odyssey's recommendations
74 --- 10 (this is 1% of base Amps setting, = 0.3A)
As others have noted, the stock fans are annoyingly loud. Not having appropriate resistors on hand, but having a large stock of 5Amp Schottkeys, I put 4 Schottkeys (with matching male & female connectors) into each fan line. This reduced the noise noticeably at low fan speed, but at low currents and with the shop at ca. 30oC it went to high speed at currents less than 1 Amp even, and that was still quite noisy. I therefore raised the transition temp a bit:
Eprom address --- Value
50 --- 55 (up to 55o from the default 50o)
and I added some Arctic silver between the heat sink and the left side plate of the case. The fan still gets pretty noisy at float, when the room temp is 30o, but stays relatively quiet at room temp = 25o and the outlet air is cold and the side plate barely warm. I think I could safely raise the transition temp to 60o, but will wait till I have some more experience with this.

At one point in all my fiddling things went quite strange - output voltage and current were about 1/2 of the set values, so I re-did the auto-calibration. To do that you have to get rid of the "88" password that had been set, then shut off the power supply with the push button and re-start holding the button pressed for ca. 15 seconds. (No sense for me to attempt a manual calibration as my multimeter is un-calibrated.)
Eprom address --- Value
99 --- 0 (changed from 88, and I've left it at 0 = no password so a 3 second long turn-on press brings me right to the factory menu without entering the 88)
The instructions for auto calibration in the user's manual are pretty clear - you just need to short the output when it says to, and then remove the short when it says to do that, and don't press the encoder during the rest of the multi-step sequence.

Once (with some help from Burgerman) I got used to the (translated) manuals, I found them reasonably easy to follow. I have, however, not yet set over voltage and over current values (factory menu 8). These are to protect from runaway failures of the power supply electronics and I will probably set them once I've experimented a bit to find reasonable values that don't give false errors (especially when used with motor loads than can regeneration-pulse voltages over the set voltage).

One last thing. At one point I had the front panel open with the supply unplugged but battery still connected (bad boy!) and shorted B+ to the case. I now have a nice (but hidden when buttoned up) burn mark on the case. A piece of tape is now on the case by those banana jacks. Oh yes, I also drilled a 2.5mm hole in the front fan surround and added a cable tie to stress-relieve the display/control wiring
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 22 Sep 2018, 09:00

One last thing. At one point I had the front panel open with the supply unplugged but battery still connected (bad boy!) and shorted B+ to the case. I now have a nice (but hidden when buttoned up) burn mark on the case. A piece of tape is now on the case by those banana jacks.


I find that odd. The pos/neg should be floating, so touching either one to the case should do no damage, and no burning?

But I kept a copy of your settings.
Difference here is that I regularly use 50A when charging rapidly, and do allow 60V max for testing and other occasional purposes. (Like series charging my 48V solar battery). The only supply I have that does 60V without linking in series. So those are left alone.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby LROBBINS » 22 Sep 2018, 11:28

The case was sitting on the grounded Al plate of my electronics work area.

For now I have nothing needing either more current or higher voltage, so for protection against stupid mistakes I've set things low (like the one above). Should I ever need more, it's only a few button presses away.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 22 Sep 2018, 14:45

If you have an anderson spare, its worth adding it to the chair. Wacking some power back in fast at 50A for 10 to 30 mins, before you zip off to the bar/resturant in an evening, or on occasions when you forgot to charge the night before and need to go out somewhere is invaluable. Better still, do this any time theres chance, say watching TV/eating, or when she is sat doing nothing in the house for any reason and your batts will last a decade.

Odyssey actually recommend no inrush current upper limit . And the higher the CC stage the better so it definitely wont hurt a thing at 40 or 50A.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby LROBBINS » 22 Sep 2018, 15:45

I do have an Anderson on the chair, but am using the charger I got from Espresso for it. Not ideal, but probably OK given how little Rachi draws from the Odyssey's on a normal day. This one, for now, is on my ex-garage workbench for project work.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Gnomatic » 22 Sep 2018, 16:42

Thanks shirley(and LROBBINS)
shirley_hkg wrote:
LROBBINS wrote:
At one point in all my fiddling things went quite strange - output voltage and current were about 1/2 of the set values,[/color]
.


Mine started doing that after I did the factory reset

shirley_hkg wrote:
LROBBINS wrote:so I re-did the auto-calibration. To do that you have to get rid of the "88" password that had been set, then shut off the power supply with the push button and re-start holding the button pressed for ca. 15 seconds. (No sense for me to attempt a manual calibration as my multimeter is un-calibrated.)
Eprom address --- Value
99 --- 0 (changed from 88, and I've left it at 0 = no password so a 3 second long turn-on press brings me right to the factory menu without entering the 88)
The instructions for auto calibration in the user's manual are pretty clear - you just need to short the output when it says to, and then remove the short when it says to do that, and don't press the encoder during the rest of the multi-step sequence.

[/color]
.


So I need to go in the EPROM settings to remove the password. Are those set in section 9 of the service menu?
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby LROBBINS » 22 Sep 2018, 18:42

No, they are in section E of the service menu, but do read the instructions to avoid getting into trouble.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby steves1977uk » 22 Sep 2018, 18:43

To remove the password, go to Menu E (EEPROM decimal), go to value 99 and set it to 0. Then save.

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

Postby Gnomatic » 22 Sep 2018, 19:16

Got it. Thanks guys. cheers
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Gnomatic » 22 Sep 2018, 22:12

Autocalibration successful. On a 120v AC outlet, set to 30v, the psu is now delivering up to 31-32A max. Which is about double what it could deliver before I did the reset/re-calibration.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby steves1977uk » 22 Sep 2018, 23:51

I thought a 120v 15A circuit could easily do 50A at 30v (1500 watts). Have you limited the Amps value to 32?

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

Postby Gnomatic » 23 Sep 2018, 00:18

steves1977uk wrote:I thought a 120v 15A circuit could easily do 50A at 30v (1500 watts). Have you limited the Amps value to 32?

Steve


I haven't limited amps max to 32, but I'll double check it.

A 120v 15A circuit could handle 1500w, but the psu is only rated @25A when fed by 120v AC. So 32A max output for my unit isn't too bad considering. But, maybe more is possible if I keep playing with settings???

Or, maybe the psu gets hanged if I keep fiddling with it.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 23 Sep 2018, 01:43

Not sure, but it should be able to do any combo that is 1500 watts out. And about 1700 in?

I know its fine at 28.80V out, (battery charge) and 50A. (1,440 watts) no problem.
Thats on 245V AC measured from my wall. It varies from 235 to 252V over the day due to a lot of solar input in my area.

If we call that 240V nominal, and 90% efficient, then its pulling 1,584 Watts from the wall. Thats not much, it can do 3.2kW.
At 120V if we had that, it would be the same watts. Only 84 more than your max rated?

And it would be:
240V only 6.6Amps And at 120V 13.2Amps. I dont think that it should be any problem even for 120V systems.

The only issues arise when using it at 60V where things double. And again, its not a problem in UK. Since my pressure washer is 3.2kW and it works fine. But on 120 and 60V out, you should get limited to half the output amps at 25.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Gnomatic » 23 Sep 2018, 02:02

Well, ex-Goose and Will are a couple other members here with this psu located in the USA as I am.

I'm really curios to know what the max amps they can get out of their units at 30v or less, when fed by a 120v AC wall outlet.

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

Postby Williamclark77 » 23 Sep 2018, 07:22

28 amps is the max I've tried and it was only that high for a short time. I don't have anything that'll use/require much more.
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Re: ZXD2400 modification guild 3Kw 0-60V 0-50A

Postby Burgerman » 23 Sep 2018, 09:46

28A out at presumably 3.60V per cell is 28X 28.80V = 806 Watts plus 10% losses, so around 900 watts from the wall. So it shouldnt struggle at that one bit! And 900W div by 120V is 7.5A only on the AC.
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