Zentro Elektrik ZAT1600 SERIES User manual

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1600W Power Supplies and Battery Chargers
ZAT1600 SERIES
TASHEET / OPERATING INSTRUCTIONS
Wideoutput adjustment range 0…72VDC
Analog control by external 0-5VDC voltage
Temp.comp charging, sense as on option
Power fail relay alarm
Master-Slaveconnection
Analog control
modular connector
Microprocessor controlled charging curves for all kind of
batteries
Master-Slave
connection

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DATASHEET / OPERATING INSTRUCTIONS
POWER SUPPLIES AND BATTERY CHARGERS, TRIMMER ADJUSTABLE
Type
Input voltage range
**)
Nominal
output
voltage
Voltage
setting
range
Nominal
output
current
Current
setting
range
Max
power
Installation / dimensions
(Width x Height x Depth, mm)
ZAT1600/24/60/_/
55-264VAC/78-340VDC
24 VDC
0-36 VDC
60 A
0-60 A
1600W
Wall//Bench 267x135x85
ZAT1600/36/45/_/
55-264VAC/78-340VDC
36 VDC
0-54 VDC
40 A
0-40 A
1600W
Wall//Bench 267x135x85
ZAT1600/48/30/_/
55-264VAC/78-340VDC
48 VDC
0-72 VDC
30 A
0-30 A
1600W
Wall//Bench 267x135x85
ANALOG CONTROLLABLE MODELS BY EXTERNAL 0-5VDC VOLTAGE
Type
*)
Input voltage range
**)
Nominal
output
voltage
Voltage
setting
range
Nominal
output
current
Current
setting
Range
Max
power
Installation /
dimensions
(Width x Height x Depth, mm)
ZAT1600/24/60/AI/
55-264VAC/78-340VDC
24 VDC
0-36 VDC
60 A
0-60 A
1600W
Wall//Bench 267x135x85
ZAT1600/36/45/AI/
55-264VAC/78-340VDC
36 VDC
0-54 VDC
40 A
0-40 A
1600W
Wall//Bench 267x135x85
ZAT1600/48/30/AI/
55-264VAC/78-340VDC
48 VDC
0-72 VDC
30 A
0-30 A
1600W
Wall//Bench 267x135x85
BATTERY CHARGERS WITH TEMPERATURE COMPENSATION
Type
*)
Input voltage range
**)
Output
voltage
factory setting
Programmed
output voltages
(see table)
Output
current
(see table)
Max
power
Installation /
dimensions
(Width x Height x Depth, mm)
ZAT1600/27,4/60/T/
55-264VAC/78-340VDC
27.4 VDC
5…36VDC
60 A
1600W
Wall//Bench 267x135x85
ZAT1600/41,1/45/T/
55-264VAC/78-340VDC
41.1 VDC
12…54VDC
40 A
1600W
Wall//Bench 267x135x85
ZAT1600/54,8/30/T/
55-264VAC/78-340VDC
54.8 VDC
24…72VDC
30 A
1600W
Wall//Bench 267x135x85
*) Cable sets with modular connectors are included in packing: 1.5m cable set for analog control and 2.5m for or temp.comp models
**) Reduced power 55…200VAC or 78…200VDC, see curves at next page
MODELS WITH POWER FAIL RELAY ALARM (24V models as a type number example)
Type
Option description
Cable set
ZAT1600/24/60/H
Trimmer adjustable model with power fail relay alarm
1.5 m, modular connector
ZAT1600/24/60/AIH
Analog controllable model with power fail relay alarm
Analog 1.5m + relay cables 1.5m
ZAT1600/24/60/TH
Temp.comp model with Power fail relay alarm
Temp.comp 2.5m + relay cables 1.5m
MASTER-SLAVE CONNECTION (24V models as a type number example)
Master units ***)
Slave units
ZAT1600/24/60 or ZAT1600/24/60 AI or ZAT1600/27,4/60 T
Control to slave via RS-232 bus
ZAT1600/24/60 S RS-232 control bus in and out
ZAT1600/24/60 SH slave unit with relay, RS-232 bus in only
Cable set for master slave connection is included in slave unit type number, length 0.6m modular connectors in both ends
***) Master unit or slave with RS-232 bus output can not include the relay alarm
CUSTOMISED VERSIONS ON
• Cyclic battery chargers or customzed charging curves for all kind of batteries
• Sense models
• Customised mechanics

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Status LED indication
Standard models
Orange Power OK LED
Cyclic chargers
Three color LED, red-yellow-green
Isolations
Input - chassis
1500VAC
Input - output
3750VAC
Output - chassis
500VAC
Standards
Safety
EN60335-2-29 +A2
EMC
EN55022B, EN50081-1, EN50082-2
Approvals
CE marking
Protection class
Mechanical
IP20 metal enclosure
Electrical
Class I
Connectors
Input
Output
Input power cord
10 m
2
2m output cables
Dimensions
l x w x h
267 x 135 x 85 mm with rubber ends
Weight
1,9kg without output cables
Mounting
Wall, bench
Cooling
Temperature controlled fan
Operating temperature range
Full power typically
-25ºC...+40ºC
Reduced power
+40…+ 70ºC, see curve below
Humidity
0…95%, non condensing
DATASHEET / OPERATING INSTRUCTIONS
TECHNICAL DATA
Input voltage 50…260 VAC (50…200VAC reduced power, see curve below)
50…340 VDC (50…200VDC reduced power)
Input current 9 A
Power factor >0.99
Efficiency (230VAC, 10…100% load) > 88%
Inrush current <30A, cold start
Line regulation 0.01%
Load regulation 0.2V
Output setting accuracy ± 0.1%
Output ripple (f > 50Hz) <30mVrms
Hold up time > 5ms
Nominal output voltage / current characteristics 1600W models
Output power / input voltage derating curve Output power and fan speed vs ambient temperature

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DATASHEET / OPERATING INSTRUCTIONS
INSTALLATION
←The location must be dry, dust-free indoor use. The acceptable temperature range at full power is -25°C to +40°C. A higher
ambient temperature will limit the power, see diagram at first page. The power supply is not waterproof. Keep it dry and away
from areas of high humidity to avoid the risk of electrical shock and damage to the charger.
↑The equipment may be installed either vertically or horizontally.
→To ensure sufficient ventilation, leave approximately 10cm free space to both ends of the unit.
↓The charging process generates explosive hydrogen gas. Keep the area well ventilated. Never use an open flame or equipment
that produces sparks near the charger.
WALL MOUNTING
Screw the power supply to the assembly base by using the mounting brackets on the both ends of the unit.
Plug the main power cord into electrical socket. After switching on the mains switch the unit is ready to be used.
POWER SUPPLY / CHARGING OPERATION
←Ensure that the unit is switched off and that the environment meets the conditions described previous section
↑Connect the output cables to the load / battery terminals: + cable to the + terminal and - cable to the - terminal.
→Turn the power on by turning the switch to the I position.
↓During the normal power supply operation / charging process the STATUS light will show a constant orange light.
° To avoid sparking, turn the power off before disconnecting the cables.
CONNECTION WITH DC INPUT
Wires in PSU’s power cable to be connected as follows:
L DC input positive or negative
N DC input negative or positive
PE Ground
OUTPUT VOLTAGE AND CURRENT LIMIT ADJUSTMENT
Trimmer or analog control adjustable modules, type example ZAT1600/24/60 or ZAT1600/24/60/AI:
The output voltage and output current limit of the module can be adjusted as follows:
- Trimmer adjustable models: with the multi-turn potentiometer located on the front panel
- Analog controllable models by external 0-5VDC voltage, see detailed instructions
Both voltage and current can be adjusted from zero to maximum value. Maximum 800W output power is available within the
adjustment range.
Temp. comp. models, type example ZAT1600/27,4/60/T:
Unit includes 16pcs of programmed output voltages, see temp. comp. models setting tables page. Any of these 16 different voltage
settings can be taken in use and additionally this selected voltage can be adjusted ± 5% with the trimmer on front panel. See
instructions for choosing the programmed voltage and for the fine tune trimmer adjustment.
LED
A orange LED indicates that the output of the charger module is healthy.
OUTPUT OVERCURRENT PROTECTION
Output of the unit is protected against over current and short circuits by automatic, self-resetting electronic current limit.
SERIES / PARALLEL CONNECTION
Parallel operation: No restrictions, passive load sharing.
Series operation: Up to 500V total voltage
WARNING!
Dangerous voltages, capable of causing death, are present in this equipment. Do not remove the cover. No operator serviceable parts
inside. Refer servicing to qualified service personnel.

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DATASHEET / OPERATING INSTRUCTIONS
SELECTION TABLE OF ZAT1600 FEATURES
This table shows which
features are possible at the
same time.
IF N THEN then not possible.
T
r i
m
m
er
A
n
a
L
o
g
R
e
l
a
y
B
u
s
O
ut
B
u
s
I
n
T
e
m
p
S
e
n
s
e
C
o
d
e
S
w
i
t
c
h
Trimmer adjustment
N
N
N
N
Analog control (isolated)
N
N
N
N
Relay alarm
N
BusOut (RS-232 control to slave)
N
N
BusIn
N
N
N
Temp.comp.
N
N
Sense
Customised charging algorithm
chargers with code Switch
N
N
PIN CONFIGURATION, MODULAR CONNECTORS
Front panel Rear panel
J1: Analog input 0-5VDC
J3: Temperature compensation, Sense option
J5: RS-232 bus in and out, master-slave
Alternatively power fail relay alarm
OPTIONAL ALARM RELAY
If the unit is ordered with alarm relay (for example ZAT1600/24/60/H), the potential free alarm output indicates if the charger’s output
is healthy. The alarm signal is activated at AC fail and charger fail cases. Both normally open and normally closed signals are
presented.
Pin Configuration, Modular connector J5 with relay alarm option
MODULAR JACK
Front view
CABLE
Black = common
Red = NO
Green = NC
RELAY
Isolation: Technical data:
Output to Case: 500V 1A @ 24Vdc
Output to GND: 120V 0,5A @ 120Vac
If power is off the COMMON is connected to NC
If power is on the COMMON is connected to NO

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DATASHEET / OPERATING INSTRUCTIONS
OPTIONAL ANALOG CONTROL VERSIONS
Analog control option allows full control for output current and voltages and it gives measured values for both of these.
There is also available +5V internal power source for logic use. The analog input have 500V electrical insulation to
power supply’s input and output.
PIN CONFIGURATION, MODULAR CONNECTOR
Interface to analog control card is made through AMP Modular 6 connector. It’s part number is 215-876-1. The product
specification number is 108-19064 and application number is 114-19019. Part number for cable connector that fits to
modular 1 is 737 336-1.
Pin configuration of J1:
1. Ground
2. Target value for current
3. Target value for voltage
4. Measured value for current
5. Measured value for voltage
6. +5V, (max 20mA) output
Controlling analog card:
All control voltages must be between 0 and 5 volts. Over 5V steering is not allowed. Logic for steering is positive so 5V
in target value means maximum value from power supply and 0V means minimum output. If controlling connector is
unplugged from modular connector, the power supply takes it’s minimum values for output.
Measured values can be read from measured signals. Measured voltages are scaled equal as target values. If power supply
lies on it’s voltage reference, then measured voltage should be equal as target. Same thing on current steering and it’s
measured value. Measured signals (both together) can be loaded only 20mA or proper operation is not guaranteed.
Modular connector is isolated from power supply’s input, enclosure and output terminals. That allows serial and parallel
connection to separate power supply’s so that equal steering voltages are used. Number or connected devices are not
limited. Only be sure that 500V insulation voltage is not exceeded.
Connection example, using internal +5VDC power source and external potentiometers:
+5V output can be used to feed logic
voltages for external circuits. Connection in
an example works as a potentiometer
controlled power supply. It is important to
notice that +5V output is not allowed to load
more then 20mA or proper operation is not
guaranteed.
Rear panel
Location of tuning trimmers for analog control
Tuning instructions:
Attention !!!
Analog interface is tuned in a factory before it is delivered to customer. There should
not be any reason for tuning if card is used between 0-5V voltage values. Qualified
person is needed for tuning the device. Tuning can be done with a pair of digital multi
meters and example schematic above. Procedure is following:
1. Adjust from potentiometers 5V to voltage target and 2V for current target. Connect digital voltage meter to
power supply output. Tune from “Voltage Set” trimmer maximum output voltage to right value.
2. Connect digital voltage meter to Modular pin number 5. Tune from trimmer “Voltage Meas” so that digital
voltage meter shows always equal value as is in pin 3 (target voltage).
3. Connect digital current meter to output so that it short-circuits the output. Now tune current target
potentiometer to 5V. Tune from “Current Set” trimmer output current to value that is maximum value for
device according to it’s specification. Be sure that your current meter has a right range. Do never exceed the
current values that are specified for the device. If specified value is not known, take a contact to distributor.
4. Measure with digital multi meter voltage from Modular connector pin 4 Tune from trimmer ”Current Meas”
to equal with voltage in modular pin 2 (Target Current).

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DATASHEET / OPERATING INSTRUCTONS
TEMPERATURE COMPENSATION MODELS, type number example ZAT1600/27,4/60/T
The temp.comp cable enables the charger to adjust the
output voltage in accordance with battery voltage and
temperature fluctuations
Temp.comp. / sense
Modular connector
See instructions for changing and adjusting the output
voltage
OPTIONAL MASTER SLAVE CONNECTION
Using master power supply together with Slave unit.
Master unit can be trimmer adjustable standard model ADC7520/24, analog controllable model ZAT1600/24/60/AI
or temp.comp. model ZAT1600/27,4/60/T (24V as an example).
Note !
Unit with relay alarm, type example ZAT1600/24/60/H can’t be used as a master unit.
Slave unit is separate unit without any adjustment possibility, type ADC7520/24S or ADC7520/24SH slave with relay
alarm (24V as an example).
If more current is needed adjustable Master power supply can be parallel or series connected via digital bus to Slave
power supply which equals Master but is without adjustment possibility. Then output current or voltage is doubled and
the both supplies can still be adjusted thought multi turn potentiometers. Max one slave unit can be used in master-slave
connection as a standard. (Please contact your local distributor if more slave units are needed to chain, needs special
terminals/wires). Supply’s output terminals and communication bus terminals are isolated so that output's series
connection is allowed for more voltage.
Bus cable connection:
Master unit
Slave unit
Bus cables can be connected from
previous units (J5) to the next (J5)
with the same way. The first unit
must be the master unit (with
adjusting knobs). Wrong connection
does not damage the units but in that
case slaves does not follow the
master's commands. Quantity of the
slave units is limited to max 1 pcs
due to digital bus terminals. In J5
Pins 1 and 3 are serial output pins
and pins 2 and 4 are serial input pins.
Pin 1 is connected to pin 4 of J5 in
the next unit and pin 3 to pin 2 of J5
in the next unit.

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DATASHEET / OPERATING INSTRUCTIONS
PROGRAMMED VOLTAGES FOR TEMP.COMP. MODELS, type number example ZAT1600/27,4/60/T
ZAT1600/27,4/60/T 24VDC 60A
Code switch
position
Nominal
Battery voltage
Voltage
factory setting
Adjustment range
Output
Current
-5%
+5%
0
5 VDC
4,75 VDC
5,25 VDC
60 A
1
12 VDC
11,4 VDC
12,6 VDC
60 A
2
12 VDC
13,7 VDC
13 VDC
14,39 VDC
60 A
3
15 VDC
14,3 VDC
15,75 VDC
60 A
4
18 VDC
17,1 VDC
18,9 VDC
60 A
5
20 VDC
19 VDC
21 VDC
60 A
6
22 VDC
20,9 VDC
23,1 VDC
60 A
7
24 VDC
22,8 VDC
25,2 VDC
60 A
8
26 VDC
24,7 VDC
27,3 VDC
60 A
9
24 VDC
27,4 VDC
26 VDC
28,77 VDC
60 A
A
24 VDC
27,4 VDC
26 VDC
28,77 VDC
40 A
B
24 VDC
27,4 VDC
26 VDC
28,77 VDC
20 A
C
28 VDC
26,6 VDC
29,4 VDC
see curve
D
30 VDC
28,5 VDC
31,5 VDC
see curve
E
33 VDC
31,4 VDC
34,65 VDC
see curve
F
35 VDC
33,3 VDC
36 VDC
see curve
ZAT1600/41,4/45/T 36VDC 45A
Code switch
position
Nominal
Battery voltage
Voltage
factory setting
Adjustment range
Output
Current
-5%
+5%
0
12 VDC
11,4 VDC
12,6 VDC
45 A
1
12 VDC
13,7 VDC
13 VDC
14,39 VDC
45 A
2
15 VDC
14,3 VDC
15,75 VDC
45 A
3
20 VDC
19 VDC
21 VDC
45 A
4
24 VDC
22,8 VDC
25,2 VDC
45 A
5
24 VDC
27,4 VDC
26 VDC
28,77 VDC
45 A
6
30 VDC
28,5 VDC
31,5 VDC
45 A
7
33 VDC
31,4 VDC
34,65 VDC
45 A
8
36 VDC
34,2 VDC
37,8 VDC
45 A
9
38 VDC
36,1 VDC
39,9 VDC
45 A
A
36 VDC
41,1 VDC
39 VDC
43,16 VDC
see curve
B
36 VDC
41,1 VDC
39 VDC
43,16 VDC
30 A
C
36 VDC
41,1 VDC
39 VDC
43,16 VDC
15 A
D
45 VDC
42,8 VDC
47,25 VDC
see curve
E
48 VDC
45,6 VDC
50,4 VDC
see curve
F
52 VDC
49,4 VDC
54 VDC
see curve
ZAT1600/54,8/30T 48VDC 30A
Code switch
position
Nominal
Battery voltage
Voltage
factory setting
Adjustment range
Output
Current
-5%
+5%
0
24 VDC
22,8 VDC
25,2 VDC
30 A
1
24 VDC
27,4 VDC
26 VDC
28,77 VDC
30 A
2
30 VDC
28,5 VDC
31,5 VDC
30 A
3
36 VDC
34,2 VDC
37,8 VDC
30 A
4
36 VDC
41,1 VDC
39 VDC
43,16 VDC
30 A
5
45 VDC
42,8 VDC
47,25 VDC
30 A
6
48 VDC
45,6 VDC
50,4 VDC
30 A
7
52 VDC
49,4 VDC
54,6 VDC
30 A
8
48 VDC
54,8 VDC
52,1 VDC
57,54 VDC
30 A
9
48 VDC
54,8 VDC
52,1 VDC
57,54 VDC
20 A
A
48 VDC
54,8 VDC
52,1 VDC
57,54 VDC
10 A
B
57 VDC
54,2 VDC
59,85 VDC
see curve
C
60 VDC
57 VDC
63 VDC
see curve
D
65 VDC
61,8 VDC
68,25 VDC
see curve
E
60 VDC
68,5 VDC
65,1 VDC
71,93 VDC
see curve
F
72 VDC
68,4 VDC
72 VDC
see curve

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DATASHEET / OPERATING INSTRUCTIONS
INSTRUCTION TO CHANGE THE PROGRAMMED VOLTAGE FOR TEMP.COMP./SENSE MODELS,
type number example ZAT1600/27,4/60T
←Disconnect the power cord from the power line.
↑Disconnect the output cables from the battery.
→See the current code switch position of the unit.
↓See new switch position code from the programmed output voltages sticker on the unit
° Rotate the code switch to the required position.
The hole of the code switch
The adjustment can be checked as follows:
Short-circuit the output cables of the charger (output short circuit).
Connect the charger to the power line.
Follow the Status-led color. Switch ON the charger from the on/off switch.
Count all the number of green blinks.
There must be as much number of blinks as the code switch position number is.
Note!
If the position of the code switch is O, Status-led blinks only once and returns to red.
The code switch positions A…F respond numbers 10…15
☺ Now the charger has been adjusted!
HINTS IF NOT SUCCEED
/ You didn't have chance to count the number of blinks
=> You can start the test with the on/off switch of the charger again and count.
You have made the wrong setting
=> Switch the charger off again and make the correct setting and count the blinking to check.
/ You cannot find the required charging algorithm on list available
=> Contact the seller / importer and ask if the charger can be updated with the algorithm you need.

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DATASHEET / OPERATING INSTRUCTIONS
INSTRUCTION TO ADJUST TEMP.COMP/SENSE MODELS VOLTAGE BY THE TRIMMER,
type number example ZAT1600/27,4/60T
If the battery is charged in a very cold place or desired constant voltage didn’t found from the charging algorithm list,
then there may be need to tune the output voltage. The output voltage can be tuned +/-5% from its nominal value.
←Choose such programmed output voltage, which can reach the desired voltage by +/-5% adjustment. Read the
instruction from ”Changing programmed voltage”.
↑Connect the voltage meter to output wires.
→Tune with a small screw driver the voltage calibration trimmer and check the result from volt meter. Clockwise
direction increases the voltage. Look at the position below
Voltage trimmer
When desired voltage is found the tuning is ready.
NOTE !
The voltage tuning trimmer affects to every programmed voltage settings. The original list is not valid without returning
the original tuning.
Incorrect trimmer tuning may be harmful to the battery.