ZEPIA 601 User manual

ZEPIA Energy ApS
Programmable Battery Chargers
USERS MANUAL
For chargers with the firmware versions from v2.10
Ver.: 08/2006

ZEPIA Energy ApS ZEPIA301/ZEPIA601/ZEPIA1001 User Manual (from SW v2.10) 2
ZEPIA301, ZEPIA601 and ZEPIA1001
Battery Charger Families
Microprocessor controlled, continuous duty,
fully programmable, multi-stage battery charger and battery monitor
Batteries have to be properly charged to achieve long term reliability. The ZEPIA301, 601 and 1001
charger families are fully programmable accordingly to the battery manufacturer charging
specifications. The parameters may be set in the factory or in the field through a unique PC
interface over the charger battery output leads. Through the same interface not only the charging
parameters but also a lot of other information is accessible like: charged amp-hours for the last 32
chargings, charging times, error information, voltages at which charging has been started etc.
PRODUCT FEATURES:
•Fully automatic operation
Charger may be left permanently attached to the batteries. It takes care about battery charging and also
monitors the charging process.
•Completely programmable: Nickel-zinc, Lithium, NiCd, NiMH or lead-acid (flooded, sealed and
traction) batteries may be charged accordingly to battery manufacturer specifications. Up to five charging
phases may be enabled to charge the battery with constant current, constant voltage or floating charge. For
each of the charging phases a lot of parameters may be set as: max. current and voltage, max. charging time
for that phase etc. (see example). Each charging phase (except the first one) may be conditionally executed
after a defined number of Ah put into the battery or after a defined number of completed 1st charging phases.
The fully automatic equalization charging phase is achievable with standard parameter set-up and may be
executed after every completed charging or after pre-defined number of chargings or charged Ah's.
Programmable automatic top-up cycle prevents self discharge during non-operational periods - charger starts
charging after a pre-defined number of days or when the battery voltage is lower than the parameter value.
The charger is fully re-programmable without opening the box. The software for the PC and a Z3610IF adapter
is all what you need.
•Battery monitor and Ah counter
This charger is also a battery monitor at no additional cost. It collects data about how the battery has been
charged:
total number of charging starts and total number of connections to the battery,
at what battery voltage the charging has been started – frequent deep discharges can be monitored: 16
voltage windows between 18 and 24V (24V charger) or between 36 and 48 (48V charger),
total Ah charged (has the battery pack been used a lot or not) - for each charging phase Ah counting
may be separately enabled (for example: Ah are not measured for the floating charge)
for each charging phase Ah counting may be separately enabled (for example: Ah are not measured for
the floating charge phase),
how many Ah have been put into the battery during the last 32 chargings (Ah counters tell you if the
battery capacity degrades or if the battery has been properly charged and also how the vehicle has been
used), measurement of the charging time for the last charging (each charging phase separately) and for
all chargings together.
This data may be accessed trough the same PC interface as for the charger parameters.
•High precision
Every charger is factory calibrated - no additional user calibration is necessary. No potentiometers or other
movable parts are used, therefore no vibration or corrosion problems for chargers built into the vehicles.
•Temperature compensation
The charger adjusts the charging voltage to compensate for the battery temperature, providing an accurate
charge in any climate. A low cost external battery temperature sensor may be used to monitor battery
temperature. The battery temperature monitoring and voltage compensation can be enabled for each charging
phase separately and set separately (two different values) for the main charging process and for the trickle
charge
•Battery status LED indicators
Three LED's (Error, Charging and 100%) display the executed charging phase, completed charging, float
charge. Charging LED is user programmable.
•Compact size, low weight, ruggedized construction and maintenance free operation

ZEPIA Energy ApS ZEPIA301/ZEPIA601/ZEPIA1001 User Manual (from SW v2.10) 3
1. PC Software Package KOP
1.1. System requirements: The software tool runs on the standard PC or notebook under operating
systems from Windows ’95 to Windows ’XP. It allows the modification of battery charger parameters and
the insight into all the information that the charger saves during operation. The software is always delivered
together with the PC interface module. This is an adapter that is put between the battery and the charger and
is connected to the PC serial port (COM1 .. COM8). The same PC interface can be used for all versions of
the programmable chargers.
The software is delivered on a CD or by e-mail. Updates are distributed by e-mail. The files are
delivered as a self-extracting ZIP file. See the installation instructions below.
In the DATA folder are always some sample parameter files (files with the extension .K61). When the
software is started the first time the “File Open” function will always start inside of this folder. For many
battery types ZEPIA or charger distributors already have parameter files, made according to the producer’s
references..
1.2 Installation instructions
See the INSTALL.PDF file which is distributed together with the software (on the CD or inside of a ZIP file
sent by e-mail).
1.3 First start
The following screen appears after the charger is connected to the PC interface and the PC interface is
connected either to the battery or power supply. The energy for the PC interface and for the charger comes

ZEPIA Energy ApS ZEPIA301/ZEPIA601/ZEPIA1001 User Manual (from SW v2.10) 4
from the battery or power supply. The charger should not be connected to the 230V voltage while it is
connected to the PC interface.
If the communication with the charger has failed, the following things must be verified:
1. Is the PC-interface properly connected to the battery (is the polarity OK)?
2. Is the charger properly connected to the PC-interface (look at the label on the box)?
NOTE:
A 24V power supply can be used instead of the battery to power the PC interface for all charger versions
(from 12V to 36V). For some 48V chargers a higher voltage may be necessary.
The software can also be used without being connected to the PC interface and the charger (to modify or edit
the parameter file, for example).
The software should not be started from a write protected medium like CD-ROM or write protected Flash
disk. If this will be done, then the charger parameters may be transferred and inspected. However, other data
read from the charger (Ah, Status) are not displayed correctly.

ZEPIA Energy ApS ZEPIA301/ZEPIA601/ZEPIA1001 User Manual (from SW v2.10) 5
ICONS AT THE SCREEN AND THEIR MEANING
Icon Shortcut Description of the command
<Ctrl-N> A new parameter file (NEW.K61) with the default parameter values will
be opened
<Ctrl-O> Open the parameter file
<Ctrl-S> Save the modified parameter file (or parameters loaded from the
charger) to disk.
(may be used to save status / Ah counters to the file also)
<Ctrl-P> Print the contents of the currently open window (Parameters, Ah
counters or Status)
<Ctrl-R> Read the parameters from the charger. This option is available only if
the charger is connected to the charger.
Important: The charger always load complete data from the charger
(parameters and all other information which the charger collect). If the
file is saved to the disk, then all of this parameters are saved. Thus the
complete information file from the charger can be sent to the supplier for
the analysis (for example by e-mail).
<Ctrl-W> Write parameters to the charger.
If many chargers have to receive the same parameter file, then this can
be accomplished quickly by loading the parameter file first and then just
pressing the <Ctrl-W> key combination (or clicking on this button) after
the new charger is connected to the PC interface..
Selection of the font type and size. This fonts are used in the text
windows (Ah counter / Status).
At the moment the proportional fonts are not fully supported. We
recommend the use of non-proportional fonts like "Courier New".