Changes to my Powerlab charging setup
 

With all due respect to RCTECH member "teeforb" who came up with the original concept for my charging setup, I wanted to make some changes to it.

Here's how it started:

2 Powerlab 6 chargers
2 Meanwell RSP-1000-27 power supplies
Both power supplies are PFU, 27v, 37A

This setup is reliably capable of 2000 watts of power.

http://i220.photobucket.com/albums/d...ps3e9b7d7c.jpg

As you can see, it's in a Harbor Freight tool case.

I had 2 complaints with this setup:

1. It was not very compact
2. The case did not protect the contents very well

So, I purchased this:
http://i220.photobucket.com/albums/d...pscbf2f118.jpg

Just a Pelican case, nothing special. But wait! I found something very cool. This is a flange designed specifically to sit in the Pelican case and provide a mounting surface for a panel. Cost: $17.00
http://i220.photobucket.com/albums/d...ps1eaa73c7.jpg

It even has these threaded inserts to secure the panel. (The flange can either be secured by small screws into the side of the Pelican case or adhesive.)
http://i220.photobucket.com/albums/d...ps634fe583.jpg

I went to my local plastic supplier and searched through their scrap bin and found two sheets of ABS (in case I screw the first one up) to make a panel for a whopping $2.00

First, I secured the power supplies into the bottom of the case with 3M Industrial Strength Velcro. Not visible in the photo, there are spacers underneath the 2 power supplies for airflow.
http://i220.photobucket.com/albums/d...ps78150390.jpg

Then I fabricated my surface panel. Nothing special here, cut a hole to set the chargers into. Cut another hole for the AC input plug and some holes for ventilation.
http://i220.photobucket.com/albums/d...ps173e2807.jpg

And here she is ready for action:
http://i220.photobucket.com/albums/d...psf859ba0f.jpg

I haven't secured the panel to the flange yet because I haven't purchased the hardware. (There's a great industrial hardware supply right by my track, so I'll pick up some button head screws next race night)

You can't see the partition underneath the surface panel to direct airflow. I didn't want the fans to just keep swirling hot air around under there, so I put in the partition to make sure air is entering one side and exiting the other.

I have ordered two of the MPA adapters, one for each charger.
http://www.progressiverc.com/media/c...95/m/p/mpa.png
Once I have those, I will be able to charge 6 packs on each charger. That's more than enough capacity for me now and enough room for me to grow, I think.

Interesting case, can the panel be set lower into the case?

Might look at doing something like this.

Very cool solution!

If you were real talented with a Dremel or something similar, you could lower the flange further into the case. I doubt my skills with a Dremel to that extent. There are small molded-in ribs on the vertical walls of the Pelican case that the flange sits on.

EDIT: You can see the vertical ribs in the case wall in the photo showing the 2 power supplies in the bottom.

Sweet, thanx for that.

Postage to Australia is a killer but I may still go ahead with it.

What are the internal dimensions of the lower half?

Interior Dimensions
14.62" x 10.18" x 4.25" (L x W x H not including lid depth, according to Pelican website) It's actually slightly bigger than that because they factor out the curved portion where the base meets the side walls. Lid depth is 1.75".

My 2 power supplies measure 10.5 inches from side to side and fit (just barely) in the "10.18 inch" space by spacing up off the floor of the case. I was planning on spacing them up anyway for airflow.

UPDATE:

I was a little concerned about heat buildup below the panel. I've been monitoring it as I used it. 2 race nights and 2 race prep sessions. (I like to show up with packs fully charged)

I measured temps with a non-contact infrared thermometer (temp gun) and noticed a 15-20 increase over ambient temperature at the exhaust outlets. Never over 100 degrees F outlet temperature. Well within my comfort zone!

Really nice setup!
I don't know if you've come across this place or not but they make sick cases that you can get some ideas from.
Can't tell how your getting power into the power supply's but the PC power cable port would be nice to work into the side of your case and they also have a fan that could be used on both sides to push/pull air to keep temps under control. Sounds like temps are ok @ 100°… but its not really that warm in Calli right now and didn't get that hot this year.
Anyway, great work!
http://www.progressiverc.com/cases?cat=49

Edit: looks like you used the same type of PC power plug thing, just wasn't fitted in yet in the pic.

Thanks for the compliment.

I drooled over ProgressiveRC for quite a while before making this setup. I like the Pelican Case better than the one they use. (Little sturdier, USA Made, lifetime warranty)

If you look at the pictures, you can see where my PC power cord goes in at the upper left corner of the interior panel. I didn't want to cut any holes in the exterior of my case if I could help it (For either power port or cooling fans) It's got pretty good airflow with the current configuration, I'll monitor it when it warms back up. Right now I'm pleased with it.

Yeah, those are something to be envious about. I thought about building a pelican case, just haven't got motivated on it yet. It would be nice to just grab one case and go though instead of two separate boxes shoved in a wheelie cart thing with the setup board and notebook and other stuff.
And the PL6 really deserves more respect than that :nod:

I didn't know the pelicans come with that shelf ring thing, that makes the project that much easier. Maybe a clear plexi sheet with some awesome neon lights :D That's go into strobe mode when you are charging :o
Disco charge! :lol: Add in some bomp bomp tunes to go with it :weird:

Again, good job, it may motivate me to finally do it... probably without the disco hop ups though.

They don't. It's an optional piece. I paid $17.00 for mine. If you get serious about looking for the flange and can't find it, shoot me a message and I'll give you the hookup where I got mine.

Cool, thanx.

Here she is in all her completed glory:

http://i220.photobucket.com/albums/d...psa02afdd8.jpg

My stuff came today, but, not as sweeeeeet lookin' as yours. )))))

WOW WOW Very dang nice sir. I love it

Mark, if you can assemble a R/C kit, you can make a case setup like mine. It's not hard.

nice case Razz, yeah I looked at pelicans site also. Very cheap made cases! Pelicans are awesome! I wanted or thought I wanted an orange or yellow case at first. BUT love my carbon fiber! so the all black stealth mode looks the best! Im not quite done with it! Ill try and post pics of it out of the case! Kinda like a turtle out of his shell! Even on my Honda
generator inverter 2000, it just chugs along zero problems! Still cant believe that I never thought of parallel charging until this year!