Junsi iCharger 4010 DUO Case (incl. PSU)

thingiverse

This project is currently under development. I apologize for any subpar photos, which will be replaced at a later date. Recently, I discovered how well my iCharger 401 DUO integrates into the case used for my ground station project. As a result, I acquired another one to install my charger and its power supply into it, creating a protective case that is easily portable to the flying field. The power supply is built using two HP DPS-1200FB A units designed to power IT servers. To connect them in series requires modifications on one of the units, a process best left to experts (Google can provide additional information). Upon inspecting cheap beauty cases, I found that they often have inaccurate measurements, with two such cases varying by as much as 12mm in each direction. In response, I designed brackets for the PSUs in the lower compartment with floating bushings to account for any slight variations. The deck plate was constructed from 6mm plywood; you may need to modify this based on your actual needs. It features an opening for installing a connector into it. This is intended for a panel-mount version of an EC5-connector, which is the type provided by the charger. I still need to draw the specifications for this component. The bezels are designed to be installed in the small sides of the lower compartment and include inserts with ventilation grills as well as a cut-out for a C14-connector featuring a fuse and switch to connect a power cord on one side. I used the model found here: https://www.conrad.de/de/kaltgeraete-steckverbinder-c14-stecker-einbau-vertikal-gesamtpolzahl-3-10-a-schwarz-1-st-501638.html UPDATE 16/01/2016: an EC5 wallmount connector has been added to draw power from the PSUs through the cover plate. It hasn't yet been printed, so I would appreciate any feedback if someone decides to try it. UPDATE 28/01/2016: following a test run of the fully assembled case, the fans inside the PSUs were running at full speed and their metal housings had temperatures exceeding 50°C while the charger remained idle. In response, I have modified the grills to improve ventilation, but this now makes it possible to see through them...