Junsi iCharger 4010 DUO Case (incl. PSU)

thingiverse

This project is still in progress. Sorry for the bad photos, i shall update them at a later stage. Recently, I discovered how well my iCharger 401 DUO fitted into the beauty case I used for my groundstation project. So I bought another one to install my charger and its power supply into it to have a protective case that I can carry easily to the flying field. The PSU is based on two HP DPS-1200FB A units that were supposed to fire IT servers. To connect them in series requires some modification on one of the units, something I will not describe here and what should only be done by experts (google will give you more information). I noticed, that the cheap beauty cases are not very precise in their measurments, I have two and they differ up to 12mm in each direction. So designed the brackets for the PSUs in the lower compartment with floating bushes to compensate a few milimeters of width. The deck plate was made out of 6mm plywood, you might need to remix this based on your actual size needed. It has an opening to install a connector into it. This is foressen for a panel-mount version of an EC5-connector, as that is what the charger comes with. I still have to draw this component. The bezels are designed to be installed in the small sides of the lower compartment, their inserts feature ventilation grills and a cut-out for a C14-connector incl. fuse and switch to connect a power cord on one side. (I used this one: https://www.conrad.de/de/kaltgeraete-steckverbinder-c14-stecker-einbau-vertikal-gesamtpolzahl-3-10-a-schwarz-1-st-501638.html) UPDATE 16/01/2016: added the EC5 wallmount connector to get power from the PSUs through the cover plate. I didn't print it yet, so if one is brave enough to give it atry, let me know the results, please :) UPDATE 28/01/2016: after relatively short time at the first test run of the fully assembled case, the fans inside the PSUs were running on full speed and their metal housings had more than 50°C - while the charger was still idling! So I decided to modify the grills in order to improve the ventilation. A small drawback is that's now possible to look through them...