24V 1800 Watt Portable Charging Box

[pctomlin]

Just finished my portable charging box. It is made from a tool box from Home Depot, a couple of Dell 6650 server power supplies from ebay and an ICharger 306B and Turnigy Accucell 8150. It is capable of dual 24V and dual 12V outputs up to 72 amps total.

[Primeval]

Very Nice!!!! Hope I can get something like that made someday.

[pctomlin]

Thanks, I had a lot of fun building it and it will sure come in handy. It is nice having all of my charging stuff in one neat bundle.

[Ranger71d]

I'm ordering 2x Dell 6650s in order to do the same same up. I was wondering if you could post how you wired the power supplies up.
I understand that these PSs have an internally floating ground. So connecting them in series should be straight forward. Wanted to know if you found this to be true.
thanks!

Update: just found the thread that shows the wiring. Very nice

[MaSt0RaS]

I want the wiring too.. i Have two HPs on 1180W and 47 amps..!

[007brendan]

Where did you get your binding posts? Everywhere I look is super expensive.

[povern]

Originally Posted by 007brendan

Where did you get your binding posts? Everywhere I look is super expensive.

I have seen them at radio shack pretty resonable.

[pctomlin]

This is where I got my binding posts from. They worked great. Heavy duty and can take up to an 8 awg wire in the upper post.

http://www.ebay.com/itm/Dual-Banana-...item2eb7ce588a

[pctomlin]

I had zero issues wiring these PSUs in series. They are designed from Dell with the AC and DC grounds isolated from each other and all the appropriate safeguards. Just wire up and go.

Here is how I wired up my PSUs. I have dual 12V and dual 24V outputs up to the tray to power the chargers and have a port to share.


I wired the three red pins together using a servo connector. It slid over the pins perfectly. I then ran the servo wire up to a switch mounted in the toolbox tray. two wires went to one leg of the switch and the third servo wire went to the other leg of the switch to complete the circuit. I use this to power up the DC rail after plugging in the PSU to the AC power.


The final modification to my charging box. I added a shelf to hold the batteries while charging. Did not like setting them in the tray with the chargers.

[Wizza]

Hi Paul, Looks great... Could you give us the model / part number of the Dell power supplies..??? I'm presuming they are around on eBay..???

Many thanks...

[pctomlin]

I got them off of ebay. I was able to purchase a pair of them for $25.00 locally, but one of them was DOA. I purchased another one off of ebay for $35.00 brand new with free shipping to complete my set of PSUs. Returned the DOA PSU for a refund. You can use the below information to search ebay. Be sure and do separate searches with the 086GNR, the 7000245, and ATSN7000245 along with the full string below. If I remember correctly a couple even showed up using ASTN7000245 in the search. For some reason I would get some different hits over just using the full string below. One thing to remember, these PSUs are about 8 lbs each and 12"x6 1/2"X2 5/8". They are larger than what most other people are using but in my opinion well worth the added size and weight, especially considering the AC and DC grounds are already isolated from each other.

DELL PowerEdge 6650 900W Power Supply 086GNR 7000245

[Ranger71d]

Just got 2 of these per supplies in the mail today. $25.00 each plus shipping on eBay.
Didn't come with power cords and I didn't think much about it as I have some extra pc per cords.
These PS use a non standard plug. From what info i have found i will need a C19 plug to mate to the PS. So tomorrow I'll search locally for a C19 to 5-15p cord for each PS. The c19 end of the cord is what you will need to plug into the PS. 5-15p end is the standard US 3 prong plug.
If you grab one off the Internet make sure to grab the proper per cord too.

[pctomlin]

I got both of my power cords off ebay also. They were 8' cords and cost about $7.95 each if I remember correctly. Another alternative is to get a heavy duty extension cord and change out the plug on the end for some good spade connectors.

[bobloblaw]

Paul for the on/off switch set up from the three red pins, do you need to do this from both PS? If so, do you send the wiring from both to one switch?

[pctomlin]

Each PSI needs its own separate switch. I turn on the first PSU to get 12v and then I turn on the second PSU to get 24v. I reverse the order when powering down. You don't have to have switches, you can just jumper the three pins together if you want to. I wanted to be able to plug in the PSUs to the ac supply and then power up the dc rails when I wanted to so I added the switches.

[RCTada]

This looks amazing! You can really see the time you have spent on this has made this very enjoyable for all of us to see and hopefully learn from! Very inspiring pictures, I definitely will make one like this now for my 208b

Thank you!

[pctomlin]

Thanks for the compliment. I really enjoy building things. If you have any questions about my build feel free to contact me. This is the main thread for the build, has some more pictures.

http://www.helifreak.com/showthread.php?t=310694

If anyone is interested I documented the disassembly of the PSUs to remove the handles so they would lay flat against each other. I can post an explaination of how it is done with all the pictures and how I took them apart.

[Rick~K]

Originally Posted by pctomlin

I wired the three red pins together using a servo connector. It slid over the pins perfectly. I then ran the servo wire up to a switch mounted in the toolbox tray. two wires went to one leg of the switch and the third servo wire went to the other leg of the switch to complete the circuit. I use this to power up the DC rail after plugging in the PSU to the AC power.

Does it matter what 2 wires go to one post and the 1 remaining to the other of the switch?
Thanks

And I would be interested in the disassembly of the PSUs....Thanks!

[pctomlin]

The center pin of the three marked red pins is the ground. On my switches for powering up the 12V rail I placed the outer pins on one leg of the switch and the middle pin on the other leg of the switch to complete the circuit.

I will post up a how to on taking these PSUs apart tonight. I need to resize the pictures and add some text/arrows to point out what to do.

[pctomlin]

Just got done with the thread on how to strip the PSU cases so the handles can be removed. Here is the link to the thread.

http://www.helifreak.com/showthread.php?t=354252