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 Post subject: Testing my charging solution...
PostPosted: Mon Jun 29, 2015 5:25 am 
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Joined: Mon Jul 25, 2011 5:07 pm
Posts: 778
Location: West sussex, UK
Hi gang. With my new found interest in helis I thought I'd break out the field solution.

Image

Pulling19 amps from it and the revs haven't even gone up! Excellent...


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 Post subject: Re: Testing my charging solution...
PostPosted: Mon Jun 29, 2015 5:28 am 
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Joined: Mon Jul 25, 2011 5:07 pm
Posts: 778
Location: West sussex, UK
What do you guys use to supply the charger connections wise? These banana plugs get pretty warm...
Image

Many thanks
Steve


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 Post subject: Re: Testing my charging solution...
PostPosted: Mon Jun 29, 2015 8:59 am 
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Joined: Sun Jul 31, 2011 6:45 pm
Posts: 1550
Location: McKinney, TX
My iCharger 308DUO uses an EC5 connector.

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Team Shannon (Only Fine Helis)
DT520E V2, Protos Max V2, Nighthawk 250 Pro FPV quadcopter
ParkZone P-51 BL, Hobby King Skipper


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 Post subject: Re: Testing my charging solution...
PostPosted: Mon Jun 29, 2015 9:21 am 
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Joined: Mon Jul 25, 2011 5:07 pm
Posts: 778
Location: West sussex, UK
Thanks Alan, I'll look into it.

I am not sure if the heat is coming from the connector or the wire supplying it which is a doubled up 12 gauge wire.

it is only warm but I have some packs that I plan to charge at about 18 amps. (6100MaH)

and it was warm running 16a so when I am pulling 36 from it I expect things may go awry.

/Steve


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 Post subject: Re: Testing my charging solution...
PostPosted: Mon Jun 29, 2015 9:46 am 
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Joined: Sun Jul 31, 2011 6:45 pm
Posts: 1550
Location: McKinney, TX
All the power wiring in my case is 10AWG. Doubled-up 12AWG should be able to handle it easily.

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Team Shannon (Only Fine Helis)
DT520E V2, Protos Max V2, Nighthawk 250 Pro FPV quadcopter
ParkZone P-51 BL, Hobby King Skipper


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 Post subject: Re: Testing my charging solution...
PostPosted: Mon Jun 29, 2015 9:57 am 
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Joined: Mon Jul 25, 2011 5:07 pm
Posts: 778
Location: West sussex, UK
what do you use to connect up in the case? I am using automotive crimp style connectors that look like a big washer. perhaps this is the bottleneck?

I think I should solder direct to the power terminals rather than using the banana sockets...

thanks for the ideas.

/Steve


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 Post subject: Re: Testing my charging solution...
PostPosted: Mon Jun 29, 2015 3:42 pm 
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Joined: Sun Jul 31, 2011 6:45 pm
Posts: 1550
Location: McKinney, TX
The HP power supplies I use have power on the edge of a circuit board that protrudes out of the enclosure. I just rigged up some card edge connectors where each contact is soldered to bare 10AWG wire, thereby spreading out the current flow.

What do the outputs of your power supplies look like?

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Team Shannon (Only Fine Helis)
DT520E V2, Protos Max V2, Nighthawk 250 Pro FPV quadcopter
ParkZone P-51 BL, Hobby King Skipper


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 Post subject: Testing my charging solution...
PostPosted: Tue Jun 30, 2015 7:22 am 
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Joined: Mon Jul 25, 2011 5:07 pm
Posts: 778
Location: West sussex, UK
right I ripped the case down and started again, using 10AWG wire to the PSU.
I then went to the shop and bought 2 EC5 connectors, unfortunately when I got home with them I realised the are both male so scrapped that plan for the time being.

so I wired 10 AWG into the PSU and then each sided of the wire + and - separately into a deans plug each. with the -ve going to a male and +ve going to the female deans plugs.
Then did the opposite on the charger supply lead.

so now I have a solution that should easily handle 40a and when I am next at the shop I'll get some female EC5's and connect it up properly.

The only reason I am in a rush to get it back online is I am going flying tomorrow and need my charger setup at the field.

I have 3d printed some brackets to hold the PSU in the case and done away with the cigar lighter, it was a nice touch but I never used it and having an open cigar lighter port pointing straight up is asking for a screw to land in there and ruin my whole day.

will try it in anger tomorrow but for what I am flying tomorrow it should be fine (biggest pack is a 3000mah 3s)
ImageImageImage

cheers
Steve


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 Post subject: Re: Testing my charging solution...
PostPosted: Tue Jun 30, 2015 7:32 am 
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Joined: Mon Jul 25, 2011 5:07 pm
Posts: 778
Location: West sussex, UK
TheBum wrote:
What do the outputs of your power supplies look like?



Sorry Alan, I missed this, the PSU has 2 pairs of tongue prongs that are about 2mm apart with about 4mm between each pair.

kind of like this || || || || with the first 4 lines being + and the second 4 being - + -
I went in between them with my 10AWG wire and then bridged them all together with solder. 10 indicates the wire ||10|| ||10||

I think I found the problem, the terminals on the back of the banana plugs were quite small, and I was also mistaken on the wire thickness unter the enclosure it was doubled up 14awg, still substantial enough for 2200 packs but now I am running some big 6100mah packs obviously the increase in charge current has highlighted a flaw.

I was lucky I wasn't trying to charge 6s 5000's at 3c!

cheers
Steve


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 Post subject: Re: Testing my charging solution...
PostPosted: Tue Jun 30, 2015 9:50 am 
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Joined: Sun Jul 31, 2011 6:45 pm
Posts: 1550
Location: McKinney, TX
I've had power supplies with output tabs like that. I just used 1/4" quick disconnect connectors on them.

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Team Shannon (Only Fine Helis)
DT520E V2, Protos Max V2, Nighthawk 250 Pro FPV quadcopter
ParkZone P-51 BL, Hobby King Skipper


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