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Custom charger box build
Build a custom charger case like these:
Single charger with storage area Dual charger setup
Start with an aluminum tool box available from Harbor Freight for $29 - part # 36871
Open the case and there are 2 side folders that need to be removed. Carefully cut them away as we need to save the fabric
Once you cut them out, they look like this.
Place the Iota power supply inside the box and determine how much room you want for battery storage etc to the side. Once you have some dimensions, make a vertical panel from 1/4" ply and cover it with the fabric from the folders that we cut away earlier. If you are going to use a full size top to accommodate 2 chargers then skip the vertical panel step.
If you look closely you can see the hole cut out near the power supply's cooling fan to allow for free air flow.
Now cut the top plate from 1/4" ply and cover with fabric. Also, add a support piece of 1/2" square to the side to support the other end. If you build the 2 charger version, put the 1/2" square support pieces on each side of the box. I removed some fabric and epoxied the 1/2" sq piece to the side of the box. I added 2 banana plug outlets and wired them to the power supply. There is also a small computer box fan that sits under the charger and blows air onto the charger. This is powered from the power supply as well. The charger and balancer are held onto the box with heavy duty velcro.
On the 2 charger version you can have the fan under one charger and an open hole under the second charger as an inlet for the air.
Here is your new charging box in action. Don't hard wire the charger to the power supply unless you only will charge with 110V available. I have the charger on banana plugs so I can power it from a deep cycle marine battery at the field. In the 2 charger picture at the top, you can see I added a 12V fused power panel for power distribution. As a caution, you need to have the output wires from the power supply to the banana jacks or distribution panel to be very heavy gauge wire. Standard lamp cord wire is way too small. You will be drawing approximately 20 amps from the power supply charging one 10S pack. 2 chargers will double that amount, so minimum 8 gauge wire from power supply to the chargers.
*** Updated*** 10/26/08
When running 2 chargers at full power charging 10S packs, the total draw on the power supply exceeds 40 amps and gets it pretty hot inside the box, even with the fan below 1 charger. I modified the box to allow for the 2 1/2" diameter hole below each charger to now act as air intake openings and added a 28cfm computer fan to the box side to allow for more airflow inside the box. The fan and fan guard are simple computer items.
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