600W power supply installation

[NRG]

Guys, thanks for the safety warning. I'll take a maximum of precaution. Don't hesitate to warn me to the max in order to not burn my house.

Amifang, your advice and pictures are extremely precious, I did the same following what you've said

cwah, no you didn't. Amigafan said to use the round insulated terminals. You haven't done that...you need to solder these on to the ends of the wires and provide some sort of strain relief to each and the cable as a whole so as they do not pull out or break under use...As you are determined to see this through fit the terminals and solder as advised and at the very least tie wrap the mains cable to the PSU casing somehow to provide strain relief...

I double shrink tape my wire and checked for continuity to make sure that the L goes with the L and same for all others.

I'm going to add 10 layer of insulation tape on top of all the wire (because I don't have the plastic cover).

And that should be fine?

No not really, insulation tape moves and shrinks with age, I dont see a solution other than placing the whole unit in a separate box...maybe a plastic Maplin box with an air vent...

 

[cwah]

Ok, I suppose my actual solution isn't strong enough:

I'm going tomorrow to Maplin to get some ring terminal and see how I can insulate the metal screw without the plastic cover.

 

[eddieo]

Oh Dear......

 

[cwah]

Found the box finally:

- So the wires are double shrink wrapped and I'm going to buy ring terminal tomorrow to make sure they won't pull out.
- The ground pin is connected
- All the wire area is wrapped with 10 layer of insulation tape
- And the whole power supply is wrapped inside a carton box with hole on the back and front for ventilation.

I suppose it should be enough?

 

[bode]

Ok, I suppose my actual solution isn't strong enough

No sh*t, Sherlock!

 

[cwah]

Following your advice, I did everything possible to make it as safe as possible

1. Wires are soldered with ring terminals:

2. Then the terminal is wrapped with insulation tape (terminal on the left) and with a glued heat shrink on complement:

3. Here is what it look like connected to the power supply (I didn't connected the output wire to the ring terminal as the amps is higher and my wires are quite thick):

 

[cwah]

4. Then I covered everything with insulation tape to make sure I'm not going to touch that:

5. And the power supply is wrapped itself into a box:

Should be quite safe now.


My next step is to find a bigger box to put both the hyperion charger and power supply into the same place


Hope it's ok now

 

[neptune]

No, not really, you need to install the whole thing on an offshore island, and post armed guards in watchtowers. The beach must be liberally equipped with anti personell mines. Surveillance cameras need to be installed,and you should consider helicopter patrols. Perhaps you could reach an agreement with the armed forces to have a couple of battalions available at short notice.

 

[cwah]

Hehe, I consider this is a yes then.

I tried to charge my lipo with this charger and my hyperion, it charges way faster than my actual 150W power supply

Quite happy for now. I will probably add another layer of isolation on top of the cable later on.

Extra safety never harm

 

[Hugh]

Hehe, I consider this is a yes then.


Extra safety never harm

!!!

 

[neptune]

@Cwah. Yes, I would say that you are pretty well OK now. Make sure that you have adequate ventilation in the outer box, by drilling lots of holes, or fitting a grill.

 

[cwah]

Will do. Thanks Neptune

 

[NRG]

Drilling holes in what? A cardboard box? Are you intending to mount the PSU in the box it came in?

 

[cwah]

Just cutting some holes on the cardboard box for now for aeration.

I'm planning to get a bigger container (plastic box) to hold my hyperion and PSU together. That would be much more secure, ventilated and easy to carry.

My next step would be to find a box like this to put both the power supply and the hyperion inside:

Source: http://www.rcgroups.com/forums/showthread.php?t=1493834&page=5