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This write up is to illustrate how to build a charging box with one ISDT Q6 charger, using one of our charging plates. The hard case used in this write up is the Seahorse 300 in yellow. You can see this Seahorse plate kit HERE, and the others we offer HERE.
Disclaimer: During this build, You must accept that You and You Alone are Responsible for your safety and safety of others in any endeavor in which you engage. While the material on turtlelaboratories.com is provided in hopes that you build your own personalized box, You are Responsible for verifying its accuracy and applicability to your project. You are Responsible for knowing your limitations of knowledge and experience. If you do any work with “main power” such as 120 or 240 VAC power wiring, you should consult a Licensed Electrician.
Our illustrative photos do not depict safety precautions or equipment, but only aid in the construction of your project. These projects are not intended for use by children. Use of these instructions, kits, projects and suggestions is at your own risk. Turtle Laboratories disclaim all responsibility for any resulting damage, injury, or expense. It is your responsibility to make sure that your activities comply with applicable laws.
The ISDT Q6 charger can accept up to 30V input voltage, and the USB charger port and fan are designed to run on around 12V. Depending on your input voltage, you may need to adjust the voltage regulator for your setup.
If You choose to install an internal power supply, You must only run your box off either an AC source or a DC source. Do not run the box while both are connected.
Now, let's get to it!
The parts used for this build are as follows:
- 1 x Turtle Laboratories Dual ISDT Q6 Field Charger Plate for Seahorse 300 Hard Case (comes with mounting brackets and stainless fasteners)
- 1 x ISDT Q6 Plus Chargers
- 1 x AC Rocker Switch with Fuse
- 2 x Red Banana Jacks
- 2 x Black Banana Jacks
- 1 x USB Charger
- 1 x Voltage Regulator
- 1 x Balance Boards
- 1 x Balance Board Shims
- 1 x 60mm PC Case Fans
- 2 x XT60 Male Connectors
- A power supply. We used a 750W HP server power supply due to the high quality, small form factor, and high output. One ISDT Q6 requires up to 300W, and this power supply will power the ISDT Q6 and others via the auxiliary banana jacks.
Step 1: Begin by placing the ISDT Q6 charger face down on a soft cloth or surface, to prevent any scratching of the screens. Then, install the ISDT locating bracket over the charger. The bracket will tightly hug the outer edge of the charger. Make sure that the bracket becomes flush with the front face of the charger. During the assembly, avoid suspending the charger from the bracket. Though they have a tight fit, the charger may want to fall out of the bracket until all retaining brackets have been installed.
Step 2: Install the charger/charger locating bracket assembly onto the underside of the charging plate, using 4 long screws with 4 nuts.
Step 3: Next, install the banana jacks, in any configuration you prefer. In the case of our build, one pair of banana jacks will be used as an input when the integrated power supply is off, and will serve as an output for auxiliary power when the power supply is on. Install the fan using 4 long screws and 4 nuts. Install the power jack and switch with 2 short screws and 2 nuts. Then install the USB charging port, if you chose this option.
Step 4: Next, Position the balance board shim over the balance board hole. The shim is to space the balance board off the underside of the plate to allow for even spacing once the balance board is installed. Then, place the balance board in the shim.
Step 5: Plug the balance board cable into the charger. Then, install the balance board retaining bracket with one existing long screw from the charger locating bracket, and two new long screws in the lower two holes. Make sure and snug the bracket up, but make sure not to overtighten and warp the plate. Be sure that the balance board is centered in its hole by looking at the plate from the top side.
Step 6: Follow up by soldering an adequate length of wire (no less than 12 AWG wire) to each XT 60 terminal, taking care to notice proper polarity of each terminal. Most XT60 plugs have the polarity labeled on each side of the plug. Make sure that your soldered connections do not touch one another. Keeping the exposed wire to a short length will help, as will finishing with heat shrink tubing over the exposed connection. 
Step 7: Install the charger retaining bracket, being careful not to overtighten the nuts. Tighten them just snug enough to hold the charger in place, but not distort the charger plastic. Then install the voltage regulator board on the balance port retaining plate. We use 3M heavy duty double sided tape, but there are also holes if you wish to use them in addition to the tape. The tape should still be used, since it also insulates the board from the plate.
Step 8: Install ring connectors on the ends of the input and output wires that go to your ISDT Q6. We use the crimp on style connectors, but solder them instead of crimp them, so that they have a better connection.
Step 9: Install the wires to the voltage regulator. The input of the voltage regulator should be connected to the input banana jacks. The output of the voltage regulator will be connected to the USB charger and the fan. 
Step 10: Next we must prepare our power supply. If you are building a case without a power supply, skip all power supply related steps. We have chosen to use an HP server power supply, due to the extreme high quality, availability, and low prices. It has a cooling fan built in, also. We soldered our output power leads directly to the PCB terminals, and also soldered the input wires directly to the receptacle terminals, though you may opt to use a power cord to plug in, and strip the opposite ends. There are also two smaller gauge wires that we soldered on so that we can connect it to the rocker switch on the case panel with spade connectors. These thinner wires tell the power supply to turn on, once shorted out with the power switch. Your power supply, if different than the HP server unit we used, may be wired differently. Check with your power supply provider for the proper way to turn your power supply on. 
Step 11: Now that the power supply has wires attached, connect these wires to the charging plate. The input wires of the power supply will solder to the female receptacle on the power port, the thin wires will attach to the power switch, and the output of the power supply will connect to the input banana ports on the charger plate.
Step 12: The holes on the Seahorse 300 case need to be drilled to 7/64" in order for the stainless fasteners to grab. If they are not drilled out, the plastic around the holes may split.
Step 13: Now is a good time to test your connections. Be very careful not to touch any exposed connections during this process, and do not allow any connections to short circuit. The ISDT Q6 charger should illuminate, the USB charger should display a voltage of around 12V, and the fan should begin spinning. If the voltage readout after the voltage regulator is over 12V, adjust the screw on the voltage regulator to output 12V.
Step 14: Install the power supply in the case. Carefully wipe the inside of the case with rubbing alcohol, as well as the bottom side of the power supply. Then apply 3M heavy duty double sided tape. Peel the tape and carefully install the charger as far back in the case that it can go. Press firmly when pushing down on the tape.
Step 15: Organize your wiring so that it will not interfere with the plate to case interface when lowering the plate into the case. Be sure no components make contact with the power supply, especially exposed connections. If using an HP 750w server power supply, there will be enough clearance. Install the 8 short fasteners into the holes around the perimeter, and then the charger is complete.
Step 16: Grab yourself some batteries, and get charging!
