(Part 2, Helmet electronics > http://www.whitearmor.net/forum/topic/29534-helmet-electronics-and-external-power-supply-updated/)
Part 1
Hello all. Being the noob I am, I quickly discovered how hot my melon was getting inside the bucket, not to mention I'm a freak when it comes to electronic gadgets and wanted to load it with goodies. Well, after 3 fans (2 pushing fresh air to my face and 1 rear exhausting heat down and out the back of my neck), a voice modifier, voice modifier amp (personally didn't want anything hanging behind my chest plate), a few switches and a boat load of batteries to power it all, I had myself one heck of a brick hanging on my head. The other issue and clincher to my frustration was how quickly it all would plow through batteries.
I desperately needed something that could provide 9v for my voice modifier & amp, 5v for the fans and most importantly, power it all day without having to change batteries. The reason for separate power supply voltages is because the fans create electric noise on my voice channel. Separating the power supplies to each would cure this problem simply.
My solution was the Anker 2nd Gen Astro Pro2 20000mAh battery charger with three USB (5vdc) ports and one 1.6mm (9v/12vdc) port.
After purchasing the charger I quickly realized I had a slight problem. Like most modern battery supplies there are safeguards in place to protect your electronics and their product. The safeguard is to shut it down in case of a overload, or in my case a UNDERLOAD. WHAT! I've never heard of such a thing, yes. Apparently the specifications for the Anker, like a lot of other chargers, is to require a minimum mAh draw or the supply unit shuts itself off to preserve battery life. Not a bad idea unless it's located in an area where it's difficult to access and restart, like in my back plate. My three 5v fans that run off one of the USB ports have a total of 30mAh draw. The combined mAh draw from my voice modifier and amp was 40mAh. On both, neither were enough to keep the charger alive. After a few emails and a couple phone calls to the mfg they kindly informed me they would not be modifying (at any point) the minimal mAh requirement and wished me all the luck in the world in my ventures and thanks for choosing Anker. humm :/, couldn't blame them actually.
So if your still with me and still interested, my simple fix was to first purchase a USB meter off Ebay to check my USB load and DVOM (volt meter) to check the 9/12v load. I needed 20mAh draw to meet the minimal USB requirements and 10mAh to meet the 9v.
Fix: 1) I tested a 1/2 dozen or so old USB thumb drives and found one (seen hanging in one of the pics) that could get me over that hump without excessively assisting in draining the battery. I then plugged it into one of the spare USB ports. Fix 2) I found a 9vdc LED light I could splice into that circuit, and that fixed that.
Now that I have the power supply working correctly, onto wiring the bucket. I ran the USB cable and the 9vdc cable (that came with the Anker) to my helmet via fabric I crafted to cover/camouflage the wires and protect my skin. The wire harness and fabric goes through a hole in my shirt behind the back plate and up through my neck seal. The wires are relatively light weight though I'm currently working on a setup that will reduce it from 2 harnesses to 1 with added expand-ability. In the helmet the wiring harness has a female USB and 2.5mm 9v/12v connectors to mate with the incoming power connectors. To clarify, the Anker 1.6mm connector (charger side) changes to 2.5mm on the opposite end (helmet). Also, in my pics you'll see 3 connectors in my helmet, the 3rd connector is connected to a amp that powers a 3rd speaker I use to pipe in TK chatter via my mp3 player without interrupting my voice communication system (i know it's overkill but whatever).
Test (8 hours non-stop): With 3 fans, 1 voice modifier, 1 voice amp (playing music), 1 USB thumb drive and 1 LED light. After 8 hours I still had 60+% battery life remaining. Enough to charge my phone that was almost dead...lol.
There's so much more to this trial and error story but I'm out of time . I'm open for questions, comments or concerns if any.
I think that about covers it. Enjoy
(Part 2, Helmet electronics > http://www.whitearmor.net/forum/topic/29534-helmet-electronics-and-external-power-supply-updated/)