2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing

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Kiriakos GR:
Since the year of 2003 it was in my plans to make one dedicated ATX PSU load tester.
Back then, market was full of 350W PSU, and 10% load testing it was enough as quick test.

By accepting at 7/2022 thee PSU from Seasonic for me to review, the idea of Triple Rail DC dummy load this awaken again.

New problems on this equation:
a) The average ATX PSU this grown from 350W (2003) to 750W
b) Spesific timing for DIY projects making, this is the worst ever:
1) All European citizens are now in fear of highest ever prices for natural gas and electric energy.
2) Pricing of parts for DIY projects won in a day 50% of higher cost in Greece (September 2022).
3) Business activity half frozen, and I am also feel scared and unable to predict the future.

The new solution:
To go ahead and make my new Triple Rail DC dummy load tester, by the use of salvaged parts that I do all ready own, plus few new parts that they are required.

The new PSU Tester exterior design this started in simulation, by me using the Corel-Draw software.
Within several hours I did succeed to complete the design of face-plate.

Metal case for this project: UPS MGE Pulsar ESV 22+
Height: 240mm
Width: 170mm
Length: 430mm

One picture 1000 words, but I will demonstrate shortly detailed pictures of all parts. :)

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Triple Rail DC dummy load 330W for ATX PSU tester features:

a) 5V, 3.3V, 12V: Load test at 10% & 50% (according to 80PLUS testing process) for 750W.
b) 12v Rail five step loading at increments of 4.5A (22A max)
c) Actively cooled
d) cement resistors 5% 15 Watt
e) H4 12V 60/55W
f) Banana plugs / DC voltage monitor
g) BNC Plugs / AC Ripple (oscilloscope input)

Notes:
a) immune to magic smoke. ;D
b) Signed reliability by Kiriakos Triantafillou - Real electrician ! 8)

Andrew-88:
Over the years Kiriakos did proved his talent as iron-man ;D
Extreme demonstration of high-end craftsmanship when he is dealing with all sort of metals.

Past made VARIAC project this had 5.5mm thickens of aluminum face plate, which Kiriakos successfully deal with it !!
http://www.ittsb.eu/forum/index.php?topic=1240.0

This new project it does have a first significant challenge, all parts at face-plate, they should be installed with extreme caution to detail regarding precision placing next to its other.
I am looking forwards to see all steps of upcoming progress of it, with great interest. :)

In our times they are not many hero, which they do deliver high-end craftsmanship just by the use of their bare hands. ;)

Kiriakos GR:
Best advice prior any one starting any high-end craftsmanship project = have a real good night sleep first :)

overvolt:
New adventure ahead !
This metal case seems huge, and has good design speaking of potentials for active ventilation.
I will get in the line too, so to watch the rest of the progress. :)

Kiriakos GR:
Mix of new and used parts in my ownership, so to retain total costs at minimum :)

Beginning of September project parts price gained 50% increase = 2.5 ~3.0 EUR per a single toggle switch. >:(

I am not planing to deliver any electrical schematic about this project, I am not that generous these days.
Especially when this year, Blog donations fall down to zero.

Below are detailed pictures of my part list, so my readers to use as inspiration. :)