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ITTSB Blog Specific => ITTSB - Small projects by Kiriakos & User reviews => Topic started by: Kiriakos GR on September 07, 2022, 11:32:08 AM

Title: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 07, 2022, 11:32:08 AM
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.  :)

-----------------------------------------------------------------
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)

 

Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Andrew-88 on September 07, 2022, 05:18:21 PM
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.    ;)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 07, 2022, 06:08:08 PM
Best advice prior any one starting any high-end craftsmanship project = have a real good night sleep first  :)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: overvolt on September 09, 2022, 06:13:22 PM
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. :) 

Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 16, 2022, 01:14:02 PM
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. :)
 
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Andrew-88 on September 17, 2022, 10:20:35 AM
Now I have good clues of where the huge heatsink of welder, this will be used at.  :)
(Post #1)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: overvolt on September 17, 2022, 10:46:41 AM
Mix of new and used parts in my ownership, so to retain total costs at minimum :)

My quick costs pricing estimate, by also including the wiring costs, this is close to 90 EUR, and if you get a new project box? this is plus 50E.
Sum could be 170E ~ 190E including several DC fan.
Just my note for the ones who might think to replicate it.  :)   
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 19, 2022, 08:11:55 PM
I will give detailed sum of costs at the project end.
Parts plus portion of electric energy used  ;D

Today's work = progress
a) Metal sheet (front-face) this were cut internally, and now it become a frame with 12mm surround wall, for the addition of screws.
b) Aluminum sheet this were cut accordingly.
c) First aluminum sheet this is 1mm of thickness = soft, and I was forced to cut and a second and identical one, and to add both as one = sum of 2mm of thickness.
d) Both aluminum sheet were centered - drilled - bolted.
e)  Sum of work hours = around five  (for retention of accurate made work at its step.

   
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 20, 2022, 03:07:54 PM
Today's work = progress

a) Construction of accurate paper model of panel meter dimensions.
b) Accurate positioning of top side parts.
c) Accurate slow motion cutting of ammeter hole.
d) Marking and drilling of power switch holes, all in perfect alignment.

 
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 22, 2022, 12:03:25 PM
Skipped one day and now I am moving on.
Working with aluminum this requires of you to have other than skills and a good and mistake-less strategy = systematic work.

Plan, drill, clean all particles, REPEAT
Plan, drill, clean all particles, REPEAT

This is a taste of after drill period  :)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 22, 2022, 01:16:43 PM
This thing started looking as planed !! 
Plus four work hours up to this point.  :)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 25, 2022, 08:17:06 PM
Today's work = progress (Sunday)

a) The aluminum face plate, this is now 99% ready.
The aluminum were cleaned, all major parts are now installed.
b) All wiring for measuring points, three multimeter along three BNC for Oscilloscope connections, all are in place, tested and ready.
c) Power on switch (remote control) with 5 VSB voltmeter, in place and functional.

To do:
a) wiring up to load control switches
b) ammeters wiring
c) dummy load three circuits
d) installation of PCI-E and CPU (add-on cables harness)  at the front plate as it was planned.

By me completing the construction of the front plate, due 100% of mistake-less work, 80% of my own worries or personal fears they are now vanished.  8)
There is still work to be made, but I feel now other than very tired also very confident, about the final mission success.   :)

(My digital camera, Olympus C2100, this has high sensitivity at the frequencies Ultraviolet and the colors of blue LED they look as burned)  ;)   
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Andrew-88 on September 26, 2022, 09:40:18 PM
RESPECT !!   :)

Automated CNC machines would be out of business, if most people was that talented. 
From original plan, only a single switch position this were changed.

 
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on September 29, 2022, 06:42:25 PM
Today's work = progress

a) Heat sink-ed ceramic resistors, two floor double heat-sink (Patent pending) 
b) Wiring, wires, more wiring, more wires.  ;D
c)  5V rail ready and final tests.

Notes:
a) Active air cooling will be the final touch. 
b) Its fun to see analog world getting alive again, not to speak of benefits of long-term reliability.  ;)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: overvolt on September 30, 2022, 09:41:49 PM
This project started looking as painting with wires.
The know style of expert Greek electricians - artists   :)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on October 01, 2022, 06:20:16 PM
Speaking of wires, I did pay more attention of their rooting, clear pass away of any hot-spot.
INTEL saved me again  8)
With a bunch of new added improvements (heatsinks plus active airflow) this thing it is now unable to get even warm (resistors section).

 
Today's work = progress
a) 3.3V rail also ready and final tests
b) I did use also my electronic DC load so to stress and the 12V rail ( three rails stress simultaneously)

It is a new experience for me, of how much you do learn by the use of load testing as its PSU behaves according the electronic design of it manufacturing date. ;)

Note: Length of the metal case this is extra long, so I did take photographs from my workbench so other people to admire of how much real estate this thing stealing away.

To do:  The top floor that is installation and wiring of several car bulbs at their own compartment.
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Andrew-88 on October 02, 2022, 11:11:22 PM
No matter of how hard you will search with Google, such 100% of Hellenic prototype you will not find !!!  8) 
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on October 03, 2022, 12:18:15 PM
No matter of how hard you will search with Google, such 100% of Hellenic prototype you will not find !!!  8)

This is true  ;D
Electrical design this might considered as common, but the composition of parts in use, this is worldwide unique.
Now I have to come by with a third unique idea, about the 12V side of this load tester.
 
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on October 06, 2022, 08:46:27 PM
Today's work = progress  :)

ITTSB Blog R&D team = me alone = we decided the 12V section to have its own compartment.
After very careful geometrical calculations I did did all holes for the bulbs.
Keeping the bulbs in place, along the concept of easy to replace a bulb, was new challenges which they were solved.

its bulb this require 4.5A (high scale) and approximately 3.5A at medium scale.
5 x 4.5A = 22.5A  x 12V = 270 VA (Watt)   

Bulbs-load this were electrically tested, all bulbs are functional them be now mounted over their own panel.


Notes:
a)  H4 type car bulbs they come with two types of mounting base, first system called as star base and the second as barrel base.
The mounting system which I designed, this is flexible enough to support both.

b) H4 electrical connectivity -- middle pin = negative --- left pin = High --- Right pin = Low   
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on October 10, 2022, 04:39:58 PM
Gentlemen  ... ;D 8)

WE HAVE a Working triple DC LOAD  !! (20 minutes tested).  8)



To do:
a) I will do minor wiring corrections at two 12V switches.
b) Add one 120x120 DC fan too.
c) Inspect ammeter measuring error if any.
d) Case cover tweaks in assistance to ventilation.
 
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Andrew-88 on October 11, 2022, 12:10:57 PM
Just spotted the first brief power efficiency results of this load tester
 https://www.ittsb.eu/forum/index.php?topic=1752.0

So, it does truly work  ;D ;D 
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on October 11, 2022, 12:36:24 PM
Just spotted the first brief power efficiency results of this load tester
 https://www.ittsb.eu/forum/index.php?topic=1752.0

So, it does truly work  ;D ;D

According to 80Plus certification, an PSU test procedure this it should last for an hour.
My current goal, this is to make sufficient ventilation (case closed) which will hold at 40C and below the top cover.
Yes, my monster it is truly working with open case.    ;) 
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on October 12, 2022, 07:14:47 PM
YES today it is the day to describe this project as 100% READY.   8)

I did take the last set of photographs, some are special ones just to my eyes (future servicing and or special details for me to remember the how-to).
To find the last needed solution so to solve thermals / cooling, it was not easy but I did find it.

This Triple Rail DC dummy load, its now ready to be the benchmark, for any PSU as it simulates DC load at gaming condition.
I consider the 12V Rail load this be close to INTEL CPU this gaming with GeForce RTX 30 Series of Graphics Cards, and specifically a GeForce RTX 3060 Ti.

RTX 3060 Ti = Graphics Card Power (W) 200
Modern INTEL CPU, this could be simulated by another 70 Watt.
 
Load capability this is 22A at 12V = 264 Watt 
In summary, I did succeed to come close speaking of total of watts above the 322 Watt from the theoretical expectations of 330 Watts.

To do:
I have to evaluate my load due the new standards, that is better thermal stability at 12V rail, and electrical calibration (written report) of all rails.
By doing that I will have hard evidence of final electrical specification of it as DC load.  ;)
 


 

Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on October 12, 2022, 07:23:45 PM
FINAL 3D VIEW  ;D 8)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on October 31, 2022, 12:19:19 PM
I did start writing a document named as: ITTSB.EU Triple DC Load tester electrical specification ..
But this alone it would not deliver the complete pack of details, speaking of the maximum of my new DC Load testing capabilities at my lab.

I am now consider the text bellow as summary and epilogue, which this fill me up with unimaginable pride and happiness. :) 
Everything when as planed.
My triple DC load it has worked so far for five hours at max load and medium load, and all three circuits they did prove their robustness and stability.

I will simply say that I did won and at this battle too.
This is (or was) a combination of electrical design, metal processing skills, proper selection of parts, and an extremely well planed strategy from start to finish.  8)   

Some one might think this project as the poor man testing DC load, I have news for you, analog electronics helped science to build or develop first tools for space technology and to explore outer space.
Now feel free to build or become a maker of your own spaceship.  ;D

---------------------------------------------------------------------------------------------------------------------------

ITTSB.EU Triple Load tester electrical specification

3.3V Rail load options:
Low 1.8A = 5.94 VA (3.30V)
High 5.9A = 19.47 VA

5.0V Rail load options:
Low 1.45A = 7.25 VA (5.00V)
High 6.7A = 33.5 VA

12 Rail load options:
Load OFF = 370mA (dual DC fan for cooling) on all times.
Low 4.5A (12.00V)
Step 2 = 9A
Step 3 = 13.5A
Step 4 = 18A
Step 5 = 22.5A
Actual sum this is 22.87A (load + cooling) = 274.44 VA

All rails combined 327.41 VA   

By the use of my additional electronic DC load (110W), this is adjustable from 200mA ~ 9.4A at 12.00V and this is 112.8VA
https://www.ittsb.eu/forum/index.php?topic=1316.0

Both DC load unit combined as one, they can now stress the 12V rail up to 32.27A.
Combined use of loads can stress any computer power supply up to 440.21 VA and or 440.21 DC Watt.

Examples of computer PSU unit wattage VS obtained testing DC load in percentage:
450W = 97.83 % (testing load)
500W = 88.04 %
550W = 80.04 %
600W = 73.37 %
650W = 67.73 %
700W = 62.89 %
750W = 58.70 %
800W = 55.30 %
850W = 51.79 %
900W = 48.92 %
 
INTEL ATX12V Power Supply Design Guide, considers as Test pass, any DC rail deviation +/- 3% of the named output (at full load).
Eventually this +/- 3% of voltages deviation, this is expected to be included and or influence the sum of obtained testing DC load in percentage at fixed resistive loads.
 
The good news are that TOP-10 of the chart of PSU manufacturing brands, they compete so to improve 12V rail voltage regulation at tighter specification (lesser than 3%).
And therefore 5V rail along 3.3V rail and their wattage combined, this is a small portion of energy compared to the load caused at the 12V rail, which is a much higher quantity of electric energy.
Seasonic at their top models, advertises +/- 0.5% at 12V rail as voltage regulation.
 
80 Plus certification program, this requires 50% of load for PSU efficiency validation.
My new PSU testing platform this is sufficient to test up to 900W PSU unit, but a true high performance AC power meter, this is still missing from the lab. :)
 

In conclusion, the new build testing setup at my lab, which includes and or combine the use of triple resistive DC load along of my electronic DC load, now delivers to me a wide range of choices at load testing.
Both DC load unit’s they now offer to me a combination of settings (adjustments and control), along of the ability for me to adjust or fine-tune the testing load with a great precision if this is required.
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: overvolt on November 05, 2022, 10:33:14 PM
Some one might think this project as the poor man testing DC load, I have news for you, analog electronics helped science to build or develop first tools for space technology and to explore outer space.
Now feel free to build or become a maker of your own spaceship.  ;D

Do not bother with what others might think.
Very few own such a well organized workshop (mini factory) as you do.
The end-product this is second to none, and it can won an award at any DIY contest.   ;)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Andrew-88 on November 06, 2022, 03:35:29 PM
Therefore combined two DC loads, can do 80Plus efficiency testing up to 900W PSU.  :)
How many more secrets you do have under your sleeve?

 8)
Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on November 06, 2022, 04:39:20 PM
Thank you both for the delivery of positive energy!

Now I feel satisfied and I can move on.  :)

Title: Re: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing
Post by: Kiriakos GR on July 31, 2023, 02:03:32 PM
Both DC load unit combined as one, they can now stress the 12V rail up to 32.27A.
Combined use of loads can stress any computer power supply up to 440.21 VA and or 440.21 DC Watt.

Today I have all the answers about how total loading capacity due both loads 440.21 DC Watt., this translate as wattage at input AC Side.
Due the fact that entire DC load this is resistive,  even one low-cost power meter this can measure energy at minimum error.

Resistive load alone = All rails combined 327.41 VA   
Programmable load = 11.5V at 9.0A =  103.5 VA
Total = 430,91 VA
AC side this measured  476.6 Watt ( 235V AC)
AC side this measured  745.1 W   (90V AC)

https://www.ittsb.eu/forum/index.php?topic=1729.msg4740#msg4740

In conclusion, the combined loads at DC side, this is of what exactly required for 750W PSU (at the label) testing.
Especially when testing input voltages at the range 90 ~ 240V AC.
When I did the original design, of Triple Rail DC dummy load , I could not calculate or foreseen, PSU loading behavior at 120V AC and or lower.