Author Topic: 2022 ITTSB Project: Triple Rail DC dummy load 330W for ATX PSU testing (Read 15282 times)

Andrew-88 · « **Reply #12 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.

Kiriakos GR · « **Reply #13 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.

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.

overvolt · « **Reply #14 on:** September 30, 2022, 09:41:49 PM »

This project started looking as painting with wires.
The know style of expert Greek electricians - artists

Kiriakos GR · « **Reply #15 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

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.

Andrew-88 · « **Reply #16 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 !!!

Kiriakos GR · « **Reply #17 on:** October 03, 2022, 12:18:15 PM »

Quote from: 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 !!!

This is true

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.

Kiriakos GR · « **Reply #18 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

Kiriakos GR · « **Reply #19 on:** October 10, 2022, 04:39:58 PM »

Gentlemen ...

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

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.

Andrew-88 · « **Reply #20 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

Kiriakos GR · « **Reply #21 on:** October 11, 2022, 12:36:24 PM »

Quote from: 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

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.

Kiriakos GR · « **Reply #22 on:** October 12, 2022, 07:14:47 PM »

YES today it is the day to describe this project as 100% READY.

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.