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Twin (El Cheapo) PSU with crowbar circuit project

KH0UJ

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Location
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System Name Air Cooled Gaming / Shop PC
Processor AMD Athlon II X2 Regor 250
Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#1
I just bought two Power supply unit (ORION HP585D) this morning, Damn I just void directly the warranty of the units just to satisfy my thought of having a steady volt @ 100 amp. max. load on the 12 volt rail,:laugh: since its nearly impossible for the manufacturers :confused:( I think) to build such an ambitiuos steady volt amp. draw @ 100 amps. continuos PSU unit without a single .03V drop on the output (+12V) this Twin PSU is a preparation for my second soon to be rig (Hopefully:rolleyes:) SLI 8800 Ultra and an AM3 CPU and a 4 Gb Dominator memory, My plan is to construct a crowbar circuit on the high frequency oscillator circuit in conjunction with the built-in over volt protection circuit that comes along with the PSU units, it functions as a voltage leveler on the output (+12V):D the more amp. draw it can automatically adjust the output volt to compensate the huge current drain, basically the circuit functions as an automatic voltage regulator just on the +12 volt rails:laugh:, it automatically steps up the voltage if it senses a bigger current drain, hopefully this will be an eye opener to the manufacturers, :respect:WE NEED A STEADYVOLT PC PSU:respect::laugh:
 

KH0UJ

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System Name Air Cooled Gaming / Shop PC
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Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#2


No more warranty on the PSU`s:cry:
 

KH0UJ

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Location
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System Name Air Cooled Gaming / Shop PC
Processor AMD Athlon II X2 Regor 250
Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#3


I just started taking out the wires on the first PSU to calibrate and install my crowbar circuit for further bench test;)
 
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#4
interesting! subs!
 

KH0UJ

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System Name Air Cooled Gaming / Shop PC
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Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#5


Viola! no more wires:laugh: this project also serve as a test for me on how far i can push myself to successfully fulfill my nonsense ambition:laugh: 100 AMP. steady +12V rail, no drops, not even 0.01V(hopefully) geeezz! what for? :laugh:
 
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Processor e6300 @ 3000, stock Volts
Motherboard msi p35 neo2-FIR
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Memory 2gb tracers 1066 micron d9GMH, cooled by a modded CoolIt Memory Cooler
Video Card(s) HIS 4850 ICEQ4
Storage WD Caviar 16 320gb WDAAKS + 640gb WDAAKS
Case CM RC-690 sligthly modded
Power Supply Bequiet darkpower PRO 850W (say overkill? :D)
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#6

KH0UJ

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System Name Air Cooled Gaming / Shop PC
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Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#7


This is the most interesting part on this island:eek: "NO ELECTRONICS PARTS STORE" i cant even buy a single 1/4 watt resistor:banghead:meaning, i need to be resourceful again, im gonna start scavenging this server PSU for parts:ohwell: serves as an extreme test for me :cry: modify the unit while scavenging the parts used, life is really great:banghead:
 
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#8
If you're doing this kinda thing I can't imagine you'll need the warranty on the PSU (that's provided nothing actually blows up of course), you'll probably know how to fix it yourself.
Subscribed
 

KH0UJ

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System Name Air Cooled Gaming / Shop PC
Processor AMD Athlon II X2 Regor 250
Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#9
I tried waiting on the Buy-Sell-Trade-Giveaway Forum (Techpowerup) hoping to catch someone seeling a 750W non modular PSU, everytime someone sells in a blink of an eye its sold:eek::wtf: I guess im not that lucky buyer, that`s why i just gamble my $60 on this project:ohwell: I prefer a soldered type PSU (non modular) to minimize the VDrop on the connectors, every connector there`s a powerloss specially on the low voltage connections, unless its a rhodium plated connectors:eek: minimal Vdrop but still there`s a drop:laugh: nothing can beat the soldered wires I guess:laugh:
 

KH0UJ

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System Name Air Cooled Gaming / Shop PC
Processor AMD Athlon II X2 Regor 250
Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#10




Day 2 of my project right after work:ohwell: ived cut all my connector pins to create a custom length on each of my harness:laugh: carefully soldering it piece by piece,
 

KH0UJ

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Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#11




Here you go, a custom length connectors:laugh:
 
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#12
the silverstone olympia, pc power and cooling 1000w & 1200w andf the enermax galaxy have 90a on the 12v rail... is that not close enough :D
 

KH0UJ

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Motherboard Asus M4A78 plus
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Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#13




getting ready to attach my crowbar circuit:rolleyes: the heart of my crowbar circuit is the undesputed LM 7812 1 Amp. voltage regulator I.C.:respect: connected as a feedback voltage leveler on the input oscillator to compensate the voltage drop due to high amp load
 
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#14
this is interesting.. mainly because it feels like im in chem class and ur saying words i dont know :)
 

KH0UJ

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Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#15
the silverstone olympia, pc power and cooling 1000w & 1200w andf the enermax galaxy have 90a on the 12v rail... is that not close enough :D
That`s one of a hell high end PSU bro:( this project only cost me $60, $30 each:laugh:
My aim is to reach 100 Amp continuous and 0.02V drop is not acceptable:rolleyes:

So meaning 12.06V on idle, when i load orthos and NVidia stress test it should not drop to
12.04 on load is not acceptable:laugh:
 
Last edited:

KH0UJ

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System Name Air Cooled Gaming / Shop PC
Processor AMD Athlon II X2 Regor 250
Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#16
That`s it for now:) I need to sleep and relax:eek: I think I can finish this project in 10 days:laugh: Thanks for viewing guys and welcome to my unecessary thread:laugh: I just wanna see my stars counting, right now its only 3 stars and some members already exceeded to a super nova:eek: how did they do that? I just wanna see my stars go into 5:laugh:
 

KH0UJ

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Location
Cebu City Philippines
System Name Air Cooled Gaming / Shop PC
Processor AMD Athlon II X2 Regor 250
Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#17
I wish I can buy an OFC (Oxygen-free Cable) wires over here, I miss those Car Audio Sound System set-ups:( OFC wires are rated "low loss" meaning AWG #18 OFC single wire is equivalent to a #14 ordinary wire, small wire but High amperage capacity...and expensive too:laugh:
 

MKmods

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#18
well I am subscribed... you sound like you know whats going on (crosses fingers)

Let us know at "The Bad Boys of Case Modding Clubhouse" if we can help you out with your mad experiments by sending materials....
http://forums.techpowerup.com/showthread.php?t=56727
 
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#19
The PSU is only one part of the voltage drop problem. Even with no drop on your 12v rail, you will still have drop on CPU, GPU, NB and even mem voltages when under load.
 

KH0UJ

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System Name Air Cooled Gaming / Shop PC
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Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#20
hoooo! damn! that was kind of hard:banghead: speacially on the 0.02V drop, I continued working on this project yesterday after work (5:00pm-2:00am) and continued today (10:00am-3:00pm) I did not eat lunch until im finished:laugh: I calibrated each PSU with only a 50 amp. dummy nicrome resistor that I made out of nicrome wire of a heating element on a dryer:laugh: the reference voltage is +12.12 volts no load, I load it with the 50 amp draw
its +12.24:eek: at least I know the crowbar circuit is working, so I recalibrate again the biases of my voltage leveler to the point that its not stepping up that much of a crowbar(0.12 Volts) Finally I got the stabilized output, now I can drink a beer :toast:
 

KH0UJ

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System Name Air Cooled Gaming / Shop PC
Processor AMD Athlon II X2 Regor 250
Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#21




I installed directly the PSU`s on my main rig to test the actual current drains on the +12V outputs, the first picture is my reference voltage whch is 12.13 volts no load, just the windows starting-up
 

KH0UJ

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System Name Air Cooled Gaming / Shop PC
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Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#22




I installed all my test instruments to monitor everything, from noise sensors to voltage output frequency (DC ripple sensor) to voltmeter
 
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#23
I don't know jack about what you're doing or saying, but this is definately interesting:laugh:
 

KH0UJ

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Location
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System Name Air Cooled Gaming / Shop PC
Processor AMD Athlon II X2 Regor 250
Motherboard Asus M4A78 plus
Cooling Air Cooled (Upward Airflow)
Memory Corsair Dominator PC-8500 2GB 1066 MHZ
Video Card(s) Palit GTS 250 E-Green
Storage Hitachi Deskstar 160 GB
Display(s) Samsung EX2020 20 inch LED
Case Wooden Case Painted and Modified
Audio Device(s) Realtek ALC887 8 Channel (Onboard)
Power Supply Orion HP 585D X2 Dual Modified PSU (585W+585W)
Software Windows XP SP3 / Windows 7 32 bit
#24






I run the NVidia stess test together with Orthos:rockout: damn its a rock solid +12.13 volts
:respect: my nonsense effort paid off:laugh:
 
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#25
I run the NVidia stess test together with Orthos:rockout: damn its a rock solid +12.13 volts
:respect: my nonsense effort paid off:laugh:
Congrats! :) does this meen that you have accomplised what no other PSU manufacturer has done before?