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Custom 1kW PCI-E PSU

5509 Views 45 Replies 17 Participants Last post by  Smirnoff
I am beginning to both buy and mod parts for my dream build and seeing as how no standard ATX power supply will give me the stability I desire, I have decided to go with not one, but two PC Power & Cooling Turbo Cool 1200W ESA PSUs. One will power the motherboard, processor, hard drives etc., while the other will power two NVIDIA GeForce GTX 395s and an NVIDIA GeForce GTX 360. I have started removing wires from the first PSU, leaving only enough for six 6 pin and two 8 pin PCI-E connectors.Once I finish the diagram of what terminals are hot and which are ground I will remove all of them and very neatly solder an even higher gauge wire to them, build a custom housing complete with EMI shielding, EMI absorbing material, and modular connectors.



EMI Shielding
Shield
Absorber

Connectors:
Male
Female
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What a tremendous undertaking! Do you plan on building your own chassis for this monstrosity?
No, I am going to mod a TJ07 to fit two of them side by side. Maybe I can get Johnny Guru or hipro5 to test them.
2
Quote:


Originally Posted by RockNRolla
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I am beginning to both buy and mod parts for my dream build and seeing as how no standard ATX power supply will give me the stability I desire, I have decided to go with not one, but two PC Power & Cooling Turbo Cool 1200W ESA PSUs. One will power the motherboard, processor, hard drives etc., while the other will power two NVIDIA GeForce GTX 395s and an NVIDIA GeForce GTX 360. I have started removing wires from the first PSU, leaving only enough for six 6 pin and two 8 pin PCI-E connectors.Once I finish the diagram of what terminals are hot and which are ground I will remove all of them and very neatly solder an even higher gauge wire to them, build a custom housing complete with EMI shielding, EMI absorbing material, and modular connectors.



EMI Shielding
Shield
Absorber

Connectors:
Male
Female


Uhh...GTX 395? GTX 360?

Did I miss something?
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No, I am just assuming they will be called that.
2
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Originally Posted by Arbiter419
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Uhh...GTX 395? GTX 360?

Did I miss something?

It's called planning for the future.
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Wow.

That's pretty badass.

Good luck man.
2
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Originally Posted by RockNRolla
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No, I am going to mod a TJ07 to fit two of them side by side. Maybe I can get Johnny Guru or hipro5 to test them.

You should had bought hipro5's 1.2kW PSUs.


Anyway, looking good so far, keep us posted.
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how dangerous is it to play with 2400 W ? And even for you future zomg rig, this is complete overkill in my opinion.
I know I don't have the cahones or the cash to tear apart a $500-550 PSU. You mentioned EMI filters. If you are planning on ferrite beads on your output wires you are wasting your time. And EMI shielding for the PSU itself will be pointless unless you have a very good UPS filtering your incoming AC. Any noise in your mains electricity from other devices will have much more of an effect than any stray EMI.

I also have to point out that the 3.3V and 5V rails have a minimum load requirement of 0.8A and 0.5A respectively. If you are going to do this correctly you will need some dummy loads on those two rails to ensure the PSU is operating properly since you will only be utilizing the 12V rail.
I had thought that drastically under-utilizing (for lack of a better term) a PSU makes it run very inefficiently. Wouldn't it make more sense to use some PSU's that have a lower wattage while still being efficient?
How can I put a dummy load on them? Solder in some resistors? Actually, the voltage adjustment is right on the side, can I disable the 3.3 and 5v rails?
Quote:

Originally Posted by dralb View Post
I had thought that drastically under-utilizing (for lack of a better term) a PSU makes it run very inefficiently. Wouldn't it make more sense to use some PSU's that have a lower wattage while still being efficient?
As long as you are above ~15% of a units capacity, efficiency should be reasonable. On a 1200W unit an OCed quad would satisfy that. I would have to agree that a 1200W PSU for just the mobo, CPU and HDDs is silly. But for a high number of future GPUs, the other 1200W will probably see some action.
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Originally Posted by RockNRolla View Post
How can I put a dummy load on them? Solder in some resistors? Actually, the voltage adjustment is right on the side, can I disable the 3.3 and 5v rails?
There isn't an easy way to outright disable the other rails. It would require a complete redesign.

Now I am not an EE, but you can use resistors for the dummy loads. Some PSUs already have dummy loads on their rails to ensure it never operates out of spec. I'm going to have a look to see if the Turbo-cool uses anything like that. If not, you will have to use a ~4 Ohm resistor for the 3.3V rail and ~10 Ohm for the 5V, both of which should be rated for at least 30W. But let me get back to you on that.
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Okay, I figured it out. I will use a 1 AMP resistor on the +3 and +5v rails to simulate a load.
Quote:

Originally Posted by shinji2k View Post
There isn't an easy way to outright disable the other rails. It would require a complete redesign.

Now I am not an EE, but you can use resistors for the dummy loads. Some PSUs already have dummy loads on their rails to ensure it never operates out of spec. I'm going to have a look to see if the Turbo-cool uses anything like that. If not, you will have to use a ~4 Ohm resistor for the 3.3V rail and ~10 Ohm for the 5V, both of which should be rated for at least 30W. But let me get back to you on that.
Thank you very much! I will await you reply. +Rep
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Quote:

Originally Posted by RockNRolla View Post
Okay, I figured it out. I will use a 1 AMP resistor on the +3 and +5v rails to simulate a load.
Well, they are rated by their resistance and the power dissipation.

If you want a 1A load on the 3.3V, you will need a 3.3 Ohm resistor. If you want a 1A load on the 5V you will need a 5 Ohm resistor. You will also need to disappate 3.3W and 5W respectively. But a resistors power rating is usually at room temperature, not something you find inside a PSU. You will need a good amount of headroom since the resistor will be in those operating conditions for long periods of time. That's why I recommended at least 30W, if not more if you can find it and have the space.
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Ok there doesn't seem to be a dummy load in place already. Those thick film power resistors must be mounted to a heat sink to perform at their rated wattage. If they are free air it is much lower, like 1.5W. Lemme take a look to see if I can find something.
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