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Server PSU Based Radio Power Supply: Difference between revisions

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{{Project
{{Project
|Title=Server PSU Based Radio Power Supply
|Title=Server PSU Based Radio Power Supply
|Status=In Progress
|Status=Completed
|Project Lead=User:Stealthbird97
|Project Lead=User:Stealthbird97
|Description=A low cost, high current power supply for Amateur Radio utilising a Server PSU.
|Description=A low cost, high current power supply for Amateur Radio utilising a Server PSU.
|Image=Psu_distro.png
|Image=PSU Completed.jpg
}}
}}


Designs are available at [https://github.com/Stealthbird97/PSU_Distribution Github]
Designs are available at [https://github.com/Stealthbird97/PSU_Distribution Github]
Construction guide on the [https://github.com/Stealthbird97/PSU_Distribution/wiki/Construction-and-Setup-Guide Github Wiki]


=== Feature Ideas ===
=== Features ===


* Near 13.8VDC Output, 47 A (Exact specs to be determined)
* Near 13.8VDC Output, 47 A (Exact specs to be determined)
* Various Fan Control Options.
* Various Fan Control Options.
* Distribution (2 Fused Anderson Powerpole connectors)
* Distribution (2 Fused Anderson Powerpole connectors)
 
* Current Sharing / Parallelisation of 2 PSUs (2 boards required).
=== Tasks (To Do) ===
 
* Design Interface (There are some that already exist, however most of this use ATX 6pin connectors or other less useful connectors - if you can actually find the designs)
* Look into reducing EMI


=== Tasks (Completed) ===
=== Tasks (Completed) ===
Line 26: Line 23:
* Modify PSU to boost voltage 12v->13.8v (or as close as possible)
* Modify PSU to boost voltage 12v->13.8v (or as close as possible)
** This is possible using a resistor between the 12v sense-return pin and ground. 260Ohm resistor suggested.
** This is possible using a resistor between the 12v sense-return pin and ground. 260Ohm resistor suggested.
* PCB designed (See Github)
* Check EMI (Noise on outputs seems to be low, suggest using ferrites core on DC power leads)


=== Parts List and Costings ===


=== Parts List ===
{| class="wikitable"
 
! Type
* 1x HP DPS-600PB Server Powersupply
! Item
* 1x HP DPS-600 Distribution Board PCB by M0YCH
! Board Marking
* 1x Amphenol FCI 51760-10201202AALF Connector
! Cost
* 1x Vishay / Sfernice 1k Trimmer T93YA102KT20 (Fan Control) (R4)
! Link
* 1x Vishay / Sfernice 5k Trimmer T93YA502KT20 (Voltage Control) (R3)
|-
* 1x LM34 (Fan Control) (IC1) (Optional)
| PSU
* 4x Keystone 3522 Fuse Holder
| HP DPS-600PB Server Powersupply
* 2x 330ohm though hole 0.25w
| N/A
* 2x 3mm LED
| ~£15
* 2x 0.1u Capacitor
| [https://www.ebay.co.uk/sch/i.html?_odkw=HP+DPS-600PB+Server+Powersupply&_osacat=0&_from=R40&_trksid=p2045573.m570.l1313.TR0.TRC0.H0.XHP+DPS-600PB.TRS0&_nkw=HP+DPS-600PB&_sacat=0]
* 2x black 45A Powerpole Housing
|-
* 2x Red 45A Powerpole Housing
| PCB
* 4x 45A Powerpole PCB Contacts
| DPS-600 Distribution Board PCB by M0YCH
| N/A
| ~£30 for ~10 +p&p
| [http://dirtypcbs.com/]
|-
| Connector
| 4*45A pcb contacts
| N/A
| £9.90 for 15
| [http://www.torberry.co.uk/superbasket/category/89/PCB+Contacts+/+Powerpole+Connectors]
|-
| Connector
| 2* red 45A housings
| N/A
| £2.65 for 10
| [http://www.torberry.co.uk/superbasket/category/89/PCB+Contacts+/+Powerpole+Connectors]
|-
| Connector
| 2* black 45A housings
| N/A
| £2.65 for 10
| [http://www.torberry.co.uk/superbasket/category/89/PCB+Contacts+/+Powerpole+Connectors]
|-
| Connector
| Amphenol FCI 51760-10201202AALF Receptacle
| N/A
| £3.82 each
| [http://www.mouser.co.uk/ProductDetail/FCI-Amphenol/51760-10201202AALF/?qs=%2fha2pyFaduiXRb9hzG6iBFugB6UHrpiGSw86C8fIY%2fV6kPg6nisnj3b31jJ%252b5D0knXX7GZ5kHl4%3d]
|-
| Fuseholder
| Keystone 3522
| N/A
| £6.56 for 100
| [http://onecall.farnell.com/keystone/3522/fuseholder-pcb-mount/dp/1608218]
|-
| Trimmer Resistor
| 1*Vishay / Sfernice 1k Trimmer T93YA102KT20
| R3
| £1.23 each
| [http://www.mouser.co.uk/ProductDetail/Vishay/T93YA102KT20/?qs=%2fha2pyFaduiRTIn8lBf0T%252bOxB5d3Ixfpsmy3QQu7SjYVHyhDM4u1TA%3d%3d]
|-
| Trimmer Resistor
| 1*Vishay / Sfernice 5k Trimmer T93YA502KT20
| R4
| £1.23 each
| [http://www.mouser.co.uk/ProductDetail/Vishay/T93YA502KT20/?qs=%2fha2pyFaduiha0Qd7DX8mLYS%252bFwYHADuGWgWC1%2f3SdC2ktWgCdFBcA%3d%3d=]
|-
| Resistor
| 2*330ohm though hole 0.25w
| R1,R2
| £0.23 for 10
| [http://onecall.farnell.com/te-connectivity/cfr16j330r/resistor-carbon-330r-0-25w-5/dp/2329514]
|-
| LED
| 2*3mm red/yellow
| LED1,LED2
| £0.24 each
| [http://onecall.farnell.com/kingbright/l-937eyw/led-3mm-he-red-yel/dp/1142490]
|-
| Capacitor
| 2*0.1uF Capacitor
| C1,C2
| £0.0897 each
| [http://onecall.farnell.com/multicomp/mc0805b104k500a5-08mm/cap-mlcc-0-1uf-50v-x7r-rad/dp/2395773]
|-
| IC
| LM34 Temperature Sensor (Optional)
| IC1
| £2.76 each
| [http://onecall.farnell.com/texas-instruments/lm34dz-nopb/ic-temp-sensor-30v/dp/1469231?ost=LM34DZ%2FNOPB-ND&searchView=table&iscrfnonsku=true&ddkey=http%3Aen-GB%2FOnecall%2Fsearch]
|}


=== Complications ===
=== Complications ===
Line 52: Line 122:
* https://www.rcgroups.com/forums/showthread.php?1005309-A-simple-high-quality-12Volt-100Amp-Power-Supply-Part1/page40
* https://www.rcgroups.com/forums/showthread.php?1005309-A-simple-high-quality-12Volt-100Amp-Power-Supply-Part1/page40
* https://www.rcgroups.com/forums/showpost.php?p=18276967&postcount=702
* https://www.rcgroups.com/forums/showpost.php?p=18276967&postcount=702
*




Latest revision as of 16:01, 28 June 2017

Server PSU Based Radio Power Supply
Server PSU Based Radio Power Supply
Status Completed
Project Lead User:Stealthbird97

Server PSU Based Radio Power Supply

A low cost, high current power supply for Amateur Radio utilising a Server PSU.


Designs are available at Github Construction guide on the Github Wiki

Features

  • Near 13.8VDC Output, 47 A (Exact specs to be determined)
  • Various Fan Control Options.
  • Distribution (2 Fused Anderson Powerpole connectors)
  • Current Sharing / Parallelisation of 2 PSUs (2 boards required).

Tasks (Completed)

  • Identify maximum voltage obtainable from supply.
    • OVP cuts in at about 13.9v, however OVP protection will trip if a 1A load is suddenly attached by 13.75v.
  • Modify PSU to boost voltage 12v->13.8v (or as close as possible)
    • This is possible using a resistor between the 12v sense-return pin and ground. 260Ohm resistor suggested.
  • PCB designed (See Github)
  • Check EMI (Noise on outputs seems to be low, suggest using ferrites core on DC power leads)

Parts List and Costings

Type Item Board Marking Cost Link
PSU HP DPS-600PB Server Powersupply N/A ~£15 [1]
PCB DPS-600 Distribution Board PCB by M0YCH N/A ~£30 for ~10 +p&p [2]
Connector 4*45A pcb contacts N/A £9.90 for 15 [3]
Connector 2* red 45A housings N/A £2.65 for 10 [4]
Connector 2* black 45A housings N/A £2.65 for 10 [5]
Connector Amphenol FCI 51760-10201202AALF Receptacle N/A £3.82 each [6]
Fuseholder Keystone 3522 N/A £6.56 for 100 [7]
Trimmer Resistor 1*Vishay / Sfernice 1k Trimmer T93YA102KT20 R3 £1.23 each [8]
Trimmer Resistor 1*Vishay / Sfernice 5k Trimmer T93YA502KT20 R4 £1.23 each [9]
Resistor 2*330ohm though hole 0.25w R1,R2 £0.23 for 10 [10]
LED 2*3mm red/yellow LED1,LED2 £0.24 each [11]
Capacitor 2*0.1uF Capacitor C1,C2 £0.0897 each [12]
IC LM34 Temperature Sensor (Optional) IC1 £2.76 each [13]

Complications

  • Original PSU was going to be a Dell POWEREDGE 2950 Redundant Power Supply however upon testing this supply, voltage would not rise above 12.2v and would drop to unusable voltages under load.

Notes/Resources


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