ATX Computer Power Supply Spark in Non-computer Application
Hello! I would like to ask for your assistance with using a Silverstone DA1650 Gold computer power supply (you can find more about it here: Silverstone DA1650 Gold) for a non-computer application. In this specific setup, I intend to utilize only the 12V rail, which could potentially draw up to 110A. My plan involves cutting the connectors of 9 EPS 8-pin CPU +12 and GND power connectors and connecting them using solderless crimp terminal connectors (yellow 10-12 AWG). Each of the 3 application inputs will require 3 EPS connectors, each consisting of 4 wires.
Brief Problem Description: I encountered some issues and questions during my initial power supply testing. When I connected the Green PS-ON wire to GND, the power supply turned on successfully. I applied a 1A electronic load to measure the 12V rail, and it displayed a stable voltage. However, every time I turn on the power supply, I hear a loud noise resembling a spark. I initially thought it might be a relay, but after multiple attempts, I'm certain it's a spark. Despite this noise, the power supply continues to function. The spark noise is not consistently present, particularly if I turn the power supply on shortly after turning it off. However, when the power supply has been off for an extended period and is turned back on, the spark noise returns.
My Question: I'm seeking guidance on identifying and addressing this significant spike or spark issue. My primary concern is whether I can continue using this power supply for testing. Additionally, if there are any questionable choices in my setup or testing approach, I would greatly appreciate any feedback. Thank you in advance for your assistance, and please let me know if you need any additional information.
Detailed Explanation of My Steps (probably not necessary to read): Here, I'll outline the steps I took that led to these problems, as there may be some relevance. Initially, I connected the Green PS-ON wire to GND, successfully turning on the power supply. Next, I aimed to measure the 12V line using an electronic load. Initially, I applied a 100mA load to the single pins of the EPS 8-pin CPU +12 and GND, resulting in a measurement of only around 1V. I sought help online and learned that newer computer power supplies often require a larger load to activate the power rails. Consequently, I decided to gradually increase the load, starting with 1A. However, when I applied the load and turned on the power supply, I heard a large spark sound, hence, I turned it off. I suspected that I might have damaged the power supply, so I connected it to an old computer, where it successfully powered up the system, making me think that it is working properly. However, I still occasionally heard the spark noise when turning on the power supply, which concerned me. Why I did not get the 12V before, turned out to be because I did not connect the 6 additional sense wires (originally attached to the EPC 24-PIN motherboard connector) to the power supply. Now, I disconnected it from the computer to test it as before. When I applied a 1A load again, the 12V rail remained stable, but the spark noise persisted. As mentioned before, this spark noise doesn't consistently occur, especially when turning the power supply on shortly after turning it off. However, when the power supply has been off for an extended period and is turned back on, the spark noise reappears, and it's quite noticeable.
1 answer
Do you supply the PSON# signal before or after the main power comes on, or before connecting the load? Looking at the datasheets, the correct sequence is VAC power on, then PSON# signal to ground, then DC rails come on. Your load should be connected before PSON signal is taken to ground, because this power supply doesn't support hot plugging. Before disconnecting a load, you'll need to bring PSON up again/release it from ground.
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