Server Power Supply Interface Board - for standalone miners and GPU rigs

[pmorici]

I have stock of 30 amp 2 pos 7.62mm screw terminals I can sell you.  I use them in some of the Gigampz breakout boards I build.   They have little channels on the side so you can join them together to be any length you need as long as it is a multiple of two.

Help me out.
2000 or say 2200 watts at 12v DC
Push 180 amps give or take
four of those can't handle that?
Trying to find a heavy duty lug, but not much luck

No way, they are rated for 30 Amps each you want a bare minimum of 6  (180 / 30 = 6)

[1714512544]

1714512544

[1714512544]

1714512544

[1714512544]

1714512544

[pekatete]

Got the perspex fittings to put together the Mk1 with two three pole connectors ..... this is for a 550W Dell server PSU (not sure it fits the 750W one, but I'll be getting that later this week). I also added a switch for the power  and had also designed a spare hole for the fan swicth (where the wires are protruding) but left it out on this one since the model I am going to run this on does not seem to turn down the fan.

Front view


Rear view


In situ


I also have a Mk2 which is top monted, as opposed to the side mounted Mk1 above, but have not put it together yet.

[takagari]

Got the perspex fittings to put together the Mk1 with two three pole connectors ..... this is for a 550W Dell server PSU (not sure it fits the 750W one, but I'll be getting that later this week). I also added a switch for the power  and had also designed a spare hole for the fan swicth (where the wires are protruding) but left it out on this one since the model I am going to run this on does not seem to turn down the fan.

Front view


Rear view


In situ


I also have a Mk2 which is top monted, as opposed to the side mounted Mk1 above, but have not put it together yet.

That is exactly what I'm wanting, but I'd like a heavier duty terminal,

[pekatete]

That is exactly what I'm wanting, but I'd like a heavier duty terminal,

The 32Amp terminals are the biggest (amperage wise) that I have had reason to search for, but there could be higher rated ones .... look at the usual places, aka digikey et al.

I mentioned the Mk2's I had in progress, here are some images .... all that is left is wiring in the switch and gluing them together.

The individal parts


The semi assembled plug

[takagari]

That's super cool.
I'd love to see a higher rated, been looking. 60 amps would be nice

[sidehack]

I can tell by looking that it won't work on the 750W, at least not the ones I carry.

[pekatete]

I can tell by looking that it won't work on the 750W, at least not the ones I carry.

What's the part number for the Dell 750W PSU's connector if you care to share?

[takagari]

I can tell by looking that it won't work on the 750W, at least not the ones I carry.

What's the part number for the Dell 750W PSU's connector if you care to share?

I'd like to build them for the dps 2000bb but at 2000watts, I feel a need to find a larger terminal block to effectively build them.

[pekatete]

I can tell by looking that it won't work on the 750W, at least not the ones I carry.

What's the part number for the Dell 750W PSU's connector if you care to share?

I'd like to build them for the dps 2000bb but at 2000watts, I feel a need to find a larger terminal block to effectively build them.

If you think outside the box, you can actually put one together capable of handling 2000W + with just the 32A terminal blocks ... just use  some imagination ....

@sidehack - the actual model / description is Dell NY526 PowerEdge 2950 750W Redundant Power Supply

[takagari]

I can tell by looking that it won't work on the 750W, at least not the ones I carry.

What's the part number for the Dell 750W PSU's connector if you care to share?

I'd like to build them for the dps 2000bb but at 2000watts, I feel a need to find a larger terminal block to effectively build them.

If you think outside the box, you can actually put one together capable of handling 2000W + with just the 32A terminal blocks ... just use  some imagination ....

@sidehack - the actual model / description is Dell NY526 PowerEdge 2950 750W Redundant Power Supply

Well by imagination your mean math..
I'm expecting to see 2000-2400 off my psu if I max it out
That works out to be 200 amps on the high end.

200/32 = 6.25 so let's say 6.

I only want to run to four lines.
for 50 amps max per line.
Even that with an est. 3% loss would have me using 6 AWG wire... Which is nuts.
That runs to a terminal than breaks out into dual PCI connectors.

If I'm unable to find a 50amp terminal for the back of the plug, I need to somehow split the wires into either more wire' at an uneven/unblanaced number or overload them little 32 ampers.

I'd rather not have 12 terminals on the back of the plug, 4 and 4 would be as ideal as they come.

Finding a 50 terminal I can solder to the back of the plug, is my next issue!

[pekatete]

Well by imagination your mean math..
I'm expecting to see 2000-2400 off my psu if I max it out
That works out to be 200 amps on the high end.

200/32 = 6.25 so let's say 6.

I only want to run to four lines.
for 50 amps max per line.
Even that with an est. 3% loss would have me using 6 AWG wire... Which is nuts.
That runs to a terminal than breaks out into dual PCI connectors.

If I'm unable to find a 50amp terminal for the back of the plug, I need to somehow split the wires into either more wire' at an uneven/unblanaced number or overload them little 32 ampers.

I'd rather not have 12 terminals on the back of the plug, 4 and 4 would be as ideal as they come.

Finding a 50 terminal I can solder to the back of the plug, is my next issue!

Short of finding your prefered 50A rated terminal block, I can not see another solution aside from side mounting the 32A terminal blocks onto your connector, which'd make each power connector capable of serving 64A (as opposed to the max out put of 50A). In my estimation, you'd then have a total of 16 terminals on each connector (or 12 if you prefer it that way). For bitcoin mining, I can not find any reason to make it more complicated than that, but of course, you may have other use cases I am not privy to.

I am assuming here that you'd like to do this on the basis of cost reduction, if not, then you have the breakout board option, and with that you do have options, literally!

[takagari]

Well by imagination your mean math..
I'm expecting to see 2000-2400 off my psu if I max it out
That works out to be 200 amps on the high end.

200/32 = 6.25 so let's say 6.

I only want to run to four lines.
for 50 amps max per line.
Even that with an est. 3% loss would have me using 6 AWG wire... Which is nuts.
That runs to a terminal than breaks out into dual PCI connectors.

If I'm unable to find a 50amp terminal for the back of the plug, I need to somehow split the wires into either more wire' at an uneven/unblanaced number or overload them little 32 ampers.

I'd rather not have 12 terminals on the back of the plug, 4 and 4 would be as ideal as they come.

Finding a 50 terminal I can solder to the back of the plug, is my next issue!

Short of finding your prefered 50A rated terminal block, I can not see another solution aside from side mounting the 32A terminal blocks onto your connector, which'd make each power connector capable of serving 64A (as opposed to the max out put of 50A). In my estimation, you'd then have a total of 16 terminals on each connector (or 12 if you prefer it that way). For bitcoin mining, I can not find any reason to make it more complicated than that, but of course, you may have other use cases I am not privy to.

I am assuming here that you'd like to do this on the basis of cost reduction, if not, then you have the breakout board option, and with that you do have options, literally!

Well, I was planning to mount the PSUs a meter or two from the miner's, so having less wirer would be best.
I was thinking of running 8AWG from the psu to beside the miner than breaking out with smaller terminal boards. For wire management.
I'd like to have 8 wire's come off the back of the pcb to make  it the most organized, but this is seeming to be a harder option. I may need to double my wires up like you stated

This kicks my OCD into overdrive.

[pekatete]

Well, I was planning to mount the PSUs a meter or two from the miner's, so having less wirer would be best.
I was thinking of running 8AWG from the psu to beside the miner than breaking out with smaller terminal boards.  .....

And what is stopping you from doing that now? That you got the 32A terminal blocks does not mean you have to use them on the connector! I know it looks neat, but it is not the only practial way to achieve what you want.
Of-course, nearly everyone's setup is different, but if I were in your position, all I'd do was to solder the 8AWG wires onto the connectors and use the terminal blocks on the other end of the 8AWG wires to break out to the rigs ..... or am I over simplifying this one ? !

PS. I hope those 8AWG's are copper wires ..... and you've factored in the 1-2 meter resistance they introduce to the circuit, thus the output the other end.

[takagari]

Well, I was planning to mount the PSUs a meter or two from the miner's, so having less wirer would be best.
I was thinking of running 8AWG from the psu to beside the miner than breaking out with smaller terminal boards.  .....

And what is stopping you from doing that now? That you got the 32A terminal blocks does not mean you have to use them on the connector! I know it looks neat, but it is not the only practial way to achieve what you want.
Of-course, nearly everyone's setup is different, but if I were in your position, all I'd do was to solder the 8AWG wires onto the connectors and use the terminal blocks on the other end of the 8AWG wires to break out to the rigs ..... or am I over simplifying this one ? !

PS. I hope those 8AWG's are copper wires ..... and you've factored in the 1-2 meter resistance they introduce to the circuit, thus the output the other end.

Likely my only option, just not the best.option.

[takagari]

Factored in some loss yes.
was thinking of going with 6 awg just to make it easier and for fudge factor.

The issue being, properly soldering a 6 awg wire to a plastic plug...

[pekatete]

The issue being, properly soldering a 6 awg wire to a plastic plug...

Same way you were going to solder the 1mm terminal blocks .... only this time, since 6 (or 8 ) AWG wires are bigger, easier! Just pre-tin them, put them in place and away you go.

[pmorici]

I can tell by looking that it won't work on the 750W, at least not the ones I carry.

What's the part number for the Dell 750W PSU's connector if you care to share?

I'd like to build them for the dps 2000bb but at 2000watts, I feel a need to find a larger terminal block to effectively build them.

They make larger terminal blocks like 65 Amp and 125 Amp but no distributors stock them so there are 6-8 week lead times and minimum orders of 1000+ pieces.

This is all a fun creative exercise but I really don't get the point beyond that.  You are still buying the two most expensive parts of any adapter board; the mating connector and the terminal blocks.  Once you figure in your labor costs these things probably cost twice as much as just buying an adapter board from any of the several establish supplies. 

As an aside it's a bad idea to use plastic that doesn't meet 94V- standards like you are since if you have an over heating incident you are more likely to have a serious fire instead of just some melted plastic.

[pekatete]

As an aside it's a bad idea to use plastic that doesn't meet 94V- standards like you are since if you have an over heating incident you are more likely to have a serious fire instead of just some melted plastic.

Not sure if that was in specific reference to the images I posted, but if it is, I can not think how you came to the conclusion as to the standards it meets / complies with. I did (after your post) look up the details on the perspex material I am using and I have no concerns whatsoever in that regard.

[takagari]

I've only seen one maker of my.psu and it was way more.cumbersome than I'd like.

[pmorici]

As an aside it's a bad idea to use plastic that doesn't meet 94V- standards like you are since if you have an over heating incident you are more likely to have a serious fire instead of just some melted plastic.

Not sure if that was in specific reference to the images I posted, but if it is, I can not think how you came to the conclusion as to the standards it meets / complies with. I did (after your post) look up the details on the perspex material I am using and I have no concerns whatsoever in that regard.

I mean using it in the manner you are sandwiching components that are going to get warm if they are over loaded.  Not that the particular plastic you are using is or isn't 94V-0 or better rated.  94V is a fire retardant spec for those following along.