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Old Feb 21, 2009, 06:33 PM
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Melbourne, Australia
Joined Jul 2005
8,254 Posts
A simple high quality 12Volt 100Amp Power Supply- Part2

I’ll describe how I converted a HP PROLIANT DL580/ML570G3 RPS Redundant Power Supply into a 12V 100A charger power supply.

But first a disclaimer: This is just a description of what I successfully did. I am not a qualified electrician and I am not offering any advice, representations or suggestions. If you choose to build one of these it is entirely your responsibility. If you burn down your garage, electrocute the cat or create a Black Hole that swallows up the State of Kansas and the Sydney Opera House, it’s entirely your responsibility (and those of us down-under are going to be a bit annoyed about the Opera House).
I bought this supply as a bit of a gamble since it is virtually impossible to find any information on what the pinouts are (or even what the output current rating is until you get one). All I knew was the input power spec given in the Proliant fact sheet. I was hoping it would deliver at least 45A on the 12V line as it had about twice the power rating of a similar Compaq supply I had seen. Turns out it was perfect for the job as it is designed to supply mainly 12V and the 3.3V and -12V lines are quite small. The supply has a connector on the back that consists of 8 high current blades and a 28 pin “logic” connection. It turns out that the blade connectors carry the 12V and some of the small pins the other voltages. By an empirical discovery-driven heuristic method (that means lots of trial and error) I got it to run by connecting two of the control pins to a third ground pin. I’ll do another post later if anyone is interested on how I figured it out which might be helpful to anyone who is trying to make a different server supply work. By stroke of good luck the three pins were in line so it was simple to use a servo connector to bridge them by just connecting the three ends of the wires together. In the final version I added a switch so that I can turn it on and off without using the wall switch.

UPDATE 1 xandrios discovered a diagram of the pinouts of this supply - see post #495. Also a data sheet with the pin logic explained. See DS1300-3 Series.pdf.
Read Post#7 if you have an unknown supply you want to turn on.

UPDATE 2 These guys are noisy and the only practical way to quieten this particular supply is to slow down the fans by adding a resistor in the supply lead.
This post shows how.

See the diagram and picture - Connections

The servo signal lead (Orange or White normally) connects to the one shorter pin of the 28 pins.
I used an old servo case to house the switch at the front and cut two little lugs off the front panel to allow the handle to swing right down and make a stand. The Tx gives you an idea of the size. I built it with two separate output connectors for convenience in using two chargers. I use a Y adapter if I want very high current as the current passes internally through the PC tracks to the blade connectors and it is a good idea to spread the load over all the tracks rather than take all the current from just one or two blades.

See the picture of the overall unit.

The supply comes with its own power cord which has a female connector on the other end that connects to a standard PC type power cord. I chose to shorten the cord and put a standard wall plug on it.
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Last edited by jj604; Oct 30, 2011 at 06:18 PM.
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