Zarcon Dee Grissom's Idea Page
EV9
Updated 23FEB2008
Home > Meet the computers > OSWATT > OSWATT Wire harness 
OSWATT, "O" Censored, What Are They Thinking!

The Power Wire harness...
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Warning.
1> I Will NOT be responsible for anyone being stupid and operating dangerous power/non-powered tools they do not know how to operate safely, and causing damage to themselves and/or equipment in the process. RTFM!
2> get all the metal shavings out of the case with a shop-vac, and compressed air, before you bring the case any where close to the final working electronic guts. the drilling and cutting shavings will do nasty things to your expensive electronic parts. they'll even destroy some vacuum cleaners.
3> Metal shavings can destroy vacuum cleaners, Don't test your eyes resilience to them. Ware safety goggles certified for metal work.
4> Sharp edges will make nasty cuts, requiring trips to the emergency room for stitches. Ware thick leather gloves, preferably Welding gloves when handling sheet-metal, and watch where BOTH your hands are at ALL times.
5> Ask many questions, do lots of research, measure allot, test on stuff you don't care about first that you own, and hesitate to cut and drill the final project.
6> And last but not least. I will not be responsible for how good or ugly your computer-mod, or any other project inspired by my sight, looks, function, or fails.



WireHarnis Intro.
Idea013.
Something about plug capacity, and the powerloss of thin wires...

WireHarnis under construction.
Rather then take all kinds of time I don't have boring everyone with long drawen out discriptions, I'll try to keep them short.. I'll run this threw a spell/gramer check latter, I have stuff to do. Yes, I finnessed the plug's pins out of the plastic befor soldering them, I don't care to test the plastics resiliance to heat this time. Yes I know, All the wires are still exposed, I'll hot glue them parts into boxes after the moduals are connected and tested.

The sketches
RFI draft
RFI draft
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Main Plug draft
Main Plug draft
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RFI bus term draft
RFI bus term draft
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Yes I took many notes, on this one. The last thing I wanted was a bounch of dead drives, and fans. I decided on terminating the bus, rather then having a million explicit purpos RFI filters everywhere.

The Main Harnis Plug, mess.
plug&draft
Plug&draft
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soldering backside
Soldering backside
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soldering frontside
Soldering frontside
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size testing
Size testing
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The Plug(s) the PSU plugs into, this will go directly infront of the PSU behind that intake thing in the lowest CDROM bay.

The Upper CDROM harnis.
CD harness
CD harness
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CD harness side
CD harness side
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CD harness top
CD harness top
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CD harness back
CD harness back
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Yes that is a make-shift Bus Terminator on top of the CDROMs. The upper terminator consistes of a 1uf, 0.1uf, 0.047uf, and a 0.01uf poly-metel-film caps per rail. The inline resistor was so close to the wire inductance, I obmitted it. The other Massive Terminator will go at the bottom of the caes, with a midpoint terminator in between the plugs on the Main Harnis Plug.

The Lower HDD harnis.
measuring out the jig
measuring out the jig
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some solder here
some solder here
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some solder there
some solder there
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looks good so far
looks good so far
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After six hard drives and two fan plugs, I added a ground strap off the capacitor terminator wad, as an after thought. The lower terminator consists of two 0.01uf, and two 1uf poly-metel-film caps per rail.

The Final Assemboly of the 5V&12V harnis.
the pieces
the pieces
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final assembly
final assembly
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final assembly
final assembly
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Lots "O" Glue
Lots "O" Glue
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Everything went smooth till I cut the heatshrink for the ground a little to short... Good thing it is just a ground.

The Upper SATA-HDD harnis.
SATA terminators
SATA terminators
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I gave up on implanting caps in the SATA power plugs for the time beeing. this works well enough.

(Final result)
Get-er done
Get-er done
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T.B.C.... when I can get five minutes to think.

OSWATT 5V&12V Power Harness stats...

Max sustained total power draw threww harness (limited by the four PSU interface plug pins);
5V 32 Amps 160 Watts
12V 32 Amps 384 Watts
GND 64 Amps 544 Watts
*1; you can only get 14Amps threw each 18AWG wire from the PSU.
uh, yea, pull out a calculator and start adding the red's(5V), yellow's(12V), and blacks(GND), going to the PSU interface, sepperately.

Max sustained power draw of each plug (total of ALL plugs is not to exceed the total harness limits above);
5V 8 Amps 40 Watts
12V 8 Amps 96 Watts
GND 16 Amps 136 Watts

Max total 2second surge power draw threww harness (limit of the Wire in the PSU interface unit);
5V (2x12AWG) 50 Amps 250 Watts
12V (2x12AWG) 50 Amps 600 Watts
GND (4x10AWG) 140 Amps 850 Watts
uh, yea. I think the 18AWG junk on the PSU would ketch fire long befor these limits become any type of concern.

12V EMI/RFI reduction... (Just the harness, excluding caps in the drives and fans).
Upper CD
-26db@147MHz
2A
6ohms
-44db @ 812kHz, -9db @ 1.07MHz,
-78db @ 3.8MHz, -21.7db @ 363+ MHz
Frount disp
-34db@147MHz
2A
6ohms
-11db @ 1.5MHz, -68db @ 3.9MHz,
-72db @ 7.2MHz, -33db @ 165+ MHz
Lower fans
-36db@147MHz
2A
6ohms
-5db @ 1.3MHz, -74db @6.4MHz,
-45db @ 10MHz, -32db @ 2.2+ MHz
Lower HDD 2A
-86db@147MHz
2A
6ohms
-12db @ 500kHz, -62db @ 9.7MHz
-190db @ 12MHz, -85db @ 250+ MHz
12V 2Amp draw per device. yep, that'll do.

5V EMI/RFI reduction... (Just the harness, excluding caps in the drives and fans).
Upper CD
-db@147MHz
-db @ kHz, -db @ MHz,
-db @ MHz, -db @ MHz
Frount disp
-db@147MHz
-db @ MHz, -db @ MHz,
-db @ MHz, -db @ MHz
Lower fans
-db@147MHz
-db @ MHz, -db @ MHz,
-db @ MHz, -db @ MHz
Lower HDD
-db@147MHz
-db @ kHz, -db @ MHz
-db @ MHz, -db @ MHz
5V 2Amp draw per device. yep, that'll do.

Final thoughts; Power suply riple, What power suply riple? Befor I could tell what the computer was doing, just by the noise it was making over the head phones. I nolonger hear any digital noise in my headset, regardles how loud my voluume is cranked up to with nothing playing.


Future ideas and plans for this case.

1) Make a permanent solution for the duck-tape on the motherboard tray.

2) DONE. make a baffle that forces air between the expansion cards. I don't know how much air is going right past the cards, and out the back of the computer. I imagine it is a substantial loss of cooling potential. Maybe another HDD rack the entire height of the motherboard tray on a hinge there.

3) Adjust the upper hard drive rack, to allow the PSU to breath better. that also includes my dislike of having magnetic storage right next to a motor.

4) Figure out where to add a support brace on the back of case next to the expansion cards, without obstructing the exhaust vents or the side panel hinge.

5) In progress. I was going to place an 8 gage power distribution system in the case with RFI filters for each drive and fan. The parts list for that project is still yet to be drafted out. I have a couple filters sketched out already, none production/prototyping ready.

6) Make a plate to hold the power button in the original switch spot. then place a ring key in series with the button where the button currently is. the idea is, if the key is not in the case, you are not going to shut down the computer.

7) DONE. Remove the Motherboard to replace the dead chip set cooler. it would have been nice if one of the big holes in the motherboard tray lined up with the clips under the cooler. "O" well, that ugly 486 fan is working well enough.

8) Fix the pealing paint, and paint the front grill red to finish the CRAY2 look.

9) Design and build that Burr-Brown headphone amp, I've been wanting to build for three years now... lol.

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