Changes in the Industry

It really wasn't until recently the Power Supply ceased to be the least understood and neglected components in desktop computers, into one of the most integral components. It was the culmination of several events which juxtaposed that role from a device where system builders commonly cut costs, into a device which could have deleterious effects on overall system performance. This became more evident with the overclocking movement and high-end gaming. One of the earliest events which began to change the PSU's role in the modern PC was the transition of the CPU power source from 3.3V and 5V-Rails to the 12V-Rail. Around the time 12V rail/s became the CPU power source, Intel's Net Burst architecture had been producing some of the most inefficient desktop CPU's the industry had ever seen. To use another Moore's Law / astronomy analogy, these proverbial "Red Giants" were rapidly on their way to the "White Dwarf" stage as Dual Core technology was introduced. As Moore's Law states in it's die-shrink / heat analogy, these processors were on the way to generating as much heat per square mm as the surface of our Sun.

All kidding aside, long before Intel's Dual Core Prescott doppelganger known as Smithfield arrived, Santa Clara's first foray into the 90nm process was creating it's own set of problems. These had been further exasberated by a premature release onto the Socket-478 platform. Specific problems associated with Prescott's release to the 478 platform can be found in [H]ardOCP articles; Prescott 2.8E overclock and Prescott Tweaks Dangerous. Ironically, many of the same motherboard power circuit problems which plagued Prescott also plagued it's dual core sibling later. As power demands continued to rise with the advent of SLI and Crossfire they were limited by the infamous ATX12V Power Supply Design Guide 2.01 and largely misunderstood EPS12V Power Supply Design Guide 2.91. As we approach another power pinnacle with ATI's R520 and the NVIDIA G70, 12VDC demands are at an all time high, leaving the consumer confused as to how much power they need and if their PSU should be multi- or single-rail.

So what has this to do with PCPower&Cooling? In an industry where it seems the bottom line is constantly sinking lower and dragging along business ethics with it, PCPower has remained true to their original ideal, to build the best PSU on the market. As an industry leader PCPower has not only challenged the 12VDC Guidelines, they've also brought some awareness to PSU specs which are purposely misused. On March 20th, 2006 PCPower&Cooling published their own Certification Program, putting any PSU purchased from the company through an additional series of tests which go beyond what PCPower already offers. An example of a test report can be viewed here. It is doubtful many companies could match the criteria PCPower demand of their own products. Their quality control standards are perhaps some of the tightest in the industry. For a small fee one can have their specific unit tested and receive a hard copy of those tests.

Now more then ever we need to understand and trust the power supply we are investing in, yet the average consumer isn't armed with a manual to dispel PSU myths. How can we decipher marketing fodder disguised as specifications intended to inflate the performance of a mediocre product? PCPower responded by offering the certification report mentioned above and has included several sections at their site so that we can understand how terminology can be manipulated to benefit a product. Take a few moments to read: Power Supply Myths Exposed. In addition to 12VDC Guidelines mentioned above, the PSU industry is currently in a state of transition and the consumer pays the ultimate price. Hopefully I've succeeded in explaining what is common among most power supply manufacturers products. Let us take a look into a refreshingly uncommon product.

Turbo-Cool 1KW

Our TC1KW is the "vanilla" model dressed in powder black and exuding the PCPower pragmatic yet powerful presence. There are no overload or temp warning LEDs and external potentiometers have been left out. PCPower's philosophy on this matter being; "Build it right and they will come." Or rather, build it right and you won’t need a light on the back to tell you your system is re-booting due to anemic Rails. Insofar as external Pot's and other features, PCPower will customize any model they sell. Take a gander at their Specials/Price list. There you will find a list of refurbished models. Many of these have external Pots and other accouterments.

TC1KW Specifications

AC Input
Operating Range: 90-264 VAC
.99 power factor

Frequency: 47-63Hz
Current: 15A @ 115V
Efficiency: 83%
EMI: FCC-B, CE

DC Output
Output: +5V @ 30A
+12V1 @ 18A (CPU)
+12V2 @ 18A (CPU)
+12V3@ 36A (Graphics, Drives)
+12V1,V2,V3 = 66A (70A pk.)
-12V @ 0.8A
+3.3V @ 30A
+5VSB @ 3.5A
continuous = 1000W
peak = 1100W

Regulation: 2% (+3.3V, +5V, +12V)
5% (-12V)
Ripple: 1% (p-p)
Hold Time: 24ms
PG Delay: 300ms

Safety
OV Protection: +3.3V, +5V, +12V
OC Protection: +3.3V, +5V, ±12V
Agency Approval: UL/ULC/CE/TUV/RoHS

Environmental
Temperature: 0° - 50°C
Humidity: 10% - 90% RH
Fan Type: 30 - 52 CFM ball-bearing
Noise: 32 - 40dB(A)

Miscellaneous
Compatibility: EPS12V and NVIDIA SLI
Motherboard Compatibility
M/B Connectors: 24-pin, dual 8-pin, 4-pin, dual 6-pin video
Drive Connectors: 15 (6 SATA, 8 Molex, 1 mini)
MTBF: 120,000 hours
Dimensions/Harness: See Diagram PDF
Warranty: 5 Years

(discrepancies betwen the label on our test "subject" and those re-printed from PCPower's site are due to their constantly upgrading their products)

Included Cables:

TC1KW Circuit Topology...


TC1KW

The box arrived in perfect condition and the PSU is well packaged with cardboard inserts. PCPower has always boxed their PSU's very well. The TC1KW comes in black, and its length once thought to be problematic, has fit in three different size cases here at the "lab."

Inside the box accessories include; 8- to 4-pin CPU power connector/adapter, 20/24-pin ATX motherboard connector, a manual, power cord (14-gauge) and sticker. Sorry folks, no marketing fodder here such as key-chains and little velvet pouches to place cables in. No nonsense translates throughout the PCPower design philosophy.

The Turbo-Cool Maximum Power series begins with the 850SSI, the power supply's size increases from the standard PSU approx 150mm in depth to 230mm in depth. The full dimensions of the Turbo Cool 1KW are as follows: 86mm x 149mm x 230mm (HxWxD).

PCPower has chosen to eschew any modular connectors from their product line based simply on the fact these create unnecessary points of resistance. The company feels the "convenience" of modular cables does not outweigh the potential for oxidation and failure at the quick connector points. Cables carrying current from the Rails to the PC should remain a straight forward engineering concept bereft of any interruptions. While on the topic of included cords and cables, a subject rarely if ever discussed in power supply articles, is that of the power cord gauge.

PCPower includes a 14AWG (American Wire Gauge) for most of their high current models, whereas the majority of manufacturers include an 18AWG power cord. If you are investing several thousand dollars on a high-end graphics or server tower, a 1KW power source is no longer the exception but is rapidly becoming the rule of thumb. I thought this would all change with Conroe and advancements in microchip architecture however mobile technology has not permeated through every sub-sector such as graphics. If your power supply maker is selling you an 800W+ PSU, and neglecting appropriate wire gauges on the power cord, you are getting less than you paid for. Take a look at your power cable regardless of PSU wattage I'd bet it's 18AWG.

Let’s take a look at the internals ->


Proprietary Circuitry

To reiterate, PCPower&Cooling's Turbo Cool 850/1KW models set a new standard for high end, high current, power supply design. The company gave added meaning to the term proprietary circuitry as they spec'd their own circuitboards. When the 850SSI was introduced few manufacturers where willing to go to such klengths due to cost anfd even those whom wanted to build a "better mousetrap" were limited since most out source just about every aspect of design and construction.

When a power supply is operating around 75 ~ 80% efficiency, unused power is lost forever as heat. Devices such as Field Effect Transistors (FET), which run hot, require large aluminum heatsinks to dissipate heat and until recently the added weight of these components contributed to the PSU-litmus test; "weight = quality."

The TC1KW we'll be evaluating today is a fairly efficient design at 85% yet there's still a tremendous amount of weight and cooling required to create this monster especially when compared PCPower's newest design. I'm currently in the final stages of testing the Silencer 750 EPS12V which requires an entirely new understanding of circuit design. Insofar as the TC1KW she's still far ahead of the industry, especially in the implementation of proprietary circuits.

As we investigate the internals from a side view you will note there are three distinct heatsinks, each corresponding to a specific power stage. Basically the photo below (and corresponding thumbnails) details an independent module running along the length of the unit. Below from right to left: AC power enters, reaches a rectification stage, PFC circuitry (1st Heat Sink), to the Blue Capacitor, to power field transistors (2nd HS), onto the transformer to the secondary side where it's rectified (3rd heatsink) and then through inductors (large copper wound rings) and capacitors to the individual Rail/s.

Below rotating the unit 180-degrees we see the opposite side of the "module" and what would normally be a daughterboard or the PCB except it's on its side. It’s the placement of multiple mother/daughter-board at right angles which makes this PSU so unique.

In thumbnails above note the pragmatic placement of transistors onto what looks like brass plates. Power field transistors and other devices are mounted to these plates which are in turn attached to the aluminum heatsinks. Undoubtedly a costly construction method from a material perspective and labor intensive standpoint this is what places PCPower ahead of the "pack."

Proprietary Circuitry ->


Internals Cont.

Proprietary Circuitry Continued

Looking at the unit from the rear of the PSU we see each aluminum heatsink runs the width of the unit across all three modules. Below we see the AC in stage.

And from the output end (thumbnails), final capacitance, inductor stages and finally the traces from which the Rails originate. The first thumbnail on the left provides a clearer view of the aforementioned.

The remaining thumbnails from left to right excluding the first show the rails as they originate from the board. Note the 3.3V and 5V on the far left. Next we have 12V1, 12V2 and 12V3 which are all isolated, with 12V3 originating from the center of the board. Most likely a single module is responsible for this 12V3 stage which provides power for graphics and all drives. The last two rails 12V1 and 12V2 on the far right power the CPU. This indicates the module running the length of unit photographed most is solely responsible for these rails.

PCPower&Cooling has historically included potentiometers on their power supplies, many of their enclosures would allow access holes to one or more of these pots. In the TC1KW potentiometers are available if one removes the cover, this also voids the warranty. The thumbnail below reveals these pot's are glued to prevent their movement. While the seal can be broken PCPower's philosophy is to ensure tolerances are as tight as possible and with innate circuitry to prevent "drift" the need for adjustable pots is eliminated. These are strictly for factory refurbishing and should be left alone. After all one reason you’re paying just bit more for PCPower are for its steadfast Rails under Load.

Onto testing ->


Testing / Conclusion

Test System

Noise

Per the atypical Madshrimps method, noise-levels (recorded in dB(A)) were measured utilizing an Intellisystems AR824 SPL meter from a distance of 1m. To eliminate noise from the case fans the side panel was removed for added cooling case fans were disconnected and measurements were taken.

IDLE: 33dB(A)
LOAD: 39dB(A)

Temperature Testing:

Temp testing is crucial and many PSU's begin to suffer up around 50°C which is not out of the ordinary given the variations in temp from one system to the next. PCPower doesn't necessarily design their PSU's to double as an exhaust for case heat, nor should any PSU double as a cooling device for other sub-systems. I taped an external thermistor to the under-side of the unit's cover. temps ranged from 28°C during IDLE to 49°C at full LOAD.

Voltage Tests

Rails were measured at the board utilizing a Extech Mini Tec MN26. To stress the PSU our Retail 3800X2 was overclocked at 10x250FSB running in QUAD SLI Mode. I used the CPU stress tester S&M v.1.8.1. (160). In addition to CPU Stress testing voltages were measured running both Leadtek 7950GX2's in QUAD SLI. The thumbnails below exemplify how CPU stress tests were accomplished using the CPU-stress test software. While the voltages indicated are close to the multimeter they are not nearly as reliable, the same is true of graphics tests which were tested running 3DMark06 and AquaMark 3.

Summary:
Things are as they should be although the TC1KW wasn't necessarily intended for QUAD SLI testing. With four independent cards the LOAD on the PSU would be greater and had the CPU been of the Prescott or Smithfield variety perhaps even the TC1KW would have been taxed. While I've been able to run this system overclocked to 300FSB (3.0GHz at 1.48Vcore) the 3800X2 crashes under the S&M stress-test. the fact Vcore remained stedafast and the 12V1/12V2 rails are isolated it's doubtful this contributed to the failure. At around 45C the AM2 3800X2 becomes unstable so temp is most likely the culprit.

PRO
Fairly Silent Operation
1.1KW of power on demand
Innovative design and construction
Excellent Build Quality
Pragmatic
Product Service (Warranty)

CON
Price; however, it's still worth it if your spending at least as much on a single videocard and/or CPU.

Conclusion:
Any seasoned PC-Enthusiast or Overclocker eventually comes to understand, as much as we try, we simply cannot guarantee performance beyond the manufacturer's specs. Despite this there are numerous forum threads discussing CPU-steppings, fabrication dates, even attempts to identify where the core originated off the wafer. Armed with all this information it's still a crap-shoot. In a hobby with so many variables beyond our control, the last thing we need is an unstable power source. My experience with PC Power & Cooling is that their products offer the ultimate in stability eliminating that variable. While there are a few other PSUs on the market I might consider for different reasons, when it's comes to maximum power and stability, for the last five years only PC Power & Cooling products remain in my personal high end system.

Stay tuned for my review of PC Power's Silencer 750W a unit based on design concepts sure to shape the future of the PSU.