Testing Frequently

Asked Questions
CONTENTS
Where do you measure output voltage?.......................................................3
Where do you measure input voltage?.........................................................4
What instrument did you use to measure input power,
input voltage and input current?...................................................................5
What instrument did you use to measure output voltage?...........................6
Why must we use a LISN in the input circuit for measuring efficiency?.......6
What input power source do you use?.........................................................6
Do you start at 100% load and then reduce load? Or do you start
at 10% load and increase to 100%? ……………………………………..……7
How, and when, is the load adjusted for each level?...................................7
What happens if my unit fails?.....................................................................7
Our results are significantly different from yours. Why?..............................7
What happens if my unit performance misses a Badge
performance level?......................................................................................8
How do you measure output current?.........................................................9
How do you calculate the loading for a specific unit?..................................9
Can you test and certify an open frame unit?..............................................9
Do you ensure all connectors are loaded?..................................................9
How do you ensure all connector pins or wires for a given
output are equally loaded?..........................................................................9

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Where do you measure the output voltage?

For 115V input units, the output voltage is measured at the back pin of the mating connector on
the load side of the connector. Voltage is measured with the DVM test probe and recorded
manually into the unit under test data sheet. Figure 1-1 below is an example of manual probes
being used to measure voltage on the back of the unit output connector pin. The output
connector is shown plugged into the load fixture interface board.

Figure 1-1: Back-pinning 12V2 to measure the output voltage of 12V2 rail.

For 230V input units, the same procedure is followed, unless a custom interface board is
supplied with the unit. If a custom interface board is supplied, test points must be incorporated
to measure the output voltage and return ground directly at the point they exit the mating
connector on the load side of the unit. Test points should be clearly marked on the test board, or
in photos that accompany the submitted units.

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 Figure 1-2: Sense lines, when provided, are used to measure the output voltages for 230V.

Where do you measure the input voltage?

For both 115V input and 230V input test benches, the input voltage is measured as close to the
input connector of the unit as possible. A standard cable has been prepared for common input
connectors. The input power cable provides voltage measurement leads that are attached to the
input voltage wires of the cable within one and a half inches of the unit input power mating
connector.

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 Figure 2-1: C19 Open Connector Figure 2-2: C14 Open Connector

What instrument do you use to measure the input voltage, input

For both 115V and 230V input test benches, the input voltage, input current, input frequency,
input power, power factor, and THD (%) are measured using a Yokogawa WT-2030 (Figure 3-
1). There are three channels available for measuring parameters. These are first assigned to
voltage, current, and power until data is recorded. Then two of the channels are re-assigned to
measure input power factor and THD for the current load setting.

Figure 3-1: Yokogawa WT2030

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What instrument do you use to measure the output voltages?

All output voltages are measured using test probes and a Fluke 8846A 6 ½ Digit Multimeter
(Figure 4-1). Data is captured manually, one reading at a time, and entered into the unit under
test cal sheet.

Take a sample of 10 data points per output voltage using the statistical analysis function of the
Fluke 8846A. This displays the minimum and maximum measurements along with the average
and standard deviation value at the resolution of 6 digit 10 power line cycle (PLC) setting.

For example, selecting “6 DIGIT 10 PLC” will display 6½ digit resolution and take a
measurement using ten power line cycle A/D integrate period. For 60 Hz power, a measurement
is almost once every 60th of a second, or 166.666 milliseconds.

Figure 4-1: Fluke 8846A

Why must we use an LISN in the input circuit for testing efficiency?

An LISN (Line Impedance Stabilization Network) was added to the Generalized Test Protocol
Version 6.2. The addition of the LISN provides a stable input impedance when measuring input
power factor of very lightly loaded power supplies (below 20% loading). Testing at several labs,
including OEM labs, showed the power factor readings were much more repeatable when using
the LISN.

What power source do you use?

For 115V input units we use an 8KV UPS followed by a step up/step down isolation transformer.
The output voltage is measured prior to each load level data recording step and adjusted to 115
V as accurately as possible.

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For 230V units, including the EU listed units, the source is an AMTEK MX45-3PI-480-HV solid
state voltage source.

Do you start at 100% load and then reduce load? Or do you start at
10% load and increase to 100%?
For each UUT, the protocol is to start at 10% load, run the unit for 15 minutes and then take
data. The unit loading is then increased to the next loading level and the 15-minute run time
initiated before data is recorded. The process repeats until data at 100% load is taken.

How, and when, is the load adjusted for each level?

The load is manually adjusted while the unit is in operation in a continuous linear manner.

What happens if my unit fails?

If a unit fails to meet the any 80 PLUS criteria for certification, the test for that unit is terminated.
The second unit is then tested at the specific condition of failure. If the second unit passes, the
second unit is tested fully and data used for the report. If the second unit fails then the test is
terminated and a report is issued with the failure data recorded.

Our results are significantly different from yours. Why?

The test equipment used can have a significant impact on measurements. In most cases the
difference will be due to measurement of the input power. The accuracy of the input power
measurement is dependent on power factor of the unit under test, as well as the base accuracy
of the measuring equipment. If all equipment and setups were identical, it is still possible to
have a difference in readings of twice the stated accuracy. For example, if a power analyzer has
an accuracy of ± 0.1%, the worst-case difference could be as much as 0.2%. The power
analyzer used by 80 PLUS has a base accuracy of ± 0.04% of the reading plus 0.04% of the
range.

What happens if my unit performance misses a badge performance

When a unit comes within 0.5% of the next higher badge level, on any loading parameter, the
test of that unit is completed and a second unit is tested at the failed point. Should the second
unit pass the next level then the second unit is completely tested and that data is used for the
80 PLUS report. If the second unit fails to meet the higher level then the data from the first unit
is used to create the 80 PLUS report.

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How do you measure output current?

Output current on the 115V test bench is measured using the Yokogawa WT-2030. The
electronic load box (ELB) is set to a current that is varied from 1% to 100% of the ELB rating.
The current value in amps is read from 0% to 10% loading in 1% increments. Each value is
recorded. The current is then varied in 10% increments up to 100% of the ELB rating, with data
recorded at each increment. The values are then used to create a piecewise linear calibration
curve for that load bank. The curve is recorded and used to calculate the calibrated current from
the recorded current in the efficiency tab of the cal sheet for each unit under test. This
calibration process is repeated for each load bank used in efficiency testing each year.

Output current for the 230V test bench uses calibrated current shunts. The main output is a
custom designed shunt that is capable of operation to 1000 amperes. The shunt is calibrated to
within ±165ppm. Figure12-1 shows an example of the shunt calibration certificate.

Figure 12-1: Shunt Calibration Certificate

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How do you calculate the loading for a specific unit?

The ratings shown on the label of the test unit are entered into an Excel worksheet that
performs a calculation based on the algorithm explained in the Generalized Test Protocol for
testing the energy efficiency of AC-DC and DC-DC internal power supplies (Version 6.2),
Paragraph 6.1.1 Proportional allocation method for loading multiple and single-output
AC-DC and DC-DC power supplies.

Can you test and certify an open frame unit?

Open frame units can be tested. The unit must be connectorized and if it requires specific
cooling air, instructions to provide that air must be included with the unit. If an air plenum is
required then it must be provided with the unit on submittal.

Do you ensure all connectors are loaded?

All power supply output connectors are mated to the load test fixture. Some power supply
configurations have a large number of connectors. The 80 PLUS test board has the following
connectors available for connecting loads:

Number of Connectors Type of Connector

1 24-pin Main PSU

2 AUX 8-pin 12V

4 6-pin PCI Express

4 Molex 4-pin Peripherals

2 SATA

How do you ensure all connector pins or wires for a given output are
equally loaded?

All pins of the loading fixture utilize balancing resistors to ensure the drop associated with both
connector resistance, and wire resistance in series with the load, is insignificant.

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