[Industry Application]—AI Server Cabinet DC Busbar Temperature Rise Test

DC Busbar Temperature Rise Test

As a key component of power transmission, the DC busbar is responsible for efficiently delivering power from the Power Supply Unit (PSU) to loads such as GPUs and CPUs with minimal loss. Conducting accurate and reliable temperature rise tests on DC busbars has become an indispensable part of AI server cabinet design validation and production line quality control.

DC Busbar Temperature Rise Test Requirements

The requirements for busbar temperature rise testing in AI server data centers are as follows:

FaithTech Test Solutions

Leveraging its modular high-power programmable DC power supplies, wide-range high-power programmable DC power supplies, and bidirectional programmable DC power supplies, FaithTech provides two comprehensive DC busbar temperature rise test solutions for the industry.

Solution 1: DC Short-Circuit Method

Test Principle For rapid production line screening or benchmark testing during the R&D phase, the DC short-circuit method is used to quickly evaluate busbar temperature rise. Connect the output terminals of the FaithTech FTG high-power programmable DC power supply directly to both ends of the busbar (short circuit). Set the required current (e.g., 8000A, 12000A, etc.). The power supply automatically adjusts the output voltage to maintain a constant current, and the busbar heats up due to Joule heating.

Advantages of this Solution

• High Equipment Integration: A single FTG unit acts as both the current source and measurement device, eliminating the need for an external load.
• Simple Operation: Ideal for rapid testing on production lines, saving space and cost.
• High Reliability: Built-in comprehensive protection (OVP/OCP/OTP) ensures test safety.

Common Customer Q&A for this Solution

• Q - Can the FTG output high current at low voltage?
  • A - The FTG utilizes a modular parallel architecture. Each module has independent constant current control. The entire system can output its rated current even when short-circuited (near 0V), with high precision up to 0.1%+0.1% F.S.
• Q - Does a short-circuit test equate to real-world operating conditions?
  • A - The short-circuit test provides a relatively stringent temperature rise condition (very low voltage, all current converted to heat), making it suitable for evaluating the busbar's极限 current-carrying capacity. Additionally, the FTG's sequence function can simulate stepped currents, which more closely resembles actual load variations.

Solution 2: Source + Load Simulating Real-World Conditions

Utilize the FaithTech FTP9000 programmable DC power supply as the power source to simulate the server PSU's output. Employ the FaithTech FTB9000 bidirectional programmable DC power supply as an electronic load to absorb loop energy with energy regeneration.

Test Principle The FaithTech FTP9000 high-power programmable DC power supply outputs a stable voltage (e.g., 12V, 48V) to power the busbar. Its high precision (Voltage: 0.02%+0.02% F.S.), fast transient response (<2ms), and sequence function allow it to simulate voltage fluctuations present in actual power supply scenarios.

The FaithTech FTB9000 high-power bidirectional DC power supply operates in Constant Current (CC) mode, sinking the set current (e.g., 2000A) to pass a high current through the busbar. As a bidirectional power supply, it can act as a load to absorb energy and also regenerate the absorbed energy back to the grid with an efficiency of up to 95%, significantly reducing energy consumption and cooling costs for long-duration tests.

Advantages of this Solution

• Precise Current Control: Current accuracy of 0.1%+0.1% F.S., ensuring stable output at set values.
• Supports Dynamic Current Changes: Using the sequence function, it can be programmed to simulate sudden GPU current surges to evaluate transient busbar temperature rise.
• Energy Regeneration for Savings: Particularly suitable for hours-long aging tests, saving electricity costs and eliminating the need for additional air conditioning for cooling.
• Accurate System Simulation: Fully replicates the electrical environment of PSU → Busbar → Load, providing test results with greater reference value.

Core Parameters of Busbar Temperature Rise Test Instruments

FaithTech FTG Modular Ultra-High Power Programmable DC Power Supply

• High current density: 1800A in 3U
• Single-unit range: 0~1500V / 0~20000A / 4~600kW
• High precision: Voltage 0.05% F.S., Current 0.1%+0.1% F.S.
• Three modes: Constant Current (CC), Constant Voltage (CV), Constant Power (CP)
• Supports master-slave parallel operation (up to 10 units) for power expansion
• Low ripple: e.g., <55mVp-p for 10V models
• Multiple communication interfaces: LAN/RS232/RS485/GPIB/CAN, supporting SCPI & ModBus
• Standard PC software for waveform editing and data logging

FaithTech FTP9000 Wide-Range High-Power Programmable DC Power Supply

• Single-unit range: 0~2250V / 0~6120A / 5~180kW
• High power density: 18kW in 3U
• Voltage accuracy: 0.02%+0.02% F.S., Current accuracy: 0.1%+0.1% F.S.
• Transient response: <2ms (10%~90% load change)
• Auto-ranging constant power, CV/CC priority, sequence function
• Standard LAN/USB, optional GPIB/RS485/CAN

FaithTech FTB9000 Bidirectional Programmable DC Power Supply (Regenerative Load)

• Single-unit range: 0~2250V / 0~±4500A / 0~±180kW
• Energy regeneration efficiency up to 95%, Power Factor 0.99
• Seamless switching between source and load quadrants
• Accuracy: Voltage 0.02%+0.02% F.S., Current 0.1%+0.1% F.S.

Full-Link Support from Busbar R&D Validation to Production Line Testing

Busbar Test Instrument Main Model Selection Guide

Solution 1 (DC Short-Circuit Method) Recommended Configuration

Solution 2 (Source+Load Simulating Conditions) Recommended Models

Summary

From ultra-low voltage, high-current testing for NVIDIA VPD architectures to temperature rise validation for AI server DC busbars, FaithTech continues to deepen its expertise in programmable power supplies and electronic loads, helping customers overcome one testing challenge after another. The FTG series' low-voltage, high-current output capability, the FTP9000's high-precision power supply, and the FTB9000's energy regeneration and load functionality form a comprehensive test solution covering R&D, integration, and production lines.

For more product details or customized test solutions, please contact the FaithTech technical team.

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FaithTech is a company specializing in the field of new energy power electronics testing and simulation instrumentation. We provide high-performance, high-reliability full-series test & measurement power supplies, electronic load equipment, and test solutions. Leveraging profound technical accumulation, FaithTech was among the first in the industry to introduce over 10 high-level product series, including high-density high-power electronic loads, wide-range DC test & measurement power supplies, and high-performance high-power bidirectional DC power supplies, gaining wide recognition from customers.

FaithTech is committed to technology frontiers and independent R&D, holding nearly 100 independent intellectual property rights and having obtained CE, ROHS, and ISO 9001 international quality management system certifications.

FaithTech has been honored as a "National Specialized and Sophisticated 'Little Giant' Enterprise," a "National High-Tech Enterprise," a "Major Drafting Unit for 4 National Standards including 'High-Power Switching Power Supply Technical Specifications,'" and a "Shenzhen Specialized and Sophisticated Enterprise." With reliable product quality and enthusiastic service, FaithTech has established long-term cooperative relationships with leading companies in the industry.

FaithTech – A High-End Test & Measurement Power Supply, Electronic Load, and Automated Test Integrated Solution Manufacturer