Would it be safe to run a 500W power supply with the only load being 4
12V fans (and a few LED lights) or would this not be sufficient load to
operate safely? If not, about how much load should I put on it?
It's a good idea to load each of the positive voltages with at least
1-2 amps, such as with resistors, to prevent the duty cycle of any
output from going to an extreme, which you can often notice since the
supply whistles audibly or makes a screeching noise.
Resistance = volts/amps, meaning a 2A load on the +5V output will
require 2.5 ohms, either with a single 2.5 ohm resistor (hard to find)
or 4 separate 10 ohm resistors. Also very important is the power
rating of the load. Power = volts x amps, or in this case, 5W.
However a resistor run at its maximum rating will be hot enough to
cause burns in flesh or start fires when contacted by wood, fabric, or
plastic, so the power rating should be at least 2-3 times the
calculated power. If you use multiple resistors of the same resistance
rating, the power will be divided evenly among them, meaning in the
example above, with a total power of 5W, each of the four 10 ohm
resistors will dissipate 1.25W, and resistors rated for 3W, 5W, or 10W
are commonly available from sources like Radio Shack.