Wow! I didn't think anyone would answer! I checked back a few times and thought the thread abandoned after a week (I should have been a bit more patient!)
I'll give an update.
Eventually I went back to the original power supply (Antec EarthWatts 650). I was really nervous about turning the PC back on, but after a week I decided to take the plunge. I pulled the main HD from my laptop (320 GB SATA), plugged it into the SATA PCI card, and booted with my 120GB drive. I copied everything over to the laptop drive (while praying it doesn't shut down). Once I safely had the backup I unplugged the laptop drive and started examining things again. The only thing amiss is sound is now dead (built-in motherboard audio; yet device manager detects it just fine; tried headphones and speakers max volume nothing works) and nothing else seems amiss. The weird thing is now that the audio seems gone, everything else seems stable!!!
To be exact, over time, a few components on the motherboard have been dead (one of the ethernet - gigabit by Marvell - also detected OK, but when data is sent it drops connection, with "Port A is bad" in event viewer; and on-board SATA doesn't detect 1TB drive; I disabled both long ago with jumpers), but since they didn't seem to affect anything else, I ignored it.
Conclusion? I have no idea. I'm going to guess motherboard was the problem? Triggered by bad power? Who knows?
I guess I'll keep using this until it dies. (Having no audio sucks though.) I backup new files regularly though (every other day). I'll try to get a UPS on the next PC I buy.
@ craig6928
>> check to see if the caps are bulging on the board
no. it's one of the things I checked long ago (and again after the incident). capacitors on this motherboard seem OK (at least visually).
>> allso you could be getting a ripple effect on your pc system to many items plugged in at one time.
I wish I knew more about this
but you ARE correct about one thing: my worst problems seem to occur when I have multiple items connected (3 or more hard drives - especially when I start doing an intensive copy from one drive to another - then one click, then a hang (mouse and screen frozen - needs reset or poweroff) - I HATE THAT, and I'm always nervous about it happening unexpectedly). Also the most likely time for such click/hangs, or hangs is usually at boot time - 90% of the time if I can get past boot sequence, it's fine (I don't know, it's when windows 2000 does all those reads and writes at boot time, sounds like the time the hard drive is busiest grinding etc).
I used to think having plenty of power (650 W) should handle as many as 4 connected hard drives (the old power-hungry kind, like 5-platter Hitachis) just fine. Not so sure anymore.
Upon googling, the little I could gather was that ripples were only detectable using oscilloscopes?
@ fzabkar
>> The power light is probably wired to the +5VSB standby supply. The power button at the front of your PC case doesn't directly control the PSU. Instead it is "interpreted" by a section of the motherboard chipset, and the chipset then sends a PS_ON signal to the supply to turn it on, or negates the signal to turn it off.
I wired the power/reset/etc wires exactly as per the motherboard manual (at least I think so because everything works OK).
Or does that mean that during a PSU-triggered shutdown (like to protect from surges or brownouts), the light is expected to stay on? And it's expected that the system can't be powered back on without a hard shut off?
@ drc
>> If your power supply(s) test good then it is probably a motherboard issue...
I wish I knew how to test either! But given the audio/SATA/gigabit problems, you're totally right.
@ craig6928
>> you got a ripple effect on the power supply that your problem.
>> it might not do the ripple effect all the time.
>> its called over voltage on the power unit.
>> but when it does it can damaged the motherboard and graffics card.
That likely explains the two fried graphics cards over the years (All-in-Wonder Radeon 9800 Pro, then FireGL X1 (based on Radeon 9700)). The first had a burnt power pin (where the Berg connector goes to feed the fan).
@ Russwinters
>> Those Anted earthwatts are cheap PSU, Antec is a good brand, but the earthwatts uses a badly made design (Antec doesnt actually make!)
>> If you like antec move to the Truepower
I didn't know that. The only thing I noticed was that when I got my first Earthwatts 650 two years ago (the one I'm back to using now - which works, whereas the two new ones I tried didn't), it didn't seem so common and cost quite a bit. The two replacement ones I tried last month were cheap, and the store I went to had a HUGE pile of them (like they were being mass-produced cheaply). So you're probably right about that.
This page on Antec PSU's has some interesting ramblings. The funny part is the guy has a motherboard that is very closely related to mine (mine = A7N8X-E deluxe; his = A7N8X). A lot of replies deal with Athlon-XP-era Asus mobos too. Could the two be incompatible?
http://www.pjrc.com/about/rambling/antec.html>> Also get yourself a Battery Backup. I use an APC 750 (like $60USD) and it helps regulate the power going to you PC directly.
I'll have to do that with the next PC. I'd read about UPS (uninterruptable power supplies) as being able to condition the line, so as to get stable current without spikes or drops.
Again, thanks for everyone's feedback.