Progress slow but steady

[catkicker]

With all the out of town work I have had since August it's been difficult to get much done. Picked up some more much needed tools. Picking up a torch setup and swaging tools later this week.
http://img516.imageshack.us/img516/14/tools1ry.jpg (http://imageshack.us)

And heres the start of my receiver, It's 1 1/2" x 3"
http://img511.imageshack.us/img511/1857/receiver5ax.jpg (http://imageshack.us)


Now I need to learn how to use the gagues any suggestions on a place to read up on useing my gagues

[catkicker]

Swaging tools 15.00 bucks
http://img244.imageshack.us/img244/5539/swaging5bo.jpg (http://imageshack.us)
Father inlaw provided this
http://img244.imageshack.us/img244/9932/torchset3cj.jpg (http://imageshack.us)

How's this look for my Evap.
http://img244.imageshack.us/img244/1220/evap16cy.jpg (http://imageshack.us)
http://img244.imageshack.us/img244/102/evap26od.jpg (http://imageshack.us)

Still need to get sight glass, solder and some misc fittings.

[Gimmpy224]

ahhhh so its the evap you run through the liquid to cool it?

[catkicker]

I had no real idea of how much is involved in the building of a phase cooling system. I have spent probably 100 hours reading various threads at every forum that has phase cooling sections googling everything and anything that has something to do with phase or refrigeration I must have 30 sites saved in a bookmark folder. My folder named extreme cooling is almost a 100MB's and growing. Now I have a budget folder with receipts and cost, I have not totaled it up but I'm sure it's a bit more then I figured:rolleyes:
I need to fill my Oxy-Acetylene tanks and pick up my nitrogen bottle. Waiting on a resvoir & tygon tubing I ordered.
So sometime this week I will start putting togather my chiller.
http://img268.imageshack.us/img268/2696/chillerparts17mj.jpg (http://imageshack.us)
http://img268.imageshack.us/img268/4674/chillerparts20dj.jpg (http://imageshack.us)

Looking forward to getting started. I've been getting ready to do this since November 05:D

[Nyx]

A little advice for u cat kicker. I have also a chiller with aTXV it is giving me a little of headache getting the superheat settings right but it can sure get fun. Just be sure to make the receiver right so u can get a full liquid head to the TXV. If you are not confident of using a TXV a cap tube is the best bet for fast results and and temps. Capacity wise of course the TXV wins but the captube wont lose out much. i spent ~600 USD for my this chiller as the parts list just keeps going on and on so plan real properly before starting cause at some point turning back will be a hassle. My bits of experience :D

[catkicker]

Thank's Nyx. Deciding on the TXV was a big step, I drove Chilly1 a bit nuts with all the PM's about this setup, with all the reading and help from a relative in the HVAC biz I'm looking forward to this type of setup. A couple of people here have helped with advice on the receiver. As far as $ well I just took a look at the receipts and I have $400.00 invested in the project, Thats the total amount for all componets & tools and refrigerant. I lucked out with some of the componets that I got through scrounging. A plus is in my scrounging I have aquired 3 Tecumesh compressor and several good condensors & fans. I may be able to sell some of the compressors and condensors later to help offset the cost of this chiller or use them in future projects which will lower cost on those projects. Hell I spent around 300.00 for all my watercooling equipment so this chiller seems to be a better way to spend money on cooling. The one unknowen is what my case will cost for the unit, It's going to be as nice as the one's you see that Unseen and Drewmeister are using.

[yngndrw]

Nice collection of parts and tools mate, I hope it all goes well for you.

What gas will you be using and I hope you havnt forgotted to get a vac. pump !

Anyhow cant wait to see it all go together. :)

[Nyx]

Might want to start searching for denatured alcohol and a reservoir. This will help in finetuning it. And get some armaflex sheets they will come in handy.

[catkicker]

My 2gallon res. (Rubbermaid good for -40 degrees° C.) and tygon tubing (R-1000) Flexible at temperatures as low as -100°F.° came today. I have denatured alcahol and Glycol base coolant going to run 70-30 mix. I have 2 sheets of Closed Cell Neoprene Foam 72” x 42” x 1/4” Thick, I have alot of other misc. insulation. I'm waiting on a roll of seal string and Dielectric Grease. I did not buy pump but I have access to 2 very nice ones:D I even have a bottle of nitrogen at disposal when I'm ready to purge. R290 to start but it will be easy to convert over to R507 if I decide to.

[SexyMF]

Good luck with the build, although luck isn't much to do with it. You have done your homework.

I built my rig without purging with nitrogen. It's a plus, but not necessary. A good size filter/dryer will mop up for you. Heck, I brazed up a test system without a filter/dryer and it goes fine (although it is only for testing a big condensor).

What is the tube size of the evaporator coil?

Also, I find it best not to look at how much money into a project. Perhaps you should add in terms of the 'enjoyment dollar' :)

[catkicker]

Good luck with the build, although luck isn't much to do with it. You have done your homework.

I built my rig without purging with nitrogen. It's a plus, but not necessary. A good size filter/dryer will mop up for you. Heck, I brazed up a test system without a filter/dryer and it goes fine (although it is only for testing a big condensor).

What is the tube size of the evaporator coil?

Also, I find it best not to look at how much money into a project. Perhaps you should add in terms of the 'enjoyment dollar' :)

Yes lots of reading and question asking. As far as purging, well it seems to be
a detail I don't want to leave out and the nitrogen is there for the use.
3/8" from TXV outlet to the suction side of compressor. coil 3/8"
As far as money goes I've never let the cost of a computer build or watercooling setup or other project stop me but I do try to spend wisely and get every possiable bit of performance out of the money I do spend. I've worked out a deal with a buddy to design and build my case in trade for some computer componets I have. The design will be similar to Unseen's Green Devil case
http://www.xtremesystems.org/forums/showthread.php?t=83424

[Gimmpy224]

yea im looking forward to seeing the results.

[catkicker]

Well pumps here and I could'nt pass up a great deal on the digimatic
http://img224.imageshack.us/img224/7852/pump23fi.jpg (http://imageshack.us)
http://img224.imageshack.us/img224/9384/pump18cc.jpg (http://imageshack.us)
http://img346.imageshack.us/img346/3769/calipar3xv.jpg (http://imageshack.us)

Well back to work

[catkicker]

Well my engineer bud sent me some pics of what the case will look like still need to add opening for condensor. Once I get it I will have to drill holes for some switches and thermostat control knob.
http://img258.imageshack.us/img258/4863/catsboxdrawing11ie.th.jpg (http://img258.imageshack.us/my.php?image=catsboxdrawing11ie.jpg)
http://img259.imageshack.us/img259/647/catsboxdrawing20fm.th.jpg (http://img259.imageshack.us/my.php?image=catsboxdrawing20fm.jpg)
Some other designs. With the 2 gallon Resvoir at the rear of case I will have to use side pannel for intake either 2x80mm fans or 1 120mm fan
also a pic of the front cutout for condensor.

[[cTx]Philosophy]

nice work man for reading up and going self made...I was gonna get one from chilly but after reading this im gonna folow this and see how it goes for ya...


Looking forward to some results

[Blaster]

Go for it m8 ! :)

in ur design I would only consider using the pump outside the the reservoir cause it will heat the liquid a bit when it can be cooled by the air outside :p:

[SexyMF]

in ur design I would only consider using the pump outside the the reservoir cause it will heat the liquid a bit when it can be cooled by the air outside

If it is open to air it is a heat load because the inside is cooler than the outside. If you insulate the pump the heat stays inside and is transfered to the coolant. If you put it in the reservior it is silenced and insulated and if it springs a leak then it cares not.

I don't know why people quibble about this detail when you are designing a system to freeze things. Just add 10W to your target capacity.

[catkicker]

nice work man for reading up and going self made...I was gonna get one from chilly but after reading this im gonna folow this and see how it goes for ya...


Looking forward to some results

I'm not sure what Chilly1 gets for his chillers. When this is all over and done with I may have wished I had bought a unit from Chilly1. Home built or buying a unit from a top notch builder it's not cheap either way.

" I was not payed to say this" ROFLMAO!

[SixtyFo]

Ok, noob question here... whats a reciever and how do you go about using it with a txv?

[SexyMF]

I'm not sure what Chilly1 gets for his chillers. When this is all over and done with I may have wished I had bought a unit from Chilly1. Home built or buying a unit from a top notch builder it's not cheap either way.

Respect to the DIY man. I care little for the man who has the fastest rig simply because he has money but no understanding.

When I'm rich, filthy stinkin' rich. I'll still build my rigs.

I seem to end up building everything on the floor. I'm an electronics engineer proper, and even then I still seem to work on the floor (for home stuff). You know where everything is that way ;)

[SexyMF]

Ok, noob question here... whats a reciever and how do you go about using it with a txv?

To my understanding a receiver is just a reservior to hold refrigerant so that the txv is always supplied with liquid. A sight glass is used in txv systems so ensure that the charge is adequate to provide liquid to the txv under min/max loading conditions.

[aussie_guy00000]

I take my hat off to you catkicker (interesting name btw, will make you popular around here :slapass: ), I've seen heaps of guys rush out and by stuff and try to build something without properly understanding what they're doing. It certainly looks like you've done your home work, and bought all the right gear, I wish you the best of luck:banana3: :banana2: :toast:

[catkicker]

I take my hat off to you catkicker (interesting name btw, will make you popular around here :slapass: ), I've seen heaps of guys rush out and by stuff and try to build something without properly understanding what they're doing. It certainly looks like you've done your home work, and bought all the right gear, I wish you the best of luck:banana3: :banana2: :toast:

Thank's aussie_guy It's been a long road to get to this point. Knowing absolutely
nothing about phase and how it works required alot of late nites reading till my eyes were bleeding and of course alot of question asked here and in others forums. I will say that I have visited just about every knowen forum that has phase cooling info and XtremeSystems has them all beat hands down, the more experienced phase cooling people around here are more then willing to answer questions and help people to understand ALL aspects of this type of cooling. how all of you treat the newcombers to this type of cooling says alot about this forum and the way you all feel about phase cooling. Who knows a multi. stage DD maybe in my future, who knows?;)

[catkicker]

Closed cell neoprene for insulating res. and some other stuff. Should be enough
to last me for awhile
http://img481.imageshack.us/img481/226/closedcellneoprene2iv.jpg (http://imageshack.us)
:D $20.00 bucks seemed reasonable

[speed bump]

wow thats quite alot of neoprene. Now your stuck after this you will just have to keep on building stuff to use it all up.

[catkicker]

http://show.imagehosting.us/show/1057508/0/nouser_1057/T0_-1_1057508.jpg (http://www.imagehosting.us/index.php?action=show&ident=1057508)

Ace over at the DFI forum made this up for my soon to be chilled rig:eek:

[SexyMF]

It is one thing to build the chiller and another to trust condensation proofing on $$$s of new gear.

You are brave ;)

[catkicker]

It is one thing to build the chiller and another to trust condensation proofing on $$$s of new gear.

You are brave ;)

Well none of it is new gear, the DFI Nf3 board has been replaced by a Nf4SLIDR board and the rest of the componets have been sitting collecting dust, with the exception of the 3700+ clawhammer AMD was kind enough to upgrade me on a RMA from 3200+ to the 3700+ so it's new. Of all the concerns condensation has to be right at the top of the list. "brave" I guess so I'm building my first phase cooling system with no before hand knowledge of phase cooling. You can bet on one thing the insulating process will be done right the first time.:D

[Blaster]

If it is open to air it is a heat load because the inside is cooler than the outside. If you insulate the pump the heat stays inside and is transfered to the coolant. If you put it in the reservior it is silenced and insulated and if it springs a leak then it cares not.

I don't know why people quibble about this detail when you are designing a system to freeze things. Just add 10W to your target capacity.


What ever u do dont insulate ur pump, it will melt !


A 10 watts pump wont be powerfull enough to move -30º liquid

[SexyMF]

A 10 watts pump wont be powerfull enough to move -30º liquid

A pump that is 40W doesn't produce 40W of heat. It actually uses the energy to pump. Only a small portion is heat. Otherwise it would be called a 40W heater. This is what efficiency numbers are all about. This is what people get wrong all the time.

[Blaster]

this is why u cant insulate ur pump :p


http://www.xtremesystems.org/forums/showpost.php?p=498032&postcount=66

[catkicker]

The submersable pump I have is 300GPH it's 50watts It will be sitting in a 2 gallon resvoir the evap coil is approx. 14 feet of 3/8" tubing. I'll let the 2 gallons of coolant insulate the pump.

Blaster how big is your Res?

[catkicker]

Well my chiller case should be here middle of next week and I can start assembly, lots of work to do on case before I even start on plumbing the unit.
Guess I'm going to have to buy a regulator for the oxy bottle I have for the welding outfit. Grrr! I've tried 3 different regulators and they all leaked, guess thats why the people were not using them.
http://show.imagehosting.us/show/1089071/0/nouser_1089/T0_-1_1089071.jpg (http://www.imagehosting.us/index.php?action=show&ident=1089071)

Looks kind of homeless.:(

[404Power]

Just waiting for next update! :D
Keep it up! ;)

[johann]

I was wondering why you have a 2 gallon res?

I found that the bigger the res the more heat loss and the lower the temps.

On my chiller I used 1 gallon at first, then 1 litre then no res atall.

I would suggest using a coaxial HX with no res and a fillport. Also the 50 watts from the pump is dumped in the liquid making load even more and temps even lower.

This way there is no ghetto beercooler that takes up alot of space and you dont need 2+ gallons of liquid and temps are lower.

My complete chiller is smaller than your res alone and temps are great

[catkicker]

Well johann I'm in the learning process just like you were when you first got those beer cooler units. With the 1/3+ compressor and that condensors and eventually R507 the unit should perform well for 24/7 use. There are other options if I'm not happy with temps such as your suggestions. The case I'm having built is larger then most one of the reasons is the 2 gallon res but the other reason is when I'm ready I can replace that resvoir with a 2nd compressor
for DD system. The chiller unit seemed to be the best way to break into phase cooling there's alot to learn when it comes to this type of cooling.

[catkicker]

insulation time.
started with a couple coats of laquer and then a coat of liquid electrical tape on the the back has at total of 1/2" of armaflex the MB standoffs fit through just right. Top of MB has 2 coats of liquid electrical tape and as soon as sticky string stuff comes, probably tuesday I'll finish top of MB I put a couple of coats of liquid electrical tape on the video card will probably put a layer of 1/8" armaflex on the VC.
Swiftech water block has 1/4" of armaflex on top and sides 1/8" on bottom of block.

Any suggestions or comments.
http://img27.imageshack.us/img27/1840/mbinst19qh.jpg (http://imageshack.us)
http://img27.imageshack.us/img27/549/mbinst6vm.jpg (http://imageshack.us)
http://img294.imageshack.us/img294/3616/wbinst0le.jpg (http://imageshack.us)
http://img294.imageshack.us/img294/2104/wbinst10og.jpg (http://imageshack.us)

[catkicker]

Block now has 1/2" armaflex on top and sides and 1/4" on bottom that fits around CPU. I can't get anymore on there LOL. Heres how it looks mounted on the MB. reworked the hardware so I can remove block with ease.
http://img390.imageshack.us/img390/5453/blockinstalation2gt.th.jpg (http://img390.imageshack.us/my.php?image=blockinstalation2gt.jpg)

Hopefully I'll have MB insulating done later this week.

[johann]

Good job on the insulation. :D

[[cTx]Philosophy]

Lets say you need to sell this after ur done with it and move on to newer HW

Is this easy removal? like does it all just peel str8 off or wut?

Looking forward to seeing some results, Good luck bro keep up gr8 work

[catkicker]

Good job on the insulation. :D

Thank's. Very time consuming. I hope that 1/2" of insulation will be alright.

[[XC] mysticmerlin]

Keep it coming. I am watching hoping to learn something. ;-)

[RussC]

Umm, once you do all that stuff to a MB, its done. It's only good to someone who will be doing the same thing as you are. Why would someone buy it like that for regular cooling. But, it is what it is.

Nice insolation job. I hope mine comes out that way when Im done. Looks great.

The 1/2in insol should be OK to ~-20c. Lower an it may not be.

RussC


Lets say you need to sell this after ur done with it and move on to newer HW

Is this easy removal? like does it all just peel str8 off or wut?

Looking forward to seeing some results, Good luck bro keep up gr8 work

[catkicker]

Actually the board would clean up with some work, the liquid electrical tape will come up once you get it started it will peel right off which will make it easy to remove alot of the insulation off the board.

Russ that would really bum me out if I had to worry about lower temps then minus 20:D

[catkicker]

Well started working on the chieftec matrix tower once again prep work for the chiller unit Mounted a Panaflo120mm, 86.5 CFM @ 2100 RPM, 35.5 dBA. and sleeved up some fans for the case. I need to dremel out the lower rear 80mm fan grille for the insulated water lines to pass through case.
http://img54.imageshack.us/img54/8320/fanpanaflo7ph.jpg (http://imageshack.us)
http://img54.imageshack.us/img54/3739/sleeving5tj.jpg (http://imageshack.us)



next weekend the phase chiller construction begins

[Hell-Fire]

Teh fan sleeving is sexy! :hehe:

Looking forward to the real deal building of the chiller.

[catkicker]

the big brown truck came today Woot!
http://img91.imageshack.us/img91/539/casepan19cb.jpg (http://imageshack.us)
http://img91.imageshack.us/img91/7193/casepan23rx.jpg (http://imageshack.us)
http://show.imagehosting.us/show/1126594/0/nouser_1126/T0_-1_1126594.jpg (http://www.imagehosting.us/index.php?action=show&ident=1126594)
http://show.imagehosting.us/show/1126599/0/nouser_1126/T0_-1_1126599.jpg (http://www.imagehosting.us/index.php?action=show&ident=1126599)

Now the case is unfinished at this point, once I install all the componets and get it running and tuned I will then unbolt everything and with some help lift the whole unit out of the case and then I can finish the prep on the exteior of the case. It will then ship out to my buddy in NY. who has a custom metal fab shop and powdercoating setup it will be sandblasted and powder coated with a mirror black finish. I have lexan for the window in the case and thesePabst 120MM fans for the case
http://show.imagehosting.us/show/1067768/0/nouser_1067/T1_-1_1067768.jpg (http://www.imagehosting.us/index.php?action=show&ident=1067768)
Then a wee bit of lite for the case the case feet are lighted replacement case feet for cheiftec cases (BLUE and of course some cold cathode for the chiller
http://img218.imageshack.us/img218/9656/litesforcase2ik.jpg (http://imageshack.us)


Well thats it for now

[catkicker]

Well heres a update.... The tower is done I had to use a bucket of ice water in order to load the OS and programs and of course tune it up a bit 2.7GHz stable
be glad to have some real chilly liquid on that chip
http://img412.imageshack.us/img412/4066/towerdone1yi.jpg (http://imageshack.us)
http://img412.imageshack.us/img412/458/casefront4nz.jpg (http://imageshack.us)
Started putting the chiller togather today
http://img419.imageshack.us/img419/9824/ttsmartfan9nv.jpg (http://imageshack.us)
http://img472.imageshack.us/img472/7428/evapandshroud8um.jpg (http://imageshack.us)
http://img137.imageshack.us/img137/4245/bluefeet3hd.jpg (http://imageshack.us)
http://img137.imageshack.us/img137/5761/feetdone3nq.jpg (http://imageshack.us)
http://img419.imageshack.us/img419/748/evapcompmounted2nr.jpg (http://imageshack.us)
http://img419.imageshack.us/img419/4042/frontliteup4dq.jpg (http://imageshack.us)
http://img141.imageshack.us/img141/282/liteupwicked0vb.jpg (http://imageshack.us)

It's ready to plumb. Hopefully next week I will be doing the plumbing,

[[XC] mysticmerlin]

Looken good

[p00 p0wer]

very nice keep it up

[Son1990]

Great insulation. Keep it up!

[Fhqwhgads6680]

Hey man great build! one of the best chiller builds I've seen. Keep up the good work and keep us posted!

[catkicker]

Finally the work schedule allowed a weekend for me to work on the chiller.
Fhqwhgads6680 and I started cutting and bending some 1/4" tubing for going from comp. to condensor and putting togather a receiver. Going to work on some more of it tomarrow. Pics. soon.

[Fhqwhgads6680]

Hey everyone, I don't hang out in this section too often I'm usually a DD guy, but me and Cat have been working on his chiller and I gotta say...chillers are fun :) I took some pics while we worked. Before anyone points it out, we know we need a schraider on the high side thats not that, but it was easier to do that all in one piece and we didn't have the right T at the time, so I'm just gonna cut and add that in next time we work on it. anyway so here are the pics!

Me getting my Braze on, this is the reciever we made:

http://www.surrealtextures.com/Pics/pic1.jpg

The setup:

http://www.surrealtextures.com/Pics/pic2.jpg

The evap we made:

http://www.surrealtextures.com/Pics/pic3.jpg

and the final aerial photo:

http://www.surrealtextures.com/Pics/pic4.jpg

We still have to make the suction line, with our 1/4 equalization line from the txv, then gotta add schaiders and then we should be ready to pull a vac. Hope you guys enjoy the pics!

Brandon

[chilly1]

I'm not sure what Chilly1 gets for his chillers. When this is all over and done with I may have wished I had bought a unit from Chilly1. Home built or buying a unit from a top notch builder it's not cheap either way.

" I was not payed to say this" ROFLMAO!
THX Checks in teh mail ;)

[catkicker]

THX Checks in teh mail ;)


Your to generous:D So looks good so far?