Ok, I'm Chilled. I'm Chilled. Relax....56K Warning!
Well, I've had a lot of fun with my other projects, but I realized a while back that a chiller would probably be my best bet all the way around. So, after doing the car rad(s)--indoor/outdoor, geothermal, bongs and HVC....I finally decided to do the chiller-thing. http://i50.photobucket.com/albums/f3...ies/tongue.gif Of course, the chiller scraps everything else...except the indoor rad--I can still use that for winter heat. http://i50.photobucket.com/albums/f3...s/thumbsup.gif
I started surfing around checking out this years A/Cs, rechecking on coolers, etc. I wanted one of the Coleman 150qt. 5-day coolers....but I ended up going with an Igloo Polar 120qt., because of price and availability. http://i50.photobucket.com/albums/f3...s/thumbsup.gif Still a good cooler, but the Coleman 5-day's (Extreme/Marine) reviews are outstanding! http://i50.photobucket.com/albums/f3...ilies/yepp.gif
Anyway, I ran into a snag with the window that I had always intended to mount the A/C in (yeah, I've been thinking about this for a long time)--most/many of the smaller A/Cs require a minimum 14" window opening (height), but there are a few that don't. In the end though it didn't matter, because I said screw the window, I'll pull the rads and reverse the fans and blow some of the heat out the window. http://i50.photobucket.com/albums/f3...ilies/rotf.gif
So, while still trying to talk myself out of this for at least a while longer ( http://i50.photobucket.com/albums/f3...lies/rofl2.gif )--I started surfing craiglist. I found a small Frigidaire 5KBTU locally for $50. Said: "Screw it". Picked up the cooler. Picked up the A/C. So, this was done....just a little assembly required...http://i50.photobucket.com/albums/f3...es/biggrin.gif
So, this is what I've come up with:
http://i50.photobucket.com/albums/f3...-6-5-09003.jpg
http://i50.photobucket.com/albums/f3...-6-5-09027.jpg
Plumbing coming out of the chiller headed toward the PCs:
http://i50.photobucket.com/albums/f3...-6-5-09038.jpg
Return to the chiller:
http://i50.photobucket.com/albums/f3...-6-5-09032.jpg
I really wanted electronic thermostat/controls and "Energy Saver", but I would have had to buy a new A/C, so that would have about doubled the cost.
http://i50.photobucket.com/albums/f3...-6-5-09017.jpg
I cut a small opening in the lid for the wires, etc to pass through:
http://i50.photobucket.com/albums/f3...-6-5-09020.jpg
Filled it with weather stripping foam just to help prevent the transfer of air:
http://i50.photobucket.com/albums/f3...-6-5-09076.jpg
Marked my spot for when I close the lid:
http://i50.photobucket.com/albums/f3...-6-5-09086.jpg
Pix of the guts:
http://i50.photobucket.com/albums/f3...-6-5-09055.jpg
http://i50.photobucket.com/albums/f3...-6-5-09065.jpg
http://i50.photobucket.com/albums/f3...-6-5-09073.jpg
I added a small 11w 200gph pump to help circulation inside the cooler. It definitely helps even out temps:
http://i50.photobucket.com/albums/f3...-6-5-09069.jpg
2 temp probes side-by-side:
http://i50.photobucket.com/albums/f3...-6-5-09062.jpg
These are the low end temps that I have it set for--the compressor kicks on:
http://i50.photobucket.com/albums/f3...-6-5-09050.jpg
http://i50.photobucket.com/albums/f3...-6-5-09105.jpg
And then kicks off at:
http://i50.photobucket.com/albums/f3...-6-5-09110.jpg
http://i50.photobucket.com/albums/f3...-6-5-09115.jpg
I set this up in the morning and it ran fine all day. No problems whatsoever. About 20 hrs later--I had alarms going off. I checked the coolant temp=116F/46C. I'm not 100% sure what the cause of it was, but I think and guessed that it was the temp probe. I'm assuming that the part exposed to the outside of the cooler was effected by the low ambient temps--so the compressor didn't kick on. So, I put some tubing over the probe length to help it read the temp inside the cooler only. Seems to have worked:
http://i50.photobucket.com/albums/f3...-6-5-09080.jpg
I haven't had any problems since....:up:
When the compressor is off the unit uses 47-48w for the fan motor. When the compressor is running it uses right at:
http://i50.photobucket.com/albums/f3...-6-5-09094.jpg
I took some on/off cycle times. The off cycle averaged 11min 55sec and the on cycle averaged 12min 12secs. So, for me that's close enough to say that it's going to run ~50% of the time. Problem is: that's ~5 cycles every 2 hours or 60 cycles/day. Seems like a bit much. So, I added 6 more gals of water. Hopefully that will help it cycle just a bit less. I encountered a small leak toward the top of the return bulkhead fitting. So, before I can add anymore (water or anti-freeze) I am going to have to remove a bit of the fluid and tighten that sucker up a bit more. Once it's sealed properly I can add quite a bit more fluid. Physics says that there isn't much I can do about the 50% run time. But it also says that more fluid mass should reduce the number of cycles/day. http://i50.photobucket.com/albums/f3...s/sasmokin.gif
Here's a 38sec video showing the circulation and return flow:
http://i50.photobucket.com/albums/f3...ler-6-5-09.jpg
No, I'm not interested in sub-zero, etc. I'm sub-ambient now....just above the dewpoint<--worst case. Hoping I stay just above the dewpoint. http://i50.photobucket.com/albums/f3...ies/tongue.gif
Cost:
A/C--$50
Cooler--$57
Anti-freeze--$77
I had everything else.
Other then a few very minor issues....I really didn't have any problems setting this up. My estimate is that it should cost ~$20.29/month to run this, so:
Looks like I'm ready for summer!
ApogeeGT water blocks:
http://i50.photobucket.com/albums/f3...41i76-5-09.jpg
http://i50.photobucket.com/albums/f3...94506-5-09.jpg
http://i50.photobucket.com/albums/f3...600-6-5-09.jpg
Goes from the chiller/pvc to this manifold and then to the PCs:
http://i50.photobucket.com/albums/f3...IMG_0002_1.jpg
Crunchin' Boinc: WCG + GpuGrid:
http://i50.photobucket.com/albums/f3...i7PC5-3-09.jpg
Index of prior Projects:
Yes, Another Car Radiator Thread....Major 56K Warning!
Bong! Bong! Bong! --56K Warning!
Horizontal Volenti Cooler.....56K Warning!
The Hole…Geothermal Loop…56K Warning!