Small Contest for a nice Christmas Gift
Hey you cooling nut cases!
I have been given a brand new Foxconn Quantum MARS P35 motherboard to give out to anyone. (No pic let’s cut pimping to a minimal) This contest is pretty straightforward!
A Build Log plus finished project Contest!
- Must be Phase Change :P
- Must be complete with Pictures – No bigger than 640pixels width
Reply this thread with Work log to enter!
Keep all your work pictures and updates within 4 posts, just keep editing to add in. I’d propose you post one post and then reserve 3 spaces below it immediately to keep your work log in a single file.
Single stage and Cascades are equally welcomed, of course the nature of each will be evaluated on equal grounds – ie won’t compare performance of single to a Cascade.
You will be judged on Ease to understand of detailed work log, Innovation, aesthetics, and Performance! The shady area will of course be performance so try to convince us of it's performance the best way you can, benched on a CPU/GPU, etc...
Contest starts now, winner announced on Christmas Day!
jan's worklog for singel stage cooler
Lets see if i this works out nicely. It's been a while since i've built a singlestage
I went to the garage and collected some parts to start with...
I'll make a simple single stage unit using the following parts:
-ACC GP16FB compressor (16cm³ displacement)
-decent condenser, no pics now as it arrives not until next week (pic will follow)
-some evap that i found in the garage. It fits into the vapo mount so i'll try if its ok.
-CPEV (never used one before :D)
-refrigerant: R402a
The unit will be mounted on a simple aluminium sheet. I've not planned a case for now.
All parts except the condenser:
http://www.coldbug.de/Bilder/sstage/parts.jpg
Today I prepared and brazed the evaporator. Its an simple stepper design so nothing special. I modified it to increase the surface area a bit.
And always remember, while using a bench drill you should wear your safety glasses. :D
http://www.coldbug.de/Bilder/sstage/jan.jpg
http://www.coldbug.de/Bilder/sstage/evap.jpg
The cooker helps warming it up. At least a bit.
http://www.coldbug.de/Bilder/sstage/evap1.jpg
Brazed and cooling down. Now i've to clean it and lap the bottom.
http://www.coldbug.de/Bilder/sstage/evap2.jpg
Today I got some work done. I assembled the suctionline and highside of the unit. Pics below:
First I lapped the evaporator. As my lathe is disassembled right now I did it manually :(
Start with rough paper and as you progress use finer paper until you get a flat evaporator bottom without grooves.
http://www.coldbug.de/Bilder/sstage/lapping.jpg
When I finished this I assembled the evaporator with the suction line.
http://www.coldbug.de/Bilder/sstage/suction1.jpg
Next I added the feed line for the CPEV
http://www.coldbug.de/Bilder/sstage/suction2.jpg
Now that the evaporator, suctionline and feedline were assembled I insulated it and put the evap into the Vapo mounting kit
http://www.coldbug.de/Bilder/sstage/suction3.jpg
This is the condenser I was waiting for:
http://www.coldbug.de/Bilder/sstage/condenser1.jpg
I did cut in M4 threads for easy fan mounting:
http://www.coldbug.de/Bilder/sstage/condenser2.jpg
With mounted fan it looks like this:
http://www.coldbug.de/Bilder/sstage/condenser3.jpg
http://www.coldbug.de/Bilder/sstage/condenser4.jpg
Now I mounted the compressor on the baseplate
http://www.coldbug.de/Bilder/sstage/mount1.jpg
next comes the condenser
http://www.coldbug.de/Bilder/sstage/mount2.jpg
http://www.coldbug.de/Bilder/sstage/mount3.jpg
Starting with the discharge line. I forgot a access valve, I'll add it later on when I finish the cooler.
http://www.coldbug.de/Bilder/sstage/hs1.jpg
http://www.coldbug.de/Bilder/sstage/hs2.jpg
http://www.coldbug.de/Bilder/sstage/hs3.jpg
Added CPEV and filterdryer
http://www.coldbug.de/Bilder/sstage/valve1.jpg
http://www.coldbug.de/Bilder/sstage/valve2.jpg
http://www.coldbug.de/Bilder/sstage/valve3.jpg
http://www.coldbug.de/Bilder/sstage/valve4.jpg
As I ran out of brazing rods the last thing I did was adding the suction line and some insulation:
http://www.coldbug.de/Bilder/sstage/suction4.jpg
http://www.coldbug.de/Bilder/sstage/suction5.jpg
http://www.coldbug.de/Bilder/sstage/suction6.jpg
Ok, here is the last part of my worklog.
I decided to use captube instead of cpev...
http://www.coldbug.de/Bilder/sstage/captube1.jpg
http://www.coldbug.de/Bilder/sstage/captube2.jpg
I did not have a t-connector to install a access valve in highside so i did one myself
http://www.coldbug.de/Bilder/sstage/t.jpg
http://www.coldbug.de/Bilder/sstage/t2.jpg
evacuating...
http://www.coldbug.de/Bilder/sstage/evac.jpg
...charging...
http://www.coldbug.de/Bilder/sstage/charge.jpg
...with r402a
http://www.coldbug.de/Bilder/sstage/r402a.jpg
Its some time ago I've built my last singlestage so i had to make a new load tester.
http://www.coldbug.de/Bilder/sstage/load1.jpg
http://www.coldbug.de/Bilder/sstage/load2.jpg
http://www.coldbug.de/Bilder/sstage/load3.jpg
255 watt :)
http://www.coldbug.de/Bilder/sstage/load4.jpg
Insulated evap mounted on loadtester
http://www.coldbug.de/Bilder/sstage/mounted.jpg
the insulated unit ready to test
http://www.coldbug.de/Bilder/sstage/unit.jpg
http://www.coldbug.de/Bilder/sstage/unit2.jpg
And this is the temp under load. Roomtemp was ~ 20 - 22°C
http://www.coldbug.de/Bilder/sstage/temp.jpg
The temp is not that good. I think the evaporator is not capable of this load. Also I've to change the captube as it is to restrictive. I won't have time for this until early january :( So this is is the cooler as it is for now...
But I'll change captube and evaporator to yield better performance as soon as I've the spare time for it.
Also I could not test the unit under a lower load as I don't have a variac right now.
SubZ Twins for UFO Duality
One of our members approached me a while back to see if I was interested in assembling a phase change system for him in a case he had fabricated completely out of aluminum; I said "sure".... then he started explaining what he wanted to do :yikes: At first I wasn't sure..... then I saw some pics of the case he had made and that won me over :yup: The thing blew me away with the looks and quality of the build. :thumbs:
http://i8.photobucket.com/albums/a5/...d/DSC00050.jpg
http://i8.photobucket.com/albums/a5/...pty-case-2.jpg
http://i8.photobucket.com/albums/a5/...both-cases.jpg
We agreed on the deal and it wasn't long until 2 large packages arrived at my house. One contained the case with a box inside of it containing enough parts for 2 complete phase change units (except for copper tubing and insulation), plus some extras, the
other contained 2 brand new Danfoss NF11FX compressors. :chit:
Build Specs: (everything X2;))
Danfoss NF11FX 3/8th HP Compressor
Chilly 1 Evap with Jinu braided flex line
"New Style" Chilly 1 mounts
.031 captube
Jinu's condenser
Xtreme Cooling Controller w/LCD (green lcd to match lcd in UFO pc case)
http://i8.photobucket.com/albums/a5/...regs-parts.jpg
At first I figured this would be a simple "assemble the parts and be done" deal...... that was before I got the tape measure out and found out just how much (or how little as it turned out) room I had for this project. Both phase units had to fit inside an area measuring 16"X 17" and the small measurement was front to back where I really could use more room. You can see in the pics with the compressors and condensers sitting in the case, just how much room there is with the front and back case fans..... very little room between the compressor and condenser. :scratch:
http://i8.photobucket.com/albums/a5/...d/P1010004.jpg
I grabbed a bunch of new 1/4" tubing and my trusty tubing benders and set out to try to fit some kind of subcooler coil in this system, after much trial and error (I have a lot of bent 1/4" tubing if anyone needs some ;)), I finally got it done.:thumbs: I am really pleased with the tubing; I felt with the small condensers and general limitation on build room that we really needed a subcooler coil with these units, and I really wanted it in the airflow from the condenser fans if possible. I made a cardboard template that fit in the bottom of the case and set the compressors and condensers in where they had to go and marked the mounting holes for them on the white cardboard. I could then take the cardboard out and use it on the workbench to do all the bending and tubing layout work. This was pretty nerve wracking work for me.... it had to be right the first time and there was very little margin for error..... it also had to look good and I wanted both sides to be as close as possible to each other. Anyway, here is the final tubing layout (with exception of flex lines, which will exit the rear of the accumulators).
http://i8.photobucket.com/albums/a5/...d/layout-1.jpg
http://i8.photobucket.com/albums/a5/...d/layout-2.jpg
http://i8.photobucket.com/albums/a5/...d/layout-3.jpg
I brazed the first unit together today and it's leak testing now, if everything is ok it will be vacuumed tomorrow and maybe an initial charge.
Brazed pics..
http://i8.photobucket.com/albums/a5/...d/brazed-1.jpg
http://i8.photobucket.com/albums/a5/...d/brazed-2.jpg
http://i8.photobucket.com/albums/a5/...d/brazed-3.jpg
Ok..... got the first unit all insulated today and decided to run the load tests. We had a target load of 200w max since Greg is running a dual core X6800 and plans on going to 45nm quad next; Plus the fact that with our limited space we were very marginal on condenser size.;) I was expecting app. -30c at 200 watt, at first that is about what I was getting when I initially charged the unit with r507. I had some r502 here that a friend had given me to try, I knew it had more capacity and would run lower pressure than the r507, so I decided to try it. I charged the unit to around 60psi static pressure with the r502, then started the compressor and tuned to load with propane. It turns out that mix worked very well, I got more capacity and lower temps than with either gas by itself. :D Anyway...... here are the load test results... enjoy:thumbs:
Temps measured at top of evap (runs around 5-6v colder than with probe in base), unit was run at least 30min at each load except for 235 watt, it ran it for at least an hour.
ambient 22c
idle -53.8c
100w -45.6c
150w -42.5c
200w -39.4c
235w -35.4c (never expected it to run this much load, that is max this load tester would do)
http://i8.photobucket.com/albums/a5/...emp-unit-1.jpg
http://i8.photobucket.com/albums/a5/...200w-unit1.jpg
http://i8.photobucket.com/albums/a5/...35w-unit-1.jpg