AIRCHILLER + Single-stage (worklog)

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04-24-2009, 03:19 PM
piotres

AIRCHILLER + Single-stage (worklog)

Hi

Mine next project - rather won't be boring like all 2 stagers :D- it'll be cooling chamber (to put inside mobo + all other stuff, except hdd and psu ;) ) plus SS , all on one plate ...

Specs :

Compressor: two Danfoss SC18CL - one for airchiller, one for SS
Evap for SS: Steeper 40mm tall/42 mm diam., enclosure for all newest CPUs, 1.0 meter braided DN10 suction line (with
stainless steel mesh)
Evap for airchiller : Evaporator from split A/C unit
XV: captube 0.9 mm for SS, Alco TI-HW for airchiller
Condensor: two 1.9 kW + 254 mm fans
Refrigerants : R507 in both
Case : custom made, welded frame, custom perfored side panels, all powdercoated on black color, wheels.
Chamber :HARD moded Ladycook small fridge
Others: Control panel on top of chamber (switches for both SS and airchiller, switch for PC), Danfoss controller for airchiller, Frigomec 0.88l receiver.

http://www.piotres.boo.pl/chamber/1.jpg

http://www.piotres.boo.pl/chamber/2.jpg

http://www.piotres.boo.pl/chamber/3.jpg

http://www.piotres.boo.pl/chamber/4.jpg

Bone stock frigde ...brand new ... :up:.
http://www.piotres.boo.pl/chamber/5.jpg

http://www.piotres.boo.pl/chamber/6.jpg

http://www.piotres.boo.pl/chamber/7.jpg

http://www.piotres.boo.pl/chamber/8.jpg

http://www.piotres.boo.pl/chamber/10.jpg

http://www.piotres.boo.pl/chamber/11.jpg

http://www.piotres.boo.pl/chamber/12.jpg

http://www.piotres.boo.pl/chamber/13.jpg

http://www.piotres.boo.pl/chamber/14.jpg

http://www.piotres.boo.pl/chamber/15.jpg

http://www.piotres.boo.pl/chamber/16.jpg

Some reduction on parts used in frigde :ROTF:.

http://www.piotres.boo.pl/chamber/17.jpg

http://www.piotres.boo.pl/chamber/18.jpg

http://www.piotres.boo.pl/chamber/19.jpg

Mine new welding machine- MIG/MAG Esab C250 3ph . :up:

http://www.piotres.boo.pl/chamber/20.jpg

http://www.piotres.boo.pl/chamber/21.jpg

Mine father helped me with welding a bit and later with grinding :clap: .

http://www.piotres.boo.pl/chamber/22.jpg

That was only 4 fun ...just a try on trash piece of metal :rofl:.

http://www.piotres.boo.pl/chamber/23.jpg

http://www.piotres.boo.pl/chamber/24.jpg

http://www.piotres.boo.pl/chamber/25.jpg

http://www.piotres.boo.pl/chamber/26.jpg

http://www.piotres.boo.pl/chamber/27.jpg

http://www.piotres.boo.pl/chamber/28.jpg

http://www.piotres.boo.pl/chamber/29.jpg

http://www.piotres.boo.pl/chamber/30.jpg

http://www.piotres.boo.pl/chamber/31.jpg

http://www.piotres.boo.pl/chamber/311.jpg

Fridge got small accident and had must been painted ...so paint is fresh high gloss black acryl :yepp:).

http://www.piotres.boo.pl/chamber/312.jpg

http://www.piotres.boo.pl/chamber/32.jpg

http://www.piotres.boo.pl/chamber/33.jpg

http://www.piotres.boo.pl/chamber/34.jpg

http://www.piotres.boo.pl/chamber/35.jpg

http://www.piotres.boo.pl/chamber/36.jpg

http://www.piotres.boo.pl/chamber/37.jpg

http://www.piotres.boo.pl/chamber/38.jpg

http://www.piotres.boo.pl/chamber/39.jpg

http://www.piotres.boo.pl/chamber/40.jpg

I decided to weld suction line holder for more safety :yepp:.

http://www.piotres.boo.pl/chamber/41.jpg

http://www.piotres.boo.pl/chamber/42.jpg

http://www.piotres.boo.pl/chamber/43.jpg

http://www.piotres.boo.pl/chamber/44.jpg

http://www.piotres.boo.pl/chamber/45.jpg

http://www.piotres.boo.pl/chamber/46.jpg

http://www.piotres.boo.pl/chamber/47.jpg

http://www.piotres.boo.pl/chamber/48.jpg

http://www.piotres.boo.pl/chamber/49.jpg

http://www.piotres.boo.pl/chamber/50.jpg

http://www.piotres.boo.pl/chamber/51.jpg

http://www.piotres.boo.pl/chamber/52.jpg

Clear coat this time also :).

http://www.piotres.boo.pl/chamber/53.jpg

http://www.piotres.boo.pl/chamber/45.jpg

http://www.piotres.boo.pl/chamber/54.jpg

http://www.piotres.boo.pl/chamber/55.jpg

http://www.piotres.boo.pl/chamber/56.jpg

http://www.piotres.boo.pl/chamber/57.jpg

http://www.piotres.boo.pl/chamber/58.jpg

http://www.piotres.boo.pl/chamber/59.jpg

http://www.piotres.boo.pl/chamber/60.jpg

First time I've must use ladder when I build cooling system :ROTF:.

http://www.piotres.boo.pl/chamber/61.jpg

http://www.piotres.boo.pl/chamber/62.jpg

http://www.piotres.boo.pl/chamber/63.jpg

http://www.piotres.boo.pl/chamber/45.jpg

http://www.piotres.boo.pl/chamber/64.jpg

First tests, temperature inside chamber without any fans mounted.

http://www.piotres.boo.pl/chamber/65.jpg

http://www.piotres.boo.pl/chamber/66.jpg

Here with two 120mm - nice gain :D.

http://www.piotres.boo.pl/chamber/67.jpg

http://www.piotres.boo.pl/chamber/68.jpg

http://www.piotres.boo.pl/chamber/69.jpg

http://www.piotres.boo.pl/chamber/70.jpg

I was pumping hot air inside chamber from hairdrier working at 1st speed and taking over 700W energy - during 30min test temperature moved from -31*C (I've wait long, for lowest temperature) till -10 C - thermal probe was mounted in piece of cooper put inside chamber. It's not final .

http://www.piotres.boo.pl/chamber/71.jpg

http://www.piotres.boo.pl/chamber/72.jpg

Some heavy piece of brass inside - that's tip from future owner of this unit to use big pieces of cooper (but I don't have it, only brass) as a "cold magazine" .

http://www.piotres.boo.pl/chamber/73.jpg

http://www.piotres.boo.pl/chamber/74.jpg

Probe inside small cooper piece (don't have bigger :( ).

http://www.piotres.boo.pl/chamber/75.jpg

That's what we should say "ARCTIC FAN" :rofl:.

http://www.piotres.boo.pl/chamber/76.jpg

That's loadtest of SS loop - make -40C@260W but I don't think that's most important part of this unit :p:.

Regards
Peter
04-24-2009, 11:31 PM
biglipzit

Wow very impressive as usual piotres! I wonder if the board in the airchiller will be affected by condensation at all. I love -40 at that load on a SS. You are the chiller god!
04-25-2009, 04:52 AM
quintus

Hi piotres,
Just an ideea: the enclosure of the hole setup shoud be purged with CO2 or N2;)
What about the hdd and dvdrw and psu, what are the plans?
regards,
q
04-25-2009, 02:53 PM
biglipzit

Its a refrigerator... I doubt that is has the sealing air tight capabilities to do so and when benching, to do anything you will have to vent the gas out. Won't be worth it. Just have to run it for a while before putting equipment in to ensure ample humidification. Probably worth setting up in a dehumidified room.
04-25-2009, 04:53 PM
sdumper

Love the work and attention to detail ... but am wondering how your going to condensation proof the mobo, psu, videocard ect...also wondering how it will perform with a hot video card inside and psu inside. I think my 4870x2 is much hotter than a blow drier...

Cant wait to see it tested with live equipment its going to be very cool ... yes the PUN was intended :)

Again wonderful work!!
04-26-2009, 01:33 AM
t800

Since im getting this unit, i give some answers :)

Quote:

Originally Posted by [cTx]biglipzit

Its a refrigerator... I doubt that is has the sealing air tight capabilities to do so and when benching, to do anything you will have to vent the gas out. Won't be worth it. Just have to run it for a while before putting equipment in to ensure ample humidification. Probably worth setting up in a dehumidified room.

Quote:

Originally Posted by sdumper

Love the work and attention to detail ... but am wondering how your going to condensation proof the mobo, psu, videocard ect...also wondering how it will perform with a hot video card inside and psu inside. I think my 4870x2 is much hotter than a blow drier...

Cant wait to see it tested with live equipment its going to be very cool ... yes the PUN was intended :)

Again wonderful work!!

- Actually good fridges are airtight and reason why they get frost is because ppl will open and close fridge door. And if some reason it would not be airtight, i have some ideas in my pocket to make it air proof.

- Unit is for daily use :)

- Of condensation, i will use many silica gel moisture bags to remove moisture (eg one bag is capable remove moisture from 1..1.5 cubic meter of air). Basically i put parts inside (in dehumidified/very low moisture room) , tens of gel bags and then do several test runs (only compressors are turned on, not computer) and let bags to catch the moisture. No moisture, no condensation

-4870X2 is far away from hairdryer, it produces about 300w heat. But even -45c air temprature, gpu's wont be below 0c under load, due air temp condictivity is bad...but freezer gives possibility to run 4870X2 fan very high rpm due lowers the incoming noise from fan, what normally is way too much :)

-PSU,HDD,DVD will stay outside of system.
04-26-2009, 04:58 AM
EvoCarlos

it looks great i must say but

as for the frost
our home fridge has a fan so one opened and closed the air is sucked out by the fan as if to create a vacuum in the case maybe you could do something like this?

would be easy to set up just a fan with a rubber flap on the back so when the fans off the rubber flap seals it shut
04-26-2009, 05:36 AM
Sink

Vacum are bad if you want the air to cool something down really.
04-26-2009, 12:10 PM
piotres

Please nottice that on few last picutres there is a lot of frost inside because I've been pumping hot air by hairdrier inside the chamber for 30 minutes ;).
04-26-2009, 04:26 PM
biglipzit

Quote:

Originally Posted by piotres

Please nottice that on few last picutres there is a lot of frost inside because I've been pumping hot air by hairdrier inside the chamber for 30 minutes ;).

Oh yeah that would do it. I am sure it will work great, even for everyday use. Once it is setup and running there won't be much need to open the fridge. Should be pretty neat. Can't wait to see what performance will be like when it is all up and running with the PC inside.

Keep us posted!
04-27-2009, 01:50 AM
quintus

The fridge is air tight enought.
I think will work fine just having a CO2 botle of say 2 liters, open it up and blast the enclosure, purge all air outside, when you set up the system or when u open up the door for dealing with the hardware...and u will have 0 humidity;) silicagel cant remove all water from air;)
04-27-2009, 03:55 AM
t800

Quote:

Originally Posted by quintus

The fridge is air tight enought.
I think will work fine just having a CO2 botle of say 2 liters, open it up and blast the enclosure, purge all air outside, when you set up the system or when u open up the door for dealing with the hardware...and u will have 0 humidity;) silicagel cant remove all water from air;)

I think with silica gel packs i can remove most of water from air (i hope so), that rest is just so minor that it can't do any harm (we are talking 1~ gram).

Of course if this method is not sufficient, then replacing air with co2 or nitrogen is only solution.
04-27-2009, 01:54 PM
piotres

Sorry pics should be working again tomorrow - I've reached limit for transfer for basic web account (3.4GB sucked from http in 12 days by You (mounthly limit is 3gb) :D- thanks a lot people :P - really I'm happy that so much people look at mine topics) so I must have upgrade for plus account which should be active tomorrow.
04-28-2009, 05:13 PM
one_servant

Rock and Roll Peter. Keep up the great work. I look forward to seeing where this goes.
05-04-2009, 03:56 PM
piotres

More photos, unit is nearly finished :

http://www.piotres.boo.pl/chamber/77.jpg

http://www.piotres.boo.pl/chamber/78.jpg

http://www.piotres.boo.pl/chamber/79.jpg

http://www.piotres.boo.pl/chamber/80.jpg

http://www.piotres.boo.pl/chamber/81.jpg

http://www.piotres.boo.pl/chamber/82.jpg

http://www.piotres.boo.pl/chamber/83.jpg

http://www.piotres.boo.pl/chamber/84.jpg

I've added 4 pcs of 80mm fans behind the evaporator - to mount them I had must cut hole in back of fridge which later I've covered with styrofoam and new cut piece of steel plate. I couldn't mount fans before evaporator because in that way motherboard with long GPUs can't be put inside chamber (too little space) .

http://www.piotres.boo.pl/chamber/85.jpg

Testing Rig.

http://www.piotres.boo.pl/chamber/86.jpg

Noloaded I've reached nearly -49.5C air temperature inside chamber :D (I haven't shooted that on photo, only -48.2C) .

http://www.piotres.boo.pl/chamber/87.jpg

From that temperature I started load testing - pumping hot air throught 30 mintes produced by hairdrier (taking over 700W from 230V) by hole for cables on back of fridge .

http://www.piotres.boo.pl/chamber/88.jpg

http://www.piotres.boo.pl/chamber/89.jpg

Big brass block (that round one) temperature after 30 minutes loadtest (remember - over 700W) .

http://www.piotres.boo.pl/chamber/90.jpg

And same but measured by small cooper block .

http://www.piotres.boo.pl/chamber/91.jpg

http://www.piotres.boo.pl/chamber/92.jpg

SS unloaded.

http://www.piotres.boo.pl/chamber/93.jpg

SS loaded with 260W after 1 hour test .

Now unit is standing for next 2-3 weeks for testing if it's leak free for sure (of course leak detector sprays haven't showed any leaks but I must be sure), after that - packing & shipping :).

Regards
Peter
05-31-2009, 01:25 PM
piotres

Hello

Unit is already 100% completed :

http://www.piotres.boo.pl/chamber/94.jpg

Finaly, small cooper block after temperature (so also air temperature inside chamber) pumping hot air by hairdrier (30 min test) - start of test was from -43*C.

http://www.piotres.boo.pl/chamber/95.jpg

Big brass block after same test .

http://www.piotres.boo.pl/chamber/96.jpg

Then I start some real loadtests ;)

http://www.piotres.boo.pl/chamber/97.jpg

http://www.piotres.boo.pl/chamber/98.jpg

http://www.piotres.boo.pl/chamber/99.jpg

http://www.piotres.boo.pl/chamber/100.jpg

http://www.piotres.boo.pl/chamber/101.jpg

http://www.piotres.boo.pl/chamber/102.jpg

http://www.piotres.boo.pl/chamber/103.jpg

http://www.piotres.boo.pl/chamber/104.jpg

http://www.piotres.boo.pl/chamber/105.jpg

http://www.piotres.boo.pl/chamber/106.jpg

http://www.piotres.boo.pl/chamber/107.jpg

http://www.piotres.boo.pl/chamber/108.jpg

http://www.piotres.boo.pl/chamber/109.jpg

http://www.piotres.boo.pl/chamber/110.jpg

http://www.piotres.boo.pl/chamber/111.jpg

http://www.piotres.boo.pl/chamber/112.jpg

http://www.piotres.boo.pl/chamber/113.jpg

http://www.piotres.boo.pl/chamber/114.jpg

http://www.piotres.boo.pl/chamber/115.jpg

And that's all, unit is 93kg, total pack weight is 157 kg without palette . As You can see packing is heavy, but it must be heavy to be safe .

Regards
Peter
05-31-2009, 02:00 PM
Duniek

ladycook overclocking lol
great job Peter
05-31-2009, 02:01 PM
tiborrr

1-5-7kg! :O

Respect Peter! :D
05-31-2009, 02:32 PM
sdumper

Nice house too...oh and yes the unit looks like its mass produced by a factory very very professional in appearance much respect!!
05-31-2009, 04:03 PM
SexyMF

Unit looks good but I suspect it will be a motherboard killer due to condensation.
05-31-2009, 04:11 PM
sofos1990

Congrats piotres this is a innovative construction:D
06-02-2009, 10:13 AM
Rise

that is awesome, i love seeing *inside the box thinking ;)
06-02-2009, 01:25 PM
eligray

Very great looking and innovative system there Piotres :)

And to Rise: Condensation will not be an issue I'd imagine. Most would form on the evap anyways. And the Silica will get it out of the air pretty well.
06-02-2009, 01:32 PM
systemviper

Wow you do great work, love the ladder to access the project.

I just love innovation, and that's what you keep pumping out,

Top NOtch!
10-05-2009, 11:16 AM
t800

Okay, After months of tuning & testing finally so small results available of this cooler. Currently bit different look of cooler

http://img49.imageshack.us/img49/9456/33004734.jpg
http://img261.imageshack.us/img261/1183/67688941.jpg

Added sound insulation and rerouted aircirculation inside of compressors, eg air is doing S loops before getting out and walls are insulated with bitium + softcells. Currenly doing 55-60db from 2m away (using iphone as meter :P)

Also controlbox added quickswitch for resetting cmos..eg holding switch does reset. The fridge door is sealed with silicon and havind side bolt+screw lock system that door is not opened by accidently.

Before closing door:
http://img410.imageshack.us/i/img0243k.jpg/
http://img202.imageshack.us/img202/2246/img0245.jpg
http://img96.imageshack.us/img96/1962/img0248w.jpg

Air inside is circulating from behind blowed with fans end of fridge (door), and there is goes behind mobo (eg where all wires are) back to evap.

Small results with set to keep air 0+ to -15c ...takes 15mins to cool down and 10mins to cool back to -15c.

Result after running 30mins of 3Dmark03 NatureTest
http://img124.imageshack.us/img124/387/1pic.png
idle
http://img202.imageshack.us/img202/1676/img0252.jpg

And finally, the myth of condensation, does it exsist? Simply no..i have opened door during run, no water visible and during run haven't have any symptons of condensation failures so far.

In future pushing more cold (-40c) and see what happens :)
10-05-2009, 07:36 PM
eligray

Great to see!

I'd imagine that the little amount of water in the air will mostly condense on the evaporator.

:)

edit: how thorough of an insulation job did you give the socket area?
10-06-2009, 12:02 AM
SexyMF

Quote:

And finally, the myth of condensation, does it exsist?

Well, for your tests inside your house you are ok for the moment. But dew point is entirely calculable and very real.
10-06-2009, 01:38 AM
t800

Quote:

Originally Posted by eligray

edit: how thorough of an insulation job did you give the socket area?

Just by bluesticker around socket surface and pressing evap "armaflex circle" tightly against it.

Quote:

Originally Posted by SexyMF

Well, for your tests inside your house you are ok for the moment. But dew point is entirely calculable and very real.

Hmm, what's your point?
10-06-2009, 02:38 AM
zipdogso

It is a moot point as you don't appear to be having condensation problems anyway but you might be interested in using molecular sieves (it is granular like small gravel. I can get it easily here in UK.) instead of silica gel so long as you can pass the air through the stuff with a fan it will remove more water than silica gel and get you as near as 0% humidity.

it is said that due to the composition of air it is impossible to achieve 0% Rh you will always have between 1% - 3% Rh. Only gas purging gets 0% Rh.
10-06-2009, 02:48 AM
cooling storm

that unit was nice. how much did it cost to build.
10-06-2009, 06:11 AM
t800

Quote:

Originally Posted by zipdogso

It is a moot point as you don't appear to be having condensation problems anyway but you might be interested in using molecular sieves (it is granular like small gravel. I can get it easily here in UK.) instead of silica gel so long as you can pass the air through the stuff with a fan it will remove more water than silica gel and get you as near as 0% humidity.

it is said that due to the composition of air it is impossible to achieve 0% Rh you will always have between 1% - 3% Rh. Only gas purging gets 0% Rh.

Yes of course i can't never reach 0% Rh in chamber with gel bags, but currently amount "water",inside chamber is so small that i highly doubt it can create damage to hardware.

Quote:

Originally Posted by cooling storm

that unit was nice. how much did it cost to build.

pm Piotres

Quote:

Originally Posted by MeltedDuron

WTF, why do so many people take great pride in destorying and messing with bits of art work and pure skilled work. Peter made it do the job and everything and now look at it! Yuck, sorry man

Destroying? Mainly visible changes are side plates from metal to plastic plates + visible silicon doors. But anyway this wasn't "open the box & use" cooler, than rather most SS/Cascades are. Yes of course i could see lot of effort make everything nice, but due i needed to open fridge several times -> add silicon again and again, you are not always so excited to do it nice & clean.
10-06-2009, 08:32 AM
trance565

should put a shrader valve on the fridge next time, see if it holds vacuum without the silicon :) that and you can vacuum and purge
10-06-2009, 12:20 PM
SexyMF

Quote:

Hmm, what's your point?

You said your unqualified comments like condensation in the fridge arrangement doesn't exist. People don't build this type of setup because you are just asking for trouble. It's working for you at the moment - but with conditions attached (like, country, time of year, household air-con etc etc)
10-06-2009, 12:42 PM
t800

Quote:

Originally Posted by SexyMF

You said your unqualified comments like condensation in the fridge arrangement doesn't exist. People don't build this type of setup because you are just asking for trouble. It's working for you at the moment - but with conditions attached (like, country, time of year, household air-con etc etc)

Those conditions hasn't nothing do with this system due it is sealed.
10-06-2009, 01:31 PM
quintus

I would purge the fridge with anything like: argon, nitrogen, co2... Just to be 100% sure.