[Scratch Build] Phase Changer RIG.

[rakesh_sharma23]

Some Update:
First proud to inform

KINGSTON is supporting the project with some good Hardware.

Sorry for late update.
My father had a surgery, so all spare time goes in Hospital.
Still done some tit bit updates
Some real time temperature displays on place.




Some holes for Fans.




Front USB panel and hole for card reader.


Thanks

[LMB]

I have to go with Buckeye on this .

Ok ..... your building a custom computer in the phase change section with a thousand pics of a custom case build . Wonderful ! Is there a thousand pics of the actual phase unit ? Is there a condenser , compressor, oh ... maybe some refrigerant and a metering device? Is there any plans for that? You know ... the actual PHASE part of the build in the PHASE section of the forum .... ??

[rakesh_sharma23]

Yes i am working on collecting parts for Phase changer also You can see Post No. 14.
I am from a Small town and have a very low budget for this build.. so arranging all parts is taking some time.. Condenser and tubes are in.. will post some pics soon..

Main problem is to sourcing soild copper cylinder for evapo.. i am tring hard for it.. until then i just cant start to build the phase changer..

Rakesh Sharma

[rakesh_sharma23]

Sunday update:

Worked late night and finished all major holes creating work on the case and PSU holder plate also done.
Now in morning testing all fittings.

First some good Black M4 5/6 Screws for fan and Phase changer Controller installed ..




















The Phase changer controller can be programmed for ten preset settings.
I have set three settings.
One for max oc.. maintain lowest possible temperature.
Second -2 degree for normal OC
And finally 6 degree for normal working.
It will control the compressor and the condenser fan according to preset setting.




Now here comes my bad luck in action.
Controller is working fine . I have programmed it to start my test PSU at 40 degree C , which in turn start all four 140 fans.. cool..
But everything not went like this .
First mistake I selected same single color wires for all AC test wiring. (One must take different color wire for AC , line neural and earth ) then somehow I connected the main AC wires to the controller in such a way that it created a shot circuit better say a big blast and a black out in the house , as soon as I increased the temperature on the sense to 40 degree.
I have killed my brand new controller… Don’t have words to shout on myself
Even after two hours, one can sense a PCB burning type smell in whole house.









Very bad Sunday .. Anyhow tried some cable sleeve one few old Fans.. first time sleeve so please don’t mind it.



Rakesh Sharma

[rakesh_sharma23]

Thanks to Rex Liang from KINGSTON, for supporting my PC build.

[rakesh_sharma23]

Still waiting for evaporator.. mean while just done some new hardware test run and OC the i7-2600k with stock cooler on saturday night.. it was quite a fun.
Sabertooth P67 is a solid board when combined with Kingston Hyper X RAM i got some good result.... below is the best stable OC with Windows booting good and all my program running fine..

I was able to boot windows in safe mode at 5.7 ... hope to do some good OC with Phase Changer unit..



http://img196.imageshack.us/img196/9437/newoc2.jpg

Regards
Rakesh Sharma

[rakesh_sharma23]

Hello to all.. first sorry for a late update..

Due to some health issue, modding was on hold for me.. but I am fine now, and was working for two days to finish the evaporator. And happy to tell you all that, at last I have finished it.. and tested it under high air pressure for any leak… will be assembling the phase change soon.

Here are some pics before final polishing,





The bottom plate have 85% pure silver lining …



After polishing the evaporator is ready.





Made evaporator holding bracket from acrylic..







First I have painted the case, a mat black finishing by professional and received the case yesterday

So started assembling of phase changer unit..

From 5pm till 12 worked and assembled major parts.. rest will be finished by evening or night… hope for a test run of the unit today.
It was late in night do did’nt took many pics… but few are here , hope you all like the update.

[Gray Mole]

I had to interrupt my stuff working on coolers, just to have a read through your thread.

It's crude, but amazingly thorough and your use of hand tools defies imagining.

The use of MDF is creative, and in a way could be more interesting that any other material. It can be carved, sculpted, carpeted, virtually anything.

I thought at first you would weld the alu but to drill and tap is simply amazing.

The time it would take is something most don't have, but you're doing an amazing job.

I'm glad it's in the phase section honestly, case construction is a part of phase as much as anything else, though your method isn't what I'd use but it's really turning out well.

Chiselling out by hand...I can't even begin to think what it takes to get as clean a cut as you have. Like a savant from the stone ages, you're bringing it all.

That evaporator will be fairly terrible if it is what I think inside, but if you charge heavily it can compensate for a completely open design, and the high silver content should help a little. Did you at least 'Waffle pattern' the base inside? Even 'peening' it with a hammer to force a bit of swirl in there?

I haven't seen a hollow evap since the old VapoPE I had. But like I said, flooding it heavily will help to keep the liquid boiling on that base. If you can attach a probe to the back of that evap and the base, you'll see what I mean. The evap will be cold, but the base will likely be 30 to 40 warmer with a heavy load from the cpu. It's just the limitation of a large open evap.

But I have to say I've learned something and had a few inspirations from your work I'm having to modify and make new cases, but I have the luxury of Jig, Coping, Scroll, Table, Mitre and compound, grinders/cutters and most power and air tools. As well as welding equipment. And metal

Sorry if it's hard not to laugh but at the same time be so completely impressed with your stamina and dedication!

Keep going! I'd love to see how the phase works and the case looks when you get through it all


Gray

[Gray Mole]

Oh, and I would be VERY careful how much you tighten that plexi plate. It looks like 3/8" or less? Not strong.

Also you may find that the board could have caps or mosfets in the way of that plate. I'm not familiar with that one but I'd watch out for that. You can use a large 'C' clip or 2 so it's shimmed higher if it there is though.

[rakesh_sharma23]

So Here I am with first Test run of my Phase Changer unit.

Yesterday evening I have started working on the Phase changer.. till 9 PM I am finished all fitting and ready to fill gas a test run..

Since this is initial testing so I have not vacuumed the unit.. instead I have just flushed some gas through first and then just filled the R404a gas.. and started the unit.

Initial temp was good but fine tuning the capillary placement in the evaporator.. I was able to reach
-36C.. YES…COOL

Turned off the unit let it heat up to the ambient temperature.. Now again started the unit to check time used to reach a temperature .. for ambient to -36c in just 3 minutes.. and power consumption is just 0.4 amp …
(All analog and digital thermometer are calibrated in a Laboratory.)






























Not tested with 200W- 220v AC of thermal resistance .. At full load for more than ten minutes temperature remains to -32C.. …
Mind I have not vacuumed the unit (It takes about 2 + hours).. after that I hope to reach -40C.. will do vacuum afterwards.


Now assembling the PC together and insulating the evaporator.. it’s 1am so should have a sleep now..











Will update more soon..
Rakesh Sharma

[MaRtIe]

its not generally a good idea to have a solid suctionline due to compressor vibrations plus the possibility of a pipe fracture/cpu failure. looks like you may have a few issues with floodback looking at the pipe routing.

That filter is upside down too, i would have had it coming out the other outlet on the condensor and reverse that filter so that the captube is at the bottom, not top.

Nice build though and very inventive case. must have taken some time to build i know how long it takes to drill and tap holes straight, it's a nightmare.

Well done

[Gray Mole]

Well that is a really small compressor. I can't find a spec on it based on that number though.

Some of the really tiny compressors wouldn't vibrate a lot but I still wouldn't like to have it solid. A cpu can get damaged, pins can get damaged. It's going to be very cold, and any vibration isn't going to help.

Captube would be a lot better wrapped around the line. Any help in subcooling is good and it would also help the liquid vaporise on the way back.

I see filters up in window AC units, portable ac units, and they work. We put them down because it's a bit better for what we do, but at the same time, holding to the theory that it's not liquid going into the captube, it's gas, then it could make no difference at all. Not saying it isn't, just that my own testing points to it being mostly gas there, and developing into liquid further into the captube.

But it's not bad. it works, in fact and that's something we were all just a little curious about

We'll see if it's charged enough for the cpu yet. I think it won't be but not by too much under load.

You're doing really great though keep it going!

Gray

[Gray Mole]

Something I do want to add. Your line (suction) going up to the Evap. Try to bend the pipe so that it's pointing a bit more down from the compressor before it goes up.

Everytime you run it, and then shut down, it will collect oil in that line. It will then all drain down into the intake port. So when you start the compressor it's going to be fighting a lot of oil.

If you bend it down so it's got that small area of the line to 'store' that oil in, it will be much better for the compressor.

A full 'J-bend' would be better, but just a better angle so it's got a place to be and not all the way back into the compressor.


Gray

[rakesh_sharma23]

Nice feedback from you all guy.. Thanks.. this is my first phase change build... got to learn a lot...
I am from small town...tried hard to find a flexible suction tube... but cant find one.. so tried with a solid tube..

As per compressure.. it is a laboratory grade compressure used in some lab equipment...

Hope to follow all suggestion.. but first i want to test some overclocking..

Some More update...

Insulated the mobo...(Still waiting for i7-2600K from RMA)..



















Have to purchase a GFX.. and a good one...

Hope all are enjoying the build same as me.

Rakesh Sharma

[Gray Mole]

Found it!

Had to look on Tecumseh India's site but it's a 4cc compressor. Bit enough to do the job, but small enough that it's vibration should be miniscule. You'll know as you use it, but I'd be inclined to check how much vibration. You've got a long (1/4"?) pipe with 2 bends, which should take up a lot of that vibration as well.

I'm really looking forward to how it goes. Your temps seem right on the money for that compressor unloaded though I think you will need a bit more charge if you up the voltage and clocks.

Looking forward to when the rest of your HW arrives, see what your cooler can do

Gray

[rakesh_sharma23]

Yes Sir, Compressor is same..but i am using R404a
This is the best i can get at my place and under my budget... but for beginners like me... this is good start. (i think so)...

As per vibration .. it is not too much right now ... but lets see what can be done later...

Thanks for your kind feed back..

[Gray Mole]

Considering your use of a solid suction, a low vibration 4cc compressor is probably a better idea. Temps won't be spectacular but it should hold the load you're after.

As well, SB's are a good cpu for higher temps. I really hope it works out, it would be something to see, having a decent overclock with it

Now that the case is so close to it's finished state, I'm actually starting to like it I'm hopeful for your cooler, how soon is Mr. Sandy coming back to town?

[rakesh_sharma23]

Thanks for showing some confidence in my build...
CPU was dispatched yesterday, may reach with in one or two days...

Searching for a (for Sale) good GFX card.. new one is too expensive for me.. low budget...

Will update more soon..

[MaRtIe]

looking good, cant wait to see it in action now
is the case going to have side panels or going for the open look?

the center shelf where the suction line goes though looks like it's packed well and probably would take some of the vibration that would be there i guess?

[rakesh_sharma23]

More Updates
RAM Cooler

















Adding Handles







Some Cable Managament..






Some OC..




Evaporator at -36c, CPU socket backside at -23c..




5.2Ghz. it was easy..

Now have to refill the Phase changer for better temp..

Will do more OC till Sunday..

Rakesh Sharma

[rakesh_sharma23]

Fan grills Installed...

[MaRtIe]

impressive temps there rakesh, well done mate

[rakesh_sharma23]

Hello to all.


After four months off from Pc modding Now iam fine and back in action.
Made some insulation fixtures for Phase changer unit.
Added another controller SMPS Pcb.
Some cable management.
Added handmade power/restart switches and knobs
Installed all Hardware..
Just making of side panels are left…. Will have to wait more ( give health some more time ) before going for heavy modding.


Enjoy pics..
Thanks
Rakesh Sharma

[Buckeye]

Nice work man, looks very good !