Goliath Triple Cooling System

[Sweeper]

I’m starting this thread to share my experience of building a custom cooling system and hope with the help of some of the expert builders on this site, I can accomplish this difficult task. I’ve been a member for a long time and I’ve read many threads that inspired me to put my skills to work. My primary skills are in metal work, welding, electronics and I’m learning about refrigeration, which I hope the members on this site can help me through some troubled times during the build. So, I decided to build a mixture of systems that are discussed on this website. There will be documented pictures throughout the build and I ask that members be patient, because this system will not be built in a few days. I have been planning this for about a year and purchased many parts during that time.

Now, its time to put it all together!

I’m sure some of you are wondering what will be involved in this build. Let me say this…. Everything will be custom made, all metal work for the case will be fabricated from stock aluminum metal, all water blocks, distribution manifolds and reservoir will be made from copper stock. The only thing that will not be custom, will be the compressors and electrical components. With that said, here is a list of things to look forward to in this build.

1. The custom case is fabricated from aluminum and will be designed to house three cooling systems. This case is very large 48” W x 48” H x 18” D. This will not be something you can put on a computer desk.

2. There will be two ½ HP compressors with R507 refrigerant cooling two different systems. I’m hoping to get the temps down to around -40 for each system.

3. The first cooling system will cool down a low temp heat transfer fluid to -40 that will remove heat from the CPU and two video cards. Each component will have separate cooling loop.

4. The second cooling system will cool down a custom air tight chamber, which the motherboard, CPU and video cards will be mounted. The idea is to keep the air inside down to -40 and not have to insulate any of the components. Also, the ram and chipset will be cooled by the circulating -40 air in the chamber.

5. The third cooling system will be a water loop outside the cooling chamber that will cool four hard drives, due to hard drives do not operate well under low temperatures.

6. The cooling blocks will be designed for maximum flow of heat transfer fluid under 150 PSI. The high pressure fluid will move through the cooling blocks rapidly removing heat from the components. Needless to say, there will not be any rubber hose and clamps in this build.

These are the highlights of the custom build and there will be a lot more to come. I know similar systems have been done on this website and others, but I’m sure everyone will be interested in knowing how “Goliath” will turn out.

[knightwolf654]

i cant wait to see it!
might want to add a dehumidifier just in case.

[n00b 0f l337]

Trust me the air cooler will act as a dehumidifer, when its off he'll need a water pan. As for a single 1/2 hp compressor (generalizing on size wont help you either) to get -40C with a 600-700 watt load, you might have some problems

[knightwolf654]

then again all if the case is ait tight you would continue to recirculate the same air over and over again. which you would only need to remove the water once. but since he is using two 1/2 HP compressors wouldent the A/C one take away half the heat. i'll go do some math when i get home

[Sweeper]

I'm thinking along the same line....the compressors are rated at low temp -40. The receiving tank and distribution block for the liquid loop is mounted inside the cooling chamber. So, I'm thinking the two systems should stay around the same temps, because each system will be cooling in the same sealed space. I guess we will find out!

I've completed the case structure and most of the water blocks for the liquid loop. I will be posting pictures within a few days. I'm currently mocking up the case for installation of the components. Lot of prep work involved to make sure everything fits in the right place.

Thanks for the replies!

[[XC] gomeler]

This will be very interesting. I've got my fingers crossed that you can complete, a few people have refrigerated chambers like what you speak of for benchmarking, hope you can pull it off

[Sweeper]

Thanks for the vote of confidence! I had a little extra time tonight, so I will start by posting a few picture.



The case is starting to take shape, but still has a lot of work to finish.



Notice the metal texture, once it is painted ( ice blue ) it will look like frozen water drops.



The evaporator coil for the cooling chamber.



The plate heat exchanger for liquid cooling loop....its should be big enough.



The liquid receiver with a Y strainer.

Well, this it for tonight. I will post more tomorrow.

[knightwolf654]

what else do i spy! one massive pump!!!
got to say you crazy! cant wait to see the end result!

[[XC] gomeler]

Love the polished copper and the attention to detail on those welds

[TopherTony]

Yeah, that is some awesome brazing. Did you use anything before brazing to keep it shiny, or just polish after wards?

Do you have your compressors yet? What kind are they? Are you using txvs or cap tube?

Looking great so far.

[Sweeper]

Yeah, the pump will not be problem with this system. It is capable of pumping 330 gph at 250 psi. As far as the brazing....the main thing in welding or brazing any metals is cleaning before welding. The polishing of copper after brazing is a old method of dipping, instead of hand polishing for hours. Dipping cleans inside and outside of the copper, polishing only cleans the outside to make it shiny.

I do have the 2200 BTU compressors " Tecumseh " and 98% of all components to complete the system. I will be using TXV's and alot more goodies for the refrigeration system.

I will post more pictures tonight.

[Sweeper]

Below is few more pictures....enjoy!



Massive pump that is rated for 330 gph at 250 psi.



Distribution block milled from a soild bar of copper. This will have three individual lines to the CPU and two video cards. All my copper blocks are milled with a manual mill, so they take alot of time to make.



Distribution block side view.



Distribution block with 1/2" thick clear lexan window to view the flow of liquid.

Now, I must get back to work, still have a lot to do.

[[XC] mysticmerlin]

Looking good, Sub'ed

[Zytek_Fan]

This is something CyberDruid would do...

[[XC] 2long4u]

Why did you use copper for the distribution block? You could have used brass, cheaper and easier to machine. You even could have used a 2" thick piece of clear plastic. You wouldn't have to worry about it cracking since everything will be the same temp. Great work by the way!

[n00b 0f l337]

Wow very clean work!

[[XC] riptide]

Subscribed. This looks good.

[Sweeper]

I'm working on the condensers for the refrigeration cooling cycle. I know this may be a little over the top...but, I like to go to the xtreme with everything. Someone ask why use copper for my distribution block...well, because I have lots of copper bars in my shop and brass bars are almost as expensive.

Below are few more pics...



Two condenser coils that will be joined together for better cooling.







I think the condensers fit well in the case and should do a great job to cool down the high pressure gas. I will have 6 fans on each condenser and they are rated at 175 cfm each for a total of 1050 cfm. Now that is some cooling power

[Starkiller42]

*Drools

That's gonna be one sweet project, dude!

My one concern is your use of Lexan as a block top; I heard stories of it becoming very brittle at -30*C or so, even though it can supposedly handle -40*C. YMMV.

[TopherTony]

Wow, you are at home in these forums. Xtreme is right. This is insane.

What is that hanging bracket for?

[DetroitAC]

Nice work so far Sweeper, mind showing me the other side of those condenser coils so i can see the circuiting, might be able to offer some advice there.

I also think you will not be able to hold the CPU and two video cards at -40C with a 1/2hp compressor, maybe but do you know the heat output from the cpu and cards? Since you'll be using a chiller loop, you might think about using some of the cooling power of the 2nd compressor to help.

You will likely have to have some sort of defrost controls or other scheme for the air evaporator. If you pull down from ambient to those temps, the core would get a bit frosty. I'm not sure though, if it's well sealed to air infiltration it might be OK.

How are you going to insulate the cooled space?

[Sweeper]

StarKiller, Lexan has a low temp rating of -60 and shouldn't have any problem with the temps in the cooling chamber. The view window for the cooling chamber will also have 1/2' Lexan.

TopherTony, The brackets are to hold the liquid receiver in place....scroll up to the pictures, you can see that it is huge and is heavy.

DetroitAC, The picture you requested is attached. I don't see much that can be changed....but, I could be wrong. I have some concerns about the 1/2 hp compressor keeping up with the amount of heat the CPU and two video cards put off. But, I have a back up plan if the compressor cannot keep up. I've designed the case to be able to house a phase exchange for the CPU if needed. I'm tring to keep the project running with 110V power. Larger compressor means higher voltage and less room in the case. I also have a couple of inline heat exchangers for the suction line, if the condensing coils can't remove the heat.

Think I have a plan to make this project work.....but, only time will tell. I'm sure as this thing starts to come together, I will need a lot of help from you guys and I will greatly appreciate it.

[BNDMOD]

Suscribed... very impressived...

[DetroitAC]

Nicely circuited for condenser coils. The airflow should go in the face with no side-flange overhang, and out the face with side-flange overhang. Refrigerant in the top-most port, jumper between coils from the two ports that are close to each other, and liquid out of the bottom port. That'll put the refrig. to air delta temperatures the best way. This looks like exactly what you were planning, so maybe this isn't any news. Just thought it might be nice to get a second opinion

[Sweeper]

DetroitAC, thanks for the advice. That was the plan for setting up the condenser coils, but I don't understand what you mean by the fan installation.

Checkout the picture below...this is what my plan is for the installation of the fans. The picture doesn't show the aluminum shroud that will be fabricated for mounting the fans. Which air direction is better? Air being pulled through the coils or air being blown through the coils? I think it doesn't matter which direction....what do you think?