Look Ma No Rads!!!

[utnorris]

Ok, so I will be posting my new chiller build here this week. I have been working on it for over a month and I am about done. Basically I had a top notch water cooling system in a MM UF2O case with pedestal and decided to go chilled. Here are a few pics of my old system:

http://img120.imageshack.us/img120/259/img1344ww1.th.jpg (http://img120.imageshack.us/my.php?image=img1344ww1.jpg)

http://img98.imageshack.us/img98/6083/img1362sp7.th.jpg (http://img98.imageshack.us/my.php?image=img1362sp7.jpg)

http://img401.imageshack.us/img401/7213/img1346xt1.th.jpg (http://img401.imageshack.us/my.php?image=img1346xt1.jpg)

http://img98.imageshack.us/img98/3466/img1356lv7.th.jpg (http://img98.imageshack.us/my.php?image=img1356lv7.jpg)

http://img509.imageshack.us/img509/2632/img1352bx6.th.jpg (http://img509.imageshack.us/my.php?image=img1352bx6.jpg)

http://img509.imageshack.us/img509/4435/img1350tb5.th.jpg (http://img509.imageshack.us/my.php?image=img1350tb5.jpg)

http://img399.imageshack.us/img399/6420/img1354bf3.th.jpg (http://img399.imageshack.us/my.php?image=img1354bf3.jpg)

http://img201.imageshack.us/img201/9495/img1327pn6.th.jpg (http://img201.imageshack.us/my.php?image=img1327pn6.jpg)

http://img201.imageshack.us/img201/4048/img1335nk5.th.jpg (http://img201.imageshack.us/my.php?image=img1335nk5.jpg)

http://img201.imageshack.us/img201/6641/img1340dw7.th.jpg (http://img201.imageshack.us/my.php?image=img1340dw7.jpg)

[utnorris]

I don't have a pic of the AC before I tore it apart, but it looked just like any other window AC. I pulled the casing off of it and this is what I had to work with:

http://img296.imageshack.us/img296/3395/img1415zn6.th.jpg (http://img296.imageshack.us/my.php?image=img1415zn6.jpg)

http://img147.imageshack.us/img147/971/img1411gc8.th.jpg (http://img147.imageshack.us/my.php?image=img1411gc8.jpg)

http://img291.imageshack.us/img291/9876/img1409vl0.th.jpg (http://img291.imageshack.us/my.php?image=img1409vl0.jpg)

Close up of the compressor:

http://img291.imageshack.us/img291/2636/img1408jb5.th.jpg (http://img291.imageshack.us/my.php?image=img1408jb5.jpg)

A side view of the compressor, condenser and evaporator:

http://img296.imageshack.us/img296/3395/img1415zn6.th.jpg (http://img296.imageshack.us/my.php?image=img1415zn6.jpg)

The goal is to have sub-ambient temps but too stay above the dew point so I do not have to worry about condensation.

[utnorris]

For initial testing I just used an old cooler I had laying around:

http://img525.imageshack.us/img525/6558/img1435zh6.th.jpg (http://img525.imageshack.us/my.php?image=img1435zh6.jpg)

http://img260.imageshack.us/img260/647/img1436yw6.th.jpg (http://img260.imageshack.us/my.php?image=img1436yw6.jpg)

Ok, how about some ice:

http://img525.imageshack.us/img525/2189/img1438yc5.th.jpg (http://img525.imageshack.us/my.php?image=img1438yc5.jpg)

http://img525.imageshack.us/img525/7131/img1439hw0.th.jpg (http://img525.imageshack.us/my.php?image=img1439hw0.jpg)

http://img266.imageshack.us/img266/5930/img1440hr8.th.jpg (http://img266.imageshack.us/my.php?image=img1440hr8.jpg)

http://img266.imageshack.us/img266/4414/img1441sz7.th.jpg (http://img266.imageshack.us/my.php?image=img1441sz7.jpg)

http://img266.imageshack.us/img266/2939/img1442ug4.th.jpg (http://img266.imageshack.us/my.php?image=img1442ug4.jpg)

http://img266.imageshack.us/img266/7352/img1443wr8.th.jpg (http://img266.imageshack.us/my.php?image=img1443wr8.jpg)

http://img266.imageshack.us/img266/9504/img1444ne9.th.jpg (http://img266.imageshack.us/my.php?image=img1444ne9.jpg)

Initial water temp - 67f
5 min - 66f
10 min - 61f Compressor turned off since this was the lowest I could set it at.
15 min - 57f
20 min - 56f
25 min - 56f
30 min - 56f

I then pulled the temp probe out of the water and let the compressor run another 10 minutes before shutting it off. After a little over 30 minutes it has settled at 38f. Not quite freezing but close.

[utnorris]

So after that you are probably thinking, geez 30 minutes to get to 38f, well keep in mind I was using a large cooler and I didn't let the pump run the entire time. Once it shut off it still dropped in temperature.

So moving on here are some pics of the case I am building for it:

http://img361.imageshack.us/img361/7653/img1466ug8.th.jpg (http://img361.imageshack.us/my.php?image=img1466ug8.jpg)

http://img361.imageshack.us/img361/1681/img1467oz4.th.jpg (http://img361.imageshack.us/my.php?image=img1467oz4.jpg)

http://img384.imageshack.us/img384/3886/img1468so8.th.jpg (http://img384.imageshack.us/my.php?image=img1468so8.jpg)

New cooler in the case:

http://img384.imageshack.us/img384/3128/img1469dg0.th.jpg (http://img384.imageshack.us/my.php?image=img1469dg0.jpg)

Once I had the basic layout figured out, I sprayed the bottom with liquid rubber to absorb vibrations, no need to have a loud chiller. :D I then cut the new cooler for the evaporator and placed the compressor, condenser and evaporator in the case and got the pipes insulated:

http://img213.imageshack.us/img213/7528/img1485xs1.th.jpg (http://img213.imageshack.us/my.php?image=img1485xs1.jpg)

http://img213.imageshack.us/img213/1206/img1487ha1.th.jpg (http://img213.imageshack.us/my.php?image=img1487ha1.jpg)

http://img149.imageshack.us/img149/6627/img1488ca5.th.jpg (http://img149.imageshack.us/my.php?image=img1488ca5.jpg)

http://img149.imageshack.us/img149/2043/img1489ue9.th.jpg (http://img149.imageshack.us/my.php?image=img1489ue9.jpg)

http://img149.imageshack.us/img149/4521/img1490tq6.th.jpg (http://img149.imageshack.us/my.php?image=img1490tq6.jpg)

[utnorris]

Quick test of the top panels:

http://img179.imageshack.us/img179/7241/img1492ml6.th.jpg (http://img179.imageshack.us/my.php?image=img1492ml6.jpg)

http://img179.imageshack.us/img179/8379/img1493id0.th.jpg (http://img179.imageshack.us/my.php?image=img1493id0.jpg)

I still need to cut holes for air vents and tubing ports, but it gives you an idea of how it will look when it is done.

Moving on to wiring. This was the original controller module that came with the AC:

http://img222.imageshack.us/img222/8886/img1412xq9.th.jpg (http://img222.imageshack.us/my.php?image=img1412xq9.jpg)

I was going to use that, but decide to go with this controller:

http://www.coleparmer.com/Catalog/product_view.asp?sku=9352010

It's a much better controller and can go down to -58c not that I will do that, but still nice to be able too if needed later on.

So taking the module apart this is what I was faced with:

http://img248.imageshack.us/img248/4288/img1511tr0.th.jpg (http://img248.imageshack.us/my.php?image=img1511tr0.jpg)

http://img248.imageshack.us/img248/1374/img1512km0.th.jpg (http://img248.imageshack.us/my.php?image=img1512km0.jpg)

http://img248.imageshack.us/img248/6228/img1514er7.th.jpg (http://img248.imageshack.us/my.php?image=img1514er7.jpg)

http://img248.imageshack.us/img248/65/img1515vo1.th.jpg (http://img248.imageshack.us/my.php?image=img1515vo1.jpg)

http://img75.imageshack.us/img75/5698/img1516yp1.th.jpg (http://img75.imageshack.us/my.php?image=img1516yp1.jpg)

http://img75.imageshack.us/img75/9333/img1517xs7.th.jpg (http://img75.imageshack.us/my.php?image=img1517xs7.jpg)

Thank god for wiring diagrams:

http://img399.imageshack.us/img399/6228/img1509tw2.th.jpg (http://img399.imageshack.us/my.php?image=img1509tw2.jpg)

Without that I would not have figure jack out. :D Anyway, I rewired everything and got the new module mounted. As you can see I also got the 120mm holes cut:

http://img512.imageshack.us/img512/6099/img1528ev9.th.jpg (http://img512.imageshack.us/my.php?image=img1528ev9.jpg)

Ok, so some final pics. This is where I am at with this build, almost done and just about ready to do some testing.

http://img512.imageshack.us/img512/3370/img1527gn2.th.jpg (http://img512.imageshack.us/my.php?image=img1527gn2.jpg)

http://img512.imageshack.us/img512/8968/img1526wb6.th.jpg (http://img512.imageshack.us/my.php?image=img1526wb6.jpg)

http://img372.imageshack.us/img372/1632/img1525sz9.th.jpg (http://img372.imageshack.us/my.php?image=img1525sz9.jpg)

http://img372.imageshack.us/img372/1875/img1522bd0.th.jpg (http://img372.imageshack.us/my.php?image=img1522bd0.jpg)

I will be using quick disconnects to connect the chiller to the case, this way it can be disconnected easily if I need to move it. I also will be using a Pentek filter to to clean the chiller before using it. I have already flushed my old system and have started putting it back together. I will post pics of that tomorrow. Anyway, hope you enjoy this as much as I have. It has been a great little project that I hope will yield me some nice temps.

[RedRaider]

Nice work...:up: That is awesome...:up:

[ZeniTH]

Thats a really nice "crib" for your chiller

[Xilikon]

Very interesting build, I'm a n00b when it come to chilled setups so I will keep a look at this build.

[skinnee]

Kick ass...I always enjoy seeing chilled water setups.

[Demthios]

Very nice, what compressor did you use? And Refrigerant?

[Septim]

nice Buddy, maybe some bigger pic size money shots?

[Big_Daddy]

nice Buddy, maybe some bigger pic size money shots?


Money shots.. heh.

They are clickable.

Just an FYI UT, you can post whatever size you want here, I set it up where the images automatically resize to 640x480.(user selectable) So post em as big as you want.

[zlojack]

Very interesting! The one thing about chillers that I've noticed is that they're always so MASSIVE!

[utnorris]

Thanks guys. The compressor is just whatever came with the AC and same with the refrigerant. I took a shot of it early on so if you click on it I think you can see the specs. Originally I was going to do an open bench case on top of the chiller, that's whay I made it so deep. I could have dropped about 6-8 inches off of it, but once I got to a certain point I decided to just use the quick disconnects and keep the chiller separate, by then it was too late to really modify the case without completely tearing it down. I will take some more shots today that are hi-res and post them. Also, I will post some pics of my new layout of my MM case. I dropped the pedestal and am back to just the UF2O by itself. Without rads there is so much room it's ridiculous. I should be able to start testing it tomorrow and getting it cleaned up. The case is a little rough, but it still looks decent. If I ever get around to making a new case I will probably make it out of aluminum and as small as possible. Since I didn't do any modifying of the original AC parts I can only make it so small, didn't want to have to drain and refill the refrigerant due to costs. So far the chiller has set me back less than $150 which is about the cost of a good set of rads, so that's a plus right there. Anyway, got to get back to work on this. :D

Red - love the new site. You guys did an awesome job, I can't say enough about how professional it looks. Congratulations.

[utnorris]

Some pics of my loop:

http://img370.imageshack.us/img370/6149/img1625eh4.jpg
By utnorris (http://profile.imageshack.us/user/utnorris), shot with Canon PowerShot A540 (http://profile.imageshack.us/camerabuy.php?model=Canon+PowerShot+A540&make=Canon) at 2008-12-16

http://img370.imageshack.us/img370/5739/img1622ts7.jpg
By utnorris (http://profile.imageshack.us/user/utnorris), shot with Canon PowerShot A540 (http://profile.imageshack.us/camerabuy.php?model=Canon+PowerShot+A540&make=Canon) at 2008-12-16

I am doing one single loop since this will be for the chiller. What is really amazing about this current setup is that the loop consists of the mosfets, cpu (QX9650 @ 4.16Ghz, 1.41v vcore), NB, SB and GPU (HD4870x2), pump is two MCP355's combined using a EK dual top, a Swiftech Micro res (temporary) and as a temporary cooler the PA120.3. Those pumps combined push the water flow very high. I thought my tubes were going to come off at first. :D Now that's a lot for one loop and under the chiller shouldn't be an issue, but what I find amazing is the fact that the PA120.3 with San Ace fans has no problem cooling the entire loop. Ambient is 21c and at idle the CPU is at 26c and the GPU is at 31c, under load (OCCT) the CPU is under 60c, the GPU under load (3DMark06) only hits 36c. That's friggin unbelievable for a single rad with all of that in one loop. I guess that is why the Thermochill is considered the best you can get. I wish I had a Feser laying around to compare them.

Update on the chiller:

I leak tested it tonight and found I have a leak in the res. :( So now I need to figure out how to fix it. It's a tight space inside the res, so getting some JB Weld in there is going to be a challenge. I will work on that tomorrow and hopefully will be able to retest it Thursday. Fingers crossed.

[systemviper]

Wow that is some great stuff, You took a while and built your self a steller MM setup, but I think the curse of being Extreme is never sitting still.

top notch!

[Gir]

Awesome stuff.

I was working on a chiller earlier this year, but one of the copper pipes broke on it right before I finished. :(

Can't wait for more.

[utnorris]

Some pics, just about done:

http://img61.imageshack.us/img61/1229/img1632yj6.th.jpg (http://img61.imageshack.us/my.php?image=img1632yj6.jpg)

It will go lower, but this is just for sub ambient temps, so I didn't take it further.

http://img61.imageshack.us/img61/9502/img1633op4.th.jpg (http://img61.imageshack.us/my.php?image=img1633op4.jpg)

http://img57.imageshack.us/img57/9351/img1634tp0.th.jpg (http://img57.imageshack.us/my.php?image=img1634tp0.jpg)

http://img81.imageshack.us/img81/5720/img1635ow2.th.jpg (http://img81.imageshack.us/my.php?image=img1635ow2.jpg)