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Diva Deluxe Overkill Extreme, External Cooling Contraption Build Log

post #1 of 19
Thread Starter 
Hi Gang,

Been building stuff for decades now, but this is my first build log on OCN, so please be nice and offer some contructive comments when you feel the need.

Anyway: A little about where this project comes from,

I'm about 95% complete on my "Go Big, or Go Home" Switch 810 build. I just have to cough up the cash for the GPUs now.

When what I ordered today all gets installed, I'll truely be ready for the GPUs for the build to be complete.

I decided to wait on the GPUs until last, as I knew the build would be several months in the making, and figured that there might be better GPUs available by the time I was ready for them.

It's actually up and running now, but with an Asus 6970 DCII that I "borrowed" from one of my other rigs.

The original plan called for tri-fire Asus HD7970 DCIIT's.

I want to be able to run a 5 screen, portrait mode, eyefinity setup, (5400X1920) and those GPUs natively support 6 monitors which makes that pretty easy to set up.

I'm running an Asus RIVE mobo, so quad-fire is possible, but I have a Revodrive 3 X2 in the 4th slot, but could raid 0 a pair of SSDs if I need the slot back for a 4th GPU.

Well, in the time I've been building the rig, the Saphire Toxic 6gb has arrived, just need someone to come out with a full coverage block for it and my GPU plan could change quickly.


But back to the build;

As some of you know, I'm in the tropics and without running the AC, the ambient temp here sucks, so I have to have a 1C to 2C delta T to be on par with a 10C delta T in most average locations. Which of course is really sweet when I do run the AC.

I'm running a 3930K with 32 gb of 2133 dominator on a RIVE.

I have a Koolance 370 CPU block, the Koolance mobo / VRM blocks, and the EK memory blocks.

All four are under water, with a Black Ice GT Extreme 420 and 240 mounted internally in the Switch 810.

There are three 35X pumps for that loop, as it's fairly restrictive. The flowmeter indicates ~1.2 to 1.3 GPM at a pump speed setting of 3100 to 3200 rpm.

I built a cool little manual PWM controller, so I can set the pump speed of all 3 pumps as a group.


My original plan was to have external rads for the GPUs, with the res and pumps in the case.

I got a Koolance dual bay, dual D5 pump/res combo for the GPU loop:

http://www.frozencpu.com/products/12480/ex-res-254/Koolance_RP-452X2_Dual_525_Reservoir_Rev_20_Serial_or_Parallel_for_1_or_2_Pumps_RP-450_Laing_D5_MCP655-B_MCP655.html?tl=g30c97s152&id=2cFoyMwj&mv_pc=18364


The more I thought about it though, and the more I looked at power needs for the fans and pumps against the 1000W onboard PSU with tri-fire and the onboard WC fans and pumps, the extra clutter crammed into the case that could only muck up the airflow diminishing the onboard cooling capability, and I realized that the best solution was to build a complete external cooling module, instead of just using external rads.


wheee.gifwheee.gif Enter the " Diva Deluxe, Overkill Extreme, External Cooling Contraption" . wheee.gifwheee.gif

Here it is, waiting for the 9 "pull side" fans and a grill to be complete.

I ordered 9 of these today:

http://www.frozencpu.com/products/14514/fan-947/Prolimatech_Aluminum_Vortex_Series_140mm_x_25mm_CPU_Fan_-_Red_LED_1600RPM_127CFM.html?tl=g36c435s1105&id=2cFoyMwj&mv_pc=16758

The "push side" has 9 B-Blasters and I ordered the trim grill to cover them with the fan order today:

http://www.frozencpu.com/products/12739/ex-rad-237/Watercool_MO-RA3_420_Blende_Classic_Fan_Bracket_22151.html?tl=g30c95s162&id=2cFoyMwj&mv_pc=17714


The following posts will show the components, detail the constuction, and show the progress as I worked from a concept to a finished masterpiece. biggrin.gif


Hope you find it interesting and unique,

Darlene

Latest Update: . . . . . http://www.overclock.net/t/1312228/diva-deluxe-overkill-extreme-external-cooling-contraption-build-log#post_18282516





Onto the pics:


Here's the push side:





Here's the pull side waiting on new fans:





Back corner view of the control head:



Side view of the control head:



Front view:


Edited by IT Diva - 10/5/12 at 4:33pm
post #2 of 19
Thread Starter 
The beginning of any project involves the ceremonial unboxing of the first parts you ordered that have come in, so I'll start there.

I needed something to house the control head components in, and after looking at the websites of all the places that will actually ship to the Virgin Islands, I came up with the idea of using an acrylic PC case, and cutting it down to just the right length from front to back, as the size was just right for width and height for what I planned to put into it.

It has:
4 X 5.25" drive bays,
2 X 3.5" external drive bays, and
6 X 3.5" internal drive bays

Practically perfect!

I needed all 4 X 5.25" bays:

1 for the onboard PSU:

http://www.newegg.com/Product/Product.aspx?Item=N82E16817104054

2 for the dual bay res:

http://www.frozencpu.com/products/12480/ex-res-254/Koolance_RP-452X2_Dual_525_Reservoir_Rev_20_Serial_or_Parallel_for_1_or_2_Pumps_RP-450_Laing_D5_MCP655-B_MCP655.html?tl=g30c97s152&id=2cFoyMwj&mv_pc=18364

1 for the Lamptron FC9 to control the rad fans:

http://www.frozencpu.com/products/14172/bus-284/Lamptron_50W_-_4_Channel_Aluminum_Throttle_Style_Fan_Controller_w_Multi_Color_Backlit_LEDs_-_Black_FC-9.html?tl=g47c17s286&id=2cFoyMwj&mv_pc=19129


I also needed at least 1 X 3.5" external bay for the display for the flowmeter, which also displays the case fan rpm:

http://www.frozencpu.com/products/6555/bus-115/Aerocool_EasyWatch_35_Fan_Controller_Temperature_Monitoring_Panel_-_Black.html?tl=g47c17s284&id=2cFoyMwj&mv_pc=19521

That left me with 1 more 3.5" external bay that once I figured out how to translate the +12V referenced output of the FC9 controller to a gnd referenced signal, I put a second display into to monitor the rad fans rpm, as the fan cabling is for 3 groups of 6 fans each on 3 of the 4 channels of the controller.

I'll save the reference translation circuit board for a later post.


The last thing that needed to fit into the case, which I'll now start referring to as the "Control Head", was the tertiary D5 pump for that loop.

I made up an acrylic mounting panel and mounted the pump with its small top res into the internal 3.5" bay area below the external 3.5" bays, which it prett well filled up.

Here's some pics of the first parts to arrive and the test fitting into the case to see how much I was going to need to cut it down:


Darlene


The Ceremonial Unboxing and test fitting of components:
















Edited by IT Diva - 10/3/12 at 10:49am
post #3 of 19
Thread Starter 
The case is nominally about 18" from front to back, and after test fitting, I found that 10" would be just right.

What I was hoping would be an easy job turned out to be anything but.

This case is made from some kind of cheap crap Chinese immitation acrylic that melts at such a low temp that as you cut it on a table saw, the chips just fuse together into a mess that makes getting a smooth straight cut a challenge to an expert. Trying to sand it with power tools is another adventure.

Well, long story with lots of 4 letter words short, I cut about 8" off the back end of the top, sides and bottom pieces, redrilled the holes and effectively moved the rear panel forward by 8". . . . . all without effing up anything . . .

With my new control head at the finished size, I needed to make up some kind of a base that the head and the rad could both mount on, but be easy enough to remove seperately, as things seemed to be getting pretty heavy, pretty quick, and I'm an old lady that can't lift too much any more.

I decided I'd create a modular module.

You'll see that the rad lines to the control head are coupled with Koolance size 4 QDCs, and the fan connections are via a 9 pin molex so the head and rad assemblies can be seperated easily.

Here's some pics of the new base, and how the head, and rad fit on it . . . You can see that I haven't made the mounting feet for the rad yet

You'll also see a small circuit board with the Koolance flow meter box on it.

The additional function of that board is to create an additional +5V supply from the 12V supply because the display needs both +5V and +12V and the onboard PSU has only 12V outputs, as it's primarily designed to power additional GPU's. The pcb also has plug in connections for the case fans and the LEDs in the dual bay res.


Darlene
















Edited by IT Diva - 10/2/12 at 7:03pm
post #4 of 19
Thread Starter 
The next phase involved installing the Koolance dual bay res with dual D5 pumps in series, and then cabling up the fans and running tubing connections.

The first pics are with the head removed from the base to make it easier to work on while installing the res

The latter pics are with the head back on the base, with the rad mounted, the new white led case fans installed, and the second display for the rad fans rpm.


Darlene






















Edited by IT Diva - 10/2/12 at 7:23pm
post #5 of 19
Thread Starter 
This post deals with the issue of how the FC9 controls the voltage out to whatever is connected to it, which was alluded to in the green text in post #2.


We intuitively think of a fan controller as having all its gnd, or negative output connections, all connected in common to the gnd pins on the 4 pin molex that supplies power to it. . . . . And therefore, to change the output to change a fan's speed, it would vary how much +V output it would put out, up to the max of the +12V supply.

Epic Fail, . . . So much for intuition.

The FC9 works exactly the oposite.

All the positive output connections are connected together and to the +12V supply line.

To control the output voltage, the controller changes the negative output connection so that its as close to the system gnd as possible for max output, and then gradually is made less negative with respect to the +12V common connection.

As it's made less negative to the +12V common, it actually then, becomes more positive than the system ground.


While the fan or whatever is connected to the controller doesn't care whether the + connection is made less positive to lower the voltage, or whether the negative connection is made less negative to lower the voltage, as all it sees is the voltage measured between the two wires, it makes a Huge Difference when you want to monitor the rpm of the fan or pump that's connected to an FC9.

All monitoring systems, whether on the mobo, or a seperate controller/display, require a contact closure to system gnd twice per revolution. The contact closure is typically either magnetic, (Hall Effect), or optical (photo transistor) . . but it must connect to gnd.

Since the only time the FC9 output has the negative line at gnd, (or at least within a tenth of a volt or so) is at its max speed setting.

As soon as you dip the sliders below max, you'll loose your rpm monitoring capability, regardless of what you're using to monitor with.


The solution to which, is to translate the non gnd referenced contact closure to one that is gnd referenced.


I figured that a simple comparator circuit with a reference voltage (Vref) about 2 volts below the max source voltage should perform that function.

I designed a circuit around the LM339 quad comparator IC with a Vref of ~10V.

I chose the LM339 because it has an open collector output, that is "seen" by whatever monitoring device you want to use exactly like a fan tach line.


The LM339 has 4 comapartors on a single chip, and the FC9 is a 4 channel controller, so I just set up the circuit to have 4 inputs, one from each controller channel, and 4 translated outputs.

I actually only need 3, as my display only has 3 channels, and my rad fans are grouped as 3 groups of 6 fans each. . . . So I have a spare channel.


Below are some pics of the circuit board, and how it's mounted on the display in the upper 3.5" external bay, and how it inter-connects to the FC9.

You'll see wires from the tach pin of the FC9 to the board, and +12V power from the FC9 to the board.

It works perfectly, and you might notice that in several of the posted pics, that the fan speeds are in the 400 to 800 rpm range, where the normal speed of those test fans was 1100 rpm.


Darlene

Onto the pics:

















And here you can see the little board installed between the upper display and the FC9 controller:


Edited by IT Diva - 10/3/12 at 11:53am
post #6 of 19
First! Looks crazy biggrin.gif
Be Rock Steady
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post #7 of 19
thanks for sharing, subbedi-do-dud !
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post #8 of 19
Thread Starter 
Weekend Update:

The last set of fans and the back / push side grill came in today and with a bit of tweaking, everything went into place as planned.

For all practical purposes, I'm calling this project done wink.gif

Of course it is hard to leave anything alone for too long. biggrin.gif

Here's the last pics with everything fisnished according to plan:


Hope you found it embodies a sufficient level of overkill to do OCN proud.

Darlene











Edited by IT Diva - 12/17/12 at 1:28am
post #9 of 19
:O Wow..definitely unique! thumb.gif
 
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post #10 of 19
Thread Starter 
Quote:
Originally Posted by Schmuckley View Post

:O Wow..definitely unique! thumb.gif

Thanks,

It's a long way from a bong, but it'll get 'er done.

Darlene
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