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My Xmas Box Bencher

post #1 of 14
Thread Starter 
Hey everyone

I've been meaning to sign up over here forever, and finally have.

There's a good chance the only place I'll post much is in here since phase change is my biggest hobby and I work as a fridge guy so it's kind of where I belong.

I see a few faces around I recognise though, which is awesome!

I figured instead of just 'hello', I'd post a cooler I just built. You may find I attach silly names to them, sorry

I'm sort of cheating a little, but I've posted this one at XS as well. Just seems the best way to introduce myself.

This one has a Xmas theme since it's Xmas and all. Hope you like it

It started out as a little test of captube lengths and ended up a 'theme' unit again. I seem to get a thought in my head and can't really leave it alone, but that's the OCD kicking in, as always.

So the unit specs are...

Matsus/hita Rotary - 49LRA/3/4hp
Chilly1 spiral evap
9000btu condensor
200cfm barrel fan
30" flex line
R290 gas
7.5' .031" captube
Max capacity 360w
Square black vented case on wheels


So first, it was a little exercise on captube tuning. I started with 9' and worked my way down to this length. 9' was just too restrictive, so I tried 8' and it was close, but far too slow to cool down, so I ended up at 7.5'.

Edit - oh, I changed the plug wire just a bit, didn't get a pic of that, when I put the switch-plug on. It exits down instead of to the side now,and I found a real clamp for the wire. That was 'ok' but ugly, and the new one is better and safer. That was just a strap I insulated with rubber. The new one is a proper clamp, and I lined the hole with the same edge beading I used on the suction line exit hole.

The condensor and fan are a match, but the shroud wasn't sealed, so I just cut up some sheet metal to seal it up. Works fine, though not pretty like it could be. It's in a case so I was more worried about it being solid than pretty inside. I also added that flap on top to block the air. The fan blows upwards, and the case was a few inches higher than the fan/condensor, so that directs the air out the one side vent




Just used the 'plug switch' setup like the other SS bencher. Works pretty good.
That's a bit longder that I'd been using, but it seems to work well on this one. The static pressure is around 110psi, which isn't terribly high but a little higher, normally around 80-90psi.




The results are good though, it's been great for R290, from 0w right up to 360w. Pretty linear temperature curve, and no drastic drop from 0w to any of the load ranges, though 0 to 50w was about 10 degrees. Funny how it pulls so cold unloaded. Unusual for high load tuning, and I think the long captube does that. Makes it so you can 'show off' but at the same time, still have the high load unit.

These are all out of order, sorry :


250w

360w

100w

0w

175w

50w

I tried to get the full 400w max of the new tester but it wouldn't hold, so the max is around 360w or so, which should hold even the 6 core cpu's at full load
I suspect that at the slightly higher head pressure, the refrigerant coming out of the captube is 'jetting' more so, maybe creating a finer mist. Since it's normal to see a mixture of liquid and vapor even right at the end of the captube (according to refrigerant theory) then the behaviour of the exiting refrigerant may change with the pressure behind it being slightly higher or lower. If it's fully liquid, then the amount of pressure should have less effect, but more and more I think it's still in transition, at least partially.

I woudn't say I knew that for sure, just guessing from the results I get, trying to extrapolate why it's working how it is.








So that's the project though, more or less ready to use

Only things I'd like to do is make up a set of plates that I know for sure is ok for i5/i7 use, and possibly get a display and switch in, though it's not needed. Not everyone has a K temp meter though, so a basic display is nice too. I have one here that's busted I was going to use for PT100, and one that's PTC1000 that I have no sensor for but I might grab one for it. Just depends who ends up with it and if they care about that.

The red line with the braided stainless K probe wire kinda made it look 'festive' in a way, so the 'Christmas Box' idea came to mind with the season and all that

I do like the way that part worked though, The wire is just a wrap, so can be pulled, but I made up a red extension wire for the sensor too, can be seen there, so the wire could stay if a person liked it.





And in keeping with the season, one last parting shot to say happy holidays to everyone here Merry Xmas guys.




Gray
post #2 of 14
Awe man that is awesome!
 
Gsvlip Dudyrm
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Oda'maksv
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Gsvlip Dudyrm
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Oda'maksv
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Samsung 850 Pro 1TB Seagate 2TB H105 EVGA Hybrid GPU cooler 
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Bitfelix Prodigy Logitech G400 Razer Goliath AKG A701 
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post #3 of 14
comeing from one a/c pillager to another i prove of what ur doing one qetion how did u make the dummy block as i might leave the world of chillers and build a direct die this winter so will need a dummy block to load test
Be
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post #4 of 14
Thread Starter 
Thanks guys, and yeah that was a good project, that tester.

I'll post a thread at some point, I got pics of it for that reason.

I'm in 110v land, so that's the stuff I used. You'd have to adjust the resistors for 240v if you're in the UK or something...


But it's 2 x 47ohm resistors bolted to a copper block.

The Killawatt is actually a Canadian Tire brand version, 25 bucks so cheap.

the variable part is just a dimmer with a switch, rated to 600w. Leviton brand, 15 bucks

Wire that together and you have a tester that's good for up to 400 watts, fully variable.

The Variac would've cost 100 bucks or more, and I was trying to find another alternative that wouldn't be so pricey. This was ideal, since it's rated that high. Little less precise than a Variac, but you fiddle and get your load.

But I'll post a thread tomorrow or something. I'm working to finish up a Cascade tonight and we'll see how it goes. It's done for the 'guts' but I'm wiring up a controller for it, and it's getting close


Gray
post #5 of 14
Thread Starter 
Oh, it would've been good to 500+ watts, but the dimmer steals a little voltage. I think they all do, it's why a 110v fan always buzzes when you try to use one with a fan.

I don't think more than 400w on a plate tester is needed though. A higher immersion tester for a chiller, sure, but I've gotten 500w to hold on a single stage and the temp difference from evap to plate is just too high. Need a seriously big evap for that


Gray
post #6 of 14
Again great work
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post #7 of 14
Looks good Gray Mole, nice case you use .
Edited by pcnazz - 12/22/10 at 6:59am
post #8 of 14
Thread Starter 
Quote:
Originally Posted by pcnazz View Post
Looks good Gray Mole, nice case you use .
Thanks ended up working out pretty good.

I actually lucked out. This was an older window AC case, I was able to strip it down and get it in reasonable shape and paint it.

Took quite a few hours to get it looking good though. I don't know if it was 'worth the effort' when maybe I could have just bought a case that was already nice but it was an interesting project.

Last couple of projects I've been doing a bit of work in trying to get a plan for building up cases. Not always 'standard' when you're trying to work with taller or larger compressors, and condensors that are a lot bigger than what you can fit into cases you can buy.

So you do what you can

Only a couple days to Xmas now


Gray
post #9 of 14
Quote:
Originally Posted by Gray Mole View Post
Thanks ended up working out pretty good.

I actually lucked out. This was an older window AC case, I was able to strip it down and get it in reasonable shape and paint it.

Took quite a few hours to get it looking good though. I don't know if it was 'worth the effort' when maybe I could have just bought a case that was already nice but it was an interesting project.

Last couple of projects I've been doing a bit of work in trying to get a plan for building up cases. Not always 'standard' when you're trying to work with taller or larger compressors, and condensors that are a lot bigger than what you can fit into cases you can buy.

So you do what you can


Only a couple days to Xmas now


Gray
Funny, I didn't notice it was a window ac case until I read this post. Looks great, very professional
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post #10 of 14
Thread Starter 
Heh

Little sanding, filling the old mounting holes, bit of paint.

Can make almost anything pretty if you try hard enough

Sure beats the Fugly case I threw together for shipping out a rotary cooler.

Mainly I just hate to ship out a cooler with no case. You can be as thorough as you like, there's always a huge risk when you send one 'open' and I'm trying to avoid it.

A lot cheaper if you don't have to deal with a case I suppose.

But it took 3 cans of paint to make it look nice and it adds up



Gray
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