External Watercooler Prototype

[FatboyHK]

First, I would like to dedicate this project to my grandfather, who pass away suddenly by peacefully in my arms during a family gathering yesterday, just before the finally assembly of this prototype

What you see below is a protoype of an External Water Cooling setup. I was greatly inspired by a similar project done by newls1, and I would like to push the bar even further. If you guys really like it, may be I can sell it just like his excellent Waterkeg III.

And you may think it looks and feels like Aqua Computer's Aquaduct. Indeed it is, but I came up the idea before I knew about Aquaduct. What you can be 100% sure is that my prototype's design, quality, and performance is a light year ahead of Aquaduct. (but unfotunately, cost is a light year ahead)

This is the original design, which some of you guy may saw in my post before:

And this is which it looks now:

in the dark, it look really cool

Aquaero is the most difficult part in this project. To enable all the functions, but put it in an external box, I need a lot of wiring. My goal is to use one cable to connect the box to my PC, so it will be much more tidy and managable:

Individual wirings would split out from this component box, which sits underneath the PSU after installation

Below is the interior of the box. In this prototype I decided to use 2x DDC2, BIGTX480, 4x YL High Speed Fans, EK 250 Res, and Swissflow flow sensor (which is not connected to Aquaero yet). I am thinking about using a TC PA120.3 in the mass production version, so The box can be a bit smaller.

The tubings between PC and this external WC box are connected using CPC Quick Disconnect. They have valves so it is really easy to handle.

Back to the exterior. In this ptototype I use the same design scheme of my PC case:

Similar to what I did to my PC I will make some "sponsor stickers" for this Prototype:

Of course, design scheme can be customized to individual customer's need.

on the other side of the box there is also a mount space for Aquaero so that I can mount it on either side. Now I leave it open so that people can see the parts inside

This Prototype is now being used to cool my PC. I use Swiftech Apogee GTX for my AMD FX60 and EK blocks for my 8800GTX in SLI. For extreme performance I also bow my Apogee GTX. The water path is CPU first and then to 2 GPUs in parallel. The tubing arrangement is quite unique, which is much more tidy, and give more cooling for the CPU.

I have setup Aquaero's temperature sensors in the Water in, Water out, Air in and Air out of the raditator, so collecting temperature data is very convenient.

Performance Data:

Idle:
Water in: 26c
Water out: 23.2c
Air in: 23.2c
Air out: 24.9c
CPU (FX60 @ 3GHz):35c
GPU1 (8800GTX @635/1000): 40c
GPU2 (8800GTX @635/1000): 44c

CPU Full Load (ORTHOS Small FFT):
Water in: 26.5c
Water out: 23.5c
Air in: 23.2c
Air out: 25.4c
CPU (FX60 @ 3GHz):44c
GPU1 (8800GTX @635/1000): 41c
GPU2 (8800GTX @635/1000): 45c

System Full Load (3DMark06 @2560x1600):
Water in: 28.8c
Water out: 23.9c
Air in: 23.2c
Air out: 27.3c
CPU (FX60 @ 3GHz):44c
GPU1 (8800GTX @635/1000): 48c
GPU2 (8800GTX @635/1000): 52c

Please give me commet and suggestion so that I can make this external watercooler even better.

 

[Arcygenical]

Is the front made of some sort of acrylic? How did you fabricate it

 

[Sunni Warlord]

Looks like a winner!!

Much nicer build than the Waterkeg III which always seemed clunky to me. So when can we buy? We also need more pics with better light.

Is the DDC's operated through the software?

 

[FatboyHK]

Looks like a winner!!

Much nicer build than the Waterkeg III which always seemed clunky to me. So when can we buy? We also need more pics with better light.

Is the DDC's operated through the software?

I think I will make one or two design changes before I can finalize it as a mass production version. Most proably changing from BIGTX480 to TCPA120.3, to reduce the overall size.

DDCs are running by itself, but their RPM are monitored by Aquaero

And yes I am getting back my own camera to shoot again!

 

[FatboyHK]

Is the front made of some sort of acrylic? How did you fabricate it

so you are interested, let me show you some more photos:

What I got from my metalsmith

Five layers of finishing, each with a layer of modelling putty and a layer of spray-on surfacer

3 layers of black paint

 

[Sunni Warlord]

So how are you interfacing the SwissFlow to the Aquaero? I thought that this wasn't possible due to the Aquaero's maximum impulse of 2500 and the SwissFlow's 6000 impulses per liter.

 

[FatboyHK]

So how are you interfacing the SwissFlow to the Aquaero? I thought that this wasn't possible due to the Aquaero's maximum impulse of 2500 and the SwissFlow's 6000 impulses per liter.

yes, I will make a simple electronic circult that will divde the signal rate by a factor of 10

the problem is, I am an electronic n00b.... I am looking for help from my friends now

 

[annaconda]

Excellent Work.

 

[Nicepants42]

The concept and components are certainly very nice, although I question the need to use two DDC2 @ 18W instead of the quieter (and arguably more reliable) DDC. Also, the $50 EK reservoir (that you can't even see) doesn't seem worth it to me at all.

I would imagine that, instead of using a single radiator that costs over $100, you may be able to get better performance using two Swiftech MCR320s (~$55/each) stacked with ~6 fans. This would make the unit shorter, and may provide more cooling power than (while costing less than) a PA120.3. The added resistance will be negligible with two DDCs.

As far as the enclosure design goes, I find it hard to express my dislike strongly enough without sounding disrespectful. I generally prefer simple, symmetric designs (for instance, the Aquaduct looks great) and so I find the large L-shaped chunk of material extremely unsightly (and doesn't it add cost?), and the white edging just makes it worse.

Other than that the mesh looks great, and I really like the flexibility of control and monitoring that you're trying to implement.

Edit: Also, I like the idea of a single cable to the PC, with a break-out box inside the PC case, however one should be able to locate the break-out box anywhere in the case. In your particular example, placing the box underneath the PSU would be extremely detrimental to PSU with 120mm or larger fans.

 

[stryder2720]

That's sweet!

 

[JC634]

Looks nice. But as you said, it is expensive. Since you are designing/fabricating the enclosure, you have a sense of "ownership" of the final design. Which is great, but costs alot.

I have a very similar solution to yours, which fit my (emphasize my) needs perfectly, with a minimal cost to implement. A tape duplicator box works perfectly for use as an external waterbox and requires almost no modifications (unless you wish to get real fancy).

Cost of the box: $77 shipped to me. Obviously, the components used in the box are a significant amount of the cost, but that would apply to any external box setup.

PIx of case:

http://www.crystalfontz.com/backlight/forum/userscreen/WB_mod/amamax_1949_10151294.jpg[/I

[color=cyan]EDIT: Unless that is your site (and it doesn't appear to be), don't be ganking bandwidth by hotlinking images. - Lethal[/color]

More pictures here: [URL]http://www.crystalfontz.com/forum/showthread.php?t=5305[/URL].

 

[Sunni Warlord]

Well I was thinking the style of the design was that which attracted me to it. Your idea has technical merit JC634, but gets a "F" on design.

 

[JC634]

Yeah, but I can buy alot of nice PC HW for the differance in the cost of my case vs. the OP"s case. And IMO, mine looks much nicer. And just as functional.

For example, style/design is nice, but unlike some poorly misguided souls in this world, that extra $10,000 for that "beamer" logo on your car is really not worth it.

And if it impressed someone that you had a BMW (or other grossly over-priced vehicle), too bad.

edit: BTW, ever hear of KISS principle? Or are you a firm believer in the "the more complicated, the more you can baffle 'em" prinicpal?

To the OP: I apologize for moving off topic. You have a neat idea and it incorporates many of the exact/similar components in my version. Gotta like that!

 

[friedchicken]

I really like your design elements. This is very close to what I was designing a few months back. I was thinking of a waterbox "Sidekick" where you could buld a thin upright waterbox that would sit on a plate that extended wide enough to sit my computer on it.

My other idea was this...

I put the rad exhausting in the rear to reduce the noise and blowing at me, and the aquaero (or any other controller panel) in the front where I could see it at all times. Also, the front would be covered with AC Ryan Mesh to provide ventalation to the 6 fans, with any colored CCFL to backlight it.

The entire case would be painted a low gloss black

The width of the case looks alot like the same as yours (with your stabilizing base)... so it just needs some decent casters.

The construction of this model is very easy with only a single welding point for the frame where the top would join to the back panel. "L" channel would be JB welded to the frame to attach the side panels and mount the rad & wire tie-downs.

 

[friedchicken]

Well I was thinking the style of the design was that which attracted me to it. Your idea has technical merit JC634, but gets a "F" on design.

I think his point is more of design doesn't equal the value. With so many case colors and sizes out there, it would be hard to make one for everyone (style-wise) and keep production affordable.

I'l use mine as an example. There is 0 extra cost for producing differnt colors of case frame (black, gloss, red, white, cream..) and CCFLs cost the same no matter the color.

However, the one thing I do like is the shroud which can cover the top and front of the case. While it's angular style may not replicate the common PC case- they aren't exactly manufactured from an esthetics point of view unless you are looking at some high end aluminum cases (Lian-Li). But even those cases have design characteristics that are subtle enough that it's not overdone, but not exaclty a plain black/silver box either.

 

[FatboyHK]

The concept and components are certainly very nice, although I question the need to use two DDC2 @ 18W instead of the quieter (and arguably more reliable) DDC. Also, the $50 EK reservoir (that you can't even see) doesn't seem worth it to me at all.

I would imagine that, instead of using a single radiator that costs over $100, you may be able to get better performance using two Swiftech MCR320s (~$55/each) stacked with ~6 fans. This would make the unit shorter, and may provide more cooling power than (while costing less than) a PA120.3. The added resistance will be negligible with two DDCs.

As far as the enclosure design goes, I find it hard to express my dislike strongly enough without sounding disrespectful. I generally prefer simple, symmetric designs (for instance, the Aquaduct looks great) and so I find the large L-shaped chunk of material extremely unsightly (and doesn't it add cost?), and the white edging just makes it worse.

Other than that the mesh looks great, and I really like the flexibility of control and monitoring that you're trying to implement.

Edit: Also, I like the idea of a single cable to the PC, with a break-out box inside the PC case, however one should be able to locate the break-out box anywhere in the case. In your particular example, placing the box underneath the PSU would be extremely detrimental to PSU with 120mm or larger fans.

As I said, it is a prototype. just like those exotic concept cars you see in a trade show. The purpose of building this prototype is to prove my design concept, and also to build a really good watercooling solution for my PC at the same time. So I spend somewhat ridicous amount of money, and more importantly time (roughly 500 hours in 3 months) for this project.

After I know what I can do, I can think about what I should be in an economic perspective. If I really going to make a production variant of this prototype, I would definitely look for cheaper alternatve.... cheaper Res, one pump only, etctec.. they are all under consideration. Also, the design must be more end-user-friendly, instead of in a DIY style, therefore the break-out box, for example, will be revamped.

And I am not disappointed if you don't like my enclourse design. You simply can't make everyone happy. Nevertheless, color scheme and even the front cover can be customized for individual's perference if I really need to

However, I must unleash my anger on you for the fact that you misjugded the color of the edge, it is a very nicely done silver, instead of the dull white you was talking about, now go away!!!!!!111 hahaha

 

[FatboyHK]

Excellent Work.

btw I am really wondered why the word "excellent" would take me to microsoft's website.... what an irony, but that made my day, lol

 

[FatboyHK]

Now I am thinking about the cabling. The single-cable approach is very good, but it is very time consuming to make. The whole cabling system is being built with "raw" materials...power cords, D-Sub plugs, Electronic boards, jumper plugs, etc.....and there are more than 100 solder joints....Do you guys have a better idea?