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21  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: November 27, 2012, 01:59:55 AM
Nice work. I really like the hitch pins for easy module removal.  Keep it up. Smiley

Thanks Cablez, that was the general idea.

Since the plan is to have at least two pumps under the center module the pins should help make things a bit easier to service.
22  Other / CPU/GPU Bitcoin mining hardware / Thanksgiving holiday 2012 update on: November 26, 2012, 04:24:17 PM
I made quite a bit of progress over the long weekend.


Drilling the rack mount holes on the final set of mounts


Testing the fit of the upper mount


Mounting the upper module



The middle module attached


Detail on the middle module


Side view of the upper and middle modules


Detail on one of the pins used to attach the middle module


Testing the fit and measuring the lower module prior to drilling





Also, Aquacomputer shipped out my replacement Aquaero 5XT and it should be in my hands in a week or two.
23  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: November 19, 2012, 04:54:34 PM
Two updates for last week:

Aquacomputer finally reviewed my damaged Aquaero 5 XT and found both the main controller and the display board to be damaged and unable to be repaired. Fortunately they offered me a replacement for a bit less than retail, which should be shipping out later this week.

The screws for attaching the mounts to the side panel of the 19" rack also arrived, and I drilled the majority of the rack mount holes for the mounts. I plan to finish this part off and attempt mounting two of the modules to the rack over the long weekend.


Next up is drilling the last of the segment holes for the lower module mounts and one final hole in each of the lower segments.
24  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: November 12, 2012, 10:45:58 PM
Cooling passive wont be that good .... I know these radiators and they are more for show effect than cooling.

I would invest in a good tripple (120, active) Radiator for backup as well. You could place it behind the Aquero and rig it to start when the in temperature in your system gets to high Smiley

I hear what you are saying, but as long as the Cape Cora modules meet spec (22.5W dissipated by natural convection alone per module segment) the design should be ok as-is w/o adding an active heat exchanger to the loop. It is definitely true that a passive heat exchanger needs to have a larger surface area to get the same temperature drop as compared with an active setup, but this has been factored in.
25  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: November 05, 2012, 05:03:10 PM
I was able to spend a few hours on the project again this weekend after having to take the last few weeks off due to family commitments. I drilled and tapped the final set of radiator segments that will make up the lower module. This picture was taken just prior to completing masking and marking the segments prior to drilling. As you can see on the right, another T-connector was damaged in shipping (I hadn't spotted this earlier.) Fortunately Aquatuning had preemptively sent me some spares on my last order so it's no big deal.


I also received the USB isolator two weeks ago and should be ready to try again when the Aquaero 5XT comes back from repair from Aquacomputer in Germany. Aquacomputer received my non-functioning Aquaero on 10/31, but thus far they haven't completed the inspection to determine what is needed in terms of repair.
26  Other / CPU/GPU Bitcoin mining hardware / Re: my system's are 1.6kwh?! on: October 17, 2012, 10:03:54 PM
Crazyates is right about underclocking your memory. If you just use MSI afterburner to underclock them to around at least the 300 mhz range you should see a decent drop in heat and power, and you really shouldn't see a noticeable drop in hashrate.
I actually see an increase in hashrate dropping my memory down. I keep it ~410. Too low, and it starts hurting performance. Idk how people run it in the 160 ranges.

I saw the same thing with my 6990 rig. Dropping the memory down to 150 made a huge difference in power consumption. I second the comment about using a Kill-A-Watt or equivalent. Being able to see the power usage in real-time will help you to tune your system to maximize profit. I went a little overboard with this for my setup (using the iMeter), but it really fills in some gaps to tell how your rigs are doing:



27  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: October 15, 2012, 12:51:54 AM
I was able to assemble the module segments for the upper module and to a test fit with the mounts and things are looking good.



I'll next need to tear it all apart again, drill the holes for the mounts to attach with the rack, re-assemble everything, rough-fit it to the rack and take the final set of measurements for the lower mount for the bottom module to make sure everything still looks ok dimension-wise before drilling the module mount holes.
28  Other / CPU/GPU Bitcoin mining hardware / Another weekend of drilling on: October 14, 2012, 06:40:46 AM
With the Aquaero 5XT on the slow boat back to Germany to be repaired, I am focusing my efforts on the radiator modules again. I spent a few hours this morning drilling and tapping the 56 screw holes of the segments for the upper module:


I still need to remove and re-tension the inter-segment clips as most of them seen to have been shaken loose (and some have fallen out) in shipping. I will then attach the segments to the mounts to ensure alignment and fit, then on to the third and final module.
29  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: October 12, 2012, 04:56:16 AM
It will be quite interesting to see if Aquacomputer takes care of you, they have an opportunity to really shine here.

After a bit of back and forth with AC they are having me send it back for repair. Unfortunately their opportunity to shine is rapidly diminishing with every exchange...

Per Shoggy on the AC forums "The damaged part is a surge protection diode. We can try to repair it but we would not exchange that board since it is clearly an overvoltage damage which is not covered by the warranty."

I have been quite clear with then on what happened, and rather than being apologetic I get snarky, terse comments like this. IMHO this is a design flaw. After all, when was the last time you blew up an external USB HDD (which requires external power) by plugging it in to a PC?

30  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: October 10, 2012, 05:46:57 AM
Watercooled ASICs??? Wink Wink Wink

Absolutely! I don't need that many coffee cups warmed Wink

In all seriousness, ASICs are a lot more efficient than prior technologies, but still generate heat. In any high density configuration the heat will need to be moved away to prevent thermal failure, so there will still be a need for fans (or water cooling).

Ahem... BFL Releases Renderings of New BFL Single WaterBlock and Heat Sink
31  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: October 07, 2012, 06:50:46 AM
I spent a little more time inspecting the Aquaero 5XT mainboard this morning and unfortunately it looks like one of the components is damaged. It's hard to make out the part number with half of the cover of the IC package blown off (you can see the upper-left lead exposed inside the package), but it appears to be a diode on the +5V supply rail:


Prior to blowing up the AQ Cry, I was having some difficulty using the touchscreen (most buttons did not respond, but one appeared to be stuck down and the plastic portion of the touchscreen kept popping out). When I inquired about this in the Aquacomputer support forum one of the Admin's suggested that I get the touchscreen replaced. Here is what it looks like:



I have reached out to Aquacomputer to attempt to get replacement parts but this undoubtedly will take some time.

In advance of the replacement Aquaero boards coming I ordered a USB isolator to prevent the same thing from happening again, but the lead time for receiving it is a full month. I will need to focus my construction efforts on completing the radiator modules in the mean time...
32  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: October 03, 2012, 08:00:16 PM
Dammit dude!

I feel your pain man...bummer

If it makes you feel better, GF called last night (I'm working on the road) and the rig I linked above is no POST no fan as of yesterday...

Thanks for the kind words and sorry about your rig Sad

Thus far I haven't heard back from Aquacomputer, but my leading theory is a ground loop due to both devices running from DC supplies, and inadequate USB isolation built in to the Aquaero. The good thing is USB isolators are relatively inexpensive, so even if AC can't offer an adequate solution, there is a path...
33  Other / CPU/GPU Bitcoin mining hardware / One step forward, three steps back on: October 02, 2012, 06:52:45 AM
I was able to finish off the hardware for mounting the Aquaero and picoPSU. Everything powered up and looked great save some issues with the touchscreen on the Aquaero 5 XT...





...but, after hooking up the USB connector and double-checking the pinouts and wire color codes I then started up Aquasuite and plugged the USB cable into my laptop and poof: the laptop shutdown, the PicoPSU and Aquaero both shut off and the acrid smell of burned electronics permeated the air Cry Nothing would power up afterwards, but after a little cooling off I was able to get the laptop to power back up, but the USB port I had used is totally dead. The PicoPSU power brick had only blown a fuse, and after replacing it, the power brick and the PicoPSU came back to life. Unfortunately, not so for the Aquaero, it won't power up no matter what I do.

Prior to plugging the USB cable in, I check and re-checked the pinouts and cable color codes and everything looked good. So you can imagine my surprise when this happened. Afterwards I checked again and nothing with the USB connection appears to have been wrong. I am using an internal to external USB adapter (the same type sold on the Aquacomputer online shop here). I am only using four of the five USB pins, leaving the outermost ground unconnected per Shoggy's recommendation in the post here: Aquastream USB Connector mod

It would appear as though the USB port on the Aquaero is not adequately isolated to allow the use of an external power supply, but have reached out to AC support for further clarification.
34  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: September 25, 2012, 07:24:37 AM
I called it a day at work a few hours early and was able to finish drilling the primary and countersink holes on the upper radiator module mount, and cut the 1.5" L channel that will serve as the mounts for the Aquaero 5 and Poweradjusts. However, after reviewing the Poweradjust 5.25" drive bay mount in the rack shelf, I have reconsidered the mounting location and decided to mount the units on opposite ends of the shelf. This is far simpler and leaves more space available in the middle for additional switches or components down the road.

Shelf and Poweradjust drive bay mount faceplate


Revised drawing
35  Other / CPU/GPU Bitcoin mining hardware / Another week of drawing and drilling on: September 24, 2012, 07:00:45 AM
I didn't make much progress on the construction this week due to family commitments but I was able to mark and drill the pilot holes for the upper radiator module mount. (no pics this time) Still remaining is to drill the primary and countersink holes, and then drill and tap the upper 14 radiator segments that will comprise the upper module. 

I also acquired the USB cabling and power plugs as well as the L-brackets for mounting the Aquaero 5 XT and Poweradjust 2's to the rack shelf and updated the controller drawings with the current plans (and a minor correction on the shelf detail.)

Higher resolution version here.
36  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: September 19, 2012, 04:34:34 AM
Veeery nice indeed.

Hey, have a quick look at my gaming/mining build, also rackmounted http://hardforum.com/showthread.php?s=4826515f8077a98d66cf9e6c9e11c7c1&t=1577248&highlight=teraractyl

That's an impressive build jojo69.

I have been tempted to get one of those mini mills myself, but first need to convince the wife Wink
37  Other / CPU/GPU Bitcoin mining hardware / Initial design of controller blade on: September 19, 2012, 12:22:52 AM
Now that the majority of the parts for the 1RU controller blade have arrived and I have taken a full set of measurements for their dimensions, I have done the initial (incomplete) set of drawings.

Shown: 1RU half shelf, Aquaero 5 XT, 3x poweradjust 2, illuminated latching toggle switch.
To be added: Pico-PSU, 12VDC power brick, wiring harnesses, detail on faceplate, detail on top cover


A high resolution version of this drawing can be found here.
38  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: September 17, 2012, 03:26:00 PM
Watercooled ASICs??? Wink Wink Wink

Absolutely! I don't need that many coffee cups warmed Wink

In all seriousness, ASICs are a lot more efficient than prior technologies, but still generate heat. In any high density configuration the heat will need to be moved away to prevent thermal failure, so there will still be a need for fans (or water cooling).
39  Other / CPU/GPU Bitcoin mining hardware / Re: Project: custom 19in rack passive cooling system on: September 17, 2012, 05:32:24 AM
I gotta say this is an awesome project. WC almost an entire KWh of heat is no small feat, and to do it passively (or close to it) is even more impressive.

I gotta ask tho: how much have you spent in parts/man hours into this project? Is it worth it for only one rig?

Thanks for the kudos.

Thus far, for the raw materials I'm into this project ~$2.5k and looking at about another $1.5k to finish it off. As far as man hours go, I can only manage a few hours every other weekend (if I am lucky) so maybe 30 hours or so since I started (including the time to design it).

Even though I am initially planning to only support a single rig, the design will support the cooling needs of emerging mining technologies. It might seem like overkill for now, but I am thinking ahead for whatever comes next.
40  Other / CPU/GPU Bitcoin mining hardware / Sept 15 2012: more parts, and more holes on: September 16, 2012, 04:38:00 AM
Another load of parts, tools and supplies arrived just before Amazon tax day. After some deliberation, I decided on a 150W Pico PSU to power the pumps, Aquaero 5 XT and Poweradjust 2s. Also shown are the PSU bypass plug (allows the PSU to run w/o being attached to a motherboard), an illuminated toggle switch, heat gun some heat shrink tubing and the last of the mounting hardware.


After the last batch of nylon washers arrived I was able to finish off the rails for the middle radiator module. It is shown here next to the rack for scale.



I also drilled the countersink holes for the nylon shoulder washers for the first of the mounts today.


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