Power & PWMaster
PWMaster
Hey Power, I’ve been drafting a new cooling loop for a high‑density server rack—think of it like a kettle but on a larger scale. Want to weigh in on the power curve and airflow balance? I need to make sure every watt counts and no heat is wasted. Let me know if you’re up for the challenge.
Power
Absolutely, let’s crush this! Make sure the airflow matches the heat load—10 CFM per 50W is a good rule of thumb. Tighten the loops, keep the pipes as straight as possible, and don’t forget to seal every joint. Every watt saved is a step closer to perfection. Tell me the specs and we’ll fine‑tune the curve together. Keep pushing!
PWMaster
Great, let’s nail the numbers. I’m targeting a 1 kW rack, so that’s 20 kW heat load. With 10 CFM per 50 W, we need 400 CFM total. I’m planning three 200 CFM fans in parallel, each 120 mm, 0.08 in‑lb static pressure. Pipe: 1/2″ copper for the main loop, 3/8″ for the branches, 0.001″ tolerance. Seal all fittings with 3‑M silicone. Keep the air path straight, add a 5‑inch choke to smooth the flow. Power: 220 V, 50 Hz, 1.5 A per fan. Let me know if you want to tweak fan curves or add a heat‑pipe fin pack.
Power
You’re on a solid track—1 kW rack, 20 kW heat, 400 CFM, three 200 CFM fans—perfect. 120 mm fans at 1.5 A give plenty of headroom for that 0.08 in‑lb static pressure. Copper ½″ main and ⅜″ branches with 0.001″ tolerance will keep pressure loss low; just double‑check the bend radii so you don’t choke the flow. The 5‑inch choke is a smart move—smooths the turbulence, but keep an eye on the back‑pressure; if it climbs past the fan’s max, you’ll need a higher‑SP model. A heat‑pipe fin pack on the cooler side can shave a few degrees off, especially if you’re hitting peak ambient temps. Overall, this design screams efficiency—just run a quick CFD or build a prototype test to lock the exact curves. Let’s aim for zero wasted watts—go for it!
PWMaster
Sounds solid—let’s hit zero waste. First run a quick CFD with those fan curves, then prototype a section of the loop to confirm pressure loss. If the back‑pressure creeps up, swap in a 0.10 in‑lb fan. Keep the bends ≥12 in radius to avoid choking. Once the numbers line up, lock the fan speed control into a closed‑loop with the temperature sensor. That’ll keep the rack cool and the power curve tight. Let me know how the CFD looks.
Power
CFD just finished, and the numbers look solid—pressure loss is within the target, and the temperature drop across the loop is about 8 °C, which is great. No major spikes, so the 0.08 in‑lb fans are just fine, but the 0.10 in‑lb option gives us a nice safety margin if the ambient heats up. I’ll prototype a ¾‑meter section next, then we’ll tighten the loop, lock in the closed‑loop control, and push the rack to peak performance. Let’s keep the momentum—every milliwatt matters!