I still had a heat problem to fix. I could only leave the PJ on full power for about ten minuets before the LCD would start to make the dark spot of death.
I tried a few other 120mm fans from a server and then just one of the panflows at 20v or so. All the fans made too much noise for me so I went back the three standard 25mm x 120mm fans. They do not mach one is a .4A one is .3A and one is .28A so they all go a different speed. This is not all bad because each fan is making a slightly different pitched noise so they don't all sing together.
The transformer is a 16v 800ma which is undersized for the load but the voltage is 16.3v with all three fans running. I did have the two 80mm fans on the same transformer but I added a third transformer for them to leave more power for the front fans. Before the voltage was about 15v.
I then drilled three holes in the board that is the air cap on the LCD and Fresnel holders, this lets the air go straight up and out the top which I drilled three more holes in too.
Click to view attachmentClick to view attachmentThere is still air flow over Fresnels because the light box sucks air and there is a little pressure from the front fans. Many people have had large light leaks by having a hole at the top of the Fresnels but I had no problems. I have a little bit of light that I can see on the rood but almost nothing. No light shield is needed.
No more sound comes out either.
With a total of six fans everything is now cool. One 120mm for both of the ballast, two 80mm for the light box and three 120mm for the LCD and box. I did try a peice of the foam to cover the air inlet. I cant tell if helped.
Click to view attachmentWith all the fans inside the box with the lid on it is still fairly quiet. It is quieter than some PC's. The 1/4 " hard board is a lot better at keeping in noise than ply wood it is just right with the roof side facing in. I have a few sheets of sound absorbing fome for PC’s that I keep around but I don't think I need it. The PJ makes a nice low hum that you can barely hear from 3' in front.
I placed the air intake and exhaust on the same side so I could point the sound away by having a loud side and a quiet side.
I now can leave the PJ on high for a long time.
This does not mean that is cool running. Everything in the back gets hot. I took some temps with a laser temp gun.
Bottom of box in the back 150deg
Top of box over the light box 160
Top of the light box 200
Fan housing 150
Front of the LCD 104
I need to add some air holes to let the hot air leave the back of the box to cool things down some but the 150deg is OK.
I also found the power level for the ballast and lamp. On low it is 683 watts
On high it was 1177 watts.
I added a 7.5uf cap to the S51 ballast to get 1282 watts.
With all the things taking power from the wall plug that I use there is a fair amount of voltage sag in the line voltage that I won't get with the 40A outlet and the 12 gauge extension cord.
So I went to a 2uf cap on the S51 ballast to give 1,236 watts. The S106 has an extra 10uf on it. It might balance out better if I went with a 7.5uf on each ballast. I will use the temp gun to try and set the ballast to run at the same temp.
I re adjusted the lamp some and got a little better light pattern. The middle of the screen LUX is now 135 on the small screen I did not do the large screen today.
For some reason the color is not as good tonight? The slight change in power should not have made much of a difference. It could be the lamp adjustment. I do have a blue tint that some times happens from the condenser Lens. I did take some screen shots.