Heatsink Modification (1 Viewer)

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McGuyver

Thread Starter
SatelliteGuys Pro
Apr 4, 2007
783
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Nuclear Testing Grounds
First I want to thank Grimnaw for his cool webpage about the Pansat 9200HD heatsink modifications. He has brought this important subject to our attention and all credit goes to him.
Pansat

After studying Grimnaw's design and thinking it over carefully I've come up with a simple mod that should be as effective costing much less and much less work and requiring less tools.

I followed Grimnaw's steps in removal of the heatsinks but I took extra precautions by placing masking tape over the pc board around the work area to keep clean and prevent possible damage and ESD. I also placed tape on the Xacto blade for ease of holding while striking it. I just used pliers to strike a small piece of metal bar placed on the pc board and against the blade, with one small tap the heatsink popped off.

Laquer thinner softens the glue to a rubbery texture and comes off easily. I compared my 9200 to Grimnaw's pics and noticed that there is no consistancy by way Pansat glues them on. Notice that the glue doesn't cover the entire center of the MPEG 2 chip and the same with the MPEG 4. Heat cannot possibly transfer efficiently, it's no wonder why these have problems. It appears that the heatsinks were merely for cosmetic reasons because they surely cannot be a functional hardware installed in this manner. The glue is thick and the surface to surface contact is very narrow. It might be possible that only about 25% heat is actually dissipated.

Notice the pic of the premium heatsink with the solid copper core, it's an old Intel CPU heatsink I saved. I was considering this monster but it will require much modification to fit it in, I may use it if this mod doesn't render satisfactory results.

Notice the bright aluminum heatsink I used, this is on the MPEG 4 chip, it's 4 times the size of the factory sink. It clears all surface mount components in this area. It should sink a lot more heat with it's larger mass. The aluminum flat bar is 1/8"X1/2" bent to shape. The top jack screw is a 6-32 machine thread @ 3/4" long. I also used longer screws to fasten the lock down bars to the chassis. These screws are 4-40 I believe, I just happened to have two in my supplies.

The small plate located on top of the sinks are cut from aluminum channel stock leaving a small amount of the sides to saddle the sink fins holding it in place. A small countersink was drilled on top of the plates for the jack screws to seat and prevent shifting. The jack screws can be adjusted for down pressure and the bars act as a spring keeping constant pressure regardless of heat distortion. I was careful to shape the base of the lock down bars so that they don't make contact with any pc board circuit tracers or surface components.

Also notice the base of the MPEG 2 lock down bar near the ribbon cable connector, the mounting screw is very close so I notched the bar to fit, it also keeps the bar from shifting off center.

This method leaves lots of room for the S2 Plus module and with smaller density parts, less heat will be trapped inside the case. Larger bars made of brass, sink and trap more heat inside.

Meanwhile, I'll be thinking about a solution for the S2 tuner heating problem and possibly, if possible, the power supply heat also. My goal is to avoid the use of fans if possible.
 

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Anole

SatelliteGuys Master
Sep 22, 2005
11,819
10
L.A., Calif.
- different strokes . . .

Very inspired clamp design! - :up

If I'd had a 9200, I think I'd have considered the chipset-sink-fan from a PC motherboard.
But, I didn't give it that much thought.
Your no-fan idea is commendable.
Did you use a swipe of Arctic Silver or similar heatsink compound?

I'd have worked out how to shove a slow-spinning (quiet) 120mm fan under the hood, too! - :eek:
 

Ironsides

SatelliteGuys Pro
Dec 4, 2008
319
0
North Carolina
Way to go!

Hey great mods to that 9200 and I hope it resolves your issues. I like the clamp down design! I also like the idea of not using the fan! They are DUST monsters which in the end results in Heat but to each his own...

Good job!
 

McGuyver

Thread Starter
SatelliteGuys Pro
Apr 4, 2007
783
0
Nuclear Testing Grounds
Very inspired clamp design! - :up

If I'd had a 9200, I think I'd have considered the chipset-sink-fan from a PC motherboard.
But, I didn't give it that much thought.
Your no-fan idea is commendable.
Did you use a swipe of Arctic Silver or similar heatsink compound?

I'd have worked out how to shove a slow-spinning (quiet) 120mm fan under the hood, too! - :eek:

Hey great mods to that 9200 and I hope it resolves your issues. I like the clamp down design! I also like the idea of not using the fan! They are DUST monsters which in the end results in Heat but to each his own...

Good job!

Considering both comments, my past experience with fans has been briefly good and long term bad, I used to have 2 pc chipset coolers but like Ironsides says, they do collect dust and sadly become very noisy even with the reduced rpm mod due to poor quality manufacturing, most fans on the market are not balanced. One way to check the balance of a fan is to let it dangle by the wires while running, they will either run smooth (balanced) or shake (unbalanced). I have yet to find small fans that don't shake using this test and/or last more than a month or two. Thus far I've only tried one set and realized that I need to spend a lot more $$$ on quality fans and you usually can't find them in your local PC store.

This unit is not yet in service, I haven't tested it yet cuz I can't find my tube of compound so I'll have to get some. I made a trip to the local computer store but they were closed, it looks like they're out of business now and I'll have to make a 20 mile trip to the next store. This town doesn't got much to choose from. Yes, I will be using a heatsink compound.

I am considering using fans but only as a last result. My last fan setup included the use of an external power adapter rated @ 9vdc to reduce fan speed and noise. It worked well while the fans lasted but they eventually became too noisy due to cheap quality.

Although there is adequate space inside the case, there isn't much choice as to where I can mount one unless I mount them on the sinks but that can cause resonant noise unless I find a way to insulate the fans with some sort of mounting damper like rubber standoffs which takes more height space for mounting which limits the height of the sink and if I choose to use a BIG sink I won't have space.

So with this in mind, I'm thinking that if I do use any fan or fans, I would consider some way to exhaust the entire enclosed space rather than individual chipset fans on the sinks that only work within the (heated) enclosed space. This would or should result in the cooler operation of all internal components including the power supply and the S2 tuner.
 
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