02/12/2018 - Original Post edited for semi-brevity and reorganization. (Click on any image to open high resolution version in a new tab/window.)
********************
This thread documents the modifications and upgrades I have made/will make to improve overall performance/capability and maximize the functional lifetime of my TiVO Bolt 500GB.
Thanks to ALL who came before and upon whose shoulders I am standing.
BoltPrime:
THERMAL CONCERNS: In my opinion, the stock machine has serious thermal management issues.
ODT (as delivered): 73° C
This temperature reading shocked me. Isolating BoltPrime completely from external heat sources reduced the temp perhaps by a degree. Initially, I was not controlling for tuners in use, recording, transfers, et al.
Disassembled the unit to take some measurements and begin analysis of the thermal design. Left top covers off as a temporary measure to keep temps down. Here are initial cover-off temps:
Stable 1 Tuner in use Temp: 54° C
Stable 4 Tuner in use Temp: 55° C
Stable 4 Tuner in use and streaming NETFLIX: 55° C
Ordered some materials to improve stock chassis thermal performance:
Noiseblocker BlackSilentFan XS-2, 50mm x 50mm x 10mm fan
4-pin MOLEX TX4 Extension Cables, 5 each
It appears the stock 15mm fan's headroom is so restrictive that it seriously hampers the already quite limited airflow rate. BoltPrime's 2-pin power supply circuit appears to be acoustically "quiet", but I am still going power the fan from the 4-pin HDD header 12 vdc rail to maximize fan speed/flow. I considered hunting up higher flow fans, but have reconsidered for now.
The prime heat generators in the device are the processor and cable card, but the shielded devices (tuner, et al) near the coax jack generate some heat as well and/or conduct heat from the inadequately cooled CableCard. The chassis engineers' thermal design intent is clear; it was simply, I suspect, compromised by higher priorities (production cost, size, et al). Ultimately, I do not think that I can adequately address the thermal management shortcomings without adding additional airflow. Such is not happening without additional ventilation and/or fan(s).
Consequently, I have purchased 2 additional "dead" Bolts to use for backup (BoltBack) and spare parts (BoltDonor). I can/will hack on the additional cases, keeping the original chassis unmodified.
====================
02/04/2017 - Thermal Management Update:
On a lark, I moved the fan from its place and simply set it on top of the heatsink, blowing down. Here are the results:
1 Tuner: 40° C
4 Tuners + Netflix: 41° C
An additional 14° C reduction vs. case removed, w/ no forced air.
A full 32° C (44%+) reduction over the "as delivered" configuration by a) blowing a little air over heatsink, and b) providing a larger delta temp between heatsink and surrounding air.
02/12/2018 - Here are the temperatures gathered for BoltPrime to date:
At Idle, OE Fan (CC): 73 ° C
At Idle, Noiseblocker BlackSilentFan XS-2 (CC): 64° C
At Idle, Noiseblocker BlackSilentFan XS-2, LS elevated (CC): 61° C
At Idle, Noiseblocker BlackSilentFan XS-2, LSFI elevated (CC): 59° C
At Idle, Noiseblocker BlackSilentFan XS-2, Vertical (CC): 54° C
Sustained transfer, Noiseblocker BlackSilentFan XS-2 (CC): 67° C
Sustained transfer, Noiseblocker BlackSilentFan XS-2, LS elevated (CC): 62° C
Sustained transfer, Noiseblocker BlackSilentFan XS-2, LSFI elevated (CC): 60° C
Sustained transfer, Noiseblocker BlackSilentFan XS-2, Vertical (CC): 56° C
TODO: control for CableCard cover removed vs installed.
The following images illustrate "Left Side elevated" (LS), fan isolator prototype, and "Left Side elevated with Fan Isolator (LSFI), and Vertical.
====================
Voltage Probing: Here are the voltage readings from selected locations. The red numbers in the following image correlate with the measurements below.
Vacant 4-pin header adjacent to the SATA header:
Pin 1: 3.55 vdc
Pin 2: 0.00 vdc
Pin 3: 4.76 vdc
Pin 4: 5.09 vdc
Fan Header:
Pin 1: 12.21 vdc
Pin 2: 0.00 vdc
HDD Power Header:
Pin 1: 0.00 vdc
Pin 2: 5.10 vdc
Pin 3: 0.00 vdc
Pin 4: 12.21 vdc
All voltages appeared rock steady on the VOM. I do not have a frequency counter or scope capable to look for switching activity on the 2-pin header power supply circuit.
====================
Wireless Network Adapter/Antennas: BoltPrime is physically connected to the network with wired Ethernet, so I decided to function test the system without the WiFi adapter installed.
02/04/2018 - Removed the Wireless Network Adapter and set it on top of the HDD to test. Rebooted the Bolt and cannot find any indication that it knows the adapter is missing. The card, antennas, and routing clips could be removed form the chassis. Set a static IP address.
02/06/2018 - Unintended consequences... Bluetooth functions are integrated on the WiFi adapter. Remove it and you lose RF remote capabilities to include VOX. Ultimately, I plan to put BoltPrime in a closet, thus I need to maintain the RF functions.
02/10/2018 - Considering purchasing a Roamio VOX remote with Bluetooth dongle. Should work, and if it does, I can remove the WiFi adapter. I've become concerned that the BoltPrime's WiFi adapter, even not being used, is interfering with my router's WiFi some 12 inches away and may be vulnerable to attack since I have no way to monitor or control it.
====================
I will continue to post back to this thread with updates as I proceed.
Love this stuff...
********************
This thread documents the modifications and upgrades I have made/will make to improve overall performance/capability and maximize the functional lifetime of my TiVO Bolt 500GB.
Thanks to ALL who came before and upon whose shoulders I am standing.
BoltPrime:
Tivo Bolt 500GB (white)
Date of Manufacture: 11 September 2017
Current Software: 21.7.2.RC12 (-USC-11-849)
Date of Manufacture: 11 September 2017
Current Software: 21.7.2.RC12 (-USC-11-849)
THERMAL CONCERNS: In my opinion, the stock machine has serious thermal management issues.
ODT (as delivered): 73° C
This temperature reading shocked me. Isolating BoltPrime completely from external heat sources reduced the temp perhaps by a degree. Initially, I was not controlling for tuners in use, recording, transfers, et al.
Disassembled the unit to take some measurements and begin analysis of the thermal design. Left top covers off as a temporary measure to keep temps down. Here are initial cover-off temps:
Stable 1 Tuner in use Temp: 54° C
Stable 4 Tuner in use Temp: 55° C
Stable 4 Tuner in use and streaming NETFLIX: 55° C
Ordered some materials to improve stock chassis thermal performance:
Noiseblocker BlackSilentFan XS-2, 50mm x 50mm x 10mm fan
4-pin MOLEX TX4 Extension Cables, 5 each
It appears the stock 15mm fan's headroom is so restrictive that it seriously hampers the already quite limited airflow rate. BoltPrime's 2-pin power supply circuit appears to be acoustically "quiet", but I am still going power the fan from the 4-pin HDD header 12 vdc rail to maximize fan speed/flow. I considered hunting up higher flow fans, but have reconsidered for now.
The prime heat generators in the device are the processor and cable card, but the shielded devices (tuner, et al) near the coax jack generate some heat as well and/or conduct heat from the inadequately cooled CableCard. The chassis engineers' thermal design intent is clear; it was simply, I suspect, compromised by higher priorities (production cost, size, et al). Ultimately, I do not think that I can adequately address the thermal management shortcomings without adding additional airflow. Such is not happening without additional ventilation and/or fan(s).
Consequently, I have purchased 2 additional "dead" Bolts to use for backup (BoltBack) and spare parts (BoltDonor). I can/will hack on the additional cases, keeping the original chassis unmodified.
====================
02/04/2017 - Thermal Management Update:
On a lark, I moved the fan from its place and simply set it on top of the heatsink, blowing down. Here are the results:
1 Tuner: 40° C
4 Tuners + Netflix: 41° C
An additional 14° C reduction vs. case removed, w/ no forced air.
A full 32° C (44%+) reduction over the "as delivered" configuration by a) blowing a little air over heatsink, and b) providing a larger delta temp between heatsink and surrounding air.
02/12/2018 - Here are the temperatures gathered for BoltPrime to date:
At Idle, OE Fan (CC): 73 ° C
At Idle, Noiseblocker BlackSilentFan XS-2 (CC): 64° C
At Idle, Noiseblocker BlackSilentFan XS-2, LS elevated (CC): 61° C
At Idle, Noiseblocker BlackSilentFan XS-2, LSFI elevated (CC): 59° C
At Idle, Noiseblocker BlackSilentFan XS-2, Vertical (CC): 54° C
Sustained transfer, Noiseblocker BlackSilentFan XS-2 (CC): 67° C
Sustained transfer, Noiseblocker BlackSilentFan XS-2, LS elevated (CC): 62° C
Sustained transfer, Noiseblocker BlackSilentFan XS-2, LSFI elevated (CC): 60° C
Sustained transfer, Noiseblocker BlackSilentFan XS-2, Vertical (CC): 56° C
TODO: control for CableCard cover removed vs installed.
- CC = with CableCard; NCC = No CableCard
- LS elevated = Left side of chassis elevated until internal fan is parallel to ground. Idea is that this will assist in breaking the air circulation short circuit and allow a little more efficient internal convection.
- LSFI = LS as above with addition of fan exhaust isolator. (aka: . See images/dimensions.
- "Sustained transfer" = Recordings being written TO the device under test (DUT) from another device.
The following images illustrate "Left Side elevated" (LS), fan isolator prototype, and "Left Side elevated with Fan Isolator (LSFI), and Vertical.
====================
Voltage Probing: Here are the voltage readings from selected locations. The red numbers in the following image correlate with the measurements below.
Vacant 4-pin header adjacent to the SATA header:
Pin 1: 3.55 vdc
Pin 2: 0.00 vdc
Pin 3: 4.76 vdc
Pin 4: 5.09 vdc
Fan Header:
Pin 1: 12.21 vdc
Pin 2: 0.00 vdc
HDD Power Header:
Pin 1: 0.00 vdc
Pin 2: 5.10 vdc
Pin 3: 0.00 vdc
Pin 4: 12.21 vdc
All voltages appeared rock steady on the VOM. I do not have a frequency counter or scope capable to look for switching activity on the 2-pin header power supply circuit.
====================
Wireless Network Adapter/Antennas: BoltPrime is physically connected to the network with wired Ethernet, so I decided to function test the system without the WiFi adapter installed.
02/04/2018 - Removed the Wireless Network Adapter and set it on top of the HDD to test. Rebooted the Bolt and cannot find any indication that it knows the adapter is missing. The card, antennas, and routing clips could be removed form the chassis. Set a static IP address.
02/06/2018 - Unintended consequences... Bluetooth functions are integrated on the WiFi adapter. Remove it and you lose RF remote capabilities to include VOX. Ultimately, I plan to put BoltPrime in a closet, thus I need to maintain the RF functions.
02/10/2018 - Considering purchasing a Roamio VOX remote with Bluetooth dongle. Should work, and if it does, I can remove the WiFi adapter. I've become concerned that the BoltPrime's WiFi adapter, even not being used, is interfering with my router's WiFi some 12 inches away and may be vulnerable to attack since I have no way to monitor or control it.
====================
I will continue to post back to this thread with updates as I proceed.
Love this stuff...