DM Cascade. My first Unit...

[Baron_Greenback]

Right guys I thought I'd share this with you as its my first attempt at building anything phase releated.

Im building this with the guidence of a couple of guys from BenchTecUK.

Advice and suggestions always wlecome :)


Luve 194 Condencer

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0074.jpg

A few shots of the case im constructing

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0081.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0082.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0083.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0141.jpg

28cc 1st Stage and 14.6cc 2nd Stage

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0140.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0138.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0137.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/DSCF0144.jpg



Lineset and a few other bit and bobs...

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0096.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0098.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0099.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0097.jpg





I'll update this thread with a bit more detail later in the week as Im waiting on bits to arrive and I gotta finish the case off.

Hopefully by next weekend I'll have some frost on the 1st stage!


Cheers,

Rich.

[n00b 0f l337]

First ever phase unit? And going to cascade? I wish you luck sir!

[bazx]

he has a fair bit of back up adam

good start barron cant wait to see ya benching with this

[[XC] gomeler]

28cc rotary.. Christ. Makes American 110v rotaries feel quite inferior :up:

[tiborrr]

I was about to say never to take on cascade on your first ever phase change build, but since you have such a great guidance from Benchtec boys (i guess bazx, SoddemFX, sacha35, ...) you will very likely do a great job.

Just remember not to be afraid to ask anything, understanding of basic principals of vapor phase change is crucial!

Best regards & best of luck!
Niko :up:

[Baron_Greenback]

Thanks for the comments guys.

I know I should really have started with a Single Stage, but Im never one for doing things by halfs! :D

I have had loads of help and encouragement from some very talanted guys, Baz, Sacha, Tom and Dulist. But the numero uno of helping me out and putting up with my constant silly questions has gotta be EvoCarlos, he a top bloke and without his help this would never have got started :p:

[Ozzfest05]

I want that condenser looks excellent in black

[runmc]

With the mentors you have, I'm sure you will have a great build.:up: Please don't leave out any details. :D

[QuantumZero]

hmm about time i should build one too.

[before]

Maybe, I'm not a good example; dunno really... but I started by building a 2-stager too.
No need to do a single-stage first (not cold enough IMHO, it doesn't worth the effort), it's all depends on how you are approaching the job.
Take care.

[sdumper]

Subscribed :--)

[Baron_Greenback]

A small update to todays progress :)

Built the HX enclosure

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0107.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0108.jpg

Painted the Case, this is not a very good pic, looks better in the flesh

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0111.jpg


Picked up a TS2 expansion Valve from RPW today

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0115.jpg

Also had a delivery from the nice people at BES :D

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0116.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0119.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0114.jpg

[runmc]

What size orifice did you get for the TXV? What number?

[Baron_Greenback]

Its a 01 size orifice mate, it may turn out to be too big and I'll need the 00

[biglipzit]

First unit being a cascade... you sir are my new Hero... Screw batman or superman... Your it!

[TheKarmakazi]

Good luck with your first build! Looks like its progressing nicely :)

[eligray]

biglipzit;3593220']First unit being a cascade... you sir are my new Hero... Screw batman or superman... Your it!

+1 :up:

good luck, going to be watching this one progress

[Baron_Greenback]

Another small update. Condencer now refitted and bolted down, 1st stage comp also bolted down. 2nd Stage positioned. Hopefully i'll have some frost on the 1st stage by tomorrow nght!


Space is gonna be tight when its all in there me thinks

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0129.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0130.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0131.jpg

"Unseen" controller from my old single stage. Im planning to use this to control the cascade. It has 2x 16A relays I can use to power on the 2nd stage when the HX reaches the right temp

http://i218.photobucket.com/albums/cc77/barron_greenback/DSCF0128.jpg


All for now.

[Baron_Greenback]

OMG what a day... After getting banished from my dads garage due to his "safety concerns" :lol: I headed over to Carls for a couple of hours to use his workshop services :cool:

13 hours later, and this is what we have....


Begining to look more like it...

http://i218.photobucket.com/albums/cc77/barron_greenback/DSC02466-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/DSC02467-1280.jpg

HX braised and installed into its box

http://i218.photobucket.com/albums/cc77/barron_greenback/DSC02468-1280.jpg

HX box, TXV, Filter and Sight glass installed and braised up

http://i218.photobucket.com/albums/cc77/barron_greenback/DSC02472-1280.jpg

Pressure tested to 20BAR and Tripple evaced

http://i218.photobucket.com/albums/cc77/barron_greenback/DSC02475-1280.jpg

After 2 hours under Vac green is for go! :D

http://i218.photobucket.com/albums/cc77/barron_greenback/DSC02481-1280.jpg

First frost! I have a lob-on :D

http://i218.photobucket.com/albums/cc77/barron_greenback/DSC02477-1280.jpg

Some temps and pressures, un-lagged and gassed with R404

http://i218.photobucket.com/albums/cc77/barron_greenback/DSC02476-1280.jpg

[Baron_Greenback]

At last, an update :biggrin:

After dragging my arse for 3 weeks, I finally got around to buying an Oil sep yesterday. So the next logical step was for us to spend till 3am building the 2nd stage, I did hope to have this finished lastnight (this morning!) but the after effects of 8 cans of redbull were not pleasent :lol:

Some pics of the nights progress....

http://i218.photobucket.com/albums/cc77/barron_greenback/Image144-1280.jpg

Controversial desuperheater mounting. This shouldn't matter as there will be no liquid in the pipes at this stage, just gas.

http://i218.photobucket.com/albums/cc77/barron_greenback/Image145-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Image147-1280.jpg

mmmmm.... sexy :cool:

http://i218.photobucket.com/albums/cc77/barron_greenback/Image148-1280.jpg


Maybe further updates later.

[runmc]

Mr Greenback - your black box is shrinking :D BRAVO :clap: Looking good :up:

[before]

Great work so far. :)

[[XC] gomeler]

Looks great. That DSH position should be fine as it's post oil-separator. I'm sure a little oil will escape the oil separator but it should eventually travel back. Looking incredibly clean for a first build :up:

[Baron_Greenback]

Another update :D

Gauges ready for mounting...

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image150-1280.jpg

2nd stage pipework now complete!

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image151-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image152-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image153-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image157-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image158-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image159-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image160-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image161-1280.jpg


And thats how shes stands now :D

A HUGE thanks must goto Carl for all his help with this unit, I couldn't have done it without you m8 :biggrin:

[Baron_Greenback]

First frost on the Evap! :D

Only running Co2 at the moment, so temps not great, but it works...

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image168-1280.jpg

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image172-1280.jpg

[GuGaCoSa]

Pure co2? Maybe a drop of another gas like propane would help the oil clogging issue, glad you didn't made your desuperheating coil too big..
Very nice unit, loved the bending

[[XC] gomeler]

:clap: Congrats on getting it up and running on the first go.

Pure co2? Maybe a drop of another gas like propane would help the oil clogging issue, glad you didn't made your desuperheating coil too big..
Very nice unit, loved the bending

He's using an oil separator, so the oil won't be freezing in the evap. He will however possibly run into dry ice issues but the use of CO2 is just temporary.

[Baron_Greenback]

Thanks for the comments guys :)

Yeah, the Co2 usage was only to get some frost and check the compressor tbh.

The system has been re-pressurised to 20Bar and will probs be left that way till next weekend for leak testing.

I still have a fair bit to do, I've gotta mount the guages, sort the controller and electrics. The 1st stage could do with some work to improve temps and 2nd stage need the cap tube cutting down.

[runmc]

Hey success - very nice :clap:

[aenigma]

Looks great Baron_Greenback and don't be so modest, those are nice temps for Co2! Congrats! :up:

[GuGaCoSa]

Have you already removed the co2 from the system? I would love to see some temps without tweaking and some load, but seems like you already took the co2 out.
Congrats for that lovely build.

[Baron_Greenback]

More progress this afternoon/evening...

All lagged up now. This was fun....

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image197.jpg


Guages fitted.... This is what happens when u let carl loose with a Label printer... He left his autograph! :lol:

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image193.jpg

[teyber]

LOL! a silly carlos :)

nice work :)

[tiborrr]

This is progressing rather nicely! Keep up the good work! What second stage gas will you be using? R23 or R1150, perhaps R170? :yepp:

Best Regards,
Niko

[eligray]

super nice man! Amazing work.

If you don't mind me asking, around how much $$$ did you put into this project?

[Baron_Greenback]

Another small update after yet another epic 13 hour stint in the shed.... The roads are quiet driving back at 4am :lol:


Started the wiring tonight. As always we tackled it the technical way using a wiring diagram... :rofl:

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image171.jpg


First problem was the IP box that I brought to house the start Caps was too small, so I had to go with 2 boxes instead. Here is the box for the 1st stage with the Huge 50 farad start cap.

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image162.jpg

Exhaust Fans mounted to the rear. I'll get round to giving the wholes a lick of paint.

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image169.jpg

Finally, I decided to bin the idea of using the Unseen controller and used a PID instead (cheers Dave i owe u a beer!) This takes a K-Type input so will be nice and accurate. Only test fitted atm to make sure it works ok.

http://i218.photobucket.com/albums/cc77/barron_greenback/Cascade%20Build/Image170.jpg


@ eligray - Total spend so far is close on £500, so iro $700US. Thats not including the cost of the Suction Line, evap, desuperheater (all from my old Single Stage) or the compressors thou :shakes:

[tiborrr]

Hi! What's the model of this PID thermometer you got there. I sure am interested in buying one! :)

[teyber]

ebay- they are abundant there for around $40

[tiborrr]

Yes, but what model/make? :)

[* icy *]

Something like this i think?
Click (http://cgi.ebay.com/PID-SSR-TEMPERATURE-CONTROLLER-FURNACE-KILN-OVEN-New_W0QQitemZ250380626328QQcmdZViewItemQQptZLH_Def aultDomain_0?hash=item250380626328&_trksid=p3286.c0.m14&_trkparms=72%3A1205|66%3A2|65%3A12|39%3A1|240%3A13 18|301%3A1|293%3A1|294%3A50)

[EvoCarlos]

Yes, but what model/make? :)
hey its this one :) here (http://cgi.ebay.com/PID-TEMPERATURE-CONTROLLER-4-Kiln-Oven-Espresso-Machine_W0QQitemZ150330226065QQcmdZViewItemQQptZAU _Business_Industrial_Restaurant_Catering_Equipment ?hash=item150330226065&_trksid=p3286.c0.m14&_trkparms=72%3A1205%7C66%3A2%7C65%3A12%7C39%3A1%7C 240%3A1318%7C301%3A1%7C293%3A1%7C294%3A50)

Something like this i think?
Click (http://cgi.ebay.com/PID-SSR-TEMPERATURE-CONTROLLER-FURNACE-KILN-OVEN-New_W0QQitemZ250380626328QQcmdZViewItemQQptZLH_Def aultDomain_0?hash=item250380626328&_trksid=p3286.c0.m14&_trkparms=72%3A1205|66%3A2|65%3A12|39%3A1|240%3A13 18|301%3A1|293%3A1|294%3A50)
thats the same thing :) same pin layout and specs as far as i can see