My cascade.... MK7

[berkut]

Hello


What can i say, she's finnaly made. Maybe a short story...

I started making her @ 11.06.2003 (9 months ago), and was supposed to be a quick project made out of a A/C unit and my thrusty Danfoss SC10b. Well, the A/C leaked on the condenser. Later came the "mk2" part where the condenser was changed with the old A/C's evaporator, also a bummer (leaks). At that time i made a preety nice heat exchanger, made of 16m 8mm OD pipe and 16m 5mm od pipe, soldered by their sides.

Later i started making the "tower" version, after i got a Tecumesh RK5510 a/c compressor in my hands. After a first failed revision i decided to water cool the condenser, the system was supposed to be dual head and everything was supposed to be nice. It even didnt leak... well, than i had to change the oil in the compressors. The system was completelly disasembled, it took me a while to drain the oil from the compressors.

Now it was some time for miniaturisation, the MK5. It was supposed to be a small system, fitted inside a 50x30x50cm box, dual stage compressing in the II stage. Then my bad luck reached its top: a brand new condenser leaked like hell. After that i had a lil depression and wanted to throw that project away, during that time i made a gas turbine (jet engine) beacause i didnt know what to do with myself. After some time i was ready to start the project again.

The MK6 was almost a succes. Dual stage compressing worked ok, non of the compressors overheated, the injector worked flavlessly, the vacuum inside the evaporator was huge. As i said it ALMOST worked... the oil separators didnt work.

And now... finally after so much pain and misery comes the MK7...

http://www.members.lycos.co.uk/berkut0/KASKADA/1.jpg
http://www.members.lycos.co.uk/berkut0/KASKADA/14.jpg

Theres no insulation on the II stage yet, exept that everything is finished. The 2nd pic is a little outdated near the 2nd stage compressor (in the II stage) beacause the oil separators outlet leads directly to the accumulator.

But from the begening, the I stage:

http://www.members.lycos.co.uk/berkut0/opisIstopnia/sideshot3.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/sideshot.jpg

How does the whole I stage look like...

http://www.members.lycos.co.uk/berkut0/opisIstopnia/compressor.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/compressormodel.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/compcon.jpg

The I stage compressor.

http://www.members.lycos.co.uk/berkut0/opisIstopnia/condenser.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/condenserside.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/fan.jpg

The condenser and fan assembly comes for my almost first refrigeration system wich i bought as a water chiller.

http://www.members.lycos.co.uk/berkut0/opisIstopnia/filter.jpg

The filter is preety oversized but it also serves a accumulator purpose during startup

http://www.members.lycos.co.uk/berkut0/opisIstopnia/hxbefore.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/hardening.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/hx.jpg

The hx is made of 16m 5mm OD pipe and 16m 8mm OD pipe... soldered together by their sides..

http://www.members.lycos.co.uk/berkut0/opisIstopnia/sideshot2.jpg

View on the filter + txv assembly

http://www.members.lycos.co.uk/berkut0/opisIstopnia/suctionline2.jpg

The suction line on the I stage....

http://www.members.lycos.co.uk/berkut0/opisIstopnia/txv.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/txv2.jpg
http://www.members.lycos.co.uk/berkut0/opisIstopnia/txv3.jpg

The TXV is a ALCO TIHW, for R22, no mop..

Ok, now the II stage.

Lets start with the 1st stage compressor:

http://www.members.lycos.co.uk/berkut0/KASKADA/7.jpg

You can see the interstage deasuperheater and the SC10B...

http://www.members.lycos.co.uk/berkut0/KASKADA/8.jpg

Its oil separator

http://www.members.lycos.co.uk/berkut0/KASKADA/5.jpg

A sideshot

Now, the 2nd stage compression:

http://www.members.lycos.co.uk/berkut0/KASKADA/16.jpg
http://www.members.lycos.co.uk/berkut0/KASKADA/12.jpg
http://www.members.lycos.co.uk/berkut0/KASKADA/18.jpg

The assembly...

http://www.members.lycos.co.uk/berkut0/KASKADA/11.jpg

Its oil filter

And now, the evaporator:

http://www.members.lycos.co.uk/berkut0/Parownik/4.jpg

The parts the evaporator consists of

http://www.members.lycos.co.uk/berkut0/Parownik/7.jpg

The base

http://www.members.lycos.co.uk/berkut0/Parownik/8.jpg
http://www.members.lycos.co.uk/berkut0/Parownik/9.jpg

How its fitted

Almost made:

http://www.members.lycos.co.uk/berkut0/Parownik/21.jpg
http://www.members.lycos.co.uk/berkut0/Parownik/20.jpg
http://www.members.lycos.co.uk/berkut0/Parownik/18.jpg
http://www.members.lycos.co.uk/berkut0/Parownik/19.jpg
http://www.members.lycos.co.uk/berkut0/Parownik/16.jpg

The injector assembly...

http://www.members.lycos.co.uk/berkut0/Parownik/10.jpg

A hole for the temp probe

And after brazing:

http://www.members.lycos.co.uk/berkut0/KASKADA/2.jpg
http://www.members.lycos.co.uk/berkut0/KASKADA/3.jpg
http://www.members.lycos.co.uk/berkut0/KASKADA/4.jpg
http://www.members.lycos.co.uk/berkut0/KASKADA/6.jpg

Any comments needed ?

I use a almost identical evaporator in my friends system and works PERFECTLY!! So far its the best one i ever made/used, its only limitation is the way it can be mounted (only 3 possible positions)

Temps... Cant really tell the temps right now, i only tested it with R22. A cascade, with a 5psi condensing pressure, dual stage compressing is "a bit" of a overkill. To see what happens with higher head pressures i filled the system with some argon. The suction pressures remained exacly the same (about 20-22hg), the middle section pressures increased slightly (from a preety deep vacuum to a little less deep) and a 20 bar head pressure... The injector still throtelled properly @ 5V (nominal)....

Further tests this week with R23....


berkut

***edit*** changed the server, pics should work

[nas]

gona leave it for the night to load the pics ^_^, looking great so far

[xxORBxx]

OMFG i cant wait for the pic. I think something is wrong with them, it just never stoppes loading. If i had more than 5mb of space i would host them. Anyone have some free space?

EDIT is spoke too soon. Looks amazing for a first time job by an 18 year old lol

Temps?

[crotale]

The images are on the heavy side.
You should be able to reduce them to 1/10th of the size using ImageReady, or something similar. Just a tip.

Looking really good BTW!

[kommando]

Lol good untill the second stage images §§§§d up.

[Maxprime]

Nice work

[DaBit]

Can't view all the images. Please resize 'em :)

[berkut]

The pics should work now preety fast

[DaBit]

Indeed, now I can see them all. Damn man, this looks more like a complete chemical plant than a cascade...

But pictures are always less clear than a real 3D view. My finished cascade (http://www.icecoldcomputing.com/generic/imagehandler.php?hval=98bbfc816116cdaf1dee482a6bd9 03f0&quality=high) also looks more like chemical plant on photo than in reality.

You're also brazing the stainless hose now?

How did you cap the MAPP bottle you're now using as oil sep?

One remark: the way you hooked up the temp sensors will give you an inaccurate reading. Use thermal paste, wrap with a piece of aluminium(foil), then insulate.

[berkut]

You're also brazing the stainless hose now?

How did you cap the MAPP bottle you're now using as oil sep?


I always brazed it

I drilled out the safety valve, and the acces valve, sealed shut the safety valve and brazed everything up nicelly...

Damn i need R23 right now...

[berkut]

http://www.members.lycos.co.uk/berkut0/KASKADA/19.jpg

Load tests.... of course treat all the frost as the heatload... Gary please dont die :D

Ill give you the temps + pressures on the I stage in a moment.

[berkut]

One remark: the way you hooked up the temp sensors will give you an inaccurate reading. Use thermal paste, wrap with a piece of aluminium(foil), then insulate.

I use thermal paste

Yes, i will insulate it in a moment when taking measurements for Gary

[kommando]

Loooka mada, whats that things on the evap?

[berkut]

what gas is in you'r 2nd stage ...and what is the evap temp's for 2nd stage.



R22 currently... didnt have any time for playing with R23 as i have test exams in my highschool tomorrow... learning, learning.... polish + biology

Im importing ethylene from germany, a 2l bottle costs 100$

Gtg and learn

[HungryForHertz]

HOLY.... Thats quite something, I can't wait for temps!

[IvanAndreevich]

berkut
Ã�îçäðÃ:banana:âëÿþ! In other words - cool! I am looking forward for some tests.