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 The 2nd pic is a little outdated near the 2nd stage compressor (in the II stage) beacause the oil separators outlet leads directly to the accumulator.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/berku.../sideshot3.jpg
http://www.members.lycos.co.uk/berku...a/sideshot.jpg
How does the whole I stage look like...
http://www.members.lycos.co.uk/berku...compressor.jpg
http://www.members.lycos.co.uk/berku...essormodel.jpg
http://www.members.lycos.co.uk/berku...ia/compcon.jpg
The I stage compressor.
http://www.members.lycos.co.uk/berku.../condenser.jpg
http://www.members.lycos.co.uk/berku...denserside.jpg
http://www.members.lycos.co.uk/berku...topnia/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/berku...nia/filter.jpg
The filter is preety oversized but it also serves a accumulator purpose during startup
http://www.members.lycos.co.uk/berku...a/hxbefore.jpg
http://www.members.lycos.co.uk/berku.../hardening.jpg
http://www.members.lycos.co.uk/berku...stopnia/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/berku.../sideshot2.jpg
View on the filter + txv assembly
http://www.members.lycos.co.uk/berku...ctionline2.jpg
The suction line on the I stage....
http://www.members.lycos.co.uk/berku...topnia/txv.jpg
http://www.members.lycos.co.uk/berku...opnia/txv2.jpg
http://www.members.lycos.co.uk/berku...opnia/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
