Mother of all Cascades, -100ºc Dual Evap that Cools the Motherboard also!!

I used a wet flame retardant rage and some wet rages to keep the head element cool.

http://www.public.iastate.edu/~nknau...ct%20(251).jpg

With the new valve in I tube them also.

http://www.public.iastate.edu/~nknau...ct%20(253).jpg

I put a pressure tape in so I could check my liquid line pressure before the TXV valves.

http://www.public.iastate.edu/~nknau...ct%20(254).jpg

http://www.public.iastate.edu/~nknau...ct%20(255).jpg

The system is setting tonight with 300 psi on it to help check for leaks. I did find 4 leaks this time before leaving for the night. I think I found them all.

I'm hopping to run the 1-Stage tomorrow. I can't wait to see if I hit the temps I'm looking for.

looks good man. Man that's a bunch of copper pipes running everywhere. Looks crazy...it really does make it look like a mad scientist contraption.

I'm also still curiouis to see how the dual TXV thing works, rather than just one handling both 2nd stages.

Quote:

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Originally Posted by gclg2000

looks good man. Man that's a bunch of copper pipes running everywhere. Looks crazy...it really does make it look like a mad scientist contraption.

I'm also still curiouis to see how the dual TXV thing works, rather than just one handling both 2nd stages.

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That is the look I was looking for.

I haven't even finished this one and I have a few ideas if I make another.

Wow, amazing work and some amazing dedication to get the project finished with all that crap that has happened to you!! Hope you get a good job with some good people quick man... ;(

nice pipework man.. that is smooth

damn you work fast.

Some more excellent work, this project has been really interest to follow, hopefully you can see some fruition from it soon.

G

simply amazing! hope you get it to work the way you want now

Very cool project, looks great! Keep going :woot:

Quote:

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Originally Posted by gclg2000

Well we all know the temporary alternative to a girlfriend. Good work man, keep it up.

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locking youself in a garage and tinkering with your motorbike, works for me

congrats on passing you exams mate and another girlfriend will come along :)

some results already :toast:
like always this keeps looking better and better :clap:

13th Update 9-29-05

With everything tube up I can get started insulating it.

On the 1-Stage I used 3/8" with 1/2" wall insulation

http://www.public.iastate.edu/~nknau...ct%20(258).jpg

One the 2-Stage I used 3/8" with 3/8" wall insulation

http://www.public.iastate.edu/~nknau...ct%20(260).jpg

http://www.public.iastate.edu/~nknau...ct%20(261).jpg

http://www.public.iastate.edu/~nknau...ct%20(262).jpg

To get the 2-Stage insulation to take the temps there going to be at I need the line to have 3/4" wall insulation. Since I couldn't find any I have taken two 3/8" wall to make my one 3/4" wall insulation.

http://www.public.iastate.edu/~nknau...ct%20(263).jpg

http://www.public.iastate.edu/~nknau...ct%20(264).jpg

I found out that Copeland puts the discharge on the bottom back side. I made a mistake and tube the discharge line to the oil return line. A dumb mistake but I caught it. When I got it and it didn't have directions in the box I made a call to my contact at Copeland and he sent me a fax. But by the time I got it I had already tube it.

http://www.public.iastate.edu/~nknau...ct%20(265).jpg

More insulating pictures of the 2-Stage lines

http://www.public.iastate.edu/~nknau...ct%20(266).jpg

Looks so pretty

http://www.public.iastate.edu/~nknau...ct%20(267).jpg

http://www.public.iastate.edu/~nknau...ct%20(268).jpg

its looking very nice, i hope ya see better first stage temps with that new compressor

excellent work !!!!keep going

damn, can't wait for the next update

a true masterpiece!
:toast:

14th Update 9-30-05

It’s alive, It’s alive and it still doesn’t work like I want it to!

What the h-ll is f--king going on!

All day yesterday I double vaced each of the systems down. I have the systems under about 300 psi with dry Nitrogen. You let out the Nitrogen until it’s almost down to 0 psi in the system. I stop at 1-2 psi. Hook up the vacuum pump and pump the system down low as I can get it with that vacuum pump and hold it there for 1 hour. After that hour I put more nitrogen in the system back up to 300 psi and let it out back down to 1-2 psi. Then vac it down for 2 hours and move on to the next system. The way this was explained to me it helps get all the moisture and air out of the system. I let the systems set over night under a vacuum. No leaks

With this done I charged the 1-Stage. I used a digital scale to find out how much of a charge I was putting in the system.

http://www.public.iastate.edu/~nknau...ct%20(269).jpg

I put 1 lb 7 oz in of the ISCEON 89.

I can only get my evap suction line down to –20C and the discharge line leaving the TXV’s down to –35C. I have 23 degrees of superheat. The suction line is at 4 psi. According to the charts I’m at –57F or –49.5C in the evap. Which sounds good to me, I would like to be –60C to –55C ideally.

The thing I don’t get is my compressor is bigger and has higher Btu/h at the low temps then Chilly1 aka Reggie and he is getting lower numbers using a smaller compressor.

You can see with my SC18 I did this on one of the evaps suction lines.

http://www.public.iastate.edu/~nknau...ct%20(222).jpg

That’s –48.9F so that’s -44.9C on the suction line where I’m only getting –20C this time around. I didn’t take the discharge TXV line temp so I don’t have that number. And the degrees superheat was high also. I don’t remember the number but it was in the 20’s. I need to get it down to 8-12. If I can do that my suction line pressure will come down and the temps also.

I forgot to add the new TXV valve is working great. They are both with in 1 to 1.5 degrees of each other all the time. So I don’t think it a mechanical problem with the valves.

For everyone to think about and if you have any ideas let me know. I’m taking day to make a lot of phone calls to people that are smarter than me to see if I can come up with a solution to this problem.

First run with SC18MLX it does 2999 Btu/h with evap at –10F, the Copeland can do 4340 Btu/h with -10F evap and 3300 Btu/h with -25F evap.

With both compressors I have had a superheat that is in the mid to low 20’s, with the
SC18 I hit –44.9C on the suction line coming out of the evap, with the TVX screwed all the way in. The system acted like the TXV’x were to big but that could have been because the compressor wasn’t big enough to do the job.

This time with the Copeland I have a 23-degree superheat, -20C suction line temp out of the evap, suction line pressure at 4 psi, the TXV’s are screwed almost all the way out. That valve now act like they’re to small.

So that’s my problem with the 1-Stage

The 2-Stage I have another. I ran out of Ethylene R1150. That sucked I was able to put about 1/3 to ½ the charge I need in one of the systems on the 2-Stage. I had to see what I could do with it. I still hit –69C with that. I think I’m going to hit my goal, but I need more R1150. Time to go shopping.

The ISCEON 89 cost about $700 for a 28lbs, so that’s $25 bucks per lb. Not cheap, I’ve used 2 lbs so far.

I’m moving home and will try to find out what is going on with the TXV’s or compressor. I will buy more R1150, so once I get the controller and all the other parts I will drive the 2 ½ hours back to Ames from my home to do some more work on this project. I’ve gotten far as I can this week.

I had someone send me this famous quote from Albert “Great things don’t come easy or everyone would be doing great things” I know I’m no Albert, but I think this project was a great idea.

keep at it mate the harder it gets the more satisfaction you will have when it works.

I want to build one now only a single stager lol

The valves are all the way out, Try running them in a little at a time until you get a temp at the second stage condenser discharge in the -40C range.. This will be the absolute warmest you want to operate at at this point... your superheat may be a little high but let it run under load first and tune it from there..

keep up the good work man.. its getting closer and closer!

I have really enjoyed reading this thread :) Altough I have noting to contribute with myself, I just wanted to congratulate you on the nice work, and wish you good luck, I really hope you get it to work according to your high standards soon :) This cooler/case is just amazing, I love all the guages on the front, it looks really cool, this is definitly a work of art.. :toast:

I'm going to keep beating my dead horse....but.....i think potentially you might have some issues w/ the dual TEV's. If you fire one 2nd stage up, the element in the TEV is going to adjust the pressure differential and flow rate of the TEV that is controlling whatever 2nd stage (of the two 2nd stages you have) your running. But even when the other 2nd stage isn't running, the other TEV will still squeeze down itself and adjust for a "no load" or "zero load" on the other 1/2 of the evaporator of the 1st stage. I think possibly that when one TEV is adjusting itself and changing the pressure differential (acting as the metering device it should be) the pressure on the inlet of one TEV is "building up" behind it and affecting the pressure on the high side of the 1st stage. This could possibly be affecting your other TEV and not allowing it to function as it should...based solely on the sense bulb and element inside the TEV.

Now that being said...i think it happening to a degree...but i'm not sure how much it could be affecting it. I still think if you had one TEV on the 1st stage and just went into your #1 2nd stage and then channeled it through your #2 2nd stage condenser, you could set and adjust your superheat better, and better manage the load. Cuz you have more than enough power on the 1st stage to manage both those 2nd stage compressors going at full tilt...i say think about using 1 TEV on the 1st stage...load up both 2nd stages on the evaporator of the 1st stage and "set it and forget it." This way it won't matter if you oly run one 2nd stage at a time...we know if you tune it for both 2nd stages, it can easily manage the load of just one.

I think this would elimnate alot of headache and potentialy painfull adjustments not only to each TEV on the 1st stage, but you still have both PEV's to deal with on each of the 2nd stages...

I hope it all makes sense what i said...kinda rambling on here, and i can't really put it to words that well.

gclg2000

Sporlan thinks the valves are two small, I'm getting a new kit to make them a 1/4 ton. I'm going to try this and see what happens.

But don't you think I should at least get one to come down to temp? I'm not even close to the temp I need. Everything at this point tells me the valve is to small. At this point I want it to be so when I go to the 1/4 ton it fixes my problem. Sporlan tells me there should be no problem running two valves in the system like I am. That they have seen it done before with no problems.

just a question, how much has this cost you for so far???
i would sure want on like that, but damn, the price must be awesome
keep up the good work

Quote:

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Originally Posted by GoThr3k

just a question, how much has this cost you for so far???
i would sure want on like that, but damn, the price must be awesome
keep up the good work

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you can handle that question via pm.