Stewie's Chiller Revision 3.0b Build :)

[Stewie007]

Each pump is a high capacity chemical pump. The Condenser will utilize a Little Giant 3-MD-HC Pump that is good for up to 750GPH. The Chilled side will be powered by a powerful TE-5.5MD-HC capable of up to 1200GPH.

The Smaller pump doesn't have a loud motor, and most of the noise comes from the cooling fans for the motor. The 5.5 makes a consistent whine that is less noticeable when it actually is pumping water. But like the other, its fan makes considerable noise. However, in the enclosure, most of that sound will be kept to a minimum.

[Stewie007]

The compressor is a Tecumseh model, AJA2419ZXA. It's a 0.928 displacement, 1865 BTUH, 1/2HP Compressor. I'll be using it with R507, instead of R404A (it is obviously rated for both).

[teyber]

looks sweet! those pumps are monsters!

keep it up!

Regards

[Stewie007]

I got a nice thick piece of 3/4" ply tonight, so if it rains again, I'll be workin on the chiller tomorrow.

[Stewie007]

Its designed for highly corrosive solutions. Ryton (Polyphenylene Sulfide) should suit whatever solution I use. Besides, its better than some of the pumps people use in these things .

I still don't know what kind of solution I want to use anyways. I've been thinking about a propylene glycol solution with either alcohol or water due to its better temperature properties than ethylene glycol. I'm anticipating a -20 to -10F solution temperature for normal operation.

[Stewie007]

United Refrigeration sells propylene glycol in 1 Gallon, 5 gallon and 55 gallon containers. Obviously, I'll get the 5 gallon hehehe.

Its pricey though.

It provides freeze protection in solutions with water to -60F and costs about 175 bucks pre-tax for 5 gallons.

[Stewie007]

Sorry, it being a busy time I didn't really do anything for the past few days.

[TopherTony]

Hey stewie, be very careful with that compressor. I used a tecumseh aka9455zxa r404a and it gave me nothing but problems. It drew so many amps that it destroyed the start cap. Just watch out. Other wise, looking great. That pump looks like a BEAST!!!

[Stewie007]

How do you mean?

[Stewie007]

Today was a big day for the chiller. Last weekend I bought the 3/4" plywood that I'll be using for the base, as well as a few fittings.

I used one of those lever flare tools (the ones with the squeeze handles, I like em better than the metal ones; alot easier to hold on to.



I started with the suction line and then the chill tubing. I set up the compressor in the front and center, but put the cooler in a little closer. The pump sits up on a block, perhaps the same one in the final build, just cut to better fit. The suction line and water lines are cut and fit into more clean corners and straights. The pictures on the bottom have the water line included.

The Area with the Tee and valve and stem is where the equalizer line for the TXV will go, along with the bulb.

[Stewie007]

I placed the liquid line filter running over the condenser, coming close to the stems near by, but not actually touching. Its somewhat close, but far enough away to not be a bother. And actually, in this picture, its closer than it will be, since its not brazed, and the tubes move a bit because of weight.

[n00b 0f l337]

Stewie you brazing or soldering? That hard drawn pipe or refrigeration tubing?

[Stewie007]

Then, I followed with the condenser, and the condenser water loop. Now, in the pictures, the water loop for the condenser appears quite off kilter. That is because of the fit up at the cooler. I'll fix that after brazing; although its not a problem. It just bothers me because it doesn't look right.

All in all, this is the assembled appearance of the chiller pre-brazing. It looks alot better than the last so far; I think. It's more condensed, and uses space more functionally I think.

[Stewie007]

The last of today's pictures.

[Stewie007]

As you can see, I've been busy today. I worked from about 3:15 to 6:00 getting this fit-up right. Tomorrow, its the desk project, so I won't be doing any brazing until next week.

For now, its disassembled, and separated accordingly for reassembly soon. I think I'm satisfied with how it has gone so far. I still have to insulate the cooler, and I got the official paint colors; a nice deep blue high gloss exterior paint with a grey primer.

[Stewie007]

Stewie you brazing or soldering? That hard drawn pipe or refrigeration tubing?

Sorry, was in the middle of a posting run... hehe.

Some of it is hard drawn. I'll definately be brazing.

[n00b 0f l337]

Watch out with that stuff, can expand
As for solder Q, ur access valve looks soldered in

[Stewie007]

Nahh, those are brazed, gas flux was used. One of them came partially melted at the joint.

As for brazing; I don't anticipate any problems. I'll be silvering everything, using black flux. Shouldn't be a problem.

[n00b 0f l337]

Maybe I missed something, but whats with the empty center of the hx's?

[Stewie007]

In conjunction with the offset inlets, it helps promote a vortex flow pattern, while cutting down the internal volume of the heat exchangers. I will improve efficiency by keeping the water moving through, without hanging around for too long.

[n00b 0f l337]

Oh so nothings going in that area? Gotcha gotcha! Great idea

[Stewie007]

I can't wait to get it running

So what do the rest of you guys think so far?

[teyber]

you know what we think of it XD

keep up the great work

[Stewie007]

I Insulated and painted the cooler today. This is the official color scheme. The condenser will be the same color. A Nice Blue ITs still wet, though.

[Stewie007]

5 hours later and its still tacky. I guess its not fast dry paint, hehe. Its drying to a more deep blue than the picture looks; although I did use a flash; it was dark.