Small Contest for a nice Christmas Gift

[runmc]

Wonder if I am even qualified to enter ? :P

Sure you can enter - but you don't get the prize

Can one person post more than one unit ?
and
We should post that worklogs in this topic ?

Post as many units as you like and most definately post your worklog. Worklogs are a big percentage of the overall ratings.

Are joint enteries allowed.? ie two mates building one system.?

Joint entries are no problem, but Lardy only has one mobo.

thanks Lardy for a cool contest. Happy Thankgiving

[Movieman]

Your all in trouble as I will be bringing in my quadruple cascade that goes to -300C with a write up done by Tom Clancy! I can't lose!

Oh, what's a cascade?

Yes, Gentleman, pure spam and a total joke!
Good Luck to you all!

[Noob-ftw]

Your all in trouble as I will be bringing in my quadruple cascade that goes to -300C with a write up done by Tom Clancy! I can't lose!

Oh, what's a cascade?

Yes, Gentleman, pure spam and a total joke!
Good Luck to you all!

Absolute zero is at -273.15ºC lol!

Anyways, good luck to the people who have the resources!

[jinu117]

I figured as much on not getting the prize part :P
If I can complete one of prototypes in time, I might just post that one up for fun of it ;P

[LardArse]

Are joint enteries allowed.? ie two mates building one system.?

Yes, you can, as there is also no way of monitoring how many people are actually building a rig. Of course it is evaluated as a single project. Now where's that first fresh work log..

[piotres]

*** ULTRAMARINE CASCADE BY PIOTRES ***



It's mine worklog, about mine latest build- still being builded cascade . It's ..not black . I have convinced mine very kind client to resign from very boring for me black color . He choosed blue . About hue of this blue - it's mine own choose, orginal name of powder paint is "ultramarine blau" .

Tech of that cascade is bit ordinary and boring again - just two rotaries, plate HX,4 REFCO gauges, plate HX, Danfoss TXV and R507/R1150 .

Specs :

compressors: TECO KETC176 on 1st stage (10755 BTU), LG 164PAB on 2nd stage (10000 BTU)
evap: steeper
XV: Danfoss TS2 / captube 0.9 mm
HX: plate HX , 12 plates
condenser: 3.0 Kw, alu-cu, cooled by 300mm/230V fan
refrigerants : R507/R1150
oilseparator : Shine Year automatic
safety : Danfoss KP5 cut-off, around 1.5 litre expansion tank
case : metal case, 60 x 45 x 40 cm, "ultramarine blau" powder coating
others: 4*REFCO panel gauges, ANACONDA shocks absorber on 1st stage's suction line,Dixell XR20CX controller (turn on 2nd stage automatically when 1st stage is enought cold), homemade receiver before Danfoss TS2, 4* NIDEC 120mm fans on the back wall of case.









Condensor is bit modded, becasue even in quite big, 40 cm tall case is too small space to mount huge condensor and panel gauges without colision .





First I don't have POE oil to prefill oilseparator . So I had brazed what I could, and then pour oil and made 3 last connections .









Electrics already done ;-) .



It's ...1st stage in 6*C ambient. Dixell work till sth like -59*C only, so it's out of it's rate .



Some frost with temporary insulation .



First 2nd stage run at 6*C ambient .



After first test I had got problems with 2nd stage ..low side was sth like +0.5 bara, hiside 4-5 bara (OMG what low) and cascade can hold 225W even with -80*C . So I've changed 2nd stage compressor for LG (at begining at this place had been Toshiba), 2nd stage captube, driers, and ...finally oilseprator . Yes, problem was with oilseparator, which had been releasing some hot gas from discharge line directly to suction side, all the time . So broken float . After changing oilsep for seconds pcs cascade works ...like You can see lower .



I must regulate TXV superheat screw a bit, becasue 2nd stage still fell lower than -60*C and Dixi had just turned mine 2nd stage down (when it runs with "P1" failure for longer time) .




Now "better " .



Under 225W load in 6*C ambient = -101*C .



2nd stage under load .



Leak testing with mine favourite "Amasan" leak finder spray . Any leaks founded .

Now I'll make insulation ...today or at friday .

I will finish this unit till sunday . Sunday is pick-up day .

To be continued ....

With Kindest Regards
Peter

[jan]

Lets see if i this works out nicely. It's been a while since i've built a singlestage

I went to the garage and collected some parts to start with...

I'll make a simple single stage unit using the following parts:

-ACC GP16FB compressor (16cm³ displacement)
-decent condenser, no pics now as it arrives not until next week (pic will follow)
-some evap that i found in the garage. It fits into the vapo mount so i'll try if its ok.
-CPEV (never used one before )
-refrigerant: R402a

The unit will be mounted on a simple aluminium sheet. I've not planned a case for now.


All parts except the condenser:




Today I prepared and brazed the evaporator. Its an simple stepper design so nothing special. I modified it to increase the surface area a bit.


And always remember, while using a bench drill you should wear your safety glasses.







The cooker helps warming it up. At least a bit.



Brazed and cooling down. Now i've to clean it and lap the bottom.



Today I got some work done. I assembled the suctionline and highside of the unit. Pics below:

First I lapped the evaporator. As my lathe is disassembled right now I did it manually
Start with rough paper and as you progress use finer paper until you get a flat evaporator bottom without grooves.



When I finished this I assembled the evaporator with the suction line.



Next I added the feed line for the CPEV



Now that the evaporator, suctionline and feedline were assembled I insulated it and put the evap into the Vapo mounting kit



This is the condenser I was waiting for:



I did cut in M4 threads for easy fan mounting:



With mounted fan it looks like this:





Now I mounted the compressor on the baseplate



next comes the condenser






Starting with the discharge line. I forgot a access valve, I'll add it later on when I finish the cooler.








Added CPEV and filterdryer










As I ran out of brazing rods the last thing I did was adding the suction line and some insulation:








Ok, here is the last part of my worklog.

I decided to use captube instead of cpev...






I did not have a t-connector to install a access valve in highside so i did one myself





evacuating...



...charging...



...with r402a



Its some time ago I've built my last singlestage so i had to make a new load tester.







255 watt




Insulated evap mounted on loadtester




the insulated unit ready to test






And this is the temp under load. Roomtemp was ~ 20 - 22°C




The temp is not that good. I think the evaporator is not capable of this load. Also I've to change the captube as it is to restrictive. I won't have time for this until early january So this is is the cooler as it is for now...


But I'll change captube and evaporator to yield better performance as soon as I've the spare time for it.

Also I could not test the unit under a lower load as I don't have a variac right now.

[n00b 0f l337]

Pio you sure you didnt just not prefill enough oil or something?

[piotres]

Pio you sure you didnt just not prefill enough oil or something?

No, I'm sure, I have already mounted some of those separators, all prefilled with same quantity of oil and all works ok except that one . Weird was that didn't make any hissing sound of gas comming to suction line .

[V2-V3]

Nice Im in, I just started building a SS tonight out of pure boredom. Ill start taking pix and try my hand at a work log and "How To"


* Edit * 06/12/07 06:30AM - Pictures taken and uploaded!
* Edit * as of 06/12/07 06:52AM - Pictures Updated
* Edit * 06/12/07 07:20AM - Compressor looks shot... Pulling LRA, *Searches for replacement compressor*
* Edit * 06/12/07 12:30PM - Compressor swapped pictures updated



a few years ago I to had a window ac unit for my PC room, with a phase unit built into my rig i have no need for it, and have chosen to put it to better use!





































Found replacement compressor and swapped as well as a new base for the unit!

[kayl]

nice work PIOTRES.
V2-V3 i think you might need some nitrogen, i dont think thats enough

[LardArse]

piotres, I love the attention to details, heheh you even put in a vibration hose at suction, damn... and 6C ambient, lucky man you are
V2-V3, seems like everyone is into rotaries these days

[V2-V3]

piotres, I love the attention to details, heheh you even put in a vibration hose at suction, damn... and 6C ambient, lucky man you are
V2-V3, seems like everyone is into rotaries these days

Rotary is down :P going back to the 3/4 piston for now. Damn thing weighs in at +60lbs

[boshuter]

Rotary is down :P going back to the 3/4 piston for now. Damn thing weighs in at +60lbs

Try to take more pics.... I think I missed the one where you plugged the vacuum pump into the wall outlet

[V2-V3]

Try to take more pics.... I think I missed the one where you plugged the vacuum pump into the wall outlet

Just forgot to upload it!

[piotres]

THX LardArse .

*** ULTRAMARINE CASCADE BY PIOTRES ***
Worklog - part II

Ok I've made insulation :



I've sticked almost whole 15 meters roll armaflex sticky tape there .







I must use some plastic tape, because normal insulation was too thick to mount case with 120 mm x 38 mm fans on back wall .

Same reason is for thiner insulation on 2nd stage compressor's acumulator .







To be continued ... .

With Kindest Regards
Peter

[jan]

I updated my worklog above. Cooler is nearly finished but I ran out of brazing rods.

[[XC] 2long4u]

jan, I dont know about that condenser. It will work its way down then have to go all the way up to the top 2 times.

[Duniek]

V2-V3
SS for PC @ semi hermetic
I always want to see it, but why you use vapo evap <?>

and for all
I will show my unit when I borrow/buy a new camera
only I can say now, it looks awesome

[jinu117]

Duniek? Have you played with vapo evap? (as in real tuning testing with proper components)

[Duniek]

Duniek? Have you played with vapo evap? (as in real tuning testing with proper components)

not yet
I want to make SS on vapo evap with new NL9F

I will post results in my thread for sure when it will be done

[piotres]

*** ULTRAMARINE CASCADE BY PIOTRES ***
Worklog - part III (last)

Case mounting, final tuning and pick up :



Inside of case .



As You can see condensor is big . If I look at that picture on my mind comes thinks about big from mount intercooler in tunned cars (I know - I'm sick ) - way bigger than hole in bumper . Same about that condensor (but hole is in case) .







That is what I have been thinking when I say about tricky job to fit condensor and gauges .





Nidec Beta V 120 x 38 mm 12V fans .





Transport from workshop to home .





First run in house, in 20*C ambient .





Temperatures of 2nd and 1st stage after tuning for load like 250+ wats .



On 225W dummyload after 30 minutes . I could tunned it for temperature around -98*C@225W in 20*C ambient, but I prefer to be sure that it'll cope with 250+W load good.



On 225W dummyload after 2 hours (and temperatures didn't rise in 3rd hour) .



1st stage temperature under 225W on evap .



Before closing ...
















Cascade with stuff needed for proper using it .



Last Sunday, around midday, cascade was picked up . From left : Jens (Musicismylife), Hoshi and Masterchorch .

They have traveled around 600km to pick up cascade .



After short test, I was cleaning evaporator .







Luckilly they traveled by combi car .



And one movie on youtube showing pulldown of 1st stage, and whole cascade :

http://pl.youtube.com/watch?v=V2KW3EVllYU

I hope Jens, Masterchorch or Hoshi soon will show some of their pictures here too .



With Kindest Regards
Peter

[Duniek]

JAH
next boring cascade

btw how much oil did you add to oil sep?

[piotres]

15 Oz = 466 grams

That's mine 666th post on this forum LOL.

[Polizei]

piotres... We have ounces to measure weight and ounces to measure volume.

Is the oil you used measured by weight or volume? Convert your mL to fluid ounces.