4 Stage Cascade by august123

[august123]

Last October I started planning my new cascade.
First I wanted to build an 3 Stager, later I decided to build a "really" 4 stage cascade with sould hold about 200-250W at -160°C. I hope to come in this regions with this build, we will see.

Main Compressors are Danfoss/ Maneurop Reciprocating Compressors, I get them for good prices.
Everything is mounted on an steel construction, weight of all together is about 200kg I think Dimensions are 1,3m x 0,75m

Thread with the full story: ALL PICTURES + ALL Specs
http://www.extremecooling.net/index/...ic.php?31681.0


Technical Data:

Stage 1

Maneurop/ Danfoss MT50 Compressor 14,9m³/h /85ccm
4,1HP
400V 3~ three phase current
Two Condensors, together about 7.000 Watts Capacity, even enough for hot summer days
Expansion Valve Danfoss TS2 with external equalized pressure
Danfoss OUB4 Oil Seperator painted red
Penn High Pressure Cut- OFF Switch
3,4L reciever
Emkarate RL32h Oil
Refrigerant: R507A


Stage 2

Maneurop MTZ40 Compressor 11,8m³/h /67ccm
3,3HP
400V 3~ three phase current
Plate Heat Exchanger as Condensor: 30 plates
Evaporator: 16 Plates
Expansion Valve Danfoss TEB2 with external equalized pressure
Danfoss OUB4 Oil Seperator painted red
Penn High Pressure Cut- OFF Switch
little eciever
Expansion tank
Refrigerant: R23


Stage 3

Mitsubishi NHJ41VMD Rotary Compressor (7,1m3/h) ~3HP
selfmade TXV Valve
ESK OS-10 -12 Oilseperator
Penn High Pressure Cut- OFF Switch
Expansion Tank
Refrigerant: R14

Stage 4

Rotary Compressor “QX-12”
about 18ccm

Danfoss OUB-1 Oilsep + Temprite 340 Series
huge expansion ank
Penn High Pressure Cut- OFF Switch
Refrigerant R50
4m flexline + CPU Evap


Total electrical Motor Power: ~ 11,5HP
Total power consumption: ~ 6000 Watts at 400V/ 3~




After you read all the Specs, you may want to see pictures of the "Monster":

Planning the Unit in 3D CAD:










Plate Heat Exchangers, 30 plates for first, 16 second and 12 for third stage.






Refrigerants and Oil for the Compressors:






















These days, 3rd Stage is completed and is running just fine. I will start with the last stage in some weeks, need to buy some stuff.










On this picture are the temps with actual tuning, freqency converter for extra power in first stage. T1 is condensing Temp from R23, T2 is evaporating Temp, T3 is condensing Temp R14 and T4 is the evaporating temp at the plate HX.
(need to adjust TXV in second Stage a little bit more, to get compressor ice-free)




two of the electronic temperatur controllers, they start each stage automatic when temperatur is deep enough. Need to make nice control panel for them and the Build- In Manometers.



Hope you enjoy it

august

[[XC] gomeler]

Holy.. good job Very impressive, what load are those temps at?

edit: nm, I assume the 3rd stage temps were unloaded? Damn nice man, R50 will be wicked, want to see some "suicide" shots

[before]

Looks very impressive...

[t800]

looks very nice...u have "few" wires in electric panel :P

[DagoDuck]

This project is AWESOME. Keep up the good work, my friend!

[runmc]

Excellent build!! It is a pleasure to have your build here to study.

Your work looks very clean and organize, not cluttered and dangerous looking like some.

[7499richard]

holy that is so sick looking man.....it must sound like a jet engine, and literally not just a figure of speech lol

wicked project and awesome work.

how do you like those Allen Bradley terminals, I work in automation and work with those a lot, as well as Phoenix terminals, I find the Phoenix much nicer to work with.

[kayl]

go hard or go home hey
thats going to be a mean cascade
so whats going to be used for the refrigerant in stage 4, methane or methane/argon blend??

[godmod]

It is going to be R50, Methane.
Really nice build.

[Clemmaster]

"MT and MTZ compressors have a large internal free volume that protects against the risk of liquid hammering when liquid refrigerant enters the compressor. MT and MTZ compressors are fully suction-gas cooled. This means that no additional compressor cooling is required and allows the compressors to be insulated with acoustic jackets, to obtain lower sound levels, without the risk of compressor overheating."

For those like me who were hurt seeing this :



Impressive work and very nice compressors you've got there! Second stage seem a bit overkill with only -75.5°C evaporating temperature don't you think? Don't you think you could also switch 2nd and 3rd stage compressor to get benefit of the 67ccm for a gas with high specific volume like R14? In every case this beauty may work like a charm

Can't wait to see this beast loaded!

[SoulsCollective]

Needs moar jiggawatts.

In other news, if I pledge my soul and first-born child, can I touch it

[heanwi]

Good look transporting it to LANs and other events! :P What a mean machine...

[teurorist]

my hope is in the last stage 400V 3~ rotary because then he can use a frequency converter to change load temperature on the cpu

[Sneil]

Holy crap! That is one beautiful piece of work! That is one hell of a build, im sure this would have cost you close to 10Gs!!
Looks like you're an electrician too!
Amazing!

[toaster]

nice

[Pete]

This is wild and crazy but so cool. Amazing work and some real skill been put to use here. Dread to think what it has cost but well worth it.

Not tempted to try and expand on it and get LN2 temps?

[Marvin]

impressive. Awesome.
congrats

[4Qman]

Are you implementing any features to allow control of the temperatures for Cold bugged CPU's ?

Oh and awesome work. Very skilled indeed

[quintus]

''4m flexline + CPU Evap''

and i tought that you will have at least 4heads

succes,
q

[godmod]

Why would you want to use a 4 stage cascade on a cold bugged cpu???

[teurorist]

Because i think its more impressive to use a 9650 then anny a sokel or a old Intel but i also think it's a lot of fun to bench non cold bug cpu's

[Felipe]

lol!! 11hp cascade xDD

[n00b 0f l337]

Whoa 11hp? Wee inefficienct?
One of those maneurop in autocascade could hit your goal...

[jimmyxxx]

Holy **** , 6000W @ 400v, dam having that thing on for 3 hours should be very expensive.
11,5 HP

[[XC] gomeler]

Why would you want to use a 4 stage cascade on a cold bugged cpu???

Well I guess you could spend thousands looking for a cold-bug resistant chip. There are a few that seem to be able to handle more cold than others. It's going to be very interesting seeing what this thing can accomplish. I fear though it may actually be TOO cold for our uses Good thing he's got a frequency modifier but his first 3 stages would already be overkill