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Thema: Miny Cascade : Budget Dual 1/2hp

  1. #1
    Erfahrener Benutzer Avatar von NoL
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    Standard Miny Cascade : Budget Dual 1/2hp

    So recently I had a few asks for a low budget cascade. Now normally those two terms can't be fit in the same sentence. Inherently, they are not low budget.
    But sometimes exceptions can be made. And normally that requires a bit of sacrifice. But sometimes, just sometimes, you luck out :p

    So, a miny cascade project. Dual 1/2hp 39R131F's from Rechi Precision.
    Short toppers, and they run a bit hot, but they've never shown me less than there full 1/2hp :p
    Condenser comes from a Copeland condensing unit (have about 20 of these things laying about, so time to use them).
    Desuperheater is my new miny condensers, just under the dimensions of a 120mm fan, they're absolutely midgetish! Fitting a 120mm Panaflo 12G12L fan for good air flow with mid range noise.
    Foam stack is the preinsulation first cuts for the 10 Plate HX. Which will be "bound" and insulated.

    3ft flex line, Evaporator to be determined, and HPCO on the way.

    The entire unit will most likely be cased in aluminum extrusion and acrylic/sheet metal to give it a solid indestructible approach. And of course I have a few other upgrades that can be fitted if the budget opens up a bit.

    As for refrigerant,

    R507a, R23 will be used.
    Although not many builders can get their hands on R23 due to cost, I have a 10lb cylinder to be used, and it is much more ideal than trying to muscle R1150 to condense.
    The goal will be about -70C, a solid dry ice range temperature, at the flick of a switch Of course unloaded will go lower for Spi etc giving that mid range bencher many are looking for to replace clumsy pots.

    Hope you all enjoy this build as much as I do, I expect to be done with construction when the final parts arrive by next week (tuesdayish) and tune in the week after.

    No owner on this one, so it might just go up for sale or just become a light weight show case.





    52xx btuh 1/2hp Rechi. The specs on these might as well not exist. Finding the right run cap will be hard since I've found 3 conflicting numbers, will try them all after tuning and see which produces lowest power draw.

    Progressing well, made the HX "box" from my favorite pink substance, and slot fitted the brazed and pressure tested plate HX. Using the mill I traced the ports and backside ridge into the foam. Snaps together, 3" thick, 10" tall, 5" wide. What a format.

    Enjoy. Evap ordered from Ron. And searching up the HPCO now. I have some valve mount ones, but I raelly have grown to dislike them. Getting a stable long term seal can be a pain or just a general fight. Tho I could rip one off the 3 stager...







    I'd recommend against R410a or R402a with these, they already run way to hot. I'm using r290 for oil, r507a primary, and already considering swapping to r134a if it'll do the r23.
    As to some updates, first stage done, just need to tune when second stage is finished and ready for it. But we have frost! Amazingly she's quite quiet. Certainly can here it, but if you push down lightly on the HX box to muffle the vibration, there's not much but air flow noise. And speaking of that, this condenser setup's quite nice. I'm glad I went with the 13W motor on the fan.

    I purchased a Supco vac gauge on ebay a while back, an old style one when my digital crapper out. It was sold as is, but at $25 it was hard to pass up. Even had a bidding war for it. But, I called Supco when I got it, told them I had purchased it second hand and wasn't sure if it was in Calibration.

    They said send it over, so I did. They even paid return shipping. Recalibrated, all good now. Talk about great service, it's an old model, nothing close to there new stuff even.








  2. #2
    ECrew Forum Avatar von Patrickclouds
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    clean work you did there
    i hope r23 will do a good job. if not there is r170 ethane, that has lower pressures than r1150

  3. #3
    Erfahrener Benutzer Avatar von NoL
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    Ethane is on order just in case
    It will end up being a very minimal in piping cascade, very clean. If you noticed, no oil separator! The temp range shouldn't be an issue with the Zerol 150 I changed the second stage compressor to.

  4. #4
    Erfahrener Benutzer Avatar von NoL
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    Who likes updates, I like updates!



    Most of the second stage brazed in, such a tight fit. And could barely braze it up without heat on the first stage, but wet paper towels work out great. Slight amount of heat got to the insulation of box, but it just deflected and melted away a quarter of an inch, now I can slot the pipe insulation in better! (Yay )

    We also have a date and trial time for this thing, Dumo over at XS would like a crack at it, but OCF is having there forum party and I think this will debut there.

    So three weeks. Enough time? Damn right.

    Enjoy the shot, I'll add in the HPCO later today when I finish pondering where I'll fit it, and then at this point we are just waiting on that evaporator to show up from Runmc.

  5. #5

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    i like it Looks like a clean build. Can`t wait for updates in this times of very rare compressorcooling news out there.

  6. #6
    ECrew Forum Avatar von Patrickclouds
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    what are the dimensions of the base plate?

  7. #7
    Erfahrener Benutzer Avatar von NoL
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    I'm building an aluminum extrusion around it, and it fits within...

    300mm by 480mm by 250mm

    Really small.
    Geändert von NoL (25.05.2011 um 23:00 Uhr)

  8. #8
    Erfahrener Benutzer Avatar von NoL
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    Big thanks to Runmc. Purchased an evaporator/mount on Monday, hear on Wednesday in the afternoon.
    Could not be better And if he was, he'd have to fend off the women more then I'm sure he has to.

  9. #9
    Erfahrener Benutzer Avatar von NoL
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    Update! Evap brazed, pick before cleaning, now cleaned up and ready to go. Then brazed on in, piped up, ready to do evvvilll. No, but ready to freeze stuff. Pressure testing, then vacuum and tuning. Let's have some fun.

  10. #10
    ECrew Forum Avatar von Patrickclouds
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    how long did you make your suction line?

  11. #11
    Erfahrener Benutzer Avatar von NoL
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    Went with a 4ft (1.2m) stainless steel from Yellow Jacket I had laying around. The flexibility in the line makes it feel like nearly 5ft though.

  12. #12
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    Vacuuming at the moment.

    Spent the day on the extrusions and making brackets. Production lined out 32 in a hurry.
    And a day of labor later....






  13. #13

  14. #14
    Erfahrener Benutzer Avatar von NoL
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    Yup yup!

  15. #15
    Erfahrener Benutzer Avatar von NoL
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    So the base, nicely assembled, squared out, and then filed some edges. Beautiful. Even mounted some epic 1" thick rubber feet. This won't shake any tables. Then time for the tense moment, the transfer. The big shibang. Now I wish I had Richard still around, but this was going to be an "on your own attempt". And two rotarys made it a bit of a lift.






    It survives!




    MMmmmmm pretty.

  16. #16
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    We have ice. High side of 65 psi with r23 straight... interesting.
    Will test load before going to r1150. Also need to heavily increase charge in first stage. But boy do these roto's run hot.







  17. #17
    ECrew Forum Avatar von Patrickclouds
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    keep the white baseplate clean

  18. #18
    Erfahrener Benutzer Avatar von NoL
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    Damn right I will. It's got a protective sheet on it to peel off (or try to) at the end of things.

    Just saw -95C unloaded. The more I charge the lower my unloaded, total reversal, but I think the first stage is just too cold.. At 200W it was starting to crash though (150W @ -84C) so need to add more to first stage, which I am waiting for it all to cool/warm up depending on what it needs to do .

    Current temperatures across the board at 150W so far.

    Stage 1 Discharge: 66C
    Stage 1 Suction: -55C
    Stage 2 Discharge: 54C
    Stage 2 Desuperheater bottom: 28C
    Stage 2 HX outlet: -51C
    Stage 2 Evaporator: -84C

    Rotarys are hot to the touch obviously, but with 90-110C being their upper range I am really not worried. Many get spooked when it's hot enough to burn your hand, but you get a burning sensation at about 45C on metal, after all 110F(+-) is quite hot. But rotarys will run well into the "I just cooked an egg on the .......... " territory.
    Since I think I am out of R290 I will stop by airgas tomorrow to pickup my order.

    Guess I'll get on the electrical side of things then.

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