Ultramarine cascade

[piotres]

It's cascade and ....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 :heink: 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 .



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 .









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.
:banane:



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 .



One sunday, around midday, cascade was picked up . From left : Jens (Musicismylife), Hoshi and Masterchorch (all of them are XS forum members and some of Them I bet are also members of this forum :yeah: ) .

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 :

[link=hyperlink url]http://pl.youtube.com/watch?v=V2KW3EVllYU[/link]

I can add, that this project has won in competition for best worklog on XS forum .
:banane:

With Kindest Regards
Peter

[toaster]

very nice cascade, peter

[Moc]

Awesome ...
vor allem verstehst du auch Deutsch wenn du musst

[UnRockStar]

Look good

nur die Anaconda sollte paralell zur motorachse eingebaut

[Twisterking]

RLY NICE .... beautiful cascade!

[Flexus]

I've seen the Cascade on XS, very nice build!

Congratulations for the best worklog

Edit: @ Unrockstar: Außerdem sollte die Saugleitung irgendwo fest fixiert werden, wenn schon ne Anaconda verbaut wird, erst dann wird das Teil ja richtig genutzt..

[Pumpdown]

Look good

nur die Anaconda sollte paralell zur motorachse eingebaut

Jo ^^

The Anaconda ( Vibration Damper ) is in wrong incorporated.
By this kind of compressor´s it need a vertikal position.

Apart from that, it's a very good work dude ^^

By this speed of cooling i hope you have a sufficiently overheating in the heat exchanger.
The laying from the cupper pipe isn't very clear, but the electric it is.
Do youself a favour and don't learn from the electric work from Moc

Greetings, Pumpdown

[piotres]

THX :-)

In next cascade I'll try to put anaconda vertically, but it's not easy becasue of lack of space in systems which I build .

Cooper pipes are looking like this becasue I always put even small coax on discharge line from compressors, to reduce vibrations on pipes a bit .

Best Regards
Peter

[Pumpdown]

Oh yes, we know this method to reduce the vibrations, but what i mean is the rest of the laying - after the coax. If you look at the works from the other users you will see that we german mostly use Tongs to form our Copper Pipes. 90° Curves and stuff like this

I have forgot the correct word for this kind of Tongs, do you know what i mean?

[Moc]

Pipe bender?

[ice-man]

It's easier to use these twisted pipes, instead of 90° bends. If a pipe with more 90° bends is off a few milimeters you have to trash it. With twists you still have the chance to make it fit.
Nevertheless you make it look good all the time, very nice work.

Here an example:

[piotres]

Some OC using this cascade :yeah: :

[link=hyperlink url]http://www.xtremesystems.org/forums/showthread.php?t=171162[/link]