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ULTRAMARINE CASCADE - 57 photos ;-)

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piotres


Membre
Messages : 233

mardi 25 décembre 2007 à 00:31:49     
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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.

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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 .

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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 .

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Electrics already done .

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

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Some frost with temporary insulation .

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First 2nd stage run at 6*C ambient .

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After first test I had got problems with 2nd stage ..low side was sth like +0.5 bara, hiside 4-5 bara :eek: (OMG what low) and cascade can hold 225W even with -80*C :eek: . 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 :shakes: . After changing oilsep for seconds pcs cascade works ...like You can see lower .

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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) .


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Now "better " .

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

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2nd stage under load .

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Leak testing with mine favourite "Amasan" leak finder spray .

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

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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 .

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Inside of case .

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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) .

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

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Nidec Beta V 120 x 38 mm 12V fans .

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Transport from workshop to home .

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First run in house, in 20*C ambient .

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

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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.

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

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1st stage temperature under 225W on evap .

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Before closing ...

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Cascade with stuff needed for proper using it .

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One sunday, around midday, cascade was picked up . From left : Jens (Musicismylife), Hoshi and Masterchorch (all of them are XS forum members) .

They have traveled around 600km to pick up cascade .

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After short test, I was cleaning evaporator .

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Luckilly they traveled by combi car .

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

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

With Kindest Regards
Peter

Message édité par piotresle mardi 25 décembre 2007 à 00:32:52
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mardi 25 décembre 2007 à 00:31:49     
piotres


Membre
Messages : 233

mardi 25 décembre 2007 à 14:29:57     
Today I can add, that this project has won in competition for best worklog on XS forum .
moyen_moins


aka metalazzo | Anti²Bug
Messages : 5200

mardi 25 décembre 2007 à 19:26:49     
nice work piotres
600km is a long travel for a cascade in a car
piotres


Membre
Messages : 233

dimanche 30 décembre 2007 à 01:56:13     
Some OC using the cascade :yeah: :

http://www.xtremesystems.org/forums/showthread.php?t=171162
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