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Danfoss SC18CLs GPU SLI/CF Cascade - worklog

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piotres


Membre
Messages : 369

jeudi 22 mai 2008 à 23:04:09     
Hello

It's mine first SLI cascade, some mounths ago I have tried to make dual-evap one, but it didn't work fine becasue of too small condensor . This one has quite big condensor - dual fan 200mm each 230V, 3.6 kW condensor . Cascade will be using silent Danfoss SC18CL compressors and of course oilseparator with float. Adds like Dixell controller and 4 REFCO gauges kit started to be "normal" in mine cascades - everybody want that . Cascade will be using R507 on 1st stage and R23 on 2nd stage.

Specs :

compressors: 2 x Danfoss SC18CL
evaps and suction flex hoses: two GPU evaps : steeper design, 24mm tall, 42 mm diam., plus 120 cm long suction lines DN10 braided
XV: probably Danfoss TS2 on 1st stage/ captubes 0.9 mm on 2nd stage
HX: Plate HX, 12 plates
condenser: 3.6 kW condensor + 2x 200mm, 230V fans
refrigerants : R507/R23
oilseparator : Shine Year with automatic oil back
safety : Danfoss KP5 cutoff
case : Laser cutted and powder coated case (white) plus black details, wheels
others: Dixell XR20CX to control 2nd stage start, 4* REFCO panel gauges, expansion tank 1.1l Torecilla, two white CCFLs inside, 350 mm 230V blower fan on back wall.


It's worklog, now I've got bit longer break in work over it, becasue of problems with getting case for it, one workshop had "made" mine case for over 5 weeks, and finally I have gone to another one, becasue I don't like if somebody threats me in that way :mad:. I hope case will finally arrive to me next week .

Case will be BIG one, with 350 mm blower fan :yepp:. Case will be white with black details .










Two GPU evaps after final cleaning .









Big condensor and rest of parts .




That's 350 mm fan .



Condensor which I've parted for desuperheater for 2nd stage and condensor for 1st stage .



REFCO Gauges and Danfoss KP5 cut-off.



I've new googles , special designed for acet-oxy brazing - Nemesis IRUV 5 .





Suction lines .





1.1 l Torecilla receiver modded to expansion tank.

Couple of CCFLs which will be inside of case :





And 3D project of case :




More pics during few next weeks ... :yepp:

Thanks
Best Regards
Peter
Google




     
moyen_moins


aka metalazzo | Anti²Bug
Messages : 10207

vendredi 23 mai 2008 à 00:35:41     
You must pass a lot of time cleaning and polishing all those welds

Why do you want to use R23 for 2nd stage gaz ?
R170 is better, no (or R1150 but higher pressure on HP) ?
piotres


Membre
Messages : 369

samedi 24 mai 2008 à 00:30:03     
R1150 will give rather too high pressure in system like this, in 2nd stage discharge side .

I don't have oportunity to buy R170 . R23 isn't much worse than R170 .

Thanks
Peter
moyen_moins


aka metalazzo | Anti²Bug
Messages : 10207

samedi 24 mai 2008 à 02:00:02     
I believe before was using R170 in his 1st cascade...
Worked pretty well at that time
Good luck and keep the good work
Clemmaster


Benou lover <3
Messages : 5804

samedi 24 mai 2008 à 11:14:54     
QUOTE (piotres @ samedi 24 mai 2008 à 01:30:03) :

R1150 will give rather too high pressure in system like this, in 2nd stage discharge side .

I don't have oportunity to buy R170 . R23 isn't much worse than R170 .

Thanks
Peter

That would be interesting to test it.

SC18CL can cool down up to 400w @-35°C so with a CTD let say 3K you've got a -32°C condensing temperature in second stage --> ~18bar
That's still OK for this compressor that can run with 22bar in discharge line.

When I have time (maybe after you built this unit ) I'll work this out
piotres


Membre
Messages : 369

mercredi 28 mai 2008 à 22:21:40     
Hello .

I just want to say that aluminium custom case arrive to me today . Finally . Now it's going to powder coating workshop .

Thanks
Best Regards
Peter
piotres


Membre
Messages : 369

jeudi 29 mai 2008 à 22:49:22     
Hello



I've ordered two, so who wants next cascade ?





Packing was really good :yepp:.



Now time to some white powder coating ... .

thanks
Best Regards
Peter
moyen_moins


aka metalazzo | Anti²Bug
Messages : 10207

jeudi 29 mai 2008 à 22:54:21     
It's big.
Why don't you try to do a small but efficient cascade next time ?
kissagogo27


Méchant Vieux Râleur
Messages : 27634

jeudi 29 mai 2008 à 23:13:48     
it's not made in japan , that's why it's so big bigger => stronger
piotres


Membre
Messages : 369

dimanche 01 juin 2008 à 22:47:46     
Hello

To built efficient casade with 2 evaps (yes, please remember that will be dual evap unit) You need BIG condensor - I think nobody wants shut-down in hot summer days due to too high discharge pressure am I right ? That's why I use REALLY BIG condensors in all mine cascades, which is connected with using big cases .

Thanks
Best Regards
Peter
moyen_moins


aka metalazzo | Anti²Bug
Messages : 10207

mardi 03 juin 2008 à 21:47:29     
Hello Piotres !
I did not remember that this cascade was a dual evap one
Sorry
piotres


Membre
Messages : 369

samedi 21 juin 2008 à 11:29:25     
Hello

Gah, last time mine main work in learning for exams on politechnics . That's why updates are such rare . And mine powder coating workshop has problems with buying white paint .

After one week work will go ahead for sure (after 30.06) .

Today I want to show Suction lines :













Thanks
Best Regards
Peter
piotres


Membre
Messages : 369

jeudi 03 juillet 2008 à 00:15:19     
Hi

Progress :





All powder coated parts .







Some sound insulation .



Planning ...





Finally I've decided to use ALCO TI-HW expansion valve (will be working with R507) .









and custom made black bolts made on special request :



Now work should go much faster ...


Best Regards
Peter

Message édité par piotres le jeudi 03 juillet 2008 à 00:15:56
piotres


Membre
Messages : 369

vendredi 04 juillet 2008 à 01:27:21     
Hello

Today I've brazed whole cascade :


















...and I've start evacuation of 1st stage . Tomorrow I hope to see first frost on pipes .

Best Regards
Peter
moyen_moins


aka metalazzo | Anti²Bug
Messages : 10207

vendredi 04 juillet 2008 à 09:14:45     
Wow, impressive.
Waiting for results now
piotres


Membre
Messages : 369

samedi 05 juillet 2008 à 00:45:30     
Hi again

Thanks moyen_moins .

Next portion of photos, cascade was filled with R507 and R23 today (pure R23 on 2nd) ...





first frost on here pipes and -48C on 1st stage for "welcome" ..with insulation on HX made of old cloth LOL .



more frost ...



After a little tunning for load, with no load both heads was around -75C .



And that's with 485W total on heads (260W plus 225W dummyloads) ..a lot of heat put on danfoss hermetic 5/8 HP . I hope to gain few *C after insulation . I want to beat -60C with this load, and test it also with little smaller load (like will be used in "normal" benching becasue 260W dummy is .... killler load , I'm sure any GPU now doesn't produce so much heat ) ... .



Temperature of 1st stage idle and pressures in 2nd stage idle.



Pressures 1st stage idle .



Thick froooosssttttt .

1st stage compressor "holds" me a bit, with rotary there I can gain some *C, now with 485W put on 2nd stage, first stage is only sth like -22*C . For R23 that's still fine, but could be better .

Thanks
Best Regards
Peter
Clemmaster


Benou lover <3
Messages : 5804

samedi 05 juillet 2008 à 13:59:31     
Excellent job there dude

Can't wait to see final results

You finally got R23 hehe . You'll be able to make crazy 3 stager now
piotres


Membre
Messages : 369

dimanche 06 juillet 2008 à 20:52:53     
Hello

Thanks Clem, but what I can use in 3 stage unit on last stage ? R1150 ? will be non sense a bit ...

Yesterday's work :







I apply some paint on shiny pipes ..I'm BASTARD hehe . Black paint with "plastic" effect ...style is style, cascade is white with black details .





19 mm thick insulation on HX , rest has 18mm thick of armaflex .





Cascade is going to be finished soon ...whose we'll be next ?

Thanks
Best Regards
Peter

Clemmaster


Benou lover <3
Messages : 5804

dimanche 06 juillet 2008 à 23:56:09     


In any ways, it will be better than R1150/R1150
piotres


Membre
Messages : 369

vendredi 11 juillet 2008 à 01:07:56     
Hello



hehe NO NO I'm not Yato workman , this is only picture done in that way...these tools are cheap but quite good .

Electrics started ...





Mine helper ...



Who helps me wraping cables from insulation with some sharp tools ...





White light mounted .



I've even put case ...for very short time . I've noticed that fan is making horrible vibrations, I must buy new motor , in current one axis is crooked .



Insulation helps ...with same charge as I've done -75C without insulation. No load .



Some snow done during hot summer .

Thanks
Best Regards
Peter

perecastor


Modérateur-faker/Portuguais des iles/父 亲河&a
Messages : 15091

vendredi 11 juillet 2008 à 10:20:50     
Sweet !
Nice work!
piotres


Membre
Messages : 369

lundi 14 juillet 2008 à 23:08:46     
Hello






New fan painted white ...that one rotare properly .









1105W when cascade is working in idle .



1st stage temperature when it's loaded by 2nd stage cooling down 485 W ..not too cold but enought for R23 .



on 260 plus 225W both evaps have around -63C



1st stage loaded ..even 3.6kw condensor has some work to do .



2nd stage pressures loaded, dixell shows 1st stage temperature ...



Idle .



both evaps under 115w (each one) ...





In the dark ...









I almost forgot (again ) ....





Another armaflex sheets customer order in bigger qualities .





And 2 Youtube movies :

http://pl.youtube.com/watch?v=rbxRM76Irzw

http://pl.youtube.com/watch?v=E0DDLiYrz_E


Unit is finished, only packing left .

Thanks
Best Regards
Peter
Clemmaster


Benou lover <3
Messages : 5804

mardi 15 juillet 2008 à 13:19:09     
Not the most powerfull but the nicest build you've ever done

Excellent job there dude!

This case is very nice, the next one will be with 4 SC compressors in that case

Keep up the good work
piotres


Membre
Messages : 369

mercredi 16 juillet 2008 à 23:28:51     
Thanks .

Next build will be "value" rotary cascade . For sure it won't be looking more nice that this one .
pierreg60


Home-madeur en force
Messages : 3933

jeudi 17 juillet 2008 à 06:17:58     
Good job!!
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