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(UPDATED) 3.2 kw chiller unit as a school project

post #1 of 45
Thread Starter 
hey folks im new here so hello

on this project im going to make this as a serius thing not like all the other fails ive done in the past. so i aquierd a r410a aircon that i will rebuild to a powerfull chiller yes yes i know about the high discharge pressures of r 410a an so on but i like tat its so effective of its task so thats why i went wit r410a this time also that its kinda cheap here in norway so heres som pics of the aircon itself also here a littlie clip of it running es love clips http://www.youtube.com/watch?v=qHpVXycFm-s DSC_0156.jpgDSC_0158.jpgDSC_0159.jpgDSC_0161.jpgDSC_0162.jpgDSC_0163.jpgDSC_0164.jpgDSC_0165.jpgDSC_0166.jpgDSC_0168.jpgDSC_0169.jpgDSC_0170.jpgDSC_0171.jpg

this unit is REALLY expensive like 1100 dollars new its crazy but i got this almost unused for 70 bucks biggrin.gif . so now i just need a vacum pump and gauge set for the recovery and modding of everything i also need a txv and a plate hx im gonna order that soon :shrug: the txv is a Danfoss tuae expansion valve with a 03 orfice rated for 2.9 kw and i have not yet desided on what hx to get :up: but heres some more pics of stuff i use and parts for the system biggrin.gif

well heres the recovery compressor its :banana::banana::banana::banana:ING huge copeland dwm 2 cylinder simihermetic compressor DSC_0175.jpg] DSC_0173.jpg

and the recovery tank wich i made today from an old reciver i had DSC_0176.jpg

and the filterdrier, sightglass, contoller for the temps, some relays and compressor cooling fans
DSC_0183.jpgDSC_0182.jpg
DSC_0184.jpgDSC_0181.jpg
DSC_0179.jpgDSC_0178.jpg

and i dont have dry nitrogen but i have a dry argon co2 mix here so that wil be my shield gas and purge gas cool.gif
DSC_0187.jpgDSC_0188.jpg

so thats all for today thanks for watcing this and remember this is a little project for me i dont do this for a living im only 16 so i do this for fun xD
post #2 of 45
Thread Starter 
ok progress sofar ive recoverd the rifigirant r410 a to a reciver and that is in my frezzer wich holds -48 C its REALLLY COLD almost like a cryostatic frezzer but it sits there happily at 1.5 bar witch is much less than what i thougt but when i turn the tank i can hear the liqid in there biggrin.gif but ive found a cabinet to put this in smile.gif and so here are some more pictures thumb.gif

NEW TOYS
IMG_8577.jpg
IMG_8576.jpg
IMG_8575.jpg
IMG_8578.jpg
IMG_8578.jpg
IMG_8579.jpg

heres my work space its bigger but went out of battery
IMG_8569.jpg
IMG_8570.jpg

i also got a 19mm shet of armaflex for insulaition of the heat exchanger its really expensive
IMG_8572.jpg

and the box ill have everything in perfect fit biggrin.gif
IMG_8581.jpg
IMG_8582.jpg
IMG_8583.jpg

and heres the 1.5hp compressor
IMG_8584.jpg



this is all for now and thanks for waching biggrin.gif
Edited by cooling-storm - 11/28/12 at 10:24am
post #3 of 45
Great stuff there CS.. looking forward to seeing how this progresses!

Just a some considerations that you may have already planned or thought of.
1. High pressure cutoff switch for safety
2. Mini receiver for the txv
3. Liquid line solenoid to prevent the migration of refrigerant to evap during off cycle.
4. 30 plate heat exchanger for the evap.
5. Reservoir sized for heat load.

I checked out your video.. nice unit, you might be able to wrap the compressor for sound levels. Btw...checked your other vids too, nice subs and music! 2000v thumb.gif

Thanks for posting!
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post #4 of 45
Thread Starter 
high pressure swich its a bit too expensive for my liking as im almost getting bankrup by all of this but if i can find a cheap used or unused one HELLYEA ill use it but i only have stuff thats rated for 28 bar and stuff mad.gif and the liqidline recidver is under planning its gonna be made out of some +30mm copper pipe with ends but the problem is getting a mall lenght og that tubing size i can only get it in 5 meter bundles grrrrrr thinking.gif but ill keep looking. but ill try to find a solinoyd that works i can sweep down to my local hvac place and ask if they have any used ones i can have and fush it with alcahol or r11
i want to go for a 50 plate cus its sooo cheap but im worried that that will become a ******* huge oiltrap and kill the comp mad.gif and this is going to be for multi use also for lazers and triac cooling and much more but i anm really worried that the heat exchanger will become a oiltrap or else everything is going as far as planned tongue.gif also an aditional question is how high shold the pressure cutout be confused.gif
post #5 of 45
Then run an oil separator or run the flow top to bottom for refrigerant, and counterflow with bottom to top for the fluid.
post #6 of 45
Good Advice Adam!


cooling-storm: You should be able to buy a small commercially made receiver on ebay cheap and a HPCO can also be purchased cheap on ebay (I would set it for no more than 300psi).
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post #7 of 45
When you are running it, keep in mind that R-410A is ok for AC and high temp refrigeration, but will have issues similar to R-22, and other high temp refrigerants, as the compression ratio goes up.

If you plan on going cold with it, you will likely run into issues with high discharge temperatures, which will cook the oil, and since it is a rotary compressor, cook the insulation varnish on the motor windings.
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post #8 of 45
You'd be amazed to know the r410a compressors commonly run to 140C and 450psi on hot summer days.
300psi won't cook it. Even deep in vacuum these things are very hard to damage.
post #9 of 45
Quote:
Originally Posted by NoL View Post

You'd be amazed to know the r410a compressors commonly run to 140C and 450psi on hot summer days.
300psi won't cook it. Even deep in vacuum these things are very hard to damage.

Yes, I do HVAC/R work in Texas, so I'm aware of how they can operate on a hot day. I've also seen the condensing temperature go above the critical temperature for R-410A, due to dirty condenser coils and air recirculation, on a number of occasions.

That has nothing to do with what I was warning about though.
The problem with air conditioning compressors, using high temp refrigerants, in a medium or low temp refrigeration application, has to do with the discharge superheat jacking the discharge temperature up above what is safe for the oil, or the insulation on the motor windings in a compressor that is cooled by the discharge gas.

I'm not saying it won't work, just that compressor life will be drastically shortened.
I may be unduly concerned about it though, as I'm used to working with equipment where the compressors are expected to last through 10-20+ years of use. PC coolers just don't require that kind of longevity.
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post #10 of 45
That's the same point though. We're agreeing on this one.
But part of it is while it might be running a bit high on the discharge, none of us are running even to 300psi high sides most of the time.
The discharges just aren't getting that far up there, so I don't expect to see the superheat high enough to rot these suckers.
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