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Old 06-15-2016, 11:23 PM   #1
Sparkey247
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Titan SS 1HP Build log

First and Foremost i would like to thank Drewmeister for personally helping build this beast.

it started out a few years ago when i built my first unit which can be found here (again with the assistance of Drewmeister)

Since i built that unit i been looking out for a/c units here and there and picked a few up at the local goodwill. always with the intention to maybe build a second one, maybe as a back up

one of the units was a Samsung unit with hefty condenser. I later bought another Evap (Kayl) the unit i belive was a 6kBTU. i originally ran R-290 through it (sorry no pics) and the thing ended up sitting in the garage for about a year.

eventually when a comp rolled around Drewmeister and me started talking as i was familiar with S478 he picked my brain a little bit and we got to trading hardware. one of the trades was a 1H.P. compressor. which is where all this got started.

the majority of these parts were bought from and traded from Dremeister along with his expert work.

started out with 20" x 18" high density 3/4" Slab of Wood.

I ran to the local ACE Hardware (many many many times) looking for something suitable for feet. these happen to com 4 to a pack and are meant for keeping furniture from sliding around win win. they were about a 1/4" thick and i needed them to be taller so i got washers from my shop 3/4"x2 inside 1 1/8" ubolt washers that turned out to be about another 1/4 thick which would give me enough clearance on the base for drilling and tapping (into wood) the bolts that would hold down the comp. tapping the bolts into the wood was Dremeister's idea and man it was a great idea added some nice rigidity.

i reused the cap from the original Samsung unit (for the Fan) along with the condenser and fan (which i had to modify to fit.

my only two braze joints on the unit were the brazing up the evaporator and the line coming from the condenser to the T junction at which the High Pressure Cutoff switch is bolted on. everything else was done ala Drewmeister. He's been doing this for a long time and i trust his braze joints more than my own especially when it came to brazing the flex line, in the past i have had many issues getting stainless to braze to copper

the compressor is run off a secondary capacitor both are mounted to a basic yet cool mount Drewmeister fabricated.

the beast was left to pull down over night (evac) the next day we got to filling and tuning.

initially we used straight 410A but ended up topping it off with 290.

which yielded the following temps

at a 50watt load we got -60C
at a 150watt load we got -55C
and for grins
at a 250watt load we got -50.5C

this was amazing as the last unit would max out @ 47c on a cold run after it reached O.T. it would be around -40 @ idle.

there were a few growing pains we ended up with a small leak at the high pressure cutoff switch but Drewmeister helped me fix it.

I will be taking more pictures of the unit and posting them as i have to retake some because my phone went awall and killed my SD card i will post more pics soon.

the unit is currently running with a cover that drewmeister built and it looks bad ***
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Old 06-15-2016, 11:37 PM   #2
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Old 06-15-2016, 11:50 PM   #3
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http://imgur.com/a/E3CpF

dunno whats going on but i am unable to upload images directly
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Old 06-17-2016, 06:36 PM   #4
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Just link the URLs to the individual photos in the VBscript.

Edit: Glad to see the spirit of this forum is alive and well.
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Old 06-21-2016, 03:31 AM   #5
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I'm looking forward to the rest of this build.
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Old 06-26-2016, 10:40 PM   #6
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i will be doing some touch ups on it in the next day or so and will post more pics

pics will be numbered from left to right top to bottom only way i can figure to do this a decent way lol.

1. this is how it started I traded some Hardware with Drewmeister and he Had me hooked when he said a 1H.P. would yield temps close to -65C i was sold
2. had a few different plans on the base but ended up using a high-density plywood that again drew Brought over for me
3. & 4. the feet I purchased at the local Ace Hardware they are meant to keep furniture from sliding around, they were a bit too low so I had to build them up with some 1 1/8' washers with 2 3/4' washers. this was to make space so that the bolts holding down the compressor would not hit the table before the feet do
5. & 6. Drew had an awesome idea and told me to thread the bolts into the wood instead of just drilling them to slide through
7. the clearance needed for the bolts for the comp was attained with the washers under the feet
8. finally mounted
9. my original thought was just to have a switch for on and off this idea was later scrapped
10. measuments of the hight of the condenser for building the cover
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Last edited by Sparkey247; 06-26-2016 at 11:24 PM. Reason: Automerged Doublepost
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Old 06-26-2016, 10:58 PM   #7
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1. & 2. again measurement of the hight of the condenser. (on the leg of the workbench is the most important tool any guy can have in his garage a bottle opener)
3. we decided to use the stock shroud from the original Samsung A/C unit. this Braze joint was the only joint we didn't do and that it was brazed from the factory
4. a birds eye view of everything mounted the shroud from the fan was on the loose side as well as the shroud on the condenser, both of which in this picture were only held down by 6 wood screws
5. we decided it would be easier to just run dual caps this one is the stock cap that handled the original comp and the fan, currently it only handles the fan.
6. i originally made this l shaped bracket to support the caps. later it was repurposed to hold the Drier in place as drew made a simple but nice aluminum cap bracket.
7. & 8. the condenser was quite big and curved at one end (no pun intended lmao) we had to bring it right up to the edge at the back and a little inboard on the side to keep clearance for the side panel
9. the copper tube on the bottom of the condenser was the only joint i had brazed int eh past along side the evap lol
10. another pic of the factory braze
11. 12. another pic of my braze this area was later scrutinized by me because there was a leak
13. the beast
14.the mock up of the filter drier and right behind is the port for the high pressure cut off switch
15. mock up of the piping coming out of the accumulator, behind the comp is the high side mockup going into the condenser
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Last edited by Sparkey247; 06-26-2016 at 11:40 PM.
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Old 06-26-2016, 11:01 PM   #8
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1. out of the comp the mockup for the lowside service port
2.,3., & 4. Drewmeisters awesome brazing on the copper to stainless to evap
5. & 6. after about 1 hour of so we pulled down to 305 microns
7. high pressure cut off switch
8. the bigger cap is the original cap which is utilized for the fan the smaller cap was for the comp
9. the simple bracket Drew created fo the mounting of the caps. and the shaft where we had cut of off
10. after a whole night we got down to 129 microns
11. rough placement of both caps
12. i believe we went with 10ft of .036 cap tube
13.,14., & 15. preliminary run was with straight 410A which was not all the cold but still colder than my previous unit. later it was decided to add a shot of propane. then it was time to do some testing out came the variac and drews own load tester
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Last edited by Sparkey247; 06-26-2016 at 11:50 PM.
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Old 06-26-2016, 11:05 PM   #9
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1. Drew Brought over his Variac for tuning.
2. Drew's Load tester that is hooked up to the Variac. this time I made the top plate to fit more sockets. including socket A,939,am2
3. during a first run within seconds it pulled down to about with just 410
4. got the load tester frosting up
5. & 6. @ -52c it was already colder than startup temps on my previous unit which would get -47c
7. & 8. & 9. & 10. we decided on a mix of 410 and a shot of 290. which ended up holding 248 watts at -46C
11. pressure is upwards of 300 ish psi (high side) on this unit where as my last one was about 170psi
12. got some awesome frost happening on the accumulator
13. 410
14. & 15. first night first run unloaded with the mix hitting -63.3C
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Last edited by Sparkey247; 07-10-2016 at 03:13 AM.
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Old 06-26-2016, 11:07 PM   #10
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1., 2., & 3. after an hour or so of tuning we were getting nice chunks of frost
4. comp temp reaching 78C
5. another shot of frosted Accumulator
6. taking temps reading at different points on the comp
7. & 9. & 10. 50 watts load @ -60C
8. i believe this was line draw at 50watts
11. -55C @ 150watts load
12. -50C @ 252watts load
13. total unit power draw
14. & 15. had the Pentium d 940 hooked up for some real life testing and was able to boot all the way up to 1.8 volts the old unit would crap out at 1.6volts
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Last edited by Sparkey247; 07-10-2016 at 03:20 AM.
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Old 06-26-2016, 11:11 PM   #11
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1. another shot at live testing
2. my phone had crapped out and i lost some images so i had to retake some. the front of the unit has an arming switch (left) which feeds power to comp switch (right) temp display and aux psu for fans and lights. the right switch will not function unless the left switch is on. front vent and side vents i purchased at at Menards and blacked out the louvers with satin black Rustoleum.
3. the exit hole for the evap line has old power cord rubber lining the hole as to prevent tearing of the flex line insulation and cover. at the bottom I made a holder for the evap when transporting out of an old leaf spring spacer pad
4. side vents one on each side are 10" X 10", another shot of the holder. and hard to see but the power plug stress relief is in line with the bolt that holds the evap line at the top.
5. better shot of the stress relief connector.
6. at the back of the unit i had cut the hole for the condenser. the mesh is from a screen door screen protector and the out line is made from 1" x 1/8" thick aluminum which i used as a border because my sheer skills on the panel are not that of an artist. they were painted satin white
7. made two little nice junction boxes for the DC Psu for fans and lights (yes fiddy cent @ goodwill can beat that) next to the Psu is one of the two ballasts for the cold cathode red lights.
8.clamps holding the low side line. a heap of wires, switches on front only handle upwards of 10A so for the high-pressure cutoff and the switches Drew wired in a relay mounted on top of the fan shroud on the left. also two screws tieing the shroud to one of the cross braces on the top
9. view from the top of the cross braces and how the condenser ties to the second brace. and the mounting of one of the cathodes on the right brace
10. the high pressure cut off switch which caused a leak that we had to attend to
11. another birds eye shot of the top
12. a shot of the relay
13. used a 9 position connector i bought at radio shack for the main harness
14. the bracket i originally made for the caps was repurposed here to support the Dryer with a simple hose clamp for rigidity
15. another shot of the drier
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Last edited by Sparkey247; 07-10-2016 at 03:39 AM.
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Old 06-26-2016, 11:12 PM   #12
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1. a shot of the left side of the unit where the High-Density board end panel and stainless tie into each other.
2. the top cover flipped upside down to show Drew's master placement of the armaflex tap to keep rattles down.
3. my handy work with the armaflex covering the screws for the back grill
4. front panel, Drew's wiring expertise came out looking awesome
5. the male and female 9 position connector.
6. quick connects for the front cathode and the front vent fan
7. back grill with cover insatalled
8. where she will spend her life crushing scores still have some aesthetics to take care of she is a work in progress
9. mounted and ready for work
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Last edited by Sparkey247; 07-10-2016 at 03:51 AM.
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Old 08-12-2016, 08:23 PM   #13
StuartF84
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Awesome build guys! I have a few questions. How did you choose the RKA5510EXA tecumseh compressor? Why not use a compressor designed for r410a such as HGA5453BAA? As I understand 410a is best used with POE or Polyvinylether oil. Did you drain out the Synthetic Alkylate that came with the compressor and replace it with POE? Are you able to run 24/7? Keep up the good work.
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Old 08-13-2016, 05:14 AM   #14
Sparkey247
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Thanks, the compressor was chosen by Drewmeister. it was given to me as payment for hardware that is how this whole build got started lol. as far as what oil is in it I'm not sure you would have to ask Drewmiester. I use it for benching as of writing this I just came off a 5-hour bench session where it was running non-stop.
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Old 04-04-2017, 11:16 PM   #15
Drewmeister
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Is it still alive?
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