Massive Cold Chamber Revived for Under $1,300

Massive Cold Chamber Revived for Under $1,300

A massive industrial thermal testing chamber, worth tens of thousands of dollars new, has been brought back to life for a fraction of its original cost. The creator managed to acquire the unit for less than $1,300, including delivery. This impressive feat was achieved by creatively repurposing salvaged parts and employing skilled technicians.

The chamber, a decommissioned Environics unit, was found in surprisingly good condition despite being over 10 years old and stored outdoors. It even came with complete documentation and service history. Integrating such a specialized piece of equipment into a testing lab typically runs into the hundreds of thousands, if not millions, of dollars.

From Dumpster Dive to Functional Lab Gear

The journey to get this giant cold chamber working involved overcoming significant hurdles, primarily related to its cooling system and control electronics. Initial estimates for professional integration ran up to $4 million. However, by working with the technicians who originally decommissioned the unit, the project’s cost was drastically reduced, costing less than a tenth of the initial estimate.

One of the first challenges was the chamber’s water-cooled system. Since it lacked its original large condenser or rooftop cooling unit, a new pump system had to be devised. Scrap cooling towers were considered, but they lacked the necessary capacity to dissipate the heat effectively.

Improvisation is Key

The solution for cooling involved a temporary setup using a direct city water connection. Cold tap water is run through the system to cool it, and then the warmed water is discharged. The technicians emphasized that this is a temporary measure for the video, with plans to find a more permanent solution.

The refrigeration side also presented challenges, as the unit arrived completely empty of refrigerant gases. The team successfully sourced and charged the system with R508B, an ultra-low temperature gas. This required specialized knowledge and licensing, as the gas is not commonly available and handling it can be tricky.

Mechanical Fixes and a Modern Upgrade

Mechanical issues were also addressed. One of the two compressors had a leak, causing its oil to become contaminated. This required the oil to be removed and the system purged of moisture, a critical step to prevent problems with the refrigerant.

A significant upgrade involved replacing the original Windows XP-era control system. The old touchscreen and internal PC were swapped for a modern Watlo F4 controller, similar to what’s used in many environmental chambers. This simplified the interface, making it easier to operate the chamber remotely for target temperature, duration, and shutdown sequences.

Performance and Testing

Once operational, the chamber was tested for its cooling capabilities. The original specifications indicated a cooling rate of 1.75° Celsius per minute with a significant load. While the refurbished unit is slightly slower when empty, it still performs at about 80% of its original capacity, which is more than adequate for its intended use.

The team demonstrated the chamber’s power by having a person briefly enter it. Temperatures quickly dropped to -22° Celsius, and after further adjustment to -40° Celsius, the internal temperature reached -48° Celsius. This extreme cold showcases the chamber’s impressive performance, even with its temporary cooling setup.

Who Should Care and Why?

This project is proof of resourcefulness and technical skill. While the creator doesn’t have an immediate need for the chamber’s full capabilities, it’s ideal for industrial applications requiring environmental validation for outdoor equipment. This could range from testing solar panels in extreme conditions to ensuring the durability of electronics in environments from Arizona to Antarctica.

For those needing to test equipment under extreme temperature fluctuations, a unit like this is invaluable. The cost savings achieved by refurbishing rather than buying new are immense, making advanced testing accessible to more businesses and researchers.

Specs & Key Features

• Product: Environics Thermal Testing Chamber
• Acquisition Cost: Under $1,300 (including delivery)
• New Unit Cost: Tens to hundreds of thousands of dollars
• Refurbishment Cost: Less than 1/10th of a $4 million integration estimate
• Cooling System: Water-cooled, adapted with temporary city water connection and salvaged cooling towers
• Refrigerant: R508B (ultra-low temperature gas)
• Control System: Replaced Windows XP PC with Watlo F4 controller and Raspberry Pi
• Temperature Range: Capable of reaching below -48° Celsius (tested)
• Original Cooling Rate: 1.75° C/minute (with load)
• Current Performance: Approximately 80% of original capacity
• Noise Level: Over 100 dB (requires soundproof housing)

Why It Can’t Stay

Despite its successful revival, the chamber cannot remain in its current setup long-term. The primary reasons are its extreme noise levels, exceeding 100 dB, which would require a specially built, code-compliant room for housing. This room would need to include plumbing, fire suppression, noise insulation, and adequate electrical systems.

The immense heat generated by the chamber requires significant external dissipation, estimated at up to 200,000 BTU per hour. This would necessitate a large, robust cooling tower and potentially reinforcement of the building’s roof, adding substantial costs and complexity that outweigh the benefits for the current owner.

A Second Chance for the Cold Chamber

The technicians at Carmichael, who performed the refurbishment, are offering the fully functional chamber for sale at the cost of acquisition plus transport. While the buyer will need to handle refrigerant capture and recharge, the overall expense is a fraction of purchasing a new unit of similar size and capability.

This remarkable project demonstrates that even the most specialized and expensive industrial equipment can be given a new lease on life with ingenuity and expertise. The offer to sell the revived chamber presents a unique opportunity for businesses needing extreme environmental testing capabilities.

Source: I Spent $20,000 on This and I Can’t Keep It… (YouTube)