Cooling SystemsCooling Systems

Your GoalYour Goal

To understand cooling system design and maintenance as it applies to Waukesha’s current production products with standard cooling systems.

Installation Manual

Installation Manual

• Form 1091

How Much Work Does the Cooling System Do?How Much Work Does

the Cooling System Do?

Fill/Drain Valve

W a u k e s h a Pump

Thermostat(s)

Filter

Vent Line(s)

Expansion Tank

Pressure Cap

Heat Exchanger

Static /BalanceLine

The CoolingSystem

W a u k e s h a Pump

Thermostat(s)

Filter

Vent Line(s)

Expansion Tank

Pressure Cap

Heat Exchanger

Static /BalanceLine

Fill/Drain Valve

W a u k e s h a Pump

Thermostat(s)

Filter

Vent Line(s)

Heat Exchanger

Static /BalanceLine

PressureCap

W a u k e s h a

Pressure Cap

Thermostat

Static/Bal.Line

Pump

Fill / Drain Valve

Heat Exchanger

Fill/Drain Valve

W a u k e s h a Pump

Thermostat(s)

Filter

Vent Line(s)

Expansion Tank

Pressure Cap

Heat Exchanger

Static / BalanceLine

Effect of Static Head Pressure

Effect of Static Head Pressure

SystemPressure

2.3 Ft (70cm) WC= 1 psi

System Pressure Curves - Pump OffSystem Pressure Curves - Pump Off

Pressure Rise Across PumpPressure Rise Across Pump

Pump On

With Balance Line, Pump OFFWith Balance Line, Pump OFF

SystemPressure

With balance line, pump offWith balance line, pump off

Pressure Increase at InletIncreases System PressurePressure Increase at Inlet

Increases System Pressure

SystemPressure

No balance line,pump off

No balance line,pump off

Combined effect, pump on

J.W. Pump Inlet Pressure Requirement

J.W. Pump Inlet Pressure Requirement

-10

-5

0

5

10

15

20

25

10 12 14 16 18 20 22 24 26

Water temperature to pump (X10 deg.F)

Pressure(psig)

Minimum PumpInlet Pressure

Water VaporPressure

From S7424-1

J.W. Pump Inlet Pressure Requirement (metric)

J.W. Pump Inlet Pressure Requirement (metric)

.32

.66

1.00

1.34

1.68

2.02

2.36

2.70

38 49 60 71 82 93 104 116 127

Water temperature to pump (deg.C)

Pressure(bar)

Minimum PumpInlet Pressure

Water VaporPressure

From S7424-1

VGF Surge Tank

VGF Surge Tank

Static Line

Sight Glass

Fill/Drain Valve

W a u k e s h a Pump

Thermostat(s)

Filter

Vent Line(s)

Expansion Tank

Pressure Cap

Heat Exchanger

Static /BalanceLine

Coolant Filtration

Coolant Filter Options

Coolant Filter Options

• Use on ALL engines!

• Advantages:- cleans system.- extends pump life and packing rings.

• 15 - 25 micron.

• 2% bypass flow.

• Two sizes available.

Raw (Fill) Water Recommendations

Raw (Fill) Water Recommendations

• < 1 PPM Total Dissolved Solids (TDS)

• Deionized water preferred (rental unit makes 2000 gallons, $130).

Glycol: EG vs. PG ?Glycol: EG vs. PG ?

• Glycol is NOT required.

• Glycol may be desired for freezing and boiling protection.

• Ethylene glycol (EG) generally preferred over propylene glycol (PG), due to its lower viscosity and pumping losses. However, PG has lower toxicity.

Coolant CompatibilityCoolant Compatibility

• Do not mix “Long Life” orange or red/orange coolants with yellow, green, purple, or blue coolants.

• If mixed, premature WP seal, liner cavitation, and aluminum corrosion failures may result.

InhibitorsInhibitors

• Inhibitors are required in all systems.

• Purposes of various inhibitors:- protect engine metals by preventing scale, corrosion, and cavitation.- hold solids in solution.- hold solids in suspension for filter removal.

A generic term to describe various treatment chemicals to protect the cooling system.

Cooling System ProblemsCooling System Problems

• Deposits- mineral scale- fouling

• Corrosion

• Cavitation

Mineral Scale Deposits

Mineral Scale Deposits

• Hard deposits

• Mainly calcium and magnesium.

• Occurs when mineral content exceeds saturation point (maximum solubility).

Solubility Changeswith Temperature

Solubility Changeswith Temperature

Compound

Sodium (from salt)

Calcium Carbonate (lime)

Room Temp.

High

Low

Mineral scale occurs where heat transfer is greatest.

High Temp.

Very High

Very Low

Solubility at

Mineral Scale in CoolantMineral Scale in CoolantPassagePassage

Cracked Heads From AbuseCracked Heads From Abuse

Scaled Exhaust GuideScaled Exhaust Guide

0 10 20 30 40 50 60 70 80 90 100

% Reduction in Heat Transfer

0

0.02

0.04

0.06

0.08

0.1

0.12Scale Thickness (in.)

CaSO4CaCO3

Heat TransferHeat Transfer

SiO2

Fouling DepositsFouling Deposits

• Soft gel or slime from suspended impurities or poor water treatment.

• Fouling deposits collect in quiet flow areas (lower sleeve bore, radiators, etc.).

Automotive or Industrial ?Automotive or Industrial ?

Failed Water Pump SealFailed Water Pump Seal

CorrosionCorrosion

A natural, electrochemical breakdown of a metal, by which process it returns to its native state (its oxide form).

Rust - to - RustRust - to - Rust

-

CathodeAnode

corroded

Electrolyte

(coolant)

protected

Volts- +

Metalions

Batteries Work on Principle of Corrosion

Batteries Work on Principle of Corrosion

Your Cooling

System is Like

a Battery !

Your Cooling

System is Like

a Battery !

CorrosionCurrents

Low OxygenConcentration

Crevice CorrosionCrevice Corrosion

High oxygenconcentration area (dissolved in cooling water)

CavitationCavitationA purely mechanical process of erosion through the repeated collapse of vapor (gas) bubbles in a liquid.

Cavitation PrincipleCavitation Principle

Cavitation ConceptCavitation Concept

• When cavitation occurs, flow drops off and wear occurs.

Cavitation ?Cavitation ?

Chrome Resists Cavitation

Chrome Resists Cavitation

• Harder material

• 0.003 in (0.08mm)

CoolantAnalysis Coolant

Analysis

• Cost-effective preventative maintenance foryour cooling system.

Coolant SamplingCoolant

Sampling

• Consistency

• Clean piping

• Six month intervalsor less.

Lab Report

Lab Report

Lab ReportLab Report

Review the lab report, referencing notes on this page in your recall book.

Coolant vs. Oil Analysis ?Coolant vs. Oil Analysis ?

Maintenance & TroubleshootingMaintenance &

Troubleshooting

Is Coolant Harmful ?Is Coolant Harmful ?

• A restricted substance.

• Handle with caution.

• EG more harmful than PG.

• Glycol and inhibitors make coolant toxic.

Check Coolant

Levels Daily

Check Coolant

Levels Daily

Start-up Report

Start-up Report

Standard Cooling0.5 PPM

Norkool SLHMerle Haggard (customer)

I Have Oil in My Head !I Have Oil in My Head !

Why ?

Cracked Cylinder HeadsCracked Cylinder Heads

• Mineral scale deposits

• Low water level

• Oil in coolant

• Excessive glycol concentration

SummarySummary• Install balance lines.

• Install coolant filters.

• Use soft, clean fill (raw) water.

• Use ethylene glycol if needed.

• Use inhibitors as recommended by analysis.

• Begin a coolant analysis program.

• Keep the cooling system sealed.

• Keep the coolant clean.

Naturally Aspirated Cooling System

Cooling System Thermostatic Valves

Cooling System Thermostatic Valves

1. Individual Cylinders.

2. Cluster Type (One Housing)