coolin~1
DESCRIPTION
COOLIN~1TRANSCRIPT
Your GoalYour Goal
To understand cooling system design and maintenance as it applies to Waukesha’s current production products with standard cooling systems.
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
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
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
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.).
CorrosionCorrosion
A natural, electrochemical breakdown of a metal, by which process it returns to its native state (its oxide form).
-
CathodeAnode
corroded
Electrolyte
(coolant)
protected
Volts- +
Metalions
Batteries Work on Principle of Corrosion
Batteries Work on Principle of Corrosion
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.
Is Coolant Harmful ?Is Coolant Harmful ?
• A restricted substance.
• Handle with caution.
• EG more harmful than PG.
• Glycol and inhibitors make coolant toxic.
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.
Cooling System Thermostatic Valves
Cooling System Thermostatic Valves
1. Individual Cylinders.
2. Cluster Type (One Housing)