Application Engineering Bulletin

Subject Two Pump Two Loop Low Temperature Aftercooling For High Horsepower G-Drive Applications Automotive Date: December 12, 2002 Page 1 of 12 Industrial Power Generation This AEB is for the following applications:

AEB Number 90.35

Engine Models included: QST30, KTA38, QSK45, KTA50, QSK60, QSK78 Fuel Systems included: All Author: Curtis Kwasniewski

Introduction:
Many of Cummins Inc. new G-Drive engine models require the use of Separate Circuit Low Temperature Aftercooling (SCLTA). This method of cooling uses a secondary loop (LTA Loop) for cooling the aftercoolers and is referred to as Two-Pump, Two-Loop cooling (2P/2L). The purpose of this document is to provide a system description and Cummins, Inc. requirements and recommendations for selection and installation, of a 2P/2L system. Requirements are labeled must while recommendations are labeled should. Two-pump two-loop (2P/2L) cooling differs from one-pump two-loop (1P/2L) and jacket water aftercooling (JWAC) in that it uses its own dedicated coolant pump, plumbing, and heat exchanger. The coolant in the LTA loop does not cool the engine (as in JWAC) or mix with the engine coolant (as in 1P/2L). Because of this, 2P/2L cooling can reach lower intake manifold temperatures than with jacket water or one-pump two-loop aftercooling. This lower intake manifold temperature makes it possible to reach higher power densities and certain emissions levels. The performance of the 2P/2L system is critical to the durability, performance, and emissions compliance of the engine. Failure of the system could cause power loss, increased emissions, and possible engine damage. The equipment manufacturer is responsible for the selection, design, and installation per these requirements.

Scope:
This document addresses aftercooling system requirements for High Horsepower GDrive engines that utilize the Two-Pump Two-Loop method of aftercooling. This currently includes specific ratings of the QST30, KTA38, QSK45, KTA50, QSK60, and QSK78 engine models.

Cummins Confidential

Requirements
In order to obtain the concurrence of Cummins Inc. the following requirements must be met: The System must have a high temperature shutdown that monitors aftercooler water temperature. The System must meet the heat rejection and intake restriction requirements published on the Engine Data Sheet. A Fill Line must be provided for both the Jacket and LTA cooling systems and will run between the head tank and the pump inlet respective for that system. The aftercooler loop coolant must be a 50/50 blend of Fully Formulated Coolant and water. The coolant should contain Supplemental Coolant Additive (SCA). The LTA radiator must provide 6% expansion space, 11% draw down capacity, a means for venting the LTA Loop to the top tank, a means for filling the LTA Loop, and be mounted so that it receives the coolest possible airflow. The thermostat must be located between the outlet of the aftercooler and inlet of the LTA radiator. If a customer supplied electrically controlled LTA thermostat is used then it must fail to the open position (See Table 1 for engine models that require thermostats). The LTA plumbing must meet the same requirements as piping for the engine coolant loop, steel tubing or five-ply hose, rated for temperatures and pressures experienced in the aftercooling system, and use T-bolt or constant torque type clamps for all coolant hose connections. The pressure at the coolant pump must be greater than atmospheric when the engine is operated at rated speed with the pressure cap removed and the coolant temperatures above the modulating ranges (refer to engine data sheet). The cooling system must use either a pressure cap or a pressure relief valve in the deaerating tank.

System Description, Requirements, and Recommendations:

System Flow: The 2P/2L aftercooling system consists of a dedicated coolant pump, heat exchanger, engine aftercoolers, filters, and plumbing (including a thermostat device and a bypass loop). For engines with a thermostat, the flow path is from the outlet of the aftercoolers to the thermostat valve housing. The thermostat bypasses the LTA radiator when the LTA coolant is cold. Coolant flow that is bypassed is recirculated through the aftercoolers by the LTA water pump until the temperature is high enough to actuate the thermostat (Figure 1). As the LTA coolant warms the LTA thermostat opens and blocks off the bypass loop. The thermostat will direct the coolant flow to the LTA radiator. Once cooled in the radiator, the coolant is directed to the LTA pump suction (Figure 2). Some engine models do not require the use of a LTA thermostat. In those engine models, the coolant flows from pump discharge to aftercooler to heat exchanger and back to the pump suction (Figure 3).
Cummins Confidential
2

LTA Water Pump

LTA Bypass

Aftercooler
Air Flow
Intake Airflow LTA Thermostat

Aftercooler
Engine Coolant Pump

Jacket Water LTA Piping (No Flow) LTA Flow Warm

Shut Down Temperature Sensor

Figure 1
Coolant Flow with LTA Thermostat Closed

LTA Water Pump

LTA Bypass

Aftercooler
Air Flow
Intake Airflow LTA Thermostat

Aftercooler
Engine Coolant Pump

Jacket Water Cooled LTA Coolant Hot LTA Coolant

Shut Down Temperature Sensor

Cummins Confidential

Engine Radiator
3

LTA Radiator

Engine Radiator

LTA Radiator

LTA Thermostat Open Coolant Flow with LTA Water Pump

Figure 2

Aftercooler
Air Flow
Intake Airflow

Aftercooler
Engine Coolant Pump

Jacket Water Cooled LTA Coolant Hot LTA Coolant

Shut Down Temperature Sensor

Figure 3
Coolant Flow with No LTA Thermostat

System Requirements: The LTA loop MUST: Use a high-temperature shutdown. This is accomplished by monitoring aftercooler water temperature with either a sensor or temperature switch. The set point of the shutdown will depend on the monitoring location (see Table 1 for set points). LTA Coolant temperature can be monitored in either the aftercooler outlet or inlet plumbing. A temperature sensor comes supplied in some models (see Table 1 for details). Meet the system heat rejection and intake restriction requirements listed on the Engine Data Sheet

Cummins Confidential

Engine Radiator

LTA Radiator

Engine Connections: The engine connections for the LTA loop come supplied with the engine. These connections are in addition to the jacket water connections. For specific engine connection sizes and locations consult the Installation Drawing or Sales Handbook. LTA Water Pump: The LTA water pump comes as an installed component and is a gear pump driven through an accessory drive located in the front gear cover. Flow rates for specific engines are given in Table 1 and the engine data sheet. For the LTA water pump location on a specific engine consult the Installation Drawing. LTA Coolant Filters for KTA38 and KTA50: The use of bypass coolant filters for the LTA loop is required for KTA38 and KTA50 GDrive engines. The bypass filters and the coolant filter head are supplied as a kitted option. The customer must plumb the filter head into the LTA loop. A connection is provided in the LTA water pump outlet plumbing for this purpose. The radiator supplier must supply an additional connection in the LTA pump inlet plumbing to complete the installation (Figure 4). Service filters with supplemental coolant additive (SCA) should be replaced at the normal service interval. The use of aftercooler filters is not required for the Quantum series engines (QST30, QSK45, QSK60).

Installed Connection Boss

LTA Water Pump

LTA Return Piping

Customer Supplied Connection Boss

Filter

Kit Supplied FilterHead

Figure 4
Filter Installation for KTA38 & 50

Cummins Confidential

LTA Radiator

LTA Coolant: The LTA loop coolant MUST: Be a 50/50 mix of Fully Formulated Coolant (Ethylene Glycol or Propylene Glycol) and water. The LTA loop coolant SHOULD: Contain supplemental coolant additive (SCA) In systems that do not have a coolant filter for the aftercooler loop the concentration of SCA in the aftercooler loop coolant must be monitored. The concentration should be maintained at the same level as the jacket water side. Refer to Service Bulletin 3666132 for additional information. Aftercooler Radiator: The LTA loop radiator MUST Be sized to not exceed the Maximum Aftercooler Inlet Water Temperature requirement of the engine. The heat rejected to the LTA coolant, coolant flow, maximum aftercooler inlet water temperature, and maximum allowable system restriction are listed on the Engine Data Sheet. From this information, an adequately sized core can be designed for the needs of the system. Provide 6% expansion space to allow heated coolant to expand without overflowing the top tank. Provide for 11% draw down capacity in addition to the expansion space (Figure 5). Provide a means for venting entrained air to the LTA Radiator top tank (Figure 5). Vent lines must be installed between the highest location in the LTA loop and the LTA radiator top tank. Vent lines must run uphill constantly (See Engine Installation Drawing for connection points). Provide a means for filling the LTA Loop (Figure 5). The fill line must connect the top tank and a low point in the LTA loop (such as the LTA pump inlet plumbing). Fill lines must have a continual rise from coolant piping to the top tank. Fill lines must be sized so that the system is capable of being filled to 90% capacity at a minimum rate of 20 l/min (5 GPM) on initial fill. Have seals installed between the LTA radiator and the engine radiator when mounted in series. Having an installed seal will force the air to travel through both cores. The seal also helps prevent debris from becoming entrapped between the cores.
Cummins Confidential
6

 Have a pressure cap on the top tank (Figure 5). The pressure cap must be rated the same as the engine radiator pressure cap.
Vent Line Connection (above coolant level) Tank large enough to provide minimum drawdown

Radiator Cap

Coolant Outlet

Fill Line Connection

Coolant Inlet Figure 5 LTA Radiator Top Tank (2-Pass Core Shown)

Top of Tubes

Be mounted so that it receives the coolest possible airflow. This can be accomplished in three ways. 1. Mount the radiators in series (Figure 6). In this arrangement, the aftercooler radiator must be upstream of the jacket water radiator. Care must be taken in this arrangement to minimize debris entrapment between the two radiators.

Engine Radiator LTA Radiator

Figure 6 Series Mounted Radiators

Cummins Confidential

2. Mount the radiators in parallel (Figure 7). In this arrangement the aftercooler radiator and jacket water radiator should be mounted so that the cooling airflow restriction is balanced across the fan sweep.

Engine Radiator

LTA Radiator

Figure 7 Parallel Mounted Radiators

3. Remotely mount the radiators. In this arrangement the radiators are cooled by a dedicated fan that is not engine driven. The radiators are typically in a separate compartment from the engine and can be arranged in series, parallel, or each with a separate fan. Care must be taken when using this arrangement to ensure that the cooling system restriction requirements are not exceeded (Consult the Engine Data Sheet for specific model requirements).

The LTA loop radiator SHOULD: Match the engine radiator fin density. Matching the fin density of the aftercooler radiator to that of the engine radiator will allow debris to pass through both cores without becoming trapped between the two.

Cummins Confidential

LTA Thermostat: Table 1 identifies the engine models that require the use of a LTA loop thermostat. This thermostat bypasses the LTA loop heat exchanger when the coolant temperature is low. As the temperature of the coolant rises, the thermostat begins to open to block the bypass port and send coolant to the LTA radiator. The thermostat continues to open until the bypass is fully closed off. The temperature at which the thermostat begins to open and when it is fully open defines the modulating range of the thermostat (Table 1 lists suggested modulating ranges). There are two types of thermostats that can be used in the LTA loop. 1. Electrically controlled bypass valve. This customer supplied valve must be used in conjunction with an electronic temperature sensor. This sensor must be located in the aftercooler outlet plumbing (monitoring aftercooler outlet temperature) and may be used additionally as the high temperature shut down sensor (Sensor location is shown in Figures 1-3). 2. Three-way wax-filled thermostat (Figure 8). This thermostat does not require an additional sensor to operate. The aftercooler outlet water temperature controls the position of the thermostat. As the aftercooler water temperature rises the wax in the thermostat expands causing the valve to close off the bypass loop. This directs the flow to the heat exchanger.
Outlet

Thermostat Assembly

Bypass

Inlet Figure 8 Three Way Wax Filled Thermostat Assembly

Cummins Confidential

The LTA loop thermostat MUST: Fail to the open position if it is electrically controlled. Be located between the outlet of the aftercooler and the inlet of the aftercooler radiator. This location provides cooling flow through the aftercoolers in event of a thermostat failure. LTA Plumbing: The LTA loop plumbing MUST: Meet the same requirements as piping selected for the engine coolant loop. Be of steel tubing and/or five-ply hose conforming to SAE J20R1. Typically 600 kPa (87 PSIG) and - 40 to 100 C (-40 to 212 F) with intermittent temperatures reaching 120 C (250 F). Use T-bolt or constant torque type clamps for all coolant hose connections. Clamps must be used to prevent hose blow-off. One clamp at each connection point is sufficient. Be equal to or larger than the diameter of the engine connections. The LTA loop plumbing SHOULD: Be mechanically braced on either side of flexible hoses.

Environmental Considerations
Depending upon the environment in which the engine operates there may be additional considerations that need to be taken into account. The LTA cooling system must be designed not to exceed the aftercooler inlet water temperature listed on the Engine Data Sheet under any ambient conditions. In low temperature ambient conditions the aftercooler loop is not expected to require the use of coolant heaters. Using a 50/50 blend of Fully Formulated Coolant and water will protect the coolant from freezing at temperatures of 40 C (-40 F).

Cummins Confidential

10

Fill Line (Make-Up Line): The Fill Line is very important as it routes the coolant from the deaerating tank to the engine and provides one of the key methods for purging air from the system. The Fill Line must have a continual rise from the engine coolant inlet pipe to the bottom of the top tank. The Fill Line size is typically about 19 mm (0.75 in) for coolant pump flows up to 757 liters/min (200 GPM), and 25 to 38 mm (1 to 1.5 in) for coolant pump flows greater then 757 liters/min (200 GPM). If the Fill Line is too small or improperly routed, the engine will not fill properly and reverse flow up the fill line may cause overflow of the deaerating tank. A Fill Line must be provided for both the Jacket and LTA cooling systems. Cummins recommend that this line be routed directly from the top tank to the respective pump inlet in a continual slope

Cummins Confidential

11

Engine Model Option Number Set Point C (F) Supplied on Engine No No No Yes* Yes* Yes* No No Yes* Yes* Yes* N/A N/A

Aftercooler Thermostat

LTA Water Pump

High Temperature Shutdown

Supplied on Engine TB5717 TB5717 SW6016 TB6723 TB6723 TB6723 SW6016 SW6016 TB6723 TB6723 TB6723

Recommended Modulating Range C (F)** Not Required Not Required Not Required WF2076

Fleetguard Filter Number

Installation Drawing Number

3170341 3170286 3170568 3626442 3170275 TBD TBD 3626419

QST30 G4/G5 QST30 G6/G7/G8 KTA38 G7

Not Required Not Required No

Not Required

Yes

Aftercooler Outlet 93 (200) 71 (160) 55 (130) N/A

Yes

QSK45 G4 QSK45 G6 QSK45 G8 KTA50 G7

Yes

No

Not Required Not Required Not Required WF2076 WF2076

No

TBD 3170381 N/A N/A 3170292 3170543

Yes

55 (130) 85 (185) N/A

KTA50 G8/G9 QSK60 G3 QSK60 G5/G6 QSK78

Yes

Yes

30-40 (86-104) 46-57 (115-135) 46-57 (115-135) 46-57 (115-135) 30-40 (86-104) 52-60 (125-140) 46-57 (115-135) 46-57 (115-135) 46-57 (115-135)

Flow at 2 psi Friction Head 1500 RPM 1800 RPM l/s (GPM) l/s (GPM) 4.5 5.4 (71) (85) 4.5 N/A (71) 5.9 N/A (93) 7.1 8.5 (112) (135) 7.1 N/A (112) N/A 8.5 (135) 5.9 N/A (93) 5.9 7.1 (93) (112) 7.1 N/A (112) N/A 8.5 (135) N/A 17.6 (279) Aftercooler Inlet 71 (160) 52 (125) 41 (105) 76 (170) 76 (170) 76 (170) 38 (100) 76 (170) 76 (170) 76 (170) 76 (170) Not Required Not Required WF2076

* Temperature sensor supplied on the engine. The High Temperature Shutdown set point is integrated into the engine controller. ** In the case of an electrically controlled bypass valve the valve must be fully open (not bypassing) by the high temperature of the modulating range. The valve must also fail open (not bypassing) in the event of a sensor failure. Table 1 LTA System Information