Cooling System - Cogeneration

G3516B 50Hz Generator Set Engine 7EZ00001-UP(SEBP2906 - 51) - Documentation Page 1 of 9
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Product: GEN SET ENGINE

Model: G3516B GEN SET ENGINE 7EZ
Configuration: G3516B 50Hz Generator Set Engine 7EZ00001-UP
Systems Operation
G3500B Engines
Media Number -RENR2268-09 Publication Date -01/08/2012 Date Updated -20/08/2012
i02156885
Cooling System - Cogeneration

SMCS - 1350
S/N - 7EZ1-UP
S/N - BGW1-UP
S/N - CEY1-UP
S/N - CME1-UP
S/N - CSC1-UP
S/N - CTK1-UP
S/N - CTW1-UP
S/N - CWD1-UP
S/N - E6T1-UP
S/N - GZP1-UP
S/N - KAD1-UP
S/N - L6H1-UP
S/N - L6J1-UP
S/N - ZBB1-UP
S/N - ZBC1-UP
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Note: The following information describes the cooling system for an application that uses
cogeneration. The heat that is exchanged from the cooling system is used for the purpose of heating.
Jacket Water
Illustration 1 g01093951
Typical cogeneration model
(1) Return line
(2) Bypass line
(3) Inlet line to front of cylinder block
(4) Cylinder block
(5) Adapter
(6) Inlet line to engine
(7) Electric water pump
(8) Water/air separator
(9) Water temperature regulator housing
(10) Water manifold
(11) Coolant line to the customer supplied heat exchanger or radiator
(12) Heat exchanger
(13) Outlet to electric water pump for the engine
(14) Coolant line from the customer supplied heat exchanger or radiator
(15) Wastegate
(16) Aftercooler
(17) Jacket water line from the aftercooler
(18) Jacket water line to the aftercooler
(19) Coolant supply line for the wastegate
(20) Vent lines
(21) Turbocharger
(22) Inlet line to rear of cylinder block
(23) Engine oil cooler
(17) Coolant return from the turbocharger
(24) Coolant supply to the turbocharger
(25) Turbocharger
The cooling system uses water pump (7) that is driven by an electric motor. Coolant from heat
exchanger (12) is pulled into the inlet of the water pump housing. The coolant is pulled by the rotation
of the water pump impeller. The coolant then flows through the inlet line to the engine and into
adapter (5). The coolant is divided at the adapter. Part of the coolant flow is sent through water line
(18) to the first stage of aftercooler (16). Part of the coolant is sent through inlet line (3) to the front of
cylinder block (4). The other part of the coolant is sent through engine oil cooler (23) and to the rear
of the cylinder block (4) via inlet line (22) .
Coolant is sent through inlet line (3) to the front of cylinder block (4). The coolant is then sent
through a main distribution gallery to each cylinder water jacket. The main distribution gallery is
located above the main bearing oil gallery. The main bearing oil gallery and the water gallery are in
the center of cylinder block (4). Part of the coolant travels to the back of the cylinder block to an
adapter. Coolant flow from the adapter housing is divided. Part of the coolant flows to coolant supply
line (19) and to wastegate (15). The other part of the coolant flow travels through coolant supply lines
(24) to the housings for the bearings of turbochargers (25). Vent lines (20) for the turbocharger and
the wastegate purge the air out of the cooling system. All of the coolant flow is then directed into
water manifolds (10) .
The coolant that is sent to engine oil cooler (23) flows through the engine oil cooler and through inlet
line (22) to the rear of the cylinder block at the right rear cylinder. The coolant flows to both sides of
cylinder block (4) through the rear distribution gallery. The distribution manifolds are connected to
the water jacket of all of the cylinders.
The coolant flows upward through the water jacket and around the cylinder liners from the bottom to
the top. The water jacket is smaller near the top of the cylinder liners. The temperature is hotter at the
top of the cylinders. This smaller area is referred to as a shelf. This shelf causes the coolant to flow
faster for cooling of the cylinder liners. The coolant from the top of the liners flows into the cylinder
head. The coolant flows around the hottest parts of the cylinder head. Coolant then flows to the top of
the cylinder head. The coolant flows outward through an elbow. An elbow is located at each cylinder
head. The coolant flow is directed through water manifolds (10) to the water temperature regulator
housing (9) .
Water temperature regulator housing (9) is located at the top front of the engine. The water
temperature regulator housing has an upper section and a lower section for coolant flow. The G3516B
engine uses four temperature regulators. The G3520B engine uses eight temperature regulators. The
sensing bulbs of the temperature regulators are in the coolant in the lower section of the housing. Cold
coolant is sent through the water temperature regulators to the upper section of the water temperature
regulator housing through bypass line (2) and back to the inlet of the water pump.
This cycle is completed before the engine reaches operating temperatures and the regulators remain
closed. As the temperature of the coolant increases the regulators start to open and the coolant flow in
bypass line (2) is stopped. Coolant is sent through coolant return line (1) to water/air separator (8)
then to heat exchanger (12) .
The cooling system is equipped with a heat exchanger for an application that has the CHP (Combined
Heat and Power). Heat exchanger (12) is located at the front of the engine. Water from the customer
supplied pump enters the heat exchanger through inlet connection (14). Heat is extracted from the
coolant. The water exits through outlet connection (11) .
The water temperature regulators are an important part of the cooling system. The water temperature
regulators maintain the correct temperature of the coolant.
Note: There is no mechanical control of the cooling system if the water temperature regulators are not
installed in the system.
Refer to the Operation and Maintenance Manual for the capacity of the cooling system.
Separate Circuit
(26) Coolant line connection for the separate circuit water system from the aftercooler
(27) Coolant line connection for the separate circuit water system to the aftercooler
The second stage of the aftercooler uses a separate circuit aftercooling that is customer supplied. The
coolant in the second stage is supplied from a separate heat exchanger. The temperature of the coolant
in the second stage is controlled by a thermostatic valve.
An auxiliary water pump or a water pump that is customer supplied sends water through line
connection (27) to the second stage of the aftercooler (16). The water flows through the aftercooler
core assembly and flows out of the cooler to line connection (26) to a thermostatic valve. When the
aftercooler water is below operating temperature, the thermostatic valve is closed. This will bypass a
heat exchanger that is customer supplied or a radiator that is customer supplied. The water is bypassed
and returned to a water pump that is customer supplied and returned to the aftercooler. When the
aftercooler water is up to operating temperature, the thermostatic valve opens. This will allow the
water to flow from the aftercooler to a heat exchanger that is customer supplied or a radiator that is
customer supplied. The water will then flow back to a water pump that is customer supplied and
returned to the aftercooler.
Total system coolant capacity will depend on the size of the heat exchanger or radiator. Refer to the
Operation and Maintenance Manual for the capacity of the components that are installed at the
factory.
Cooling System Schematics

Several different cooling system configurations are available for different applications. The following
schematics are examples of cooling systems for cogeneration.
Schematic for a cogeneration engine that operates at a high temperature
This installation has three cooling circuits. Two of the pumps and the three heat exchangers are supplied by the customer.
The aftercooler has two stages. The flow of engine oil from the engine oil cooler is controlled in order to prevent
overcooling.
Schematic for a cogeneration engine that has a high operating temperature
This installation has two cooling circuits. The jacket water pump is supplied by the customer. The aftercooler has two
stages. The flow of engine oil from the engine oil cooler is controlled in order to prevent overcooling.
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G3516B 50Hz Generator Set Engine 7EZ00001-UP(SEBP2906 - 51) - Documentation Page 1 of 9

Product: GEN SET ENGINE

Cooling System - Cogeneration

Typical cogeneration model

(1) Return line

(2) Bypass line

(3) Inlet line to front of cylinder block

(4) Cylinder block

(6) Inlet line to engine

(7) Electric water pump

Typical cogeneration model

(8) Water/air separator

(9) Water temperature regulator housing

(10) Water manifold

(11) Coolant line to the customer supplied heat exchanger or radiator

(12) Heat exchanger

(13) Outlet to electric water pump for the engine

Typical cogeneration model

(17) Jacket water line from the aftercooler

(18) Jacket water line to the aftercooler

(19) Coolant supply line for the wastegate

(20) Vent lines

(22) Inlet line to rear of cylinder block

(23) Engine oil cooler

(17) Coolant return from the turbocharger

(24) Coolant supply to the turbocharger

Cooling System Schematics

Schematic for a cogeneration engine that operates at a high temperature

Schematic for a cogeneration engine that has a high operating temperature

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