4/17/2019 Operation "Best Practices" Guidelines for Temperature Control of the Low Temperature (LT) and High Temperature

erature (HT) Cooling System…

Technical Service Bulletin

Technical Service Bulletin: TSB120179 Released Date: 23-May-2012
Operation "Best Practices" Guidelines for Temperature Control of the Low
Temperature (LT) and High Temperature (HT) Cooling Systems for the QSK60G
Natural Gas Fueled Engines.

Operation "Best Practices" Guidelines for

Temperature Control of the Low Temperature (LT)
and High Temperature (HT) Cooling Systems for the
QSK60G Natural Gas Fueled Engines.
Warranty Statement
The information in this document has no effect on present warranty coverage or repair practices,
nor does it authorize TRP or Campaign actions.

Contents
Issue:
This document provides a "Best Practices" guide for the operation of the QSK60G Natural
Gas Fueled Generator Set with regard to temperature control of the Low Temperature (LT)
and High Temperature (HT) cooling systems.
Verification/Confirmation:
This document can be applied to all QSK60G engine models and applications.
Low Temperature (LT) Cooling Circuit
The LT circuit is pumped through the second-stage section of the charge-air cooler and is
temperature modulated by a single thermostat at the outlet of the cooler. Off-engine cooling
systems should be sized and controlled to provide stable coolant return temperature within a
range suitable for maintaining the desired operating temperatures listed in this document.
Operating Parameters
The normal operating range for LT coolant temperature can be obtained from Table 1. Values
should be selected on the LT circuit specification.

Table 1
LT Circuit Intake Manifold Temperature C°
LT Inlet Temperature C° [F°]
Specification [F°]

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C° [F°] Minimum Maximum

Table 1 Minimum Maximum
LT Circuit Intake Manifold Temperature C°
LT Inlet Temperature C° [F°]
Specification [F°]

C° [F°] Minimum Maximum Minimum Maximum

Part Number
4014540 - 40 36 [96.8] 42 [107.6] 38 [100.4] 44 [111.2]
[104]
Part Number
4014541 - 50 46 [114.8] 52 [125.6] 48 [118.4] 54 [129.2]
[122]

Note : The intake manifold temperature is dependent on achieving an LT Inlet

temperature within the specified range. The ranges above represents the upper 50
percent of the thermostat operation range.
Additional control and/or tuning of the heat rejection system may be required to achieve the correct
operating range.

Values stated in the table are as read from the engine sensors and displayed on the generator set
Human Machine Interface (HMI). LT temperature shown on the generator set HMI or OEM control
panel is inlet temperature.
Condition Monitoring LT System
Data from the engine sensors can be collected to monitor the effectiveness of the charge-air
cooler in transferring heat from the charge-air side to the coolant side. A reduction in cooling
efficiency can indicate a problem in the coolant side cooling passages or a problem with the
fins on the air side, or a low coolant flow rate.
Data Presentation and Calculation LT System:
The data can be collected manually direct from the HMI screen or through the INSITE™
electronic service tool.
The data should be presented in a tabular form, as Table 2 below, to allow easy visual tracking
over a period of time.

Table 2
Set Identification
Date
Engine Hours
LT Coolant Inlet
Temperature - A
(C° [F°])

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Table 2
Intake Manifold
Temperature - B
(C° [F°])
Kilowatt Load
(kW)
Temperature
Delta (B - A)
(C° [F°])

Note : Data must be taken at the same load each time for representative values to be
collected.
Table 3, Temperature Delta Data Interpretation at or Near Full Load
Temperature Delta Value Condition
< 6° C [42.8° F] Correctly Operating Charge Cooling
6° C [42.8° F] to 10° C [50° F] Charge Cooling Efficiency Reduced
> 10° C [50° F] Urgent Investigation Required

Derate Factor to Avoid Condensation in the Charge-Air Cooler

When engines are being operated in regions with high humidity, the LT coolant temperature
should be maintained above the thresholds shown in Tables 4 and 5. Where this is not
possible, then the engine must have a derate applied to limit the maximum power, for a given
LT coolant return temperature.

Table 4, (1500 rpm / 50Hz) Derate Factor

Inta
LT ke
Ret Man
urn ifol
Tem d
per Tem
atur per
e C° atur
[F°] e C°
[F°]
30 35
1.00 1.00 1.00 0.89 0.77 0.67 0.57 - - - -
[86] [95]
32 37
[89. [98. 1.00 1.00 1.00 1.00 0.88 0.77 0.66 0.57 - - -
6] 6]

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34 39
[93. [102 1.00 1.00 1.00 1.00 1.00 0.88 0.76 0.66 0.57 - -
2] .2]
36 41
[96. [105 1.00 1.00 1.00 1.00 1.00 1.00 0.87 0.75 0.65 0.56 -
8] .8]
38 43
[100 [109 1.00 1.00 1.00 1.00 1.00 1.00 0.99 0.86 0.74 0.64 0.55
.4] .4]
40 45
[104 [113 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.97 0.85 0.73 0.63
] ]
42 47
[107 [116 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.96 0.83 0.72
.6] .6]
44 49
[111 [120 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.94 0.82
.2] .2]
46 51
[114 [123 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.92
.8] .8]
48 53
[118 [127 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
.4] .4]
50 55
[122 [131 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
] ]
Dew 12 14 16 18 22 24 26 28
C° 10 20 30
Poi [53. [57. [60. [64. [71. [75. [78. [82.
[F°] [50] [68] [86]
nt 6] 2] 8] 4] 6] 2] 8] 4]

Note : Use the monthly average dew point to determine the maximum power for a given
LT return temperature.
Table 5, [1800 rpm / 60Hz] Derate Factor

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Inta
LT ke
Ret Man
urn ifol
Tem d
per Tem
atur per
e C° atur
[F°] e C°
[F°]
30 35
1.00 1.00 0.91 0.75 0.64 0.56 0.50 - - - -
[86] [95]
32 37
[89. [98. 1.00 1.00 1.00 0.90 0.75 0.63 0.55 - - - -
6] 6]
34 39
[93. [102 1.00 1.00 1.00 1.00 0.89 0.74 0.63 0.55 - - -
2] .2]
36 41
[96. [105 1.00 1.00 1.00 1.00 1.00 0.88 0.73 0.62 0.55 - -
8] .8]
38 43
[100 [109 1.00 1.00 1.00 1.00 1.00 1.00 0.87 0.72 0.61 0.54 -
.4] .4]
40 45
[104 [113 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.85 0.71 0.61 0.54
] ]
42 47
[107 [116 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.83 0.70 0.60
.6] .6]
44 49
[111 [120 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.99 0.81 0.68
.2] .2]
46 51
[114 [123 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.96 0.79
.8] .8]
48 53
[118 [127 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.93
.4] .4]

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50 55
[122 [131 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
] ]
Dew 12 14 16 18 22 24 26 28
C° 10 20 30
Poi [53. [57. [60. [64. [71. [75. [78. [82.
[F°] [50] [68] [86]
nt 6] 2] 8] 4] 6] 2] 8] 4]

Note : Use the monthly average dew point to determine the maximum power for a given
LT return temperature.
Note : IMPORTANT: Tables 4 and 5 are examples only. Reference the current revision
of the engine data sheets for the latest engine specifications and information.
LT coolant temperature should be controlled by LT thermostat specification selection [see Table 1]
and/or the variable speed LT radiator cooling fans.
HT Coolant Circuit
The HT circuit is pumped through the oil coolers and the first-stage charge-air cooler in
parallel. It then flows through passages in the cylinder block and heads. Outlet from the
engine is modulated by six thermostats.
Off-engine cooling systems should be sized and controlled to provide a stable coolant return
temperature, within a range suitable for maintaining the desired operating temperatures listed
in this document.
Operating Parameters
The normal operating range for HT temperature can be obtained from Table 6. Values should
be selected on the HT circuit specification.

Table 6
HT Circuit Specification C° HT Out Temperature C° [F°]
[F°] Minimum Maximum
Part Number 135675 - 90
84 [183.2] 90 [194]
[194]
Part Number 3629205 - 95
89 [192.2] 95 [203]
[203]

Note : The ranges above represents the upper 50 percent of the thermostat operation
range.
Additional control and/or tuning of the heat rejection system may be required to achieve the correct
operating range.

Values stated in the table are as read from the engine sensors and displayed on the generator set
HMI. HT temperature displayed on the HMI is outlet temperature.

Document History
Date Details
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Date Details
2012-5-17 Module Created

Last Modified: 23-May-2012

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