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A/W Intercooler - Coolant flow direction?

Old Mar 14, 2017 | 05:13 PM
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Originally Posted by TXsilverado
I'm sure it's in the thread somewhere, but what direction do you have your lines going starting from the reservoir?
Res > Pump > IC > HE > Res
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Old Mar 14, 2017 | 05:30 PM
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I still have more testing to do but if I decide to go the route to "fix" the cooling system, this is what I have in mind for the heat exchanger...



I need to trace it out on cardboard and cut out a template to confirm fitment before sending it out for quotes.
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Old Mar 14, 2017 | 05:54 PM
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Originally Posted by Atomic
I would argue the ability for the intercooler to remove heat from the airflow quickly enough is going to be your issue during races. The larger HEX will help bring down the overall coolant level closer to ambient, but this is a much slower process than the intercooler absorbing heat from 10 second bursts. The HEX is going to help recovery times but not peak race temperatures very much.
Ummm. Not so much. Mine with one HX would see at 80-85 degree rise on a 1/4m pull. Adding a second HX dropped that to 22-24deg.
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Old Mar 14, 2017 | 06:05 PM
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I see merit in both statements. If the HEX is just adequate enough to bring coolant temps to ambient during cruising but not enough to remove all the heat the ic is dumping in it during a wot blast AND the coolant volume is low, IATs will rise as the circulated coolant temps will also rise in that brief period. However, if coolant volume were high, under the same conditions, there would be enough ambient temp coolant in reserve to circulate thru the system before the lack of heat removal from the HEX starts to overcome the system.
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Old Mar 14, 2017 | 07:30 PM
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Mine goes Tank, pump, HX, then intercoooler. With one HX it would climb like crazy from 2nd gear up. Now it tapers then quits at the top of 3rd. I went through all this same **** before with mine. Played with coolant volumes, flow rates etc.

Last edited by 03sierraslt; Mar 14, 2017 at 07:37 PM.
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Old Mar 14, 2017 | 08:16 PM
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That is theoretically wrong. The way you have it, Pat, is the tank being a reservoir of heated water. The heat removal capacity would only be what the heat exchanger was capable of, therefore the quick temperature rise. If the tank was a reservoir of cooled water feeding the intercooler, it would slow the temperature rise.

I am comparing a air-to-water heat exchanger system to a commercial building's chilled water air conditioning system. They pipe cold water around a building to point of use fan coils, FYI. The chiller machine makes cold water (with antifreeze) and stores it in an insulated tank. This is piped around the building, and the warmed water returns directly to the chiller. The reservoir maintains constant temperature to the building.

The way your heat exchanger is set up, the reservoir is only a reserve of an amount of water, not a reserve of cooled water.
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Old Mar 14, 2017 | 08:49 PM
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Originally Posted by BigKID
I still have more testing to do but if I decide to go the route to "fix" the cooling system, this is what I have in mind for the heat exchanger...



I need to trace it out on cardboard and cut out a template to confirm fitment before sending it out for quotes.
Looking forward to seeing your results.
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Old Mar 14, 2017 | 08:59 PM
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Here's the data...

Cold pre-start...


Right after cold start in cruise...


End of 15 minute stop and go cruise...


Now for the really interesting part. This is after about 15 minutes of stop and go in boost. Notice how all three temps fall when it goes in boost before the HEX in starts to rise. It does this on every boost transition. If the boost lasts for more than a few seconds the IC out/HEX in starts to rise then as soon as it goes out of boost there is a sharp up-tick of all three temps. Both HEX temps continue to rise from this point for about 3 seconds till they start dropping.
Graph cursor in boost region...


Post-boost at peak IC out/HEX in temp...


I do have a Caspers V-boost that bumps alternator voltage 2.2V at 70% throttle so that could account for the slight decrease right at 90% throttle and the sharp increase at throttle close due to increased/decreased pump speed.

Last edited by BigKID; Mar 14, 2017 at 09:11 PM.
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Old Mar 14, 2017 | 09:19 PM
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Originally Posted by MikeGyver
That is theoretically wrong. The way you have it, Pat, is the tank being a reservoir of heated water. The heat removal capacity would only be what the heat exchanger was capable of, therefore the quick temperature rise. If the tank was a reservoir of cooled water feeding the intercooler, it would slow the temperature rise.

I am comparing a air-to-water heat exchanger system to a commercial building's chilled water air conditioning system. They pipe cold water around a building to point of use fan coils, FYI. The chiller machine makes cold water (with antifreeze) and stores it in an insulated tank. This is piped around the building, and the warmed water returns directly to the chiller. The reservoir maintains constant temperature to the building.

The way your heat exchanger is set up, the reservoir is only a reserve of an amount of water, not a reserve of cooled water.
I don't disagree with you, but I tried the other routing and this yielded the lowest temps. So as long as mine stay low .....
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Old Mar 14, 2017 | 10:22 PM
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I bet the coolant resovoir is probably the hottest thing right behind the intercooler during boost. Its a metal/plastic tank sitting in the engine bay. At least the heat exchanger and intercooler have air flowing through them.
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