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Anonymous Poster

Stop Burning of Radiator Top Tank

07/31/2010 8:35 AM

We are facing issues with radiators.

Currently, we are using radiators with plastic top tank for our engines. But after certain usage, these radiator top tank gets burned. We are unable to find out the solution. Necessary back up data will be shared if asked.

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#1

Re: How do we stop burning of radiator top tank (plastic)

07/31/2010 11:53 AM

More info on engine manufa and use of engine please?

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#2

Re: How do we stop burning of radiator top tank (plastic)

07/31/2010 11:56 AM

it could be if the heat is coming from the coolant that the coolant is getting too hot for some reason.

Cooling fan or heat from exhaust is raising under hood(bonnet) temp etc

but until you supply more engine info thats just a guess

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#3

Re: How do we stop burning of radiator top tank (plastic)

07/31/2010 8:22 PM

Are you using anti freeze solution? If plain water, you may be getting localized hot spots as the coolant turns to steam momentarily when entering the radiator before cooling and returning. Is the failure always adjacent to the inlet of the radiator?

Is the seam seperating? Have you tested the pressure relief cap(s)?

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#9
In reply to #3

Re: How do we stop burning of radiator top tank (plastic)

08/01/2010 10:53 PM

Yes Sir. Your observation is perfectly right. The failure is always adjacent to the inlet of the radiator. Then it gradually goes ahead. It starts from radiator inlet only.

Seam is not separating.

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#4

Re: How do we stop burning of radiator top tank (plastic)

07/31/2010 11:01 PM

Quit overheating your engines and radiators! Heat causes the plastic to become brittle and crack!

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#5

Re: How do we stop burning of radiator top tank (plastic)

08/01/2010 1:31 AM

Where were these engines made? China?

Plastic is cheaper than metal, plastic does not corrode.

but it melts if the wrong plastic is used

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#7
In reply to #5

Re: How do we stop burning of radiator top tank (plastic)

08/01/2010 7:33 AM

You are right.

He must be using the wrong plastic for the job.

Maybe made by ... ? not to offend anybody... wrong cheap material for the job.

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#6

Re: How do we stop burning of radiator top tank (plastic)

08/01/2010 6:43 AM

Question is the plastic tank (burning) or melting. Burning indicates extreme heat and charing where as melting would be a thermal deformation. It would be nice to know the engine and application.

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#10
In reply to #6

Re: How do we stop burning of radiator top tank (plastic)

08/01/2010 10:59 PM

It's a plastic tank melting.

It is a 30 KVA diesel engine, used as genset. Engine RPM is 1500

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#11
In reply to #10

Re: How do we stop burning of radiator top tank (plastic)

08/02/2010 2:58 PM

Are you using antifreeze? Can you aid the cooling any? Is it one engine, or are there a few? If only one, it might be worth it to have a custom radiator installed. A custom radiator for your installation bight be just a radiator from a larger or different application. Good luck.

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#13
In reply to #11

Re: How do we stop burning of radiator top tank (plastic)

08/02/2010 11:06 PM

Sir, we use an antifreeze. It's a Water:Ethylene Glycol (50:50). Similar type of 20 cases of radiator failure have been observed on the field so far.

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#8

Re: How do we stop burning of radiator top tank (plastic)

08/01/2010 10:46 AM

I wonder if the engine idles under load a lot or if the fan clutch has failed.

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#12
In reply to #8

Re: How do we stop burning of radiator top tank (plastic)

08/02/2010 3:19 PM

If the antifreeze is too pure, it will end up hotter.

This means a failure in circulation of water or air through Rad.

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#14

Re: How do we stop burning of radiator top tank (plastic)

08/03/2010 9:32 PM

After reading all the reply's I suggest that when the engine is running under load take a heat gun (laser) and check engine temps along the cylinders and thermostat area. Also the hoses and the rad top tank. Diesel engines do not like this kind of heat and will self destruct. It may take some time but you should get some facts to go on. If the plastic is melding from heat that indicates that coolant is boiling resulting in higher pressure on the radiator also. About every 3 degrees F results in 1 lb increase in pressure. The cap should have relief at certain PSI> Also if the rad is not vented properly then when cold it will have a negative pressure and the coolant will boil much quicker (not sure if this can cause the symptoms) You need to collect data and the heat gun will give you that. Good luck.

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#15
In reply to #14

Re: How do we stop burning of radiator top tank (plastic)

08/03/2010 11:40 PM

GA. IR cameras are becoming more common every day. I have them on our trucks, and have watched thermostats open just from watching the hot water start to flow down a radiator. Better units will have a temperature scale on them that will tell you the temperature of what you are looking at. The simple non contact IR thermometers will give you good information, but the camera will give you a view of the whole area at once. Just better information.

What are the radiators installed in? How many of these do you have?

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#16
In reply to #15

Re: How do we stop burning of radiator top tank (plastic)

08/04/2010 1:25 AM

Sir, the radiators are used with gensets. These gensets are installed inside the canopy. In the previous comment you have mentioned regarding the failure 'adjacent to inlet pipe'. Is it something related with water content in the coolant ? We have received 10 no of radiators from the field. All shows the same kind of failure. Still we are unable to get the solution. Fitting the camera may take long time.

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#17
In reply to #16

Re: How do we stop burning of radiator top tank (plastic)

08/04/2010 10:53 AM

If I was in your position, I would be screaming at the manufacturer of the generators. If you look at the radiators, there will probably be some manufacturer's identifying marks on it. That would be my next contact. If I had the option, I would try to have a metal radiator replacement.

It is impossible to know exactly why your radiators are failing from my location, but, they seem to have all of the symptoms of heat related failure. If it was of a chemical nature, I would think the failures would be in other locations as well. If it was a physical failure, I do not think you would have described it as melting.

Do you care to share the manufacturer and model with us?

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#18

Re: Stop Burning of Radiator Top Tank

08/05/2010 10:21 PM

A cooling system that is FULL of coolant, little to no air in the system with a normal range pressure cap, 12-16 psi, and 50/50 coolant shouldn't get any hotter than roughly 250F. If you are melting the plastic, 450F or more, there is air in the system. Either coolant is forced out as the system goes from cold to hot and is not replaced for the next heat cycle or you have hot spots in the engine, possibly incorrect circulation pattern, that causes localized boiling of the coolant and subsequent air in the system that then leads to air/steam accumulation at the top/inlet of the radiator. Regular overheating causes the coolant to break down and create a muddy solution that then precipitates out at areas of low flow in the water jacket. The build-up of this sediment can cause hot spots particularly if it restricts or prevents flow all the way around a cylinders water jackets. This is a common problem in some engines that I have worked on. Pop out a freeze plug at the cylinder furtherest from the water pump to check for this.

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