Appraisal and Testing of Volvo Engine

by Generator D. Diesel Generator

Appraisal and Testing

Installation checks

Installation recommendations regarding each subject are to be found in the previous chapter. Refer to the relevant section to retrieve information so that the installation achieves a satisfactory standard. While the preliminary cooling system design is based on calculations, the suitability of any given system must be determined by actual tests. The tests must correspond to the most difficult operational conditions that may arise during use.

Optional equipment specified by the original equipment manufacturer must be clearly defined and taken into account during the tests. Moreover, the checks and tests must include, and be adapted to, such equipment. For high altitude operations, there will be additional costs for the original equipment manufacturer in regard to certain applications. Experience has however shown that if customers are not able to clearly define and check which areas the equipment will be used in, Volvo Penta recommendations to adapt the installation to the most difficult conditions are justified. International standardization is ever more common,especially within industrial and construction machinery.

This opens up possibilities for manufacturers to ship machinery between various parts of the world. Because of this we strongly recommend that the cooling system be designed so that the machinery may be used anywhere without the need to alter the cooling system. Copies of all inspection documentation must be sent to Sales Engineering Industrial, AB Volvo Penta so that information may be registered for future reference and guidance for other departments within Volvo Penta. This request applies whether or not the applications have been approved.

NOTICE! Information regarding inspections and tests are also available at Volvo Penta Partner Network under “Application Engineering Operating Procedures”

Global ambient temperatures

Set out below are maximum ambient temperatures for Volvo Penta-driven applications around the entire world. The world has been divided into the following temperature zones:

A Northern Europe: 35 °C (95 °F).

B Southern Europe: 40 °C (104 °F).

C Scandinavia and Great Britain: 30 °C (86 °F).

D North America, Canada, Central and South America, parts of Asia: 40 °C (104 °F).

E Africa, Middle East, Far East, Australia and South Pacific: 50 °C (122 °F).

The stated temperatures for the various parts of the world are based on the average of the highest monthly ambient temperatures in the shade registered over a number of years.

It is the original equipment manufacturer's responsibility to ensure that the cooling system specification is suitable for the area in which the application is to be used.

However, we must point out that cooling tests carried out according to the different stated levels do not guarantee against the occasional overheating of machinery in operational use. This applies especially to days that are hotter than average conditions, and when the application is used in direct sunlight and is exposed to heat radiation from the ground etc. We therefore recommend that the cooling system be designed with sufficient margin for these circumstances. Customers who export machinery and/or manufacture in different parts of the world are strongly recommended to implement a standardized cooling system that can be used throughout the world. This facilitates both spare parts warehousing and service.

Installation Testing

General

The test procedures described in this section are intended to provide guidance when the various tests are performed as part of installation checks. One of the main objectives is to try to ensure that temperatures and other data are always registered at the same point. Some manufacturers offer optional cooling systems. In such cases cooling specifications must be clearly defined and separate tests carried out in order to confirm each specification before any coolant tests are performed.

NOTICE! Every new or updated installation must be inspected and approved by a Volvo Penta representative. Volvo Penta Sweden uses advanced measuring and test equipment for this purpose, at registration points described in the Measurement points page 136 section.

Air to Air Intercooled Engines

In Volvo engine installations where the cooling system has not been supplied by Volvo Penta it is of the greatest importance that the pressure drop and temperature drop across the charge air cooler are within Volvo Penta specified values. Both the temperature and charge pressure sensors must be installed in the ducting before and after the charge air cooler. In many cases it is necessary to drill and tap holes in the ducting. A combined union for temperature and pressure is recommended in order to minimize the number of holes.

NOTICE! Carefully remove all swarf after drilling and tapping.

NOTICE! Calibrate the pressure sensor accurately, as the pressure differential across the CAC must not exceed 10 kPa (1.45 PSI).