how to sifon cool a changfa zs1115g

[ronsmith]

My Changfa zs1115g is a hopper feed coolant tank setup with a water pump. I want to go to a sifon feed large coolant tank. Can someone tell me how to hook it up. Can I use the existing hopper and ports or will I need to remove the hopper and install a manifold like Georges utterpower cangfa?

[rcavictim]

I suggest you get rid of the hopper and the unreliable water pump and install a interface plate like George has shown with a automobile thermosdtat included in the output line.  Be sure the cool water inlet has a dip tube to introduce the cold water lower in the water jacket.  I custom made such a plate for my JD-175 out of steel and it works perfectly.  I used 1 inch I.D. Gates heater hose to a small, 3-core automobile radiator with two 6 inch muffin fans  suspended well above the engine and a 7 PSI pressure cap and small expansion tank.  You will likely need a larger radiator. 

[ronsmith]

I have a 40 gallon water tank i could hook up to it with a manifold plate like you suggest. will that setup work as a siphon feed?

[mjn]

Hi Ronsmith,

Your 40 gallon water tank will thermosiphon just fine with the manifold plate.

My original design for my engine was exactly what you are attempting.  I ended up going with a radiator when I realized I was going to need to buy 20 gallons of antifreeze to fill my collant tank.

Here is a diagram showing how I hooked up my thermosiphon on my Chanfa 195:


In my case, I have two thermosiphon loops: one for the radiator, and one for the WVO preheat.  Ignore the WVO tank.

Notice how I have the dip tube (cold return from the radiator) at far right towards the crankshaft.  This is because the hottest water is towards the head.   I have seen serveral examples where people hook it up the other way around, but I feel that I get a better thermosiphon this way.

[ronsmith]

Great! I already have 40 gallons of antifreeze so I will go with the tank and manifold setup. I want to get a manifold from utterpower if george i still selling them, if not what thickness plate steel do I need for the plate?

[mjn]

I don't think the thickness of the manifold plate is critical.  It just needs to be strong enough to hold your pipe fittings etc. I cast my manifold plate own out of aluminum (http://martin.nile.googlepages.com/lostandfoundry).  I chose a piece of 3/8 particle board for the pattern.   By the time I had machined the inside surface I ended up with roughly 5/16".

[rcavictim]

I used a piece of 5/16 inch thick steel plate and milled a stepped hole on the lathe with a 4 jaw chuck to receive the thermostat.

[M61hops]

I've only seen photos of the 1115g but I think that they might have put that pump there to prevent hot spots inside the engine so I'd be carefull about getting rid of it.  Maybe use the hole for it as a return port?  Just a thought...            Leland

[ronsmith]

George at utterpower has a manifold plate to fit it so I will order it and give it a try. Thanks for the help guys.

[ronsmith]

i recieved my manifold cooling plate from George for my Changfa. What type of gasget or silicone should I use to seal the plate?

[mjn]

I use the stock gasket between my manifold plate and the engine.  I use blue RTV silicone on the thermostat adapter. So far I have no leaks.

[ronsmith]

I got the radiator setup today and ran the changfa for 4 hours under a steady load. It ran great and carried all my 110v and 220v loads which consisted of a washer and dryer, ref., some flo. lights , computer, tv and sat. reciever. Also ran a load of dishes in washer and 220v hot water tank. I put a fan blowing on radiator temp. until I can rig a permanent one. The temp gauge read in a range between 165 deg f and 210 deg. f depending on the load. The radiator kept up fine and never got too hot to touch. I put in a 3 section jeep cj7 heavy duty rad. I will keep the board posted, Oh by the way Georges manifold plate worked great!

[draganof]

ronsmith,
I have a question for you. Are you running your radiator pressurized or open? The reason I ask is I am having difficulty finding 1.5" ID hose that can take the pressure at 200+ degrees so I am running mine non-pressurized. I could run black iron pipe with short radiator hose coupling at each end I suppose. Also how far from your engine is your radiator?

John

[ronsmith]

I am running the radiator pressurized. My rad. had 11/2 ports on it also. I had one actual radiator on hand and on the other side I used red G.P. air and water hose rated at 250 psi. I ran the overflow hose from top of rad. to a homemade one galllon tank for overflow and evaporation.

[Doug]

Ditto on the high presure water hose....

The machanics I work with have sued the same stuff for heaters and auto aplications. Its not ment for high temperatures but seems to work. This is whats in store for Gus 1 inch 250 PSI air/water line.

Doug