Independant Intercooler Test

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09-24-2013, 11:48 AM

GTRNICK

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Independent Intercooler Test

I am going to put the intercoolers in my car through an Independent test in a special wind tunnel which is also used to test heat exchangers for F1 teams, motorsport teams, the military and so on.

I would love to know what you guys think and if you feel if there should be any changes to the data I have been advised of?

I will also test against the GT2 RS coolers as a point of reference unless you think there is any better.

The points of data below is what I have been advised to go for by the company.

<table width="624" style="width: 472pt; border-collapse: collapse;" border="0" cellspacing="0" cellpadding="0"> <colgroup><col width="78" style="width: 59pt; mso-width-source: userset; mso-width-alt: 2218;" span="8"> <tbody><tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td width="156" height="30" class="xl69" style="border: 0px black; width: 118pt; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2">CAC Test Matrix</td> <td width="78" class="xl65" style="border: 0px black; width: 59pt; background-color: white;"></td> <td width="78" class="xl67" style="border: 0px black; width: 59pt; background-color: white;"></td> <td width="78" class="xl67" style="border: 0px black; width: 59pt; background-color: white;"></td> <td width="78" class="xl67" style="border: 0px black; width: 59pt; background-color: white;"></td> <td width="78" class="xl67" style="border: 0px black; width: 59pt; background-color: white;"></td> <td width="78" class="xl67" style="border: 0px black; width: 59pt; background-color: white;"></td> </tr> <tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td height="30" class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2">Charge Air Flows:</td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl66" style="border: 0px black; background-color: white;"></td> <td class="xl66" style="border: 0px black; background-color: white; mso-ignore: colspan;" colspan="3"><table width="156" style="width: 118pt; border-collapse: collapse;" border="0" cellspacing="0" cellpadding="0"> <colgroup><col width="78" style="width: 59pt; mso-width-source: userset; mso-width-alt: 2218;" span="2"> <tbody><tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td width="156" height="30" class="xl66" style="border: 0px black; width: 118pt; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2">0.1, 0.2, 0.3 kg/sec</td> </tr></tbody></table></td> <td class="xl67" style="border: 0px black; background-color: white;"></td> </tr> <tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td height="30" class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="3">Charge Air Inlet Pressure:</td> <td class="xl66" style="border: 0px black; background-color: white;"></td> <td class="xl66" style="border: 0px black; background-color: white; mso-ignore: colspan;" colspan="2">1.5 bar (g)</td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl67" style="border: 0px black; background-color: white;"></td> </tr> <tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td height="30" class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="3">Charge Air Temperature:</td> <td class="xl66" style="border: 0px black; background-color: white;"></td> <td class="xl66" style="border: 0px black; background-color: white;">150°C</td> <td class="xl66" style="border: 0px black; background-color: white;"></td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl67" style="border: 0px black; background-color: white;"></td> </tr> <tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td height="30" class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2">Coolant Air
Flow:

</td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl66" style="border: 0px black; background-color: white;"></td> <td class="xl66" style="border: 0px black; background-color: white; mso-ignore: colspan;" colspan="2"><table width="468" style="width: 354pt; border-collapse: collapse;" border="0" cellspacing="0" cellpadding="0"> <colgroup><col width="78" style="width: 59pt; mso-width-source: userset; mso-width-alt: 2218;" span="6"> <tbody><tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td width="468" height="30" class="xl66" style="border: 0px black; width: 354pt; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="6">3, 6, 10 m/sec (High & lowest flow to be confirmed on day of test)</td> </tr></tbody></table></td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl67" style="border: 0px black; background-color: white;"></td> </tr> <tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td height="30" class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2">Air Temperature:</td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl66" style="border: 0px black; background-color: white;"></td> <td class="xl67" style="border: 0px black; background-color: white;">30°C </td> <td class="xl67" style="border: 0px black; background-color: white;"></td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl67" style="border: 0px black; background-color: white;"></td> </tr> <tr height="30" style="height: 22.5pt; mso-height-source: userset;"> <td height="30" class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2">Points in Matrix:</td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl70" style="border: 0px black; background-color: white;">9</td> <td class="xl65" style="border: 0px black; background-color: white;"></td> <td class="xl65" style="border: 0px black; background-color: white;">

</td> <td class="xl65" style="border: 0px black; background-color: white;">

</td> </tr></tbody></table>

Last edited by GTRNICK; 09-28-2013 at 03:15 AM.

09-24-2013, 12:41 PM

dewilmoth

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This should definitely be interesting. Subscribed.

09-24-2013, 12:43 PM

GTRNICK

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Quote:

Originally Posted by dewilmoth

This should definitely be interesting. Subscribed.

Thanks. I wonder if anyone else wants to test their AM intercoolers!

09-24-2013, 02:34 PM

93ls1rx7

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Anyway to test different intercooler intake options?

09-24-2013, 02:37 PM

GTRNICK

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Quote:

Originally Posted by 93ls1rx7

Anyway to test different intercooler intake options?

Could be more elaborate please.

09-24-2013, 02:57 PM

93ls1rx7

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Arent there different mounting options that use either the side intake vents or underneath? Maybe I am incorrect.....

09-24-2013, 03:00 PM

BaldBag

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09-24-2013, 03:51 PM

GTRNICK

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Quote:

Originally Posted by 93ls1rx7

Arent there different mounting options that use either the side intake vents or underneath? Maybe I am incorrect.....

Ok I'm really confused!

09-24-2013, 04:14 PM

dewilmoth

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I believe he's talking about intake options. Completely unrelated to intercooler testing.

#10

09-24-2013, 04:20 PM

GTRNICK

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Quote:

Originally Posted by dewilmoth

I believe he's talking about intake options. Completely unrelated to intercooler testing.

Either that or does he mean how they mount the coolers in the tunnel using different intake options?

#11

09-24-2013, 05:55 PM

earl3

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Awesome way to test!

Both the charge air flow through the cooler and the coolant air flow seem low for our applications. What are the maximums the test rig can support in these areas?

Ideally, I'd chose something like:

500, 750, 1000 kg/hr (assuming 1 cooler)

25, 50, 75 m/s (I would leave the factory ducting intact on both sides of the cooler and "inject" the cooling air at the ducting inlet if possible)

Other things I'd measure are time to a steady state outlet temp (this would give some insight into the heat sink capability of a cooler) and then time to recover to ambient once the thermal load is removed (keep the cooling airflow going).

At any rate, the suggested setup from the company would work for testing coolers relative to each other. I would send as many coolers as you can get your hands on.

Last edited by earl3; 09-24-2013 at 06:03 PM.

#12

09-25-2013, 12:19 AM

GTRNICK

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Thanks Earl.

I will put forward these questions and return with some answers!

#13

09-25-2013, 12:59 AM

93ls1rx7

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Alright, I have made a mess of this question....

I guess the best way to ask is just show the vendors.

Are there any differences with using a entirely new intercooler ducting like in the AMS kit:
http://www.amsperformance.com/cart/a...ooler-kit.html

Versus the "trim the factory ducting" like in the Vividracing kit (or many other kits):
http://www.vividracing.com/catalog/v...9-p-80007.html

Finally, not related to my orginal topic but do the "opened" side vents like these http://www.agency-power.com/catalog/...-p-153785.html allow a significant advantage

#14

09-25-2013, 02:02 AM

GTRNICK

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Quote:

Originally Posted by 93ls1rx7

Right thats better i get you now!

Firstly The only reason i can see AMS have created all that pipe work and the ducts is to fit their coolers without cutting any plastics plus the stock pipes will not fit these coolers!

They are still using the ideology that most AM tuners are using which is bigger is better which is not the case! Don't get me wrong it looks like an appealing kit and is marketed very well with colourful pics and a nice write up but there is no real evidence to support this product!

So think about how cheap these intercoolers would be if you removed the ducts and pipe work from the equation?

Secondly the way vivid have done it is the way my cores fit as this was the design that was created by Porsche in the first place so who knows better us or Porsche? Don't get me wrong i have heard many times removing the factory connection to a slip on connection would still be a slight improvement which i don't disagree with but i don't think it will be the downfall as the core design is the most important part IMO

Thirdly yes Porsche again changed the side scoops on the GT2 RS I'm guessing to allow more air into the scoop so it could help.

Another thing I will add to this is that most AM tuners usually sell their oversized cores with old turbo technology which are usually a lot bigger which run cooler for that reason and you do not get to see them being used with the latest VTG tech which runs much hotter so you never really see how good the coolers are.

It has also been proven a few times by forum members that the GT2 RS coolers are superior in comparison to some AM coolers which are not mentioned.

One more thing I will say is Porsche spent a lot of time and money developing their intercoolers and ducts and pipe work so to improve on that you have to spend the cash and not fit something which has just been developed in 5 mins from a brainwave which is why I personally chose the aerospace route as you cannot beat it if its in planes, military vehicles and F1 motor sport?

I hope I answered your questions in the way you wanted.

Last edited by GTRNICK; 09-25-2013 at 02:11 AM.

#15

09-25-2013, 09:26 PM

TTdude

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Quote:

Originally Posted by GTRNICK

I am going to put the intercoolers in my car through an Independent test in a special wind tunnel which is also used to test heat exchangers for F1 teams, motorsport teams, the military and so on.

I would love to know what you guys think and if you feel if there should be any changes to the data I have been advised of?

I will also test against the GT2 RS coolers as a point of reference unless you think there is any better.

The points of data below is what I have been advised to go for by the company.

<table style="width: 472pt; border-collapse: collapse;" border="0" cellpadding="0" cellspacing="0" width="624"> <colgroup><col style="width: 59pt; mso-width-source: userset; mso-width-alt: 2218;" span="8" width="78"> </colgroup><tbody><tr style="height: 22.5pt; mso-height-source: userset;" height="30"> <td class="xl69" style="border: 0px black; width: 118pt; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2" height="30" width="156">CAC Test Matrix</td> <td class="xl65" style="border: 0px black; width: 59pt; background-color: white;" width="78">
</td> <td class="xl67" style="border: 0px black; width: 59pt; background-color: white;" width="78">
</td> <td class="xl67" style="border: 0px black; width: 59pt; background-color: white;" width="78">
</td> <td class="xl67" style="border: 0px black; width: 59pt; background-color: white;" width="78">
</td> <td class="xl67" style="border: 0px black; width: 59pt; background-color: white;" width="78">
</td> <td class="xl67" style="border: 0px black; width: 59pt; background-color: white;" width="78">
</td> </tr> <tr style="height: 22.5pt; mso-height-source: userset;" height="30"> <td class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2" height="30">Charge Air Flows:</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl66" style="border: 0px black; background-color: white;">
</td> <td class="xl66" style="border: 0px black; background-color: white; mso-ignore: colspan;" colspan="3">100, 200, 300 kg/hour</td> <td class="xl67" style="border: 0px black; background-color: white;">
</td> </tr> <tr style="height: 22.5pt; mso-height-source: userset;" height="30"> <td class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="3" height="30">Charge Air Inlet Pressure:</td> <td class="xl66" style="border: 0px black; background-color: white;">
</td> <td class="xl66" style="border: 0px black; background-color: white; mso-ignore: colspan;" colspan="2">1.5 bar (g)</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl67" style="border: 0px black; background-color: white;">
</td> </tr> <tr style="height: 22.5pt; mso-height-source: userset;" height="30"> <td class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="3" height="30">Charge Air Temperature:</td> <td class="xl66" style="border: 0px black; background-color: white;">
</td> <td class="xl66" style="border: 0px black; background-color: white;">150°C</td> <td class="xl66" style="border: 0px black; background-color: white;">
</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl67" style="border: 0px black; background-color: white;">
</td> </tr> <tr style="height: 22.5pt; mso-height-source: userset;" height="30"> <td class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2" height="30">Coolant Air Flow:</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl66" style="border: 0px black; background-color: white;">
</td> <td class="xl66" style="border: 0px black; background-color: white; mso-ignore: colspan;" colspan="2">3, 6, 10 m/sec</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl67" style="border: 0px black; background-color: white;">
</td> </tr> <tr style="height: 22.5pt; mso-height-source: userset;" height="30"> <td class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2" height="30">Air Temperature:</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl66" style="border: 0px black; background-color: white;">
</td> <td class="xl67" style="border: 0px black; background-color: white;">30°C tbc</td> <td class="xl67" style="border: 0px black; background-color: white;">
</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl67" style="border: 0px black; background-color: white;">
</td> </tr> <tr style="height: 22.5pt; mso-height-source: userset;" height="30"> <td class="xl66" style="border: 0px black; height: 22.5pt; background-color: white; mso-ignore: colspan;" colspan="2" height="30">Points in Matrix:</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl70" style="border: 0px black; background-color: white;">9</td> <td class="xl65" style="border: 0px black; background-color: white;">
</td> <td class="xl65" style="border: 0px black; background-color: white;">

</td> <td class="xl65" style="border: 0px black; background-color: white;">

</td> </tr></tbody></table>

Is charged air out of turbo really that hot, 150*C? I would also measure pressure drop plus temp of exit air out of IC.