Which is better, an air-cooled or liquid-cooled diesel generator? What is the difference between the two cooling systems?

Diesel generators generate a lot of heat when running, so the internal components must be constantly cooled to ensure that the generator does not get damaged. Most diesel generators are either air-cooled or liquid-cooled. The cooling method is a basic design element of the generator today and is usually determined by the power and type of the generator. Air cooling systems are usually used for smaller generators, while larger generators require liquid cooling systems.

Air-cooled diesel generator system:

These systems use air circulation to cool the unit. With an air cooling system, the diesel engine draws cooler air from the atmosphere, blowing this air through the generator set from the inside, thus preventing the generator from overheating. Typically, air-cooled diesel engines are used in portable diesel generators up to 22 kW and standby diesel generators. For air cooling systems, you have two options: open ventilation systems and completely closed systems. Open ventilation systems use atmospheric air and then release exhaust gases back into the atmosphere. On the other hand, closed ventilation systems constantly circulate air to cool the internal generator components.

Air-cooled diesel engines have some limitations; they can overheat if used for a long time in overheated conditions, so we recommend that you pay attention to ambient temperature and usage time. When an air-cooled diesel engine fails, it may require major repairs. A more attentive approach is required for preventive maintenance and repair tasks compared to liquid-cooled systems. Air-cooled diesel engines are slightly less durable because the oil breaks down at a relatively fast rate under hot conditions. This can lead to damage without many previous symptoms.

Liquid-Cooled Diesel Generator Systems:

Liquid-cooled systems use various types of oil/coolant to cool the internal components of the generator. Liquid-cooled systems cool much better than air-cooled systems, which is why liquid-cooled generators cost more than air-cooled units. Essentially, liquid-cooled engines are comparable to small car engines.

Liquid-cooling systems include a radiator and a water pump, which distributes liquid coolant to the engine block through hoses. Heat is transferred to the coolant, which is cooled by air through the radiator. Generally speaking, modern diesel generators above 22kW are liquid-cooled, with air-cooled engines dominating the portable generators. Liquid-cooled systems cost more to produce than air-cooled diesel engines; they require additional design considerations and parts, including the radiator. Liquid-cooled are more durable and more powerful than their air-cooled counterparts. Since these types of generator sets are more expensive, they are widely used for commercial and industrial uses where cooling needs are greater than for smaller residential and portable units.

Which system do you need?

Each system has advantages and disadvantages. Air-cooled systems are simpler and less expensive than liquid-cooled systems. Liquid-cooled systems are more robust and effective. Ultimately, the cooling system you choose is likely designed to be adequate for your needs. Liquid-cooled systems have a wide range of uses and can be used in any environment.

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