ERA Trade Show Allentown Water Cooled Alternators and Electronics Apr.14 th.2012 www.waiglobal.com
Why Water? Alternators are not perfect, they generate a lot of heat!! Heat Transfer Radiation Convection: Air common in alternator. Conduction: Contact
Typical Alternator
Why Water? Alternators are mainly cooled by air, but check this data: A convection magic number: Free Convection - Air : 5-25 (Watts/ C) Free Convection - Water: 20-100 (Watts / C) Forced Convection - Air: 10-200 (Watts/ C) Forced Convection - Water: 50 10,000 (Watts/ C) Boiling Water : 3,000 100,000 (Watts/ C)
History: 1913 - Bosch released the first electrical system 1992 - First year of liquid cooled alternators technology. It was developed mainly for emergency vehicle applications 1998 - Liquid cooled alternator utilized for light cars
Bosch Family Water Cooled Alternator - Application 13815N (2003-99) BMW 540i 4.4L (2001-99) BMW 740i 4.4L (2000-99) BMW 750i 5.4L (2004-00) BMW X5 4.4L (2003-02) BMW X5 4.6L (2009-03) Land Rover Range Rover 4.4L 13815N 22952N 22952N (2003-00) Mercedes Benz C200, C220 2.2L (2004-00) Mercedes Benz C270 2.7L (2000-99) Mercedes Benz E200, E220 2.2L (2001-99) Mercedes Benz E270 2.7L (2000-99) Mercedes Benz E320 3.2L (2000-on) Mercedes Benz G400 4.0L (2005-00) Mercedes Benz ML270 2.7L (2002-99) Mercedes Benz S320 3.2L (2005-99) Mercedes Benz S400 4.0L
Bosch Family Water Cooled Alternator - Description Higher output, rated output 150A Lower noise <74db Stable operation temperature Longer reliability >= 125K miles Additional heat sources for Air conditioning OE unit cold condition RPM output (A) 1600 63 1800 88 2000 106 2400 137 3500 163 5000 173 6000 176 8000 179
Bosch Family Water Cooled Alternator - Stator Contact heat transfer Stator anchor 180 C coil wire varnish
Bosch Family Water Cooled Alternator - Rotor Brushless alternator Stationary coil Claw-pole rotates Stainless steel merging ring High quality SRE bearing 180 C coil wire varnish
Bosch Family Water Cooled Alternator - Pulley 13815N Conventional Pulley 22952N Clutch Pulley 24-91264
Bosch Family Water Cooled Alternator - Rectifier IBR2201 Lester Nos: 13815, 22952 Dimensions: M8 x 1.25 Batt. Term Notes: Delta wound stator applications Companion Regulator IB200 and IB201 Features: 6 press fit Avalanche diodes 20-24V Avalanche voltage 80 Amp power diodes Welded diode terminations
Common Failure Modes By communicating with vehicle repair shops and searching on-line forums, we found the Power Diodes to be the majority of the failure mode of an OE Bosch water cooled alternators family Rated output of Bosch family water cooled alternators is 150A Due to unit mechanical design, the majority of the heat generated by unit will be dissipated from the stator assembly which is in contact with the cooling liquid Rectifier temperature will be much higher than normal operation temperature
Transpo Solution for an OE rectifier failure 1. PPS rectifier lead frame with extra thickness in copper conductor 2. OE equivalent insulation gasket which has excellent heat dissipation capability 3. The highest amperage power diodes are used (press fit) to generate a less junction temperature
Other common failure modes Field coil terminal Tolerance ring damage Bearing damage Operation impact damage
Bosch Family Water Cooled Alternator - Regulators 13815N Transpo Regulator IB200 22952N Transpo Regulator IB201
Bosch Family Water Cooled Alternator Regulator s Pin Out 13815N Transpo Regulator MCU based IB200 Pin Out 22952N Transpo Regulator MCU based IB201 Pin Out
13815N Bosch Family Water Cooled Alternator Regulator OE Transpo - Brand B parameter comparison Features OE Parameters Transpo IB200 Market offer Results Setpoint 14.4V 14.4V 14.45V Similar Plug Definition L-IG L-IG L-IG Equal Yes yes yes Equal Choke Choke is fed by IGN terminal. Choke is fed by IGN terminal. Choke is fed by B+ terminal. Brand B has potential IGN light failure issue on ALT98 if the choke signal is fed by B+. IGN, STA or L IGN, STA or L IGN, STA or L Equal IGN voltage to activate=4.4v IGN voltage to activate=4.4v IGN voltage to activate=1.1v Similar Regulator Activation Lamp voltage to activate 0.47V Lamp voltage to activate 0.47V Lamp voltage to activate 1.1V Similar 2.2 Vpp stator signal to 8V (positive voltage) stator signal to Transpo is much closer to OE sample. OE 1.9 Vpp stator signal to activate. activate activate. is stator activation is 2V Vpp. Soft Start Duty Cycle 18% 18% 18% Equal Soft Start Delay 1st time SSD is 179 Hz 1st time SSD is 179 Hz (then LRC) after Transpo 1st Soft Start Delay is equal to (then LRC) after that No 1st time SSD, SSD is always 80/50HZ. that SSD is 75/72hz OE. SSD is 75/72hz LRC 11S to 280HZ 11S to 280HZ 11S@180HZ, 7.3S@280HZ, 0.8S@320HZ Similar Lose STA Light Yes, delay 800ms on / off Yes, delay 800ms on / off yes, delay 288ms on / 30ms off Similar Lose IGN Light Yes, IGN<11.28V lamp is on. Yes, IGN<11.28V lamp is on. yes, IGN<0.5V lamp is on Similar Over voltage Indication 17.0V 17.0V 17.2V Similar Under voltage Indication No No 10.2V OE sample doesn't have UV indication. Ignition Multi-function Ignition Terminal Compliant to OE Not compliant to OE Brand B has Incorrect Ignitition function, this regulator will not work correctly on the car. Error Light might be shown.
22952 Bosch Family Water Cooled Alternator Regulator OE Transpo - Brand B parameter comparison Setpoint 14.4V 14.4V 14.4V Equal SSD one time to 140HZ, Soft Start Delay 3.5S delay (LAMP ON FOR SSD one time to 140HZ, 3.5S Tranpso IB201 has the SSD which is No SS) (LAMP ON FOR SS) compliant to OE. Soft Start 18% @ 142Hz, back to SS @ 70HZ and out to SS @ 72Hz 20% @ 122HZ; back or out to SS @70Hz 23% 500HZ; out or back to SS @ 50Hz Similar Regulator Activation STA Lamp LRC Under Voltage Indication Over Voltage Indication Choke L or STA L or STA L only, STA keep on. Loss of STA Lamp on delay 0.83S 2.5S to 270HZ Loss of STA Lamp on delay 0.83S Loss of STA Lamp on delay 0.22S Transpo IB201 is the same with OE sample Similar 2.5S to 270HZ 2.2S to 310HZ Similar No No No Equal No No No Equal Yes, Vsat.18@.5A,.37@1A, (CURRENT LIM FOLD BACK @ 1.2A) Yes, Vsat.18@.5A,.37@1A, (CURRENT LIM FOLD BACK @ 1.2A) Yes, Vsat 1.474@.5A, 1.64@1A; no current lim Transpo IB201 has Choke current limit function Lamp Vsat.89@.5A, 1.28@1A, (CURRENT LIM FOLD BACK=1.3A MAX) Vsat.89@.5A, 1.28@1A, (CURRENT LIM HOLD BACK=1.3A MAX) Vsat 1.8@.5A, 1.9@1A;no current lim Transpo IB201 has Lamp current limit function. Brand B doesn't, and lamp load resistor is incorrect. FR resistor 500Ohms 470ohms no this resistor Brand B has no FR resistor. Flat under +10 degree C, Brand B Tempco is different with Tempco -1.7 above 10 degree C. Compliant to OE Not compliant to OE OE sample.