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ERA Trade Show Allentown
Water Cooled Alternators and ElectronicsApr.14th.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 22952N
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
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 150ALower noise <74dbStable operation temperatureLonger reliability >= 125K milesAdditional heat sources for Air
conditioning
RPM
OE unit cold condition
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 transferStator 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
22952NClutch Pulley
24-91264
13815NConventional Pulley
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 diodesWelded 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 AlternatorRegulator’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 RegulatorOE – 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 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=4.4vIGN voltage to activate=4.4v IGN voltage to activate=1.1V Similar
Lamp voltage to
activate 0.47VLamp voltage to activate 0.47V Lamp voltage to activate 1.1V Similar
2.2 Vpp stator signal to
activate1.9 Vpp stator signal to activate.
8V (positive voltage) stator signal to
activate.
Transpo is much closer to OE sample. OE
is stator activation is 2V Vpp.
Soft Start Duty Cycle 18% 18% 18% Equal
Soft Start Delay
1st time SSD is 179 Hz
(then LRC) after that
SSD is 75/72hz
1st time SSD is 179 Hz (then LRC) after
that SSD is 75/72hzNo 1st time SSD, SSD is always 80/50HZ.
Transpo 1st Soft Start Delay is equal to
OE.
LRC 11S to 280HZ 11S to 280HZ11S@180HZ, 7.3S@280HZ,
0.8S@320HZSimilar
Lose STA LightYes, delay 800ms on /
offYes, delay 800ms on / off yes, delay 288ms on / 30ms off Similar
Lose IGN LightYes, 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
TerminalCompliant 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.
Choke
Regulator Activation
22952 Bosch Family Water Cooled Alternator Regulator OE – Transpo - Brand “B” parameter comparison
Setpoint 14.4V 14.4V 14.4V Equal
Soft Start Delay
SSD one time to 140HZ,
3.5S delay (LAMP ON FOR
SS)
SSD one time to 140HZ, 3.5S
(LAMP ON FOR SS)No
Tranpso IB201 has the SSD which is
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 @ 50HzSimilar
Regulator
ActivationL or STA L or STA L only, STA keep on.
Transpo IB201 is the same with OE
sample
STA LampLoss of STA Lamp on delay
0.83S
Loss of STA Lamp on delay
0.83S
Loss of STA Lamp on delay
0.22SSimilar
LRC2.5S to 270HZ
2.5S to 270HZ 2.2S to 310HZ Similar
Under Voltage
IndicationNo No No Equal
Over Voltage
IndicationNo No No Equal
Choke
Yes, Vsat [email protected], .37@1A,
(CURRENT LIM FOLD BACK
@ 1.2A)
Yes, Vsat [email protected], .37@1A,
(CURRENT LIM FOLD BACK @
1.2A)
Yes, Vsat [email protected],
1.64@1A; no current lim
Transpo IB201 has Choke current
limit function
Lamp
Vsat [email protected], 1.28@1A,
(CURRENT LIM FOLD
BACK=1.3A MAX)
Vsat [email protected], 1.28@1A,
(CURRENT LIM HOLD
BACK=1.3A MAX)
Vsat [email protected], 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.
Tempco
Flat under +10 degree C,
-1.7 above 10 degree C. Compliant to OE Not compliant to OEBrand B Tempco is different with
OE sample.