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 .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.

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.