Water Cooled Alternators and Electronics - WAIglobal

Water Cooled Alternators and Electronics
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Why water
• Alternator are not perfect, they generate heat….a lot!!
• Heat Transfer
• Radiation: need …Nop
• 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 (W/m2K)
• Free Convection - Water: 20 - 100 (W/m2K)
• Forced Convection - Air: 10 - 200 (W/m2K)
• Forced Convection - Water: 50 – 10,000 (W/m2K)
• Boiling Water : 3.000 – 100,000 (W/m2K)

Some history
• 1913 Bosch released the first electrical system.
• 1992 First year of liquid cooled alternators
Technology. It is developed mainly for Emergency
vehicle applications.
• 1998 Liquid cooled alternator 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
13815 22952
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 = 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
180C coil wire varnish

Bosch Family Water Cooled Alternator Rotor
Brushless alternator
Stationary coil.
Claw-pole rotates.
Stainless steel merging
ring.
High quality SRE bearing.
180C coil wire varnish.

Bosch Family Water Cooled Alternator Pulley
13815
Conventional Pulley
22952
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:
-6pcs Avalanche Press Fit Diodes, 20-24V
-80 Amp diodes
-Welded Diode Terminations

Common Failure Modes
By communicating with vehicle repair shops and searching on-line
forums, we found that the majority of the failure mode of OE Bosch
family water cooled alternators is Power Diode Failure.
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 stator
assembly which 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 copper conductor
2. OE equivalent insulation gasket which has excellent heat
dissipation capability.
3. The highest amperage power diodes is used (pressfit), generating
less junction temperature.

Other Common Failure Modes
Field Coil Terminal
•Tolerance ring damage
•Bearing damage
•Operation Impact damage

Bosch Family Water Cooled Alternator Regulators
13815 Transpo
Regulator IB200
22952 Transpo
Regulator IB201

Bosch Family Water Cooled Alternator Regulators
Pin Out
13815 Transpo Regulator
MCU based IB200 Pin Out
22952 Transpo Regulator
MCU based IB201 Pin Out

13815 Bosch Family Water Cooled Alternator Regulators IB200
OE-Tranpso-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

22952 Bosch Family Water Cooled Alternator Regulators IB201
OE-Tranpso-Brand B Parameter Comparison
IB201 OE Parameters Transpo IB201 Brand B Results
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
No
SS)
(LAMP ON FOR SS)
is compliant to OE.
Soft Start
Regulator
Activation
STA Lamp
LRC
Under Voltage
Indication
Over Voltage
Indication
Choke
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
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
Similar
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
Vsat .89@.5A, 1.28@1A,
Transpo IB201 has Lamp current
Vsat .89@.5A, 1.28@1A,
(CURRENT LIM FOLD
Vsat 1.8@.5A, 1.9@1A;no limit function. Brand B doesn't,
Lamp
(CURRENT LIM HOLD
BACK=1.3A MAX)
current lim
and lamp load resistor is
BACK=1.3A MAX)
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 OE
Brand B Tempco is differen with
OE sample.

Thanks For Your Time!
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function; parameter; testing approach; specification etc.
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