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Old 27-07-2019, 16:46   #541
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Re: Alternator Size with LiFePo4

The drop in amps you get by doubling volts

while lowering stress / heating of electronics and wiring

will not reduce the HP required per kW produced, nor help with torque issues

Input power proportional to output power, less inefficiencies.

Not saying you "will" need multi-vee, but ability to de-rate will buy you some time if you empirically determine that upgrade is required.
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Old 28-07-2019, 04:06   #542
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Re: Alternator Size with LiFePo4

Thanks John,

Agreed the power requirements are the same whether it is 12v or 24v.
Bank 200a@12v or 100a@24 =2400watts
2400watts x .3C (max charge rate of LiFePo)= 720watts
Charging 720w/12v =60a and 720w/24v=30a thus a 30a@24v Alternator or 60a@12v Alt.

These loads are less than the recommended change from V-drive to serpentine belt, which tend to occur at 100a @12v according to Balmar documents.

I intend to oversize the alternator by at least 30% to improve longevity and to accommodate heat, in hopes that I can have good, adequate, continuous high output, and good low rpm performance. Alternator Size:
100-120a @ 12v
or 70a @ 24v
depending on what appears to be the best design.

Do you confirm that for a given power output (say 720watts) the heat from a 24v alternator's stator, windings and diodes are less than 12v alternator producing similar power?

From Tanglewood's post: It appears to me that changing from a 12v alternator to 24v of equivalent output, there would be less heat on the order of 180W.
Quote:
50A: 80W heat, 600W power, 88% efficient
100A: 260W heat, 1200W power, 82% efficient
Your point about the added heat from the engine due to any increased load is good.
Seldom does our old 65a@12v Balmar hit 65amps for long, it normally operates in the 45-55amp range when bulk charging, but this is due to our FLA (2)Trojan T105 6v in series 212ah batteries.

New Firefly or LiFePo Batteries (200ah@12v or 100ah@24v) would put a slightly bigger load on the alternator. 45a --->60-65a which is about 400 watts more. (I believe the Firefly batteries are rated at 1C so they could charge up faster, but they would put a bigger load on the alternator too.)

Because my alternator is working fine and while the belt ratio is poor (1.73) , making charging at anchor impractical,the alternator is fine for these batteries. I have been focused on solar lately. I will change the alternator when I change the batteries and rewire.

The real question is about wiring the batteries as 24v. It appears there are reasonably priced DC to DC Battery chargers, Renogy makes one.
  • Fit 2 Firefly 12v in series for about 100a@24v under the cabin seats (somewhere!) and charge that with alternator & solar.
  • Connect the Renogy 24DC to 12DC charger to a FLA 12v battery powering distribution panel and starter.
  • For solar 24v appears to make a lot of sense, provided the panels are big enough 60 to 72 cells.
I suppose I could increase the size of the bank (costly) so that I can charge faster to make up that 80-100a use per day (bigger alternator, more $), but the solar is going to help too.


I wonder what the difference in the cost of the alternator wiring would be between 12v & 24v? The savings has to be more than the cost of the Renogy DC to DC Battery charger to make 24v worthwhile I think.
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Old 28-07-2019, 11:38   #543
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Re: Alternator Size with LiFePo4

That 100A guideline is a WAG ballpark, but as stated de-rating will allow empirical testing as a stage 2 project.

C-rate is a proportion of bank capacity. Say yours at 12V is 400A, then .3C is 120A.

To optimize for longevity, make that an "occasional when needed fast charge" rate, and stick to 80-100A normally.

But on truly critical occasions say under 3% of cycles, a 160A rate won't cost much off the back end.

So for 24V, cut the above Amp rates in half, same watts, same belt issues.

The heat issue is a qualified yes, 24V is a bit cooler, but IMO usually not needed at such low power rates. Other possibilities, not mutually exclusive but in order of my preference

fitting an alt that is inherently designed to output near its rated capacity 24x7 - or oversized so you'll only rarely even draw over 50% of its max

moving the electronics away from the alt body

improving airflow in the compartment and specifically over to / away from the alt

The added cost and complexity of going 24V for a small boat with small power draws, though not huge just seems unnecessary to me, personally.

If you do end up using point-of-load buck converters, they can be found very cheaply in the sub-300W range, just carry plenty of spares. Or you need to rely on a pricey say Victron unit and run a 12V distribution network as well as the 24V backbone. yech.

Why are you even talking about DC-DC charging? Best to charge direct at the bank-native voltage, only convert for loads. If you're converting to a 24V alt, I would have thought everything engine related like cranking goes that way too?

But again, don't think the conversion's called for in the first place.

Quote:
Originally Posted by rgleason View Post
I wonder what the difference in the cost of the alternator wiring would be between 12v & 24v?
Supposed savings in wire gauge amortized over time will be infinitesimal, it's a once-off and bulletproof.

The "cost" factor you need more focus on is simplicity, reducing the number of gadgets that make the System as a whole less reliable, need to carry spares, more difficult troubleshooting at the **least** convenient times.

Even paying more to achieve KISS is worth it, happily here it's probably cheaper.

How about this step-wise approach?

Never mind about the bank selection for now, just set that issue aside.

Yes do your location/space carpentry mods for maximum flexibility, but not locking you into a **specific** battery size.

Big spending decision fork - invest in higher amp alt output first, or solar? Personal choice, but be sure to physically mock up your panel placement to be able to accurately judge your maximum Wattage and see its impact on aesthetics & windage.

Get all the other infrastructure in place, able to properly care for and use whatever type of chemistry you choose in the future.

But take that "which bank?" choice out of the picture for now, you're juggling too many simultaneous decision trees, focus on the charging infrastructure and loads distribution, systems monitoring etc first, pick one subsystem at a time, design and select the components to work well with "whatever chemistry", actually put it in place, and then move on to the next area

Stick to cheapest lead for meantime until you're happily working with all the rest, average daily income consistently above the average outgo, have a good idea how many bad-weather buffer days you want if by now shooting for "almost free always quiet mostly-solar".

Of course in the meantime continuing to research trustworthy domestic sourcing at reasonable pricing if you decide LFP.

And giving Bruce plenty of advance notice for your FFs if your model's back-ordered.

And of course gives you more time to save those pennies in advance so it doesn't hurt as much, that cheapest lead may work fine for quite a few years given the white-glove care it's getting 8-)
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Old 28-07-2019, 12:17   #544
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Re: Alternator Size with LiFePo4

Well, I guess I've worked may way around to Bruce and John's suggestions, albeit way late. Thanks Guys. - Its a small boat, stick with 12v and keep it simple. I had written the words below before I read your posts!

Also I've been checking out the FireFly's again and the 7" height may work. I just have to free up a drawer, but that involves discussion with my wife! (and I'll have to give up one of mine, in return...) Have to decide on which one.

I had started to think with the 24v solar panels and MPPT that a 24v House Bank would be a good idea, but I am starting to think that having a 24v battery bank and 24v Alternator is not so good an idea, because:
1. Savings in wire is about $150 but a 24DC to 12DC Battery Charger is needed and that costs a lot.
2. The utility of having all 12vdc is undeniable because there are fewer devices to fail, leaving you with what as a working system?
3. The reduced heat output of the 24v Alternator is certainly less, but perhaps it just has to be dealt with.
4. I can put the spare backup battery in the same under seat area as the main bank maybe.

And this post has an idea for stern mount solar panels, but they would be smaller, 100w-24v
http://www.cruisersforum.com/forums/...ml#post2939528


Please see attached sketch for comparison.
Attached Files
File Type: pdf Nell-Wire-Cost-for-12v-vs-24v-Alternator.pdf (51.7 KB, 43 views)
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Old 29-07-2019, 07:02   #545
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Re: Alternator Size with LiFePo4

My Catalina 30 with, an M-25 engine, came with two 85 amp-hr batteries. I upgraded to two 105 amp hr batteries. The alternator is a Motorola 55 amp.
It is my understanding that for lead acid batteries, a max alternator outputof 25% of the total battery bank amp hr capacity is about right. I.E. with a 200 amp hr battery bank anything bigger than a 50 amp alternator is wasted. Conventional wisdom is that Lead Acid batteries won't accept a bigger charging current unless they are discharged well below the recommended 50% ( ~12.1volts ) I have installed a "battery monitor" so I can monitor the alternator output and my system appears to support this. Even with deeply discharged bank, alternator current output rapidly drops below 20 amps.

If you are contemplating a larger alternator, you might want to invest in a monitor and watch your charging current before investing in a high output alternator.

George Goodall
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Old 29-07-2019, 09:09   #546
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Re: Alternator Size with LiFePo4

Quote:
Originally Posted by georgeg305 View Post
I have installed a "battery monitor" so I can monitor the alternator output and my system appears to support this. Even with deeply discharged bank, alternator current output rapidly drops below 20 amps.
With accurate voltage sensing and an alternator that could handle a higher sustained output into the bank you would see more current, unless the bank is sulfated.

Those little 55A alternators really can't handle much output. As they heat up, and are sensing voltage at the unit, before any voltage drop is occurring, charge current drops off rapidly due to both winding temp and volt sense location.

In bulk your bank will accept all that alternator can throw at it, until the regulator senses the voltage set-point has been attained.

Large current source = shorter duration to absorption target

Small current source = longer duration to attain absorption voltage
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Old 29-07-2019, 09:45   #547
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Re: Alternator Size with LiFePo4

Quote:
Originally Posted by rgleason View Post
I had started to think with the 24v solar panels and MPPT
Remember most good MPPT SCs auto-switch adapt to the bank voltage 12 vs 24V.

Solar panel voltage (Voc) is usually irrelevant to bank voltage, 40+Voc is fine no matter what the desired voltage output you want from the SC.
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Old 29-07-2019, 09:57   #548
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Re: Alternator Size with LiFePo4

Quote:
Originally Posted by georgeg305 View Post
max alternator outputof 25% of the total battery bank amp hr capacity is about right. I.E. with a 200 amp hr battery bank anything bigger than a 50 amp alternator is wasted. Conventional wisdom is that Lead Acid batteries won't accept a bigger charging current
The faulty assumption there is the phrase "a 50 amp alternator".

People conflate

an alt rated for 50A max, and

an alt that can actually put out 50A for many hours.

The latter may need to be "rated" for 100A. The former may struggle with 30A.

Until you get up to large-frame units designed for fire trucks, or more expensive specialist units from more honest sellers, that "max rating" means

this is the peak current this unit can tolerate for a few minutes without damage

how many minutes depends on airflow and temperature

So paying for a 120A alt upgrade when your goal is many hours of 70A continuous output - regulated by your MC-614 - is not at all a waste of money.

It is buying the right tool for the job.

Buying a 75A **rated** alt would be throwing money away.
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Old 29-07-2019, 14:39   #549
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Alternator Size with LiFePo4

I don’t see why if Wattage is the same why there would be much difference in heat between a 12V and a 24V alternator?
For whatever it’s worth at a temp that I am comfortable with I only see about 90 amps continuous at 14V out of my 165 A alternator, I have the temp set low at 90C and haven’t done anything to externally cool it.
I suspicion but don’t know that if I had the same temp limits that I wouldn’t get much more out of a 200 amp alternator.

However 90 amps is pushing 1300W pretty hard and that’s actually not an insignificant amount of power.
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Old 29-07-2019, 18:06   #550
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Re: Alternator Size with LiFePo4

Quote:
Originally Posted by a64pilot View Post
I don’t see why if Wattage is the same why there would be much difference in heat between a 12V and a 24V alternator?
For whatever it’s worth at a temp that I am comfortable with I only see about 90 amps continuous at 14V out of my 165 A alternator, I have the temp set low at 90C and haven’t done anything to externally cool it.
I suspicion but don’t know that if I had the same temp limits that I wouldn’t get much more out of a 200 amp alternator.

However 90 amps is pushing 1300W pretty hard and that’s actually not an insignificant amount of power.

Tanglewood gave us a great technical summary of the Wattage Heat Loads from various size alternators (stator and diode loads, not engine loads) with how he calculated it. Here is my post of his quote way further down the thread.



http://www.cruisersforum.com/forums/...ml#post2935363


Thanks for the good data.
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Old 01-07-2020, 04:16   #551
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Re: Alternator Size with LiFePo4

Quote:
Originally Posted by OceanPlanet View Post
Higher voltage better...24V highly recommended for high-energy systems. The new Integrel systems will be 48V (actually as high as 56+V)

For 12V systems it really helps to go with the external rectifiers

However one key issue we see a LOT, is that there is simply no ventilation near the alternator(s). Often there is a fan blowing air in or out of the engine compartment however without any thought as to how the air actually might get to the alternator. The air blowing in mostly just goes straight to the engine air intake and gets sucked up by the engine. If there is simply an intake vent near the alt to allow air to flow in and around it, as the air moves towards the engine intake and/or the exhaust fan/vent, it certainly helps. Otherwise, the alt is often simply sitting in the port fwd corner of the engine box, surrounded by it's own hot air essentially moving it around in a circle...
I think this is a really good point. The air flow system for the alternator needs be dedicated and designed for the purpose. It doesn't necessarily need to bring in outdoor air, in moderate climates using the cool side of the bilge to dump heat might work.

I also was looking at fan coolers + heat pipes for CPU's and these look pretty serious. To work properly they must be upright, but heat pipes that wrapped around and under the alternator with fins+fan above would also work properly. The next problem is to get the heat out of the boat.

The simplest solution in the long run may be to provide good dedicated air flow for the alternator and have external rectifiers.

https://www.newegg.com/cooler-master...82E16835103099
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Old 04-08-2020, 05:58   #552
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Re: Alternator Size with LiFePo4

Computer gaming has created a new liquid and air cooler with a pump that is nicely integrated for removing heat from CPU's. I am pretty certain it could be adapted to cool the case of an alternator. They claim "It performs effortlessly with over 200 W of heat to be dissipated, which is why your CPU can be kept cool even in extreme overlocking." There are many ways to skin the cat.

This one is about $60 Artic Liquid Freezer II-120
https://www.arctic.ac/en/Liquid-Free...20/ACFRE00067A

There are bigger ones or you could double up.
The issues are developing a method to mount the pump transfer plate (perhaps tapping the alternator case for the machined screws) routing the long enough hoses to a suitable location for the fans outside the engine compartment.

I think this is using 5vdc so a power converter would be needed. The problem with this approach is the SI28 has dual fans for good airflow, so it may be difficult to find enough surface area for the heat transfer. A fan and ducted "keel cooler" to the alternator might prove to be more effective with the SI28.

For alternator heat output see https://www.cruisersforum.com/forums...ml#post2935610 and the good point and discussion before and after.
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Old 27-08-2020, 07:28   #553
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Typical Fan(s) are Ineffective

See this post regarding the design and effectiveness of the typical fans used in dual internal and external alternators. I think this is a really good point.

https://www.cruisersforum.com/forums...ml#post3218002


There has to be a source for better fans... electrical or otherwise.

https://www.google.com/search?channe...or+cooling+fan


Billet alu fan Fits most GM-Delco, and Ford alternators.

https://www.speedwaymotors.com/Bille...saAhyQEALw_wcB
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Old 01-11-2020, 14:29   #554
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Re: Alternator Size with LiFePo4

Water Cooled Alternator Thread
"Mercedes, Audi, BMW and other use water cooled alternators on their high-end models. They are rated for 150 to 200 A."

Alternator 4.4L 4.6L 5.4L Bmw 540 750 X5 & Range Rover 1999-2009 Item Number: ABO0254
This one is 150 amps but does not include the housing.

01-02 Mercedes W215 CL600 S600 V12 Engine Water Cooled Alternator 1371500950 OEM
Nor does this include the housing.

I am wondering if the housing is an integral part of the engine block?
Also, it is likely that these are much bigger than the SI28 Alternators isn't it?


Later: 2004 2005 2006 VW TOUAREG 3.2L WATER-COOLED ALTERNATOR 190 AMP 021903026K
This one includes the housing. I wonder what it's dimension are?

Also DB Electrical has DB Electrical 400-12719 Alternator Compatible With/Replacement For 3.2L 9 Clock 190 Amp Clutch Pulley Type Internal Regulator CW Rotation 12V Porsche Cayenne 2004-2006 955-603-016-01 021-903-026K
Have to get the dimensions.
-----
1999 Design notes about a Bosch liquid cooled alternator that has more effective cooling and reduced noise.

Here is a patent for a water cooled alternator with the coolent passages built into the engine.
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Old 01-11-2020, 16:04   #555
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Re: Alternator Size with LiFePo4

It is pretty clear that LiFePo4 is a different animal than FLA
  1. Volt meters are not accurate for SoC because the dischargee voltage stays nearly the same except at the end. I expect this is similar for charging.
  2. Final SoC during charging is dependent on many factors that vary including, charge time, battery temperature, %C (% of actual amphour rating of the battery) and charging regimen. So, for slower charging rates like .1C or .2C the voltage cutoff should be lower than if the battery is charged at .3C, for example. Thus the final cutoff voltage is not a good way to determine SoC.
  3. Charging is more efficient than FLA because the efficiency is greater.
  4. Faster charging rates, and depth of drawdown and over charging, can dramatically affect the number of cycles.
  5. A LiFePo4 battery left at full SoC or pushed beyond full SoC with suffer chemically. A LiFePo battery fully depleted will also suffer much more than FLA. Another way to more accurately determine SoC is to set and use a Coulumb counter properly. (Not something most cruisers will do.)
  6. Voltage stays higher so Ham radios and equipment like Refrigeration works better.
  7. BMS Bluetooth App that connects to the BMS is a far better way to determine SoC and long term condition of the battery and cells.
Regarding #6, perhaps the BMS is what should be controlling charge sources and discharge sources, with a precursor sound alarm and then action.
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