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#21
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Are zap stoppers really needed on alternators?
Ed Price wrote: Well, pardon me for asking you to address my question. In case you didn't remember, since it always seems to slip your attention during your posts, I wanted to know why the suppression is applied to the LOAD side of the alternator diodes. Perhaps you two could stop slapping each others butts long enough to try to answer that question. True, there are none so ignorant as those who refuse to learn. Now that we're even on stupid witticisms, can you try for a technical answer? OK, I am going to try one more time. What I am about to say was verified yesterday afternoon by Randy Johnson, formerly of Cruising Equipment and developer of the Zap-Stop and confirmed by the tech support people at Balmar and Leece-Neville. When an alternator is producing a significant percentage of its capacity to a load, be it a battery, motor or other device and that load is suddenly removed the output voltage of the alternator will rise. While the rectifier diodes can handle higher than normal amperage for short periods they cannot tolerate voltages significantly over their rating for even an instant. Therefore if this voltage rise is not checked there is a very good possibility that the alternator rectifier diodes will be damaged. The physical law of conservation of energy says that the amount of energy output by a device must equal the amount supplied to it. The power output of an alternator is determined by the amount of energy being supplied by the engine. The amount supplied is a function of RPM and torque. The torque is governed by the intensity of the magnetic field. As the engine speed cannot normally be adjusted quickly the regulator is used to control the magnetic field. This control is fast but it is not instantaneous. As the field collapses, a back EMF is inducted in the field coil slowing the process. Therefore there is a lag in reducing the total power being produced. FOR AN INSTANT TOTAL POWER REMAINS THE SAME. Power is volts times amps. As there is no demand for the amps basic math says that the voltage must rise. The current practice for preventing damage to the regulator diodes is to place a sacrificial diode between the alternator output and ground to provide an alternate path for the energy. Both of the alternator manufacturers I talked to strongly recommend the installation of one of these diodes whenever there is a possibility that a heavy load might be suddenly dropped. This diode will not conduct until the voltage exceeds a certain preset limit determined by its construction. It has only one function: To provide a way for the alternator to shed the surplus current so that the voltage will not rise to a damaging level. The rectifier sees only a slight drop in current demand and a slight rise in voltage. It does not know anything about whether it is supplying the original load or the protecting diode. The protecting diode however has to bite the bullet and very often gives its life in the process but it will last long enough to handle the surge for the fraction of a second required to get the power output below a damaging level. That is about as simple as I can get it. If that is not satisfactory, go talk to JAX. He is more on your level. -- Glenn Ashmore I'm building a 45' cutter in strip/composite. Watch my progress (or lack there of) at: http://www.rutuonline.com Shameless Commercial Division: http://www.spade-anchor-us.com |
#22
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Are zap stoppers really needed on alternators?
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#23
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Are zap stoppers really needed on alternators?
Read an application note from the load dump protector
manufacturer (when still called SGS Thompson) about 1996. It's more than just putting a suppressor diode on output or using larger components. As they noted: The protection at the alternator level is a quite new concept and all the technical problems do not seem to be completely solved. The problem has long been known and has long created problems. Solutions have been installed for decades. Still an adaquate design has not been perfected. My first experience was in early 1960s when alternators used germanium diodes. The problem has been understood that long. Thompson Electronics does make load dump suppressors and are a major electronic supplier to GM. However I don't know if GM uses the parts (model numbers provided in the previous post) from Thompson. As Glenn Ashmore has so accurately noted, load dump is a serious electrical threat even to powered electronics. Simply look at the voltages that can exist on a 12 volts system (which is why electronics whose specifications specifically state load dump protection cost more). Especially susceptible are boat power systems. Master battery switch must be designed 'make before break'. IOW during battery switchover, a battery must be always connected to alternator. Better designs even transition the switchover to soften the 'change of load'. Cars typically don't suffer as easily BUT will be more susceptible as more functions become electrical (ie steering) and voltage is raise from 12 volts to the new 42 volt standards. Glenn Ashmore wrote: GregS wrote: Sounds like they need to make them properly, with higher voltage diodes. It is a matter of size and economics. Diodes capable of handling high voltages and high amperages are large and expensive. Leece-Neville makes such a rectifier for heavy EMT and construction equipment but it is a box separate from the alternator and cost more than any of us would want to pay. 99% of the alternator installations are automotive and do not have master battery disconnects. Also automotive alternators seldom run at a significant percentage of rated capacity for very long. The major load last for only a few minutes to replenish the cranking power. Boats with house banks on the other hand usually do have master switches and either the switch must have a capability to disconnect the field current before opening the battery circuit or a bypass diode of some kind on the alternator. To do otherwise is a pretty good bet that eventually you will fry the rectifier diodes. Unfortunately boats make up a microscopic percentage of the alternator market so this type of protection is not provide for. ... |
#24
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Are zap stoppers really needed on alternators?
"Glenn Ashmore" wrote in message ... Ed Price wrote: Well, pardon me for asking you to address my question. In case you didn't remember, since it always seems to slip your attention during your posts, I wanted to know why the suppression is applied to the LOAD side of the alternator diodes. Perhaps you two could stop slapping each others butts long enough to try to answer that question. True, there are none so ignorant as those who refuse to learn. Now that we're even on stupid witticisms, can you try for a technical answer? OK, I am going to try one more time. What I am about to say was verified yesterday afternoon by Randy Johnson, formerly of Cruising Equipment and developer of the Zap-Stop and confirmed by the tech support people at Balmar and Leece-Neville. When an alternator is producing a significant percentage of its capacity to a load, be it a battery, motor or other device and that load is suddenly removed the output voltage of the alternator will rise. While the rectifier diodes can handle higher than normal amperage for short periods they cannot tolerate voltages significantly over their rating for even an instant. Therefore if this voltage rise is not checked there is a very good possibility that the alternator rectifier diodes will be damaged. The physical law of conservation of energy says that the amount of energy output by a device must equal the amount supplied to it. The power output of an alternator is determined by the amount of energy being supplied by the engine. The amount supplied is a function of RPM and torque. The torque is governed by the intensity of the magnetic field. As the engine speed cannot normally be adjusted quickly the regulator is used to control the magnetic field. This control is fast but it is not instantaneous. As the field collapses, a back EMF is inducted in the field coil slowing the process. Therefore there is a lag in reducing the total power being produced. FOR AN INSTANT TOTAL POWER REMAINS THE SAME. Power is volts times amps. As there is no demand for the amps basic math says that the voltage must rise. The current practice for preventing damage to the regulator diodes is to place a sacrificial diode between the alternator output and ground to provide an alternate path for the energy. Both of the alternator manufacturers I talked to strongly recommend the installation of one of these diodes whenever there is a possibility that a heavy load might be suddenly dropped. This diode will not conduct until the voltage exceeds a certain preset limit determined by its construction. It has only one function: To provide a way for the alternator to shed the surplus current so that the voltage will not rise to a damaging level. The rectifier sees only a slight drop in current demand and a slight rise in voltage. It does not know anything about whether it is supplying the original load or the protecting diode. The protecting diode however has to bite the bullet and very often gives its life in the process but it will last long enough to handle the surge for the fraction of a second required to get the power output below a damaging level. That is about as simple as I can get it. If that is not satisfactory, go talk to JAX. He is more on your level. -- Glenn Ashmore Thanks for the more lucid explanation, despite the several gratuitous insults. After reading your new information, I'll even go so far as to retract my quip of a totally bogus explanation of energy within the alternator; I now realize you were being more condescending than obscure. To me, fast is microseconds or nanoseconds, and I guess you just live in a slower world. It further helps to hear that the Zap-stop only conducts a current similar to the original load, and that for only a few hundred milliseconds. That's probably why connecting the protection to the output of the alternator doesn't kill the alternator diodes. But that leads to another issue. You said the protection diode often fails!! Question 1.: Why does the protection diode "often fail" if it's drawing the same load as the alternator diodes? Question 2.: You assert that the protection diode "will last long enough." Is this some kind of smart silicon, in that it knows when it's OK to die? Again, I'm not familiar with your world, but devices that I have seen in which there is a failure under load usually fail under full load, or at least not when most of the load has gone away. Whenever I cook off a diode, it usually dies a lot faster than a couple of hundred milliseconds. I would think that the protection diode would be sized so that it rarely fails. After all, isn't a protection diode failure just another way of describing load shedding? IIRC, you said that diodes that could handle typical alternator currents could be had at Digikey for under a buck. Maybe you should refer Xentrex, too. Ed |
#25
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Are zap stoppers really needed on alternators?
The tone of the debate was set by you. I was only responding.
The field coil is a gigantic inductor compared to the inductors used in high speed electronics like computers and radio frequency equipment. When the field current is removed the time it takes for the magnetic field to collapse is related to the strength of the field and the number and centerline spacing of the turns. Strong fields take a lot of time to collapse through a lot of turns of relatively thick tightly wound wire so we are talking about milliseconds rather than micro or nanoseconds. Diodes are rated by the voltage and amperage they can take and how long they can take the power. The larger the combination gets the more expensive and larger the diode gets. We are facing the limits of size and economics. The Zap Stop is sized to "do the job" without pricing itself out of the market. In most cases it will rarely fail but the potential is still there. Probably the worst case would be dropping the load on a large cold alternator bulk charging at full power. All that power that was going through a 4/0 cable now flows through a few inches of #14 wire and a fraction of an inch of diode material. That can generate a lot of heat very quickly. The newer Zap Stops have a fuse in series with the diode. The idea being that in the time it takes for the fuse to blow the field strength drops below the damaging level. It would be nice however if they added a little circuitry and an LED to indicate when the diode had been fried. Right now the only way to know that your alternator is protected is to periodically test it with a multimeter. The diode that the Zap Stop uses probably only cost a dollar or two but the case probably cost another couple of bucks and it might take 5 minutes worth of labor to put it together and stick it in a box. Total manufacturing cost is probably under 5 bucks. BUT, a general rule of thumb is that manufacturing cost of any item should be no more than 25% of retail price. If you put the word "marine" in the description it can drop to 20%. Ed Price wrote: Thanks for the more lucid explanation, despite the several gratuitous insults. After reading your new information, I'll even go so far as to retract my quip of a totally bogus explanation of energy within the alternator; I now realize you were being more condescending than obscure. To me, fast is microseconds or nanoseconds, and I guess you just live in a slower world. It further helps to hear that the Zap-stop only conducts a current similar to the original load, and that for only a few hundred milliseconds. That's probably why connecting the protection to the output of the alternator doesn't kill the alternator diodes. But that leads to another issue. You said the protection diode often fails!! Question 1.: Why does the protection diode "often fail" if it's drawing the same load as the alternator diodes? Question 2.: You assert that the protection diode "will last long enough." Is this some kind of smart silicon, in that it knows when it's OK to die? Again, I'm not familiar with your world, but devices that I have seen in which there is a failure under load usually fail under full load, or at least not when most of the load has gone away. Whenever I cook off a diode, it usually dies a lot faster than a couple of hundred milliseconds. I would think that the protection diode would be sized so that it rarely fails. After all, isn't a protection diode failure just another way of describing load shedding? IIRC, you said that diodes that could handle typical alternator currents could be had at Digikey for under a buck. Maybe you should refer Xentrex, too. Ed -- Glenn Ashmore I'm building a 45' cutter in strip/composite. Watch my progress (or lack there of) at: http://www.rutuonline.com Shameless Commercial Division: http://www.spade-anchor-us.com |
#26
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Are zap stoppers really needed on alternators?
don't be upset, Ed trolls to test your conviction and real understanding.
"Glenn Ashmore" wrote in message ... The tone of the debate was set by you. I was only responding. The field coil is a gigantic inductor compared to the inductors used in high speed electronics like computers and radio frequency equipment. When the field current is removed the time it takes for the magnetic field to collapse is related to the strength of the field and the number and centerline spacing of the turns. Strong fields take a lot of time to collapse through a lot of turns of relatively thick tightly wound wire so we are talking about milliseconds rather than micro or nanoseconds. Diodes are rated by the voltage and amperage they can take and how long they can take the power. The larger the combination gets the more expensive and larger the diode gets. We are facing the limits of size and economics. The Zap Stop is sized to "do the job" without pricing itself out of the market. In most cases it will rarely fail but the potential is still there. Probably the worst case would be dropping the load on a large cold alternator bulk charging at full power. All that power that was going through a 4/0 cable now flows through a few inches of #14 wire and a fraction of an inch of diode material. That can generate a lot of heat very quickly. The newer Zap Stops have a fuse in series with the diode. The idea being that in the time it takes for the fuse to blow the field strength drops below the damaging level. It would be nice however if they added a little circuitry and an LED to indicate when the diode had been fried. Right now the only way to know that your alternator is protected is to periodically test it with a multimeter. The diode that the Zap Stop uses probably only cost a dollar or two but the case probably cost another couple of bucks and it might take 5 minutes worth of labor to put it together and stick it in a box. Total manufacturing cost is probably under 5 bucks. BUT, a general rule of thumb is that manufacturing cost of any item should be no more than 25% of retail price. If you put the word "marine" in the description it can drop to 20%. Ed Price wrote: Thanks for the more lucid explanation, despite the several gratuitous insults. After reading your new information, I'll even go so far as to retract my quip of a totally bogus explanation of energy within the alternator; I now realize you were being more condescending than obscure. To me, fast is microseconds or nanoseconds, and I guess you just live in a slower world. It further helps to hear that the Zap-stop only conducts a current similar to the original load, and that for only a few hundred milliseconds. That's probably why connecting the protection to the output of the alternator doesn't kill the alternator diodes. But that leads to another issue. You said the protection diode often fails!! Question 1.: Why does the protection diode "often fail" if it's drawing the same load as the alternator diodes? Question 2.: You assert that the protection diode "will last long enough." Is this some kind of smart silicon, in that it knows when it's OK to die? Again, I'm not familiar with your world, but devices that I have seen in which there is a failure under load usually fail under full load, or at least not when most of the load has gone away. Whenever I cook off a diode, it usually dies a lot faster than a couple of hundred milliseconds. I would think that the protection diode would be sized so that it rarely fails. After all, isn't a protection diode failure just another way of describing load shedding? IIRC, you said that diodes that could handle typical alternator currents could be had at Digikey for under a buck. Maybe you should refer Xentrex, too. Ed -- Glenn Ashmore I'm building a 45' cutter in strip/composite. Watch my progress (or lack there of) at: http://www.rutuonline.com Shameless Commercial Division: http://www.spade-anchor-us.com |
#27
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Are zap stoppers really needed on alternators?
"phil" wrote in message et... don't be upset, Ed trolls to test your conviction and real understanding. "Glenn Ashmore" wrote in message ... The tone of the debate was set by you. I was only responding. The field coil is a gigantic inductor And thank YOU, Phil, for your cogent contributions to this discussion. The definition of a troll is not someone who poses a question which confuses you. The best trolls usually reply to any reasonable answer with a new set of conditions which defeat the original answer. If they are fast enough, they can keep sliding out from under your logical hammer. I will admit that I'm quite skeptical of the claims of almost any marketer. When someone tells me that I need their latest gadget to protect a system that is not known for failure, then the little BS flag starts to wiggle. At the beginning of this thread, I went to the Xentrex site, and found market hype, not engineering data. No schematics, no info on joules ratings, no waveforms of with and without a Zap-stop. It took several exchanges just to understand what this thing really does. There are a vast number of auto owners, with alternator systems, who will NEVER experience 60-amp load dumps. And there are many, many small boat owners whose electrical systems are close copies of automotive systems, and they also operate under nearly the same conditions as a car. So that's another whole cohort that will NEVER see those 60-amp load dumps. So who does experience these load dump conditions? How often will Glenn, in his cruiser, be pumping 60 amps back into his battery bank? And for how long? And with what probability that he will do a trick with the battery changeover switch during that short period of exposure? So help me out here, Phil; what class of vessel often sees 60-amp charging currents? Does that class of vessel usually have switch-twiddling idiots running the below-decks division? It seems to me that the Zap-stop is being hyped as needed for everyone with an alternator, while the conditions of 60-amp load dumps are experienced by only a small slice of small boat owners. Or maybe I'm just a troll. Ed |
#28
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Are zap stoppers really needed on alternators?
I will be pumping over 200 amps for as long as an hour every day while
cruising. I had to go back and look at some of your previous posts to figure out why you are thinking the way you are. Then I found the post about having a 0-75 MPH speedo and realized that you are a hot rod ski boater with no idea of how a cruising boat works. A typical 35' to 50' cruising boat with a well balanced electrical system will have anywhere from 350 to 1200 amp hours of battery bank and will regularly draw it from 75% to 50% to keep the charging cycle in the bulk current range. They will have an alternator capable of outputting 20 to 25% of the bank's capacity per hour and run it once or twice a day for up to an hour at as close to full capacity as possible. That is what those fancy three stage regulators with temperature sensors and recombinant caps are for. As an example, my boat will have a pretty heavy duty system but it is not as large as some in that size range and not all that much larger than most. It is 800 amp hours in four L16HC batteries charged by a 250 amp brushless Niehoff fire truck alternator with an external three stage regulator and external rectifier. The energy budget calls for charging and making water for 45 minutes to an hour every day while cruising. Should a guest unknowingly turn the master battery switch during that time I could be out about $1,000. In this situation, which is not unusual for a cruiser, a $25 investment in a Zap Stop is a no brainer. The single most common reason for failures in cruising boat alternators is load dump spikes with bearing failures a distant second. OTOH, a ski boat with only a cranking battery, no master battery switch and a stock 60 amp alternator would never have to worry. Ed Price wrote: snip There are a vast number of auto owners, with alternator systems, who will NEVER experience 60-amp load dumps. And there are many, many small boat owners whose electrical systems are close copies of automotive systems, and they also operate under nearly the same conditions as a car. So that's another whole cohort that will NEVER see those 60-amp load dumps. So who does experience these load dump conditions? How often will Glenn, in his cruiser, be pumping 60 amps back into his battery bank? And for how long? And with what probability that he will do a trick with the battery changeover switch during that short period of exposure? So help me out here, Phil; what class of vessel often sees 60-amp charging currents? Does that class of vessel usually have switch-twiddling idiots running the below-decks division? It seems to me that the Zap-stop is being hyped as needed for everyone with an alternator, while the conditions of 60-amp load dumps are experienced by only a small slice of small boat owners. Or maybe I'm just a troll. Ed -- Glenn Ashmore I'm building a 45' cutter in strip/composite. Watch my progress (or lack there of) at: http://www.rutuonline.com Shameless Commercial Division: http://www.spade-anchor-us.com |
#29
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Are zap stoppers really needed on alternators?
So Ed....
Again, I will ask you just like I did during our EMC discussion, what percentage of boaters have an engineering degree and would understand joules, ohms, volts, ohms law, etc. to even have an inkling of what the information meant if it were indeed included on the web page? Even if it were included, how would it relavent unless the matching information were provided by the alternator manufacturer under load dump conditions? I find it interesting that most people don't have a clue how electricity works and couldn't troubleshoot a light switch, much less understand alternator load dump waveforms versus load and rpm, joules dumped, whether their alternator diodes were damaged, and on and on. How many people come on here and ask "I have no spark and I replaced everything such as the coil, plug wires, plugs, coil driver components (mechanical or electronic), and there still is no spark". I would suggest most people would just get a protector and just feel good that there was some additional protection from battery disconnects. To me, load dump is not mysterious, I deal with it all the time in my job (don't ask cause I won't tell you). Phil "Ed Price" wrote in message news:IGmSa.1006$Ye.415@fed1read02... "phil" wrote in message et... don't be upset, Ed trolls to test your conviction and real understanding. "Glenn Ashmore" wrote in message ... The tone of the debate was set by you. I was only responding. The field coil is a gigantic inductor And thank YOU, Phil, for your cogent contributions to this discussion. The definition of a troll is not someone who poses a question which confuses you. The best trolls usually reply to any reasonable answer with a new set of conditions which defeat the original answer. If they are fast enough, they can keep sliding out from under your logical hammer. I will admit that I'm quite skeptical of the claims of almost any marketer. When someone tells me that I need their latest gadget to protect a system that is not known for failure, then the little BS flag starts to wiggle. At the beginning of this thread, I went to the Xentrex site, and found market hype, not engineering data. No schematics, no info on joules ratings, no waveforms of with and without a Zap-stop. It took several exchanges just to understand what this thing really does. There are a vast number of auto owners, with alternator systems, who will NEVER experience 60-amp load dumps. And there are many, many small boat owners whose electrical systems are close copies of automotive systems, and they also operate under nearly the same conditions as a car. So that's another whole cohort that will NEVER see those 60-amp load dumps. So who does experience these load dump conditions? How often will Glenn, in his cruiser, be pumping 60 amps back into his battery bank? And for how long? And with what probability that he will do a trick with the battery changeover switch during that short period of exposure? So help me out here, Phil; what class of vessel often sees 60-amp charging currents? Does that class of vessel usually have switch-twiddling idiots running the below-decks division? It seems to me that the Zap-stop is being hyped as needed for everyone with an alternator, while the conditions of 60-amp load dumps are experienced by only a small slice of small boat owners. Or maybe I'm just a troll. Ed |
#30
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Are zap stoppers really needed on alternators?
You're just a troll.
The cruisers that buy other Xantrex products, like the Link 2000R monitor/regulator are the people that frequently charge over 60 Amps at a time. If I'm at anchor for an extended period, I'll likely be running an engine an hour a day, charging at about 85 Amps. Although many new cruising boats don't have the "Big Red Switch," almost all older boats have one, just waiting for the mischievous nephew, or helpful brother-in-law to flip. I know of one case where a friend, and experienced oat owner, had a brain stall and flipped the switch, killing a GPS and sounder. "Ed Price" wrote in message news:IGmSa.1006$Ye.415@fed1read02... "phil" wrote in message et... don't be upset, Ed trolls to test your conviction and real understanding. "Glenn Ashmore" wrote in message ... The tone of the debate was set by you. I was only responding. The field coil is a gigantic inductor And thank YOU, Phil, for your cogent contributions to this discussion. The definition of a troll is not someone who poses a question which confuses you. The best trolls usually reply to any reasonable answer with a new set of conditions which defeat the original answer. If they are fast enough, they can keep sliding out from under your logical hammer. I will admit that I'm quite skeptical of the claims of almost any marketer. When someone tells me that I need their latest gadget to protect a system that is not known for failure, then the little BS flag starts to wiggle. At the beginning of this thread, I went to the Xentrex site, and found market hype, not engineering data. No schematics, no info on joules ratings, no waveforms of with and without a Zap-stop. It took several exchanges just to understand what this thing really does. There are a vast number of auto owners, with alternator systems, who will NEVER experience 60-amp load dumps. And there are many, many small boat owners whose electrical systems are close copies of automotive systems, and they also operate under nearly the same conditions as a car. So that's another whole cohort that will NEVER see those 60-amp load dumps. So who does experience these load dump conditions? How often will Glenn, in his cruiser, be pumping 60 amps back into his battery bank? And for how long? And with what probability that he will do a trick with the battery changeover switch during that short period of exposure? So help me out here, Phil; what class of vessel often sees 60-amp charging currents? Does that class of vessel usually have switch-twiddling idiots running the below-decks division? It seems to me that the Zap-stop is being hyped as needed for everyone with an alternator, while the conditions of 60-amp load dumps are experienced by only a small slice of small boat owners. Or maybe I'm just a troll. Ed |
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