ARCO Zeus A225S High Output Alternator Instruction Manual

ARCO Zeus A225S High Output Alternator

Background and overview

Testing Protocol

• ARCO internally developed tests to assess components for its high-output alternator line. These tests are designed to identify the highest-performing components, replicating real-world conditions for accuracy.

Comparative Analysis

• ARCO applies the same testing procedures to compare its new alternators with popular market models, ensuring a comprehensive evaluation of performance.

In-House Testing

• ARCO conducts all tests in-house, maintaining full control over the evaluation process.

Quality Assurance Measures

• ARCO takes all reasonable measures to minimize errors and biases, though the possibility of honest mistakes is acknowledged.

Transparency and Consistency

• Enhancing transparency and consistency in alternator testing benefits customers by highlighting the highest-performing products.

Strategic Sampling

• Unable to test every alternator on the market, ARCO selects representative examples for comparison, all of which are new units.

ARCO Testing Equipment

Units Tested

• ARCO Zeus A275L
• ARCO Zeus A225S
• American Power Systems APS 360
• Balmar XT250
• Balmar XT170
• Nations XP280
• Mechman 250

Cold Power Curve Overview

Testing Procedure

• Alternator output is tested at 7 RPM speeds using a Motoplat CV-623A Alternator Tester.

Consistency Assurance

• Tests are repeated on 3 separate days with overlapping RPM intervals to ensure data consistency.

Standardization Efforts

• Where possible, a uniform 44mm, 6-groove pulley is used to reduce variables, although variations exist in shaft diameter and pulley nut thread pitch.
• Where lack of compatibility prevented the installation of the 44mm pulley, the manufacturer’s original pulley was measured, used, and input into the tester to ensure the accuracy of results.

Outlier Handling

• Clear outliers from the power curve data are removed for accuracy.

Controlled Environment

• Tests are conducted in a climate-controlled building with an ambient temperature of 19-24°C, ensuring consistent conditions.
• It is worth noting that minor discrepancies in ambient temperature can make minor impacts on “Cold” curves, while any such ambient temperature discrepancies make zero tangible impacts on “Hot” curves.

Cold power Curve Results in Large Frame

ARCO A275L at Idle

• The ARCO A275L exhibited the highest amperage output at idle speeds.

APS 360 Comparison

• While the APS 360 recorded the most amps at over 4,300 alternator RPMs, it demonstrated the lowest output at low idle speeds.

Cold power Curve Results in Small Frame

ARCO A225S Outperforms

• The ARCO A225S significantly outperforms similarly sized alternators across all speeds.

Low RPm endurance test overview

Operational Conditions

• Alternators were run at 3,000 RPMs for 60 minutes beneath a plexiglass shield to simulate engine compartment conditions. During the 60-minute test, alternators typically reached 100°C, with temperatures inside the shield hitting 60°C.

Performance Trend

• All alternators exhibited a significant output drop within the first 10 minutes, followed by a gradual decline over the next 20 minutes, stabilizing for the remaining 30 minutes.

ARCO A275L Performance

• The ARCO A275L demonstrated the highest amp production at idle speeds. While initially matching the ARCO A275L’s performance, the Balmar XT250 experienced a more pronounced output decline as it heated up.

Hot power curve overview

Simulation of Extended Idle Conditions

• The alternator undergoes a 60-minute test at 3,000 RPMs under a plexiglass shield, replicating prolonged idle speed conditions.

Power Curve Analysis

• Immediately post-endurance test, the machine conducts 3 overlapping and redundant power curve tests, charting output at various RPMs.

Data Refinement

• Overlaying the 3 power curves allows for outlier identification, with any clear outliers removed for accuracy. The resulting curve reflects the expected alternator output during extended periods at a given speed.

Hot power curve results from large frame

Heat Build-Up

• Extended idle operation leads to significant alternator heating without adequate fan cooling, resulting in reduced performance.

ARCO A275L Dominance

• The ARCO A275L demonstrated superior performance, surpassing all alternators below 3,500 RPMs and outperforming all except the APS 360 above this threshold.

The hot power curve results small frame

Product Comparison

• The smaller ARCO unit, A225S, was compared against a popular unit of the same size, the Balmar XT170.

Performance Differential

• The ARCO A225S boasts approximately 30% more power output compared to the similarly sized Balmar XT170.

High rpm endurance test overview

High-Speed Evaluation

• Each alternator underwent a 60-minute test at 9,000 alternator RPMs, catering to those focused on performance at extreme speeds.

Enhanced Performance at High RPMs

• Higher RPMs result in increased alternator output, fan speed, improved air circulation, and cooler alternator temperatures compared to idle speeds.

Performance Rankings

• For those prioritizing high RPM performance, the APS 360 emerged as the top performer, followed closely by the ARCO A275L.

Warm Power Curve Overview

Testing Procedure

• Immediately after the high RPM Endurance test, which runs the alternator at 9,000 RPMs for 60 minutes, alternator output is evaluated at various RPMs.

Standardization Effort

• All alternators are tested with a uniform 44mm, 6-groove pulley to eliminate variables. Where lack of compatibility prevented the installation of the 44mm pulley, the manufacturer’s original pulley was measured, used, and input into the tester to ensure the accuracy of results.

Data Refinement

• Three power curve tests are conducted, and the resulting curves are overlaid to identify and remove outlier data points.

warm power curve results

Consistent Performance

• Performance across all units showed slight improvement but remained very similar to the results after an hour of running at low RPMs.

Low RPM Dominance

• The ARCO A275L demonstrated the highest output at low RPMs. The APS 360 excelled at high RPMs but performed poorest at low RPMs.

Test results summary table

Performance Comparisons

• ARCO alternators outperformed units of similar size, delivering the highest amperage at lower RPMs.
• The APS 360 excelled in amperage output at higher RPMs but demonstrated the least output at idle speeds.
• The Nations XP280 required the highest RPMs for activation.

Appendix: Power curve samples

• These results are from the second test of each alternator, referencing the original test conducted on a different day for the same alternator.

Appendix: Power curve samples

• Results were compared to the original test to confirm the absence of significant deviations.
• The second test served solely to validate the original test, utilizing data from the initial assessment.

Appendix: testing extreme rpm ranges

Speed Range Extension

• The CV-623, originally set to test 7 data points from 1,800 to 6,000 alternator RPMs, was adapted with a false pulley ratio setting to capture more data across a wider speed spectrum.

Result Adjustment

• Following testing, the results were exported to Excel and recalibrated to align with the actual alternator speeds. The examples below are cold power curves from an ARCO A275L.

Appendix: combining data

• The data from the previous page was converted into actual RPM values to ensure accuracy in analysis.
• Overlaying three distinct power curves, covering different yet overlapping RPM ranges, facilitates comprehensive result validation and aids in outlier detection.

Appendix: power curve protocols

• The three separate datasets are merged and sorted based on alternator RPMs, streamlining the analysis process. Outlier points are systematically identified and removed from the dataset to ensure data integrity.

Example

• The data point indicating 279 amps at 3,463 RPMs was eliminated as it was identified as an outlier, despite being a positive outlier for ARCO.

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