alternator failure
 

I went though probably two dozen of the first generation alternators from Vans. Used to carry one in the plane with me cause I couldn't get through three weeks of flying on the road without losing the alternator. The alternator that I have now has around 2500 hours on it and is still working fine it is the PP. I just put it on the third engine. I did have to change the connector as it was brittle and crumbled when I took it out. My install has a cooling blast tube. I torture these big time as we spend a lot of time in slow flight. Mike

DENSO
 

2300 hours on a small Denso Automotive alternator over 16 years. No failures, never removed from aircraft. No cooling blast tube either.

I bought my 2 B&C alternators (40amp up front and 20amp on the rear) together with 2 B&C external voltage regulators in 2007 and the plane did not have an engine start until 2015. I have 160 hours on both alternators now and no problems.

However one of the B&C voltage regulators was faulty out of the box and I sent it back to B&C for checking in 2015 after the first engine start. They found the fault and sent me a new replacement unit at no cost (even paid for the freight to Australia). They effectively replaced the regulator 8 years after I bought it....just amazing customer service.

B&C are a company of the highest integrity and their alternators are extremely reliable. As others have pointed out they're not cheap but no-one else comes close when it comes to reliability. The poll is showing that B&C have a 1% failure rate in the first 250 hours while Plane Power have a 24% failure rate in the first 250 hours.

I have an externally regulated ND 45 amp on my O-320. 270 hours with no problems. No blast tube.

I would not use an internally regulated alternator, as the VR seems to be the most common component to fail on the older alternators. I believe that it is difficult to produce an electronic component that will survive in those conditions. The external regulator can be made much larger with and lives in a cooler environment.

Larry

Vans nipendenso 35amp alternator from the late 90's & external regulator. Blast tube installed. No failures in 400 + hours.

Post-failure experience with Plane Power
 

At about 800 hours tach time, 950 hrs hobbs time, my Planepower alternator dropped to 1/2 output (26-28 Amp) maximum output enroute to OSH last week. I spoke to PlanePower's reps at OSH last week (including the alternator product line lead). Here's the summary:

- PlanePower suggests it's either a diode failure, or (more likely) a failure of part of the stator (due to a known issue with PlanePower alternators manufactured in the past).
- PlanePower won't repair this alternator.
- PlanePower won't repair the new version that they currently sell for RV's. "It's not worth our time."
- PlanePower won't offer any consideration or discount for those who purchased an alternator that failed.

This is consistent with other reports I've heard regarding Hartzell Engine Technology (PlanePower owner) customer service.

So I spoke to B & C about their alternator. Yes, they offer repair service. Yes, they'll overhaul or IRAN their alternator.

I bought a B&C alternator and external controller at OSH. I'd be better off right now if I'd just spent the extra money on a B&C in the first place.

My mentor and my avionics guru finally talked me into upgrading my Vans Nippon Denso internally regulated 60 amp alternator (no longer available from Van). The impetus was some new and expensive ADS-B in/out equipment I had recently installed.

I also was overdue on replacing the alternator belt (12 years old). So while the prop was removed I took the opportunity to make the alternator change.

The Vans ND unit worked fine for 715 hours without issue. I guess it's just random for those who've had failures.

So a new B&C 40 amp unit is now installed along with a new belt. If this thing fails in the first few hours, I will be really upset :(

BTW, the old alternator belt, which looked fine viewed from the outside, did show signs of cracking when I flexed it from the inside out. So I suggest that 12 years is a bit too long to leave it in place.

Happy flying.

Chris

"I spoke with Hartzell who claims that this is a rare issue, maybe just 2 or 3. I also confirmed that the newer version is the same as the older version."

That's interesting, maybe they just haven't heard about the 4 x PP 60amp units I am replacing (I have the serial numbers as I installed them) as a result of failures.
2 are due to the Volt Regulator (earlier models had themexternally attached) falling off the back plates at 200-300 hours, the other 2 had max amp ouput (50-60) with 1 found with 4 diodes failed & mine has to be tested yet to determine the cause. As the fault happened outback Oz I fly back home on # 2 Alt (PP FS-14B) I am now really concerned about it too.

Denial by any manufacturer is something I can not tolerate especially when customers ask my opinion about a particular product, needless to say I have subsequently bought 5 x B&C units.

IMO we should be advising anyone we know of the reported proven problems with critical to flight/engine products.

Be careful out there.

Alternator
 

Had 2 of the 30 amp Honda Civic aleternators, first one from vans, second from a parts store, both removed in working condition but with excessive bearing play. The first one lasted about 200 hours, the second one about 150. Replaced with b&c alternator, this is still in n service with over 500 hours.

Bryan

I can't add it to the poll, but my PlanePower 60a alternator just quit after 261hrs. Internal wiring failure due to movement of the stator according to the technician.