Installation Manual WP120 Electric Water Pump

Installation Manual WP120 Electric Water PumpRev Rev By Date Description of Change Approved By A ME 5/12/21 New Release ECN6067
9970137000 Rev. A – 05/12/2021 © 2021 EMP, Inc. 1
Installation Manual WP120 Electric Water Pump
This manual is effective for aftermarket and OEM installations of the following parts:
Base Part Number 1030137xxx
Product Overview
The information contained in this manual is updated periodically. While great care is taken in compiling the information contained in this manual, Engineered Machined Products, Inc. cannot assume liability for losses of any nature arising from any errors and/or omissions.
The information and specifications contained throughout this manual are up to date at the time of publication. Engineered Machined Products, Inc. reserves the right to change the content of this manual at any time without notice.
© 2021 EMP, Inc. 2
www.emp-corp.com [email protected]
Product Overview The WP120 is an electrically powered fluid pump available in 12 volt DC and 24 volt DC configurations. The pump uses a stainless steel shaft for fluid compatibility. Proper installation of the pump will help ensure the performance and reliability of the electric pump while reducing the risk of damage to other components in the system. Installation Review Checklist for EMP Water Pumps, EMP document 9890085150, provides a check list to confirm that the pump and the installation of the pump fall within the hardware and operational capabilities of the pump. System integration is the responsibility of the system engineer. EMP will work with OEMs to ensure integrators understand the installation requirements. Use the Installation Review Checklist to submit installation information to EMP for review.
Purpose ........................................................................................................................................................ 4 Service Technician Responsibilities .............................................................................................................. 4 Liability Disclaimer ........................................................................................................................................ 4 Development Engineer Responsibilities ........................................................................................................ 4 Additional Information ................................................................................................................................... 4 Technical Help .............................................................................................................................................. 4 Warranty ....................................................................................................................................................... 4
About This Document ........................................................................................................................................ 5 Warnings, Cautions and Notes ...................................................................................................................... 5 Definition of Terms ........................................................................................................................................ 5
Product Safety Warnings ................................................................................................................................... 6 Identification ...................................................................................................................................................... 7
EMP Water Pump Model Codes ................................................................................................................... 8 Operation .......................................................................................................................................................... 9 Technical Information ........................................................................................................................................ 9
Specifications ................................................................................................................................................ 9 Dimensions and Hole Locations/Bolt Spacing ............................................................................................. 10 Material Listing of Major External and Fluid Contacting Parts ..................................................................... 10 Pump Performance Curves ......................................................................................................................... 10
Pump Operating Limits .................................................................................................................................... 14 Temperatures ............................................................................................................................................. 14 Environment ................................................................................................................................................ 14 Orientation .................................................................................................................................................. 14 Inlet Pressure/Configuration Requirements ................................................................................................. 15
Installation ....................................................................................................................................................... 16 Installation Review Checklist ....................................................................................................................... 16 Pump Mounting ........................................................................................................................................... 16 Wiring ......................................................................................................................................................... 16 Plumbing ..................................................................................................................................................... 17
Service Parts Replacement ............................................................................................................................. 18 System Fill Procedure ..................................................................................................................................... 18
Approved Fluids .......................................................................................................................................... 18 Each time the cooling system is drained ..................................................................................................... 19 For production use of the WP120 ................................................................................................................ 19
Routine Maintenance ....................................................................................................................................... 20 Physical Inspection ..................................................................................................................................... 20
Troubleshooting ............................................................................................................................................... 21 Appendix A – WP120 Installation Testing ........................................................................................................ 22
Equipment Required for WP120 Data Collection ......................................................................................... 22 Inlet Pressure Measurement Test Procedure .............................................................................................. 23 Test Data Log ............................................................................................................................................. 25
Appendix B ...................................................................................................................................................... 26 Operation Manual R20C Controller Board ................................................................................................... 26
Appendix C ...................................................................................................................................................... 27 Operation Manual R20L Controller Board ................................................................................................... 27
Product Warranty Registration Form................................................................................................................ 28
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Introduction Purpose The purpose of the WP120 installation manual is to present information related to the pump’s dimensions, electrical specifications, flow and pressure capabilities, coolant guidelines, recommended plumbing, and system testing. This manual also outlines the WP120 limitations that should be recognized and adhered to. Read and understand all sections of this document to ensure your installation will provide the best possible performance and durability of your pump.
Service Technician Responsibilities Ensure that all safety messages and information messages are read and understood before installation, maintenance, or repairs are performed. It is important to use caution when service work is performed. Knowledge of impacted systems and their operation are important before the removal or disassembly of any component.
Liability Disclaimer EMP cannot anticipate every possible circumstance that might involve a potential hazard. The safety messages in this document, in related manuals, and on the product are therefore not all inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by EMP is used, you must satisfy yourself that it is safe for you and for others. You should ensure that the product will not be damaged or be made unsafe by the operation, maintenance, or repair procedures that you choose.
Development Engineer Responsibilities The organization responsible for incorporating the WP120 pump into any system must read and understand the requirements and specifications as explained in this manual. At any time during system development, EMP will participate in a design review if requested. The Installation Review Checklist may be used during system development to check the system design and integration of the pump. All questions should be answered “yes” for a successful system design. Any questions that are not answered “yes” should be brought forward for further discussion internally and if desired, with EMP. EMP engineering will review the intended installation and will contact you if there are any issues identified in the information provided. It is up to the system design engineer to ensure that all requirements are met; the installation review is a high level inspection and assumes the product installation manual has been completely reviewed and installation conforms to all stated engineering and application requirements. Elements of product performance and system integration done at the engineering level are not evaluated during this review. EMP input on the installation review is intended to provide an independent assessment of the product installation and observable areas of concern limited to the scope of the review. Product warranty claims resulting from improper system integration or improper application utilization will be denied.
Additional Information Access https://www.emp-corp.com/support/ for service software, service bulletins, service manuals, service drawings, and other documents related to your installed EMP systems and components. First time users may create a free customer login at http://www.emp-corp.com/account/register/.
Technical Help Contact EMP Customer Service for technical help at +1 (906) 789-7497 or [email protected].
Warranty Mail, Fax, or Email the completed warranty registration form at the end of the document to: EMP Advanced Development, LLC 2701 North 30th Street Escanaba, MI, USA 49829 Fax: +1 (906) 789-7825 [email protected]
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About This Document Warnings, Cautions and Notes Two headings are used in this document to stress your safety and safe operation of the system. They are styled with a graphic bullet and bold, uppercase text: WARNING and CAUTION. Warnings highlight risks to personnel – hazards, unsafe conditions and practices that can result in personal injury or death. Cautions indicate conditions or practices that can cause damage to components, systems, or other equipment. A third heading, styled as NOTE, calls attention to additional information about components and procedures discussed in the document.
Definition of Terms CAN .............. Controller area network. EMPower Connect™ service tool .. EMP service tool for diagnostics via PC. Ignition ......... An enable signal sent to the controller to turn on. This is separate from the power and ground and
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Product Safety Warnings WARNING: EMP cannot anticipate every possible circumstance that might involve a potential hazard.
The safety messages in this document, in related manuals, and on the product are therefore not all inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by EMP is used, you must satisfy yourself that it is safe for you and for others. You should ensure that the product will not be damaged or be made unsafe by the operation, maintenance, or repair procedures that you choose.
WARNING: Ensure that all safety messages and information messages are read and understood before installation, maintenance, or repairs are performed. It is important to use caution when service work is performed. Knowledge of impacted systems and their operation are important before the removal or disassembly of any component.
WARNING: Make sure the equipment cannot move before doing any work or diagnostic procedures on the EMP component, system, or vehicle.
WARNING: When working near electric components, ensure they cannot activate unexpectedly. Remove power or utilize lock out switches.
WARNING: Use extreme caution when working on systems under pressure (i.e. coolant, hydraulic fluids, air, fire suppression, etc.).
WARNING: Make sure the work area is ventilated and well lit.
WARNING: Make sure charged fire extinguishers are in the work area.
WARNING: Reinstall all safety guards, shields and covers.
WARNING: Make sure all tools, parts and service equipment are removed from the work area.
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Identification Each component is labeled with a model code, part number and serial number. The model code reflects hardware configuration options of the component (see the next page). The part number is based on the combined hardware and software configuration of the component. Each serial number is unique. Provide the component serial number with all enquiries to EMP technical service, it is used trace the component hardware configuration, software calibration, date of manufacture, and other manufacturing data.
Example Product Label
Example: WP120-24V-SS-A
WP 120 - 24V - S S - A [OEM] [Cert] [Suffix] 1 2 3 4 5 6 7 8 9 10
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Voltage 12V = 12 volt 24V = 24 volt HV = High voltage
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WP120-24V-SS-A = Water Pump model 120, 24 volt, CAN communication, Stainless shaft, Standard orientation, addressable via external resistors.
NOTE: Not every option combination is available.
Operation/Technical Information
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Operation WP120 pumps have an integral controller and are capable of on/off operation, PWM control, operation under CAN control, and service tool communication via CAN or EMP TTL/EMP-Link, depending on model. The exact address and behavior response of any given pump is set in the calibration file loaded into the controller. For example, a customer needing a specific CAN address or default speed may be able to get these settings via software. Contact your customer service representative with your specific needs to obtain information on availability. For more information about model WP120 pumps, see Appendix B, Operation Manual R20C Controller Board. For more information about model WP120L pumps, see Appendix C, Operation Manual R20L Controller Board. These EMP pumps can be operated manually by using the EMPower Connect™ service tool, and with higher license levels the factory installed calibration can be replaced with a different one supplied by EMP. It is also possible some of the values in the calibration may be adjusted for development purposes. Because of the flexibility afforded by the calibration settings for our pumps, it is important that you understand your needs and the settings programmed at the factory for your pump. If you need the calibration details for a specific pump, send the serial number of the pump to [email protected] and request them. Connector, operation, troubleshooting, and wiring information are in Appendix B or Appendix C, depending on the model of the pump.
Technical Information Specifications
Model 12V 24V
Performance
Operating Temperature Maximum 203 °F (95 °C) 203 °F (95 °C)
Operating Temperature Minimum -40 °F (-40 °C) -40 °F (-40 °C)
Motor Speed Maximum 5500 rpm 5500 rpm
Motor Speed Minimum 1000 rpm 1000 rpm
Mechanical
Component Weight 6.2 lbs (2.8 kg) 6.2 lbs (2.8 kg)
Electrical
Input Voltage 9–16 V DC (14 V nominal) 18–32 V DC (28 V nominal)
Operating Current Draw Maximum 27.5 A 22 A
Thermal Protection Auto self-protect rpm rollback Auto self-protect rpm rollback
Dimensions and Hole Locations/Bolt Spacing
NOTE: 1 inch (25.4 mm) inside diameter hose for inlet and outlet connections.
Material Listing of Major External and Fluid Contacting Parts Item Quantity Description Material Fluid Contact
1 1 Controller Cover Cast Aluminum (413) 2 1 Housing HS6 AlSi10Mg Yes 3 3 Controller Cover Bolts 18-8 Stainless Steel 4 1 Volute HS6 AlSi10Mg Yes 5 1 Impeller (Internal) 304 Stainless Steel Yes 6 1 Shaft SAE 440 Stainless Steel Yes 7 1 Product Label M-714 8 1 Connector Nylon 9 6 Volute Bolts 18-8 Stainless Steel 10 1 Bracket Bolt 18-8 Stainless Steel 11 1 Bracket 5052 Aluminum 12 1 Water Seal Faces Carbon/Silicon Carbide Yes 13 1 Water Seal Stamping AISI 304 Yes 14 1 Bellows/Cup HNBR Yes 15 1 Spring AISI 302 Yes
Pump Performance Curves The pump performance curves shown in the illustrations below (See Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6) outline the maximum capability of the pump at various operating speeds of the pump. Following the installation guidelines will result in peak performance matching the illustrated operation. Pump speed reduction will reduce the output capability. The static pressure curve represents the pressure rise across the pump for a given flow. If the inlet pressure of the pump is negative, the outlet pressure of the pump is reduced by the inlet suction. Be aware of this situation in systems with little or no head pressure on the system.
Technical Information
24V Pump (28V Supply) Flow at 20 °C
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Temperature Limitations Maximum Fluid and Ambient Operating Temperature 203 °F (95 °C)
Minimum Fluid and Ambient Operating Temperature -40 °F (-40 °C)
Maximum Ambient Storage Temperature 257 °F (125 °C)
Minimum Ambient Storage Temperature -40 °F (-40 °C)
* If the intended application fluid temperature exceeds 95°C, full system integration must be validated as the pump may not perform as expected.
NOTE: Over-temperature Protection — To protect the controller, the motor speed begins to derate when the internal controller temperature reaches a calibrated threshold. Derated motor operation will continue until the internal controller temperature drops below a safe value.
Environment Environment cleanliness is crucial to pump life. The WP120 is fully submersible. Shielding may be required to ensure debris does not enter the weep hole. If you have any questions regarding your installation contact EMP.
Orientation The WP120 is shown below in the standard orientation. The pump is orientation specific and must be installed per EMP guidelines. If you have any questions regarding pump orientation please contact EMP.
Pump Orientation
NOTE: Product failures resulting from improper system integration or improper application utilization will be denied warranty coverage.
Pump Operating Limits
Inlet Pressure/Configuration Requirements • The WP120 pumps must maintain an inlet pressure within the limits identified in the Cavitation Test
chart. The chart is applied to WP120 operating at commanded speed under all operating conditions. • Operating the pump below the inlet pressure requirement can cause excess noise and damage to
the pump impeller and seal. • Cavitation can also occur in valves or plumbing near the pump causing excess noise or mechanical
damage. Plumbing should also be reviewed when troubleshooting unexpected noise.
• If the application has low outlet restriction, the pump is current limited and may not be able to reach
the anticipated pump speed. This speed limitation is a thermal protection feature. • The maximum pump outlet pressure (gauge) must not exceed 50 psi. This includes the static system
pressure and the pump rise. • See Appendix A for installation validation testing procedures.
Installation
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Installation Installation Review Checklist Upon completion of the installation, to confirm the water pump was successfully installed reference the Installation Review Checklist for EMP Water Pumps, document number 9890085150. This document can be found on the EMP website by searching for the document number. All items should be marked “pass” for a successful installation. Any items not meeting a “pass” criteria should be corrected.
Pump Mounting Mounting Screws Mounting screws used should be M8-1.25 screws (quantity = 4). These must have a minimum thread engagement of 0.50 inch (12.7 mm) and be tightened to a torque of 15 ft-lb (20 N-m).
CAUTION: Using isolators may cause pump damage. If using the isolators, it is the installer’s responsibility to verify isolator size for pump weight and operating conditions with isolator vendor to ensure correct isolator.
Wiring Wire Sizing See Appendix B and Appendix C for example application wiring and component power specifications.
Recommended Wiring Practices • Wiring or electrical harness must not rub on sharp edges. • The electrical harness should not be stressed at connections. • The voltage drop between the battery and the pump should not exceed 5% of the rated battery voltage.
This should be verified at the pump’s maximum current draw. Wiring or electrical harness must not rub or make contact with a hot surface. There should be 5" minimum clearance from the exhaust.
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Plumbing
Recommended Plumbing Pump Inlet must be plumbed using 25.4mm (1.0 inch) diameter hose and/or thin walled tubing from the fluid supply to the pump inlet. EMP recommends new applications going into production to complete EMP Fill/Deaeration and Drawdown Test (9910085145). The test procedure is a plumbing and system verification that will identify if localized system high spots that can trap air are present and will also verify the ability to remove air from the system.
NOTE: See Appendix A for installation validation testing procedures.
CAUTION: Localized high spots in the plumbing may cause air to be trapped in the pump causing the pump to be air locked. The result of air trapped in the pump is loss of prime and no fluid moving resulting in water seal damage or potential system component damage.
CAUTION: EMP warranty does not cover seal damage due to low lubrication.
Deviations from the Recommended Plumbing must meet the Inlet Requirements.
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Service Parts Replacement The pump does not contain any serviceable components.
System Fill Procedure CAUTION: Do not run the pump without fluid present. If run dry even for a short period the seal will
be damaged.
CAUTION: Pump may start running upon connection of power, ground, and ignition. Do not make electrical connections until pump and system are filled with fluid.
CAUTION: Systems that are not properly filled may leave air in the pump, creating a condition that may damage the seal due to low lubrication.
CAUTION: When air becomes trapped in the pump, the pump will not circulate fluid with the potential to cause damage to components in the system.
CAUTION: EMP warranty does not cover seal damage due to low lubrication.
Approved Fluids 1. Fluids must conform to ASTM D6210-10 or ASTM D3306 for quality and maintenance. 2. Use of coolants containing silicates and phosphates can lead to reduced pump seal life and gel formation in
cooling system components. 3. Use of organic acid technology (OAT) coolants that are silicate and phosphate free will maximize pump seal
life. 4. Customer must verify all WP120 fluid contacting parts are compatible with system components and the
coolant selected for the application. 5. For best results cooling system materials, coolant working life, operating temperature range and other system
details should be reviewed with coolant manufacturer to ensure the proper coolant selection.
NOTE: Use distilled water to dilute coolant or use pre-mix coolant.
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Each time the cooling system is drained Caution must be taken to ensure the system is refilled properly to prevent running the pump in a dry state. 1. Install pump and piping according to installation
instructions. 2. Ensure flow path is open through the entire
system. 3. Fill the system with fluid such that the pump is
full of fluid and there are no air pockets in the piping leading to the pump.
4. Run the pump at 4600 rpm, ensuring fluid levels are topped off as air is pushed out of the system.
CAUTION: Do not allow the pump fluid supply to become empty. The fluid level in the surge tank will drop rapidly at top speed.
5. Verify the pump is moving fluid by observing the input power of the pump during the fill process using EMPower Connect service tool or a quality amp meter. With the pump operating at 4600 rpm, the input power must be above 200W (28V and 7A or 14V and 14A). If the pump is below 200W within 1 minute, turn off pump, purge system air and restart the procedure.
For production use of the WP120 A fill procedure should be developed, documented, and verified to prevent dry running conditions on the pump. These procedures should be communicated to the end customer in the system maintenance documentation. Engine Cooling systems and any Separate
Circuit Cooling Systems require fill procedure verification. All systems have different characteristics and require custom fill procedures to evacuate air.
During fill procedure development a clear hose on the inlet and outlet of the pump can serve as a visual aid to ensure the pump is not run dry.
Verify the pump is moving fluid by observing the input power of the pump during the fill process using EMPower Connect or a quality amp meter. With the pump operating at 4600 rpm, the input power must be above 200W (28V and 7A or 14V and 14A). If the pump is below 200W within 1 minute, turn off pump, purge system air and restart the procedure.
Air trapped in the pump during initial fill and maintenance procedures will cause damage to the pump seal if not completely evacuated.
If desired, OEMs may request EMP review the proposed installation and provide feedback. Documentation of the first time fill procedure is required to provide installation feedback.
IMPORTANT: EMP specification EMPTS023, document 9910085145, outlines the fill procedure acceptance criteria.
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Routine Maintenance Frequency Action
When checking/filling vehicle fluids
Ensure fluid levels are correct. Low fluid can cause a pump seal failure.
Every engine oil change
Inspect cooling system for leaks. Sample coolant and check to ensure coolant meets minimum coolant quality requirements. Before removing the pump, evaluate the leak using the methods outlined in the physical inspection of this document.
Every three months or more often if conditions are harsh*
Visually inspect exterior of pump and ensure weep holes are not clogged by debris. Check wires for wear or frayed insulation. Ensure all electrical connections are tight.
Annually+ Ensure connections are tightened to proper torque rating. Ensure all wires and pin connections are intact. Inspect support structure for any damage or loose hardware.
+ Inspections should also be conducted after any service to the unit.
Physical Inspection
CAUTION: Do not run the pump without fluid present. If run dry even for a short period the seal will be damaged.
CAUTION: Pump may start running upon connection of power, ground, and ignition. Do not make electrical connections until pump and system are filled with fluid.
1. Make sure the weep hole port is not clogged with debris. If the weep hole is plugged then open it up.
Weep Hole Port
Troubleshooting Symptom Check
Pump not running • Check electrical connections. • Check ignition enable wire. • Check if ignition enable wire is “on”. • Verify ignition enable pin location.
Pump is running but not pumping fluid
• Check system fluid level. • Check for tubing restrictions (kinks). • Make sure pump is primed. • Check for collapsed inlet or outlet hose. • Check pump inlet for trapped debris.
No CAN communication and/or pump not responding to CAN commands
• Check communication harness wiring. • Verify that CAN messages are being transmitted in the proper formats (see
Appendix B). • Verify that the proper component CAN address is being used.
Suspected water pump seal leak • Reference document 9910085143, Service Bulletin Electric Water Pump Inspection and Diagnostic Procedures.
Water pump seal leak • Verify coolant level. • Verify coolant selection (for water seal life OAT, phosphate free, silicate free
coolant is recommended). • Sample coolant and review coolant maintenance records. • Verify system is not aerated (Reference document 9910085145, Fill D&D Test
and Acceptance Criteria). • Check for cavitation or low inlet pressure.
Pump producing excessive noise • Check for cavitation or low inlet pressure. • Check pump inlet for trapped debris. • Check plumbing around pump for valves or components where cavitation may
be occurring. • Check for collapsed inlet hose.
Appendix A – WP120 Installation Testing
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Appendix A – WP120 Installation Testing The information provided in this document supplements the installation review document and provides detailed information for service tool use with the WP120. The information within this document may be helpful in developing unique system calibrations and mapping the operation of the cooling system.
Equipment Required for WP120 Data Collection 1. Computer with the EMPower Connect service tool software installed. 2. EMP harness 3170073176 and a RP1210 compatible data link adapter to connect the WP120 and
computer. 3. Data acquisition equipment capabilities:
Pump Inlet Pressure Required -15 psi to 30 psi Pump Outlet Pressure Recommended 0 psi to 50 psi Pump Inlet or Outlet Temperature Required 0°C to 100°C EMP Service Tool Required Pump Speed Control,
Pump Current Measurement, Pump Voltage
Circuit Flow Optional Ensure Flow meter does not generate a restriction in the system.
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Inlet Pressure Measurement Test Procedure 1. Install an external pressure sensor, ensure the sensor is located within 2 inches of the pump inlet and 4
inches from the last bend in the supply plumbing. 2. Application Simulation:
a. The pump shall be tested under the worst case conditions for the intended application. b. If used in a pressurized system, test with the system pressure cap open to atmosphere. c. If used in a system where supplemental flow is provided, test at the minimum anticipated
supplemental system operation. d. If possible, test at the highest anticipated fluid temperature.
3. Operate the pump using the service tool manual control, press F2 to connect. 4. Once connected, go to the “Dash” by pressing F3 or the “F3 -- Dash” button on the service tool banner.
This will provide the following screen for the component control.
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To manually control the WP120 pump speed: 1. Click the “Press to Enable Control” button. 2. Enter pump test point speed. 3. Click the “Press To Turn On” button. 4. Record Test Data on the Installation Data Sheet. 5. Adjust pump speed for the next data point and record test data. Repeat step 5 until matrix is complete. 6. Select “Press to Disable Control” to return to normal operation. 7. Record the requested test information in the data sheets below.
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Installation Description:
Fluid Type:
Fluid Type:
Evaluation Date:
Evaluation Location:
Pump Speed (rpm) 0 1000 2000 3000 4000 5000 5500
Pump Current (Amps)
Pump Voltage (VDC)
Inlet Pressure (kPa/psi)
Inlet/Outlet Temperature (F/C)
Outlet Pressure (optional)
Flow (optional)
NOTE: If the pump is being used in conjunction with another source of fluid flow (e.g. HVAC Boost Pump) perform measurements at worst and nominal operating conditions.
NOTE: Complete and submit a log page for each inlet or operational condition with the installation registration information.
Appendix B
Appendix B Operation Manual R20C Controller Board
Rev Rev By Date Description of Change Approved By E ME 7/6/20 Revisions ECN5959 F ME 5/10/21 Revisions ECN6234
9970039145 Rev. F – 05/10/2021 © 2019 EMP, Inc. 1
Operation Manual R20C Controller Board
Components FIC11 Fan
WP120 Water Pump
Product Overview
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Product Overview The R20C controller is used for brushless motor control in EMP fans and pumps. This controller was originally introduced with a double flying lead for power/ground and communication. Newer models use a single flying lead. This controller communicates on J1939 CAN networks and will respond to CAN messages for speed control. Models with on/off control and thermistor input for automatic speed control are also available. This manual provides information on electrical specifications, connectors, component applications and troubleshooting. EMP component CAN messages are documented in Component Controller CAN Communication, document 9980001068. For assistance with component calibrations and settings, please contact EMP Technical Service at [email protected] and provide a serial number for the part in question.
Purpose ......................................................................................................................................................... 4 Service Technician Responsibilities ............................................................................................................... 4 Liability Disclaimer ......................................................................................................................................... 4 Additional Information .................................................................................................................................... 4 Technical Help ............................................................................................................................................... 4
About This Document ........................................................................................................................................ 5 Warnings, Cautions and Notes ....................................................................................................................... 5 Definition of Terms ......................................................................................................................................... 5
Product Safety Warnings ................................................................................................................................... 6 Power Specification ........................................................................................................................................... 7 Ignition Enable Specification .............................................................................................................................. 7 Component Connector....................................................................................................................................... 8
10-way Male Apex 2.8mm Sealed .................................................................................................................. 8 Mating Connector .............................................................................................................................................. 8
10-way Female Apex 2.8mm Sealed .............................................................................................................. 8 Electrical Connections ....................................................................................................................................... 9 On/Off Single Speed Control ............................................................................................................................. 9
Example On/Off Application Schematic .......................................................................................................... 9 Operation ....................................................................................................................................................... 9
CAN Control .................................................................................................................................................... 10 Example CAN Application Schematic ........................................................................................................... 10 Operation ..................................................................................................................................................... 10
Temperature Input Control ............................................................................................................................... 13 Example Temperature Input Application Schematic ..................................................................................... 13 Operation ..................................................................................................................................................... 13
Diagnostic Outputs .......................................................................................................................................... 14 EMPower Connect™ Service Tool .................................................................................................................. 14 Service Parts Replacement ............................................................................................................................. 15
R20C Component Connector ....................................................................................................................... 15
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Introduction Purpose The purpose of this manual is to provide information on how the R20C controller board operates.
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About This Document Warnings, Cautions and Notes Two headings are used in this document to stress your safety and safe operation of the system. They are styled with a graphic bullet and bold, uppercase text: WARNING and CAUTION. Warnings highlight risks to personnel – hazards, unsafe conditions and practices that can result in personal injury or death. Cautions indicate conditions or practices that can cause damage to components, systems or other equipment. A third heading, styled as NOTE, calls attention to additional information about components and procedures discussed in the document.
Definition of Terms CAN .............. Controller area network. Where used in this manual we specifically mean SAE J1939 defined
CAN. Ignition Enable ......... Signal that commands the controller to turn on or wake-up. PLC ............... Programmable logic controller used to replace hard-wired relays, timers and sequencers. TPA ............... Terminal position assurance is a connector component that can reduce and potentially eliminate
contact back-out issues.
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Power Specification The battery connection provides constant power to the component controller module. All power necessary to operate the component comes from this pin.
12V Component Vehicle Battery Parameters Parameter Min Nom Max Units
Vin – Operating 9.0 13.5 16 V Operating current (oil pump) - - 25(1)(2) A
Operating current (water pump) - - 27.5(1)(2) A Operating current (fan) - - 27.5(1)(2) A
Ignition off current - - 300 µA Motor off current - 30 - mA
Inrush current - - 5 A Inrush current duration - - 1.5 S
Vin – Operating 18 27.0 32 V Operating current (oil pump) - - 25(1)(2) A
Operating current (water pump) - - 22(1)(2) A Operating current (fan) - - 27.5(1)(2) A
Inrush current - - 5 A Inrush current duration - - 1.5 S
(1) Operating current is the steady state design point of the controller for the application. Peak current is based on the current limit.
(2) To protect the controller, the motor speed begins to derate when the internal controller temperature reaches a calibrated threshold. Derated motor operation will continue until the internal controller temperature drops below a safe value. No ignition cycle is required to restore normal operation of the motor.
Ignition Enable Specification The ignition enable pin is used in power management of the controller. When this input goes high, the module will “wake up.” This input is designed for a switched power source and will not be damaged by vehicle transients. Ignition enable must be separate from component power so that power remains on when ignition is switched off to enable controller shutdown processes.
Component Vehicle Ignition Parameters Parameter Min Nom Max Units
Vin 8 13.5 or 27 32 V Ignition current (13.5V) 3 mA Ignition current (27.5V) 5 mA
Vin – Low (sleep) -50 0 3.6 V
Connectors
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Component Connector NOTE: Do not disconnect the component while it is running; stop running the component prior to disconnecting the connector.
10-way Male Apex 2.8mm Sealed See Service Parts Replacement for component connector part numbers.
Pin Wire Size and Color 1 10 AWG Black/Red 2 Plugged 3 16 AWG Black/White 4 16 AWG Black/Tan 5 16 AWG Black/Yellow 6 16 AWG Black/Purple 7 Plugged 8 10 AWG Black 9 Plugged 10 16 AWG Black/Green
Mating Connector NOTE: EMP service kit 1370106076 contains all parts needed for one mating connector.
NOTE: Ensure wires are sized appropriately for the application. Wire gauges and circuit protection shown in this document are suggestions.
10-way Female Apex 2.8mm Sealed Detail Apex Part Number Alternative Part Number
Connector 54201009 15316895 Terminal, Apex 2.8mm, Socket, 10–12 AWG 54001000 10762802 Terminal, Apex 2.8mm, Socket, 14–16 AWG 54001400 10762803 Terminal, Apex 2.8mm, Socket, 18–20 AWG 54001800 10757690
Apex 2.8mm Grey Plug 54200005 N/A
NOTE: All cavities in the mating connector must either be terminated or plugged to prevent moisture from entering the component.
Electrical Connections/Single Speed Control
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Electrical Connections The power input is a 12V or 24V DC (nominal) source depending on the component model. The ignition enable is a switched power source which is sent from the vehicle or system to initiate operation of the component. This can be wired directly to a vehicle ignition, to a PLC output, through a manual switch or through a thermal switch. This line will draw less than 10 mA of current. All switches on this line can be sized based on this amperage requirement. This input should be fused close to the source to protect the vehicle or system wiring. The following sections provide information about how to implement supported control strategies. The CAN and temperature input strategies require additional pin connections.
On/Off Single Speed Control NOTE: All cavities in the mating connector(s) must either be terminated or plugged to prevent moisture from entering the component.
NOTE: 10 AWG wire can be used for power and ground.
Example On/Off Application Schematic
Operation When power is on and ignition enable is on, the component will run in an on/off, single speed manner. The speed at which the component will run will be the pre-configured default speed. EMP also provides a “Power Hold” option which can keep the controller running for a specified amount of time after the ignition enable has been removed. This allows for post-shutdown cooling.
NOTE: For assistance with component calibrations and settings, please contact EMP Technical Service at [email protected] and provide a serial number for the part in question.
Pin Purpose 1 Battery power 2 Plugged 3 Unused 4 Unused 5 Unused 6 Ignition enable 7 Plugged 8 Ground 9 Plugged 10 Unused
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CAN Control NOTE: All cavities in the mating connector(s) must either be terminated or plugged to prevent moisture from entering the component.
NOTE: CAN wiring should follow guidelines found in SAE J1939-15.
Example CAN Application Schematic
Operation EMP controllers with CAN support two J1939 command and status messaging options. Choices are EMP Defined message format or SAE J1939 Standard message format. Command and status messages are calibrated for each application. R20C controllers expect to receive a command message at a 1 second rate. If this command is not received within the calibrated timeout (default of 5 seconds) the controller will run at the calibrated default speed. The controller can be commanded to a specific rpm or a percent of maximum rpm. Each controller also supplies a status message at a 1 second rate. The status message supplies information such as operation status, command status, service status, current rpm, power, and measured temperatures. Exact message content depends on the calibrated message choice.
EMP Messages The R20C supports a single EMP defined command message and one of two EMP defined status messages. Full details of EMP messages are available in section 3 of Component Controller CAN Communication, EMP document 9980001068.
Motor Status Message 1 Motor Status Message 1 is the original status message provided by EMP components. Support for this message remains for backward-compatibility with existing system designs. EMP does not recommend use of this message in new designs.
Pin Purpose 1 Battery power 2 Plugged 3 Address return (optional) 4 Address in (optional) 5 CAN Hi 6 Ignition enable 7 Plugged 8 Ground 9 Plugged 10 CAN Lo
CAN Control
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Status Message 2 Status Message 2 is a modern update to Motor Status Message 1 and is recommended for all new applications/designs. The message supplies the same information as Motor Status Message 1 minus Measured Percent Motor Speed, but adds:
Command Status The source of command that is currently commanding the controller. Service Indicator Shows if the controller needs service. Operation Status Shows if the motor controller is running normal, derated, or not-operable.
Measured External Temperature On R20C models equipped with external temperature capability, the external temperature measured value will be available. The value will be either available in Status Message 2 or as an additional message if using Motor Status Message 1.
SAE Messages The R20C controller supports SAE defined messages for applications already using or comfortable with the SAE J1939 protocol, and already own or willing to buy access to the SAE J1939 DA. See section 4.1 in Component Controller CAN Communication, EMP document 9980001068, for detail on available SAE J1939 PGN pairs.
Dual Message Operation The R20C supports an operating mode where both EMP messages and SAE messages are supported simultaneously. The use case for this mode is primarily for a customer that is transitioning their system from EMP Messages to SAE Messages and would prefer a single part number to satisfy both applications. Contact EMP for more information.
CAN Baud Rate At every startup (ignition enable on) R20C controllers automatically detect the CAN baud rate before transmitting any data on the CAN bus. R20C supports 250K, 500K, and 1M baud rates. Automatic Baud rate detection is enabled by default, but a fixed baud rate can be requested if required.
Measurement Tolerances In the CAN status messages, when measured motor speed and measured motor power are reported, these are calculated values. The resulting measurements are affected by circuit board component tolerances and therefore are not to be used for diagnostics and may not be suitable for control system inputs. This controller has the following tolerances on these measurements:
Speed: ± 2% Power: ± 15%
Factory Configured Addressing The component communicates using a single address set in the factory calibration.
External Addressing (Optional) The component communicates using a calibrated address assigned to an external resistance value. Component calibrations may include up to 10 addresses.
CAN Control
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External addressing is provided to reduce part number count in situations where more than one identical component is in use on a CAN bus. External addressing is most effective at reducing part number count when all of the following conditions exist:
• More than one controller • Identical hardware (same voltage, pressure/flow rating, orientation, etc.) • Each controller has an identical calibration (default speed, command/status messages, etc.)
NOTE: If all of the listed conditions are not met, EMP recommends leaving the address pins open.
External address resistance is measured across the address input pins (Reference the example CAN application schematics). An address resistor harness, part number 1370002349, and matching precision address resistors, are available for purchase from EMP. EMP recommends calibrations for applications requiring 3 or less addresses assign each address to a band of resistance values, to increase the robustness of the addressing. Using high precision resistors will also increase the robustness of addressing. The primary address is typically printed on the component label. This is the address assigned when the external resistance reads as ‘Open’.
EMP Recommended Resistor Addressing Schemes NOTE: Contact EMP for assistance if placing more than 3 pumps on one CAN bus.
Resistance (ohms) Address
Open Factory Configured
Resistance (ohms) Address
Short 2nd address
© 2019 EMP, Inc. 13
Temperature Input Control NOTE: All cavities in the mating connector(s) must either be terminated or plugged to prevent moisture from entering the component.
Example Temperature Input Application Schematic
Operation The temperature input version of the component must be used in conjunction with EMP thermistor part numbers 3130029004 or 3150010016 for liquids or 3150022024 for air. It is possible to use other sensors but special calibrations will need to be developed to ensure accurate temperature measurements. The thermistor must be connected across the thermistor input pins (Reference the Example Temperature Input Application Schematics). The speed vs temperature calibration will be programmed into the component. Contact [email protected] with the serial number of your component for details. EMP harness 3170106122 routes the temperature input pins on the component connector to an EMP thermistor connector. The remaining pins are routed to a 10-way connector matching the component connector. These components cannot have CAN addresses configured via harness address resistors.
Pin Purpose 1 Battery power 2 Plugged 3 Thermistor return 4 Thermistor in 5 CAN Hi 6 Ignition enable 7 Plugged 8 Ground 9 Plugged 10 CAN Lo
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Diagnostic Outputs Operational and diagnostic information can be gathered using EMPower Connect™ service tool via an RP1210 compatible data link adapter. Components using SAE message formats have diagnostic outputs as defined in section 4.2 of EMP document 9980001068.
EMPower Connect™ Service Tool EMP Service Suite is available at no cost on the EMP website. To use the EMPower Connect service tool, download and install the Service Suite software on your Windows PC. EMPower Connect software allows the user to monitor operation, manually control the component and collect history data from the controller. Use breakout harness 3170073176 to interface with the power and ground and communication connectors and an RP1210 compatible data link adapter.
The Service Suite User Guide and Tutorial, including connection and control instructions, is embedded in the software and available on the EMP website. To view diagnostic code lists or troubleshooting guides when not connected to a component, select the guide matching the control platform of the component from the Trouble Shooting menu.
Service Parts Replacement WARNING: To avoid serious personal injury, possible death, or damage to the vehicle, disconnect the
main negative battery terminal and/or switch off the battery disconnect switch first before removing or installing any components.
WARNING: To avoid burn injuries, allow time for the engine to cool to a safe working temperature before removing or installing any components.
CAUTION: To avoid potential damage to the wiring and/or hoses, route all wires and hoses away from any sharp edges, moving objects, and heat sources.
CAUTION: All wires should be secured every 12–18 inches. All zip ties must be placed over wire loom/convoluted tubing and not over bare wires.
NOTE: Refer to service drawings for proper torques. You can obtain the manual at http://www.emp- corp.com/support/documents/ by searching for the component part number.
R20C Component Connector
NOTE: All cavities in the connector must either be terminated or plugged to prevent moisture from entering the component.
10-Way Connector Replacement Kit 1370106126
R20C Power and Communication 10-Way Connector Replacement Kit 1370106126 Item Part Number Description Quantity
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The R20C 10-way connectors can be replaced using EMP kit 1370106126. For the mating connector, cut the old connector off and crimp new pins on the wires. Use the appropriate Apex crimper designed for use with Apex 2.8mm components. Insert the newly pinned wires into the appropriate cavity in the connector housing. Cavity plugs are included in the kit for the unused positions. To replace the component connector, cut off and replace the harness: 1. Cut/remove any zip ties that are securing the component. 2. Disconnect the component connector.
NOTE: To avoid damaging the wires and/or pin connections, do not pull back using the wire harness to disconnect the connection. Wiggling the connector body will help in freeing the connection.
NOTE: Ensure the harness connector electrical sockets remain free of dirt to ensure a solid electrical connection when reconnecting to the components.
3. Using a pair of wire cutters, cut the component wires off leaving at least 5 inches. One-by-one, cut the wires at staggered lengths. Staggering the wire lengths spaces out the butt splices. The repaired harness should maintain the length of the component lead.
4. Using a pair of wire strippers, strip 3/8” of the protective wire coating off of the component wires and the connector replacement wires ensuring not to cut through the wires.
5. Examine the wires to ensure no corrosion. If corrosion is present, cut the wire back further toward the component. Corrosion that has carried through the wires into the component indicates that corrosion is likely present on the controller board as well and the life of the controller may be compromised.
6. Fully insert the component wire into the proper butt connector and inspect to ensure there are no wire strands protruding outside the connector.
7. With the wires fully inserted, crimp the wires in place using a compatible crimper. 8. Cut the replacement harness wires to match the staggered cuts made on the component wires so that the
overall lengths of each lead are approximately equal. 9. Fully insert the matching replacement harness wire into the proper butt connector and inspect to ensure
there are no wire strands protruding outside the connector. 10. With the wires fully inserted, crimp the wires in place using a compatible crimper. 11. Gently tug on both sides of the connector to make sure it will not be shaken easily loose.
NOTE: If it does shake loose, you will have to repeat the instructions and install a new Molex butt connector, as this type of butt connector is one use only.
12. Examine to ensure the wires are fully inserted into the Molex butt connector and that there aren’t any wire strands protruding outside of the butt connector. If the wires are not fully inserted or if there are wire strands protruding outside of the butt connector, then you will have to repeat the instructions and install a new Molex butt connector, as these types of butt connectors are one use only.
13. Using a heat gun, apply heat to the butt connectors until the glue protrudes outside of the connector on both ends.
14. Pull the protective sheathing back down. 15. Test for proper function. 16. Replace any zip ties cut in step 1.
Appendix C
Appendix C Operation Manual R20L Controller Board
Rev Rev By Date Description of Change Approved By D ME 7/6/20 Revisions ECN5959 E ME 5/10/21 Revisions ECN6234
9970039144 Rev. E – 05/10/2021 © 2019 EMP, Inc. 1
Operation Manual R20L Controller Board
Components FIL11 Fan
WP120L Water Pump
Product Overview
© 2019 EMP, Inc. 2
Product Overview The R20L controller is used for brushless motor control in EMP fans and pumps. Components are available with on/off control, PWM speed control, and EMP-Link control (for use with EMP system controllers). This manual provides information on electrical specifications, connectors, component applications and troubleshooting. For assistance with component calibrations and settings, please contact EMP Technical Service at [email protected] and provide a serial number for the part in question.
Purpose ......................................................................................................................................................... 4 Service Technician Responsibilities ............................................................................................................... 4 Liability Disclaimer ......................................................................................................................................... 4 Additional Information .................................................................................................................................... 4 Technical Help ............................................................................................................................................... 4
About This Document ........................................................................................................................................ 5 Warnings, Cautions and Notes ....................................................................................................................... 5 Definition of Terms ......................................................................................................................................... 5
Product Safety Warnings ................................................................................................................................... 6 Power Specification ........................................................................................................................................... 7 Vehicle Ignition Enable Specification ................................................................................................................. 7 Component Connector....................................................................................................................................... 8
7-Way Male Delphi Metripack 150/480 Sealed ............................................................................................... 8 Connector Greasing .......................................................................................................................................... 8 Mating Connector .............................................................................................................................................. 8
7-Way Female Delphi Metripack 150/480 Sealed ........................................................................................... 8 Electrical Connections ....................................................................................................................................... 9 On/Off Single Speed Control ............................................................................................................................. 9
Example On/Off Application Schematic .......................................................................................................... 9 Operation ....................................................................................................................................................... 9
PWM Variable Speed Control .......................................................................................................................... 10 Example PWM Application Schematic .......................................................................................................... 10 Operation ..................................................................................................................................................... 10
EMP-Link Control ............................................................................................................................................ 13 Example EMP-Link Application Schematic ................................................................................................... 13
Diagnostic Outputs .......................................................................................................................................... 14 Diagnostic Outputs (PWM) ........................................................................................................................... 14 Diagnostic Outputs (TACH_OUT) ................................................................................................................ 14 Diagnostic Outputs (EMP-Link) .................................................................................................................... 14
EMPower Connect™ Service Tool .................................................................................................................. 14 Service Parts Replacement ............................................................................................................................. 15
R20L Component Controller Connector ....................................................................................................... 15
Introduction
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Introduction Purpose The purpose of this manual is to provide information on how the R20L controller board operates.
© 2019 EMP, Inc. 5
About This Document Warnings, Cautions and Notes Two headings are used in this document to stress your safety and safe operation of the system. They are styled with a graphic bullet and bold, uppercase text: WARNING and CAUTION. Warnings highlight risks to personnel — hazards, unsafe conditions and practices that can result in personal injury or death. Cautions indicate conditions or practices that can cause damage to components, systems or other equipment. A third heading, styled as NOTE, calls attention to additional information about components and procedures discussed in the document.
Definition of Terms EMP-Link ...... EMP LIN based proprietary serial data bus. Ignition Enable ......... Signal that commands the controller to turn on or wake-up. PLC ............... Programmable logic controller used to replace hard-wired relays, timers and sequencers. PWM ............. Pulse width modulation is a constant frequency square wave input signal used to communicate
a motor speed command to the controller. TACH_OUT ... A signal provided by the component controller that, with interpretation, provides a feedback for
motor speed. TPA ............... Terminal position assurance is a connector component that can reduce and potentially eliminate
contact back-out issues.
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Power Specification The battery connection provides constant power to the component controller module. All power necessary to operate the component comes from this pin.
Vin – Operating 9.0 13.5 16 V Operating current (oil pump) - - 25(1)(2) A
Operating current (water pump) - - 27.5(1)(2) A Operating current (fan) - - 27.5(1)(2) A
Inrush current - - 205(3) A Inrush current duration - - 270 µS
Vin – Operating 18 27.0 32 V Operating current (oil pump) - - 25(1)(2) A
Operating current (water pump) - - 22(1)(2) A Operating current (fan) - - 27.5(1)(2) A
Inrush current - - 370(3) A Inrush current duration - - 250 µS
(1) Operating current is the steady state design point of the controller for the application. Peak current is based on the current limit.
(2) To protect the controller, the motor speed begins to derate when the internal controller temperature reaches a calibrated threshold. Derated motor operation will continue until the internal controller temperature drops below a safe value. No ignition cycle is required to restart the motor.
(3) The inrush current occurs when the controller first receives the required voltage on the ignition pin. This current inrush is due to the charging of the bulk capacitors in the controller. The inrush current numbers are worst case. This current is not generated every time the motor is started, but only when the ignition line is first applied.
Vehicle Ignition Enable Specification The ignition enable pin is used in power management of the controller. When this input goes high, the module will “wake up.” This input is designed for a switched power supply and will not be damaged by vehicle transients. Ignition enable must be separate from component power so that power remains on when ignition is switched off to enable controller shutdown processes.
Component Vehicle Ignition Parameters Parameter Min Nom Max Units
Vin 4 13.5 or 27 32 V Ignition current (13.5V) 2.5 mA Ignition current (27.5V) 4 mA
Vin – Low (sleep) -50 0 1 V
Connectors/Connector Greasing
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Component Connector NOTE: Do not disconnect the component while it is running; stop running the component prior to disconnecting the connector.
See Service Parts Replacement for component connector part numbers.
7-Way Male Delphi Metripack 150/480 Sealed
Pin Wire Size and Color A 16 AWG Black/Tan B 16 AWG Black/Yellow C 16 AWG Black/Purple D 16 AWG Black/Green E 10 AWG Black/Red F 16 AWG Black/White G 10 AWG Black
Connector Greasing NOTE: See Service Bulletin Approved Grease, document 9910039075, for a list of dielectric grease products that have been approved for use in maintenance and service. The document can be obtained on the EMP website by searching for the document number.
NOTE: Only use clean dielectric grease.
1. Apply dielectric grease to each harness side electrical connector. See the table below for specified grease amounts.
Reference Quantities Grease Description 1.25 g Delphi 7-Way Connector
Mating Connector NOTE: All cavities in the mating connector must either be terminated or plugged to prevent moisture from entering the component.
NOTE: Refer to the appropriate control section to determine the parts needed for assembling the mating connector for your application.
7-Way Female Delphi Metripack 150/480 Sealed The connector on the component is a sealed Delphi 480/150 metri-pack mixed connector with male terminals.
NOTE: A service kit containing all parts needed for one mating connector is available from EMP. The service kit part number is 1370036093, and the service kit drawing is available on the EMP website and can be obtained at www.emp- corp.com/support/documents by searching for the service kit part number.
Item Delphi Part Number
Connector 12059472 TPA 12052486
480 Seal 15324990 150 Seal 15324973 150 Plug 12059168
Electrical Connections/Single Speed Control
© 2019 EMP, Inc. 9
Electrical Connections Components require 12V or 24V DC (nominal), depending on the model. The ignition enable is a switched power source which is sent from the vehicle or system to initiate operation of the component. This can be wired directly to a vehicle ignition, to a PLC output, through a manual switch or through a thermal switch. This line will draw less than 10 mA of current. All switches on this line can be sized based on this amperage requirement. This input should be fused close to the source to protect the vehicle or system wiring. The following sections provide information about how to implement supported control strategies. PWM, TACH_OUT and EMP-Link require additional pin connections.
On/Off Single Speed Control NOTE: All cavities in the mating connector(s) must either be terminated or plugged to prevent moisture from entering the component.
NOTE: 10 AWG wire can be used for power and ground. Use Delphi 480 cable seal #15324990.
Example On/Off Application Schematic
Operation
NOTE: Holding pin B low will cause the component to produce the TACH_OUT diagnostic output. See Tachometer Output Parameters for a description of the TACH_OUT.
When power is on and ignition enable is on, the component will run in an on/off, single speed manner. The speed at which the component will run will be the pre-configured default speed.
Pin Purpose A Unused B Optional (Ground for TACH_OUT) C Ignition enable D Optional (TACH_OUT) E Battery power F Unused G Ground
PWM Variable Speed Control
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PWM Variable Speed Control NOTE: All cavities in the mating connector(s) must either be terminated or plugged to prevent moisture from entering the component.
NOTE: 10 AWG wire can be used for power and ground. Use Delphi 480 cable seal #15324990.
Example PWM Application Schematic
Operation
NOTE: Ignition enable must be present to activate the component. The component will not activate if only the PWM input is present.
In order to control the component speed, a pulse width modulation (PWM) signal can be used. A change in the duty cycle of this signal will result in a corresponding change in component speed. See the figures on the next page for the relationship between PWM duty cycle and component speed.
Pulse Width Modulation The PWM input is compatible with low side drive devices (open/ground).
PWM Input Parameters Parameter Min Nom Max Units
VH 3.0 5 32 V VL -2.0 0 1.0 V
Frequency 100 1000 1500 Hz
NOTE: The PWM input frequency is set in the controller calibration. The controller software will not automatically adjust or detect input frequency.
The duty cycle range between 10% and 90% is used to linearly interpolate the component speed between the preprogrammed minimum and maximum speeds (See the next page for EMP pump and fan PWM input control details). There is a 2% hysteresis for the “ON” set-point. For example, the component will turn on at 10% and
Pin Purpose A Unused B PWM signal C Ignition enable D Optional (TACH_OUT) E Battery power F PWM signal ground G Ground
© 2019 EMP, Inc. 11
will turn off at 8% duty cycle. Because of tolerance stackups, component variation over temperature and inconsistencies in the incoming PWM signal, it is recommended that some margin is given for the minimum and maximum speed set-points. For example, using 12% duty cycle as the minimum speed in lieu of 10% will allow for some margin to compensate for the above mentioned factors.
NOTE: Fans allow a reverse command. Pumps do not allow a reverse command.
0% to 2% 3% to 9% 10% to 90% 91% to 92% 93% to 98% 99% to 100%
Invalid PWM command, motor goes to default speed
Zero rpm command
Min to Max speed (linear ramp), once running motor will shut off below 8%
Max rpm command
0% to 2% 3% to 9% 10% to 90% 91% to 92% 93% to 98% 99% to 100%
Zero rpm command
Min to Max speed (linear ramp), once running motor will shut off below 8%
Max rpm command
NOTE: When controlling fan speed using PWM, the component will automatically skip over the speed range of 2900 rpm to 3300 rpm for pullers and 2850 rpm to 3250 rpm for pushers to avoid a resonance.
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Tachometer Output Parameters Tachometer output is a pin that produces a variable frequency output based on motor speed. This pin will output a TACH_OUT signal when the PWM signal pin receives a valid input or the PWM signal pin is held low. The TACH_OUT is an open drain output. The TACH_OUT needs an external pull-up to be read by an external controller (See the example schematic). Tachometer output represents component speed according to the following formula:
=
∗
Vol (No Load) 0 V V Pull Up 32 V
I Short Circuit 1.5 A I Operating (Sink) 500 mA
Example TACH_OUT Schematic
At 4000 rpm, the TACH_OUT signal will have a time on (TimeOn) of 625 µs and a frequency of 800 Hz:
TimeOn = 625 µs = 0.000625 seconds Period = 2 * 625 µs = 1.25 ms = 0.00125 seconds Frequency = 1/0.00125 = 800 Hz
To recover the motor speed from the TACH_OUT signal, input the TimeOn into the rpm formula given above.
= 60
24 ∗
= 60
24 ∗ 0.000625
= 4000
EMP-Link Control
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EMP-Link Control On EMP Systems controlled via a system controller, µTMC or TMC, R20L components are controlled by the system controller via EMP-Link communication. EMP-Link is an EMP proprietary communication protocol used for component communication on EMP thermal systems. Reference the system service manual for more information.
Example EMP-Link Application Schematic
Pin Purpose A Address B Plugged C Ignition enable D EMP-Link E Battery power F EMP-Link return G Ground
Diagnostic Outputs/Service Tool
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Diagnostic Outputs Diagnostic Outputs (PWM) The EMPower Connect service tool can be used with the PWM version of the component via the EMP-Link communication protocol to view performance information.
Diagnostic Outputs (TACH_OUT) If the user has chosen to wire in the TACH_OUT signal, the reported speed can be compared against the commanded speed for diagnostic purposes. It is recommended to set a diagnostic warning if reported speed is less than 90% of commanded speed.
Diagnostic Outputs (EMP-Link) No TACH_OUT diagnostic signal is available and all diagnostics are sent from the system controller. See your system service manual for full details.
EMPower Connect™ Service Tool EMP Service Suite is available at no cost on the EMP website. To use the EMPower Connect service tool, download and install the Service Suite software on your Windows PC. EMPower Connect software allows the user to monitor operation, manually control the component and collect history data from the controller. Use breakout harness 3180036020 to interface with the 7-pin component connector and an EMP TTL/EMP-Link data link adapter 3640036049. These are available together in diagnostic kit number 7500038004.
The Service Suite User Guide and Tutorial, including connection and control instructions, is embedded in the software and available on the EMP website. To view diagnostic code lists or troubleshooting guides when not connected to a component, select the guide matching the control platform of the component from the Trouble Shooting menu.
Service Parts Replacement WARNING: To avoid serious personal injury, possible death, or damage to the vehicle, disconnect the
main negative battery terminal and/or switch off the battery disconnect switch first before removing or installing any components.
WARNING: To avoid burn injuries, allow time for the engine to cool to a safe working temperature before removing or installing any components.
CAUTION: To avoid potential damage to the wiring and/or hoses, route all wires and hoses away from any sharp edges, moving objects, and heat sources.
CAUTION: All wires should be secured every 12–18 inches. All zip ties must be placed over wire loom/convoluted tubing and not over bare wires.
R20L Component Controller Connector
NOTE: It is very important to use the correct Molex butt connectors when replacing the component connector.
Refer to the component connector section for component wire sizes and colors.
Harness Replacement Kit 1370036077 Part Number Description Quantity
3250002166 12–10 AWG Molex Butt Connector 2
3250036079 16–14 AWG Molex Butt Connector 5
3180036078 FIL11 Replacement Cable 1
1. Cut/remove any zip ties that are securing the component to the system.
2. Disconnect the component connector from the main system harness connector.
NOTE: To avoid damaging the wires and/or pin connections, do not pull back using the wire harness to disconnect the connection. Wiggling the connector body will help in freeing the connection

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