EMP WP29, WP32 Installation Manual

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Page 1

Part Number

Serial Number(s)

1030085xxx

All

Rev

Rev By

Date

Description of Change

Approved By

10/30/13

Formatting, Orientation, Checklist

ECN3149

WP29 and WP32 Electric Water Pump

Installation Manual

and

Installation Approval Documentation

This manual is effectiv e for aftermarket and OEM installations

of the following part and serial numbers:

1030002xxx

A MPL/BF 4/9/13 Original Release ECN2805

All

Page 2

Engineered Machined Products Inc.

2701 North 30th Street

Escanaba, Michig an 49829

Phone: 906-789-7497

www.emp-corp.com

[email protected]

Product Overview

The WP29 and WP32 are electrically powered fluid pumps available in 12 volt DC and 24 volt DC configurations. The pump is available with carbon steel, or stainless steel shafts 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.

This document 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. If there are parameters outside the normal application, additional information will be required for EMP Engineering to approve the installation or warranty will be void.

Use the Installation Approval check sheet located in Appendix B to submit installation inf ormat ion to EMP for approval.

The information contained in this manual is updated periodically. While great care is taken in compiling the information contained in this m anual, 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.

Page 3

Table of Contents

Product Overview ............................................................................................................................. 2

Safety .................................................................................................................................................... 4

Warnings, Cautions & Notes ............................................................................................................. 4

Product Safety Warnings .................................................................................................................. 4

Purpose................................................................................................................................................. 5

Development Engineer Responsibilities ................................................................................................ 5

Specifications ........................................................................................................................................ 6

Dimensions ....................................................................................................................................... 6

Hole Locations/Bolt Spacing ............................................................................................................. 6

Material Listing of Major External and Fluid Contacting Parts .......................................................... 7

Performance ......................................................................................................................................... 9

Pump Performance Curves .............................................................................................................. 9

Pump Limitations ................................................................................................................................ 10

Temperatures ................................................................................................................................. 10

Vibration ......................................................................................................................................... 10

Environment ................................................................................................................................... 10

Orientation ...................................................................................................................................... 10

Inlet and Outlet Pressures .............................................................................................................. 11

Fluid Level ...................................................................................................................................... 12

Approved Coolants ......................................................................................................................... 12

Supplementary Coolant Additives (SCA) ........................................................................................ 12

Plumbing ............................................................................................................................................. 13

Recommended Plumbing ............................................................................................................... 13

Electrical Specifications and Requirements ........................................................................................ 14

Schematics ..................................................................................................................................... 15

Mating Connectors .......................................................................................................................... 15

Wiring .................................................................................................................................................. 16

Wire Sizing ..................................................................................................................................... 16

Recommended Wiring Practices..................................................................................................... 16

Installation ........................................................................................................................................... 17

Orientation Specific ......................................................................................................................... 17

Dual Orientation .............................................................................................................................. 18

Incorrect Pump Orientation and Reasons ....................................................................................... 18

Physical Inspection ............................................................................................................................. 19

Troubleshooting .................................................................................................................................. 20

EMPower Connect™ Service Tool ...................................................................................................... 20

Appendix A, WP29 and WP32 Installation Testing ............................................................................. 21

Equipment Required for WP29 and WP32 Data Collection ............................................................ 21

Inlet Pressure Measurement Test Procedure ................................................................................. 22

Test Data Log Sheet ....................................................................................................................... 24

Appendix B, WP29 and WP32 Installation Approval Registration and Check Sheet ........................... 26

Installation Approval # .................................................................................................................... 26

Product Installation Questionnaire .................................................................................................. 27

Page 4

Safety



Safety

Warnings, Cautions & Notes

Three types of headings are used in this manual to stress your safety and safe operation of the WP29. They appear in the text as follows:

WARNING:

THIS SYMBOL IS USED TO MAKE YOU AWARE OF AN UNSAFE CONDITION, HAZARD, OR PRACTICE THAT CAN RESULT IN PERSONAL INJURY OR DEATH.

CAUTION:

THIS SYMBOL IS USED TO ALERT YOU TO A CONDITION OR PRACTICE THAT CAN CAUSE DAMAGE TO THE WP29 AND WP32 OR THE VEHICLE, OR BOTH.

NOTE: Is used to provide additional information that requires special attention by the technician.

Product Safety Warnings

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 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.

Ensure that all safety message and information messages are read and understood before installation, maintenance, or any repairs are performed. The person who services the product may be unfamiliar with many of the systems on the product. It is important to use caution when service work is performed. Knowledge of the vehicle system and operation are important before the removal or disassembly of any component.

Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before doing any work or diagnostic procedures on the WP29 and WP32, or vehicle.

Disconnect the main negative battery cable and/or switch the battery disconnect switch to the OFF position first before installation or servicing.

Use extreme caution when working on systems under pressure (i.e. coolant, hydraulic fluids, air, etc…)

Make sure the work area is ventilated and well lit.

Make sure charged fire extinguishers are in the work area.

Reinstall all safety guards, shields, and covers after servicing the vehicle.

Make sure all tools, parts, and service equipment are removed from the engine compartment and vehicle after all work is done.

Do not apply power to the pump without fluid since most pumps are programmed to start when power is applied and the pump

seal will be damaged if run dry.

If CAN or Serial TTL control is not used the 6 pin DTM connector must be blocked off to prevent entry of water or dirt which will result in damage to the pump. A block off plug EMP P/N 3250001030 can be purchased or one can be fabricated from the Deutsch parts listed in the table on page 12

Page 5

Purpose

The purpose of the WP29 and WP32 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 outlin es th e WP29 and WP32 limitations that should be recognized and adhered to.

Development Engineer Responsibilities

The organization responsible for incorporating the WP29 and WP32 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. Prior to production release of any system incorporating the WP29 and/or WP32, please take the time to fill out the included product installation registration form and e-mail to [email protected]. EMP engineering will review the intended installation and will contact you if there are any issues seen in the information provided. It is up to the design engineer to ensure that all requirements are met; failure to do will void product warranty.

Page 6

Specifications

Dimensions

Hole Locations/Bolt S pa ci ng

Page 7

Specifications

Material Listing of Major External and Fluid Contacting Parts

Item Quantity Description Material Fluid Contact 1 1 Cover Cast Aluminum (413) 2 1 Housings Cast Aluminum (413) YES 3 10 Bolt 18 – 8 Stainless Steel 4 1 Volute Cast Aluminum (413) YES 5 1 Impeller (Internal) 304 Stainle ss St eel YES 6 1 Shaft 1020 Carbon Steel YES 7 1 Product Label M - 714 8 2 Connector Dupont Zytel Nylon 70G33L

NOTE: SAE 440 Stainless Steel Shafts are offered as an option on EMP WP29 and WP32 Pumps. Contact customer

service for part number information.

Page 8

Specifications

Date Code

Serial Number

Country of Origin

Hardware Part Bar Code

EMP Programmed

Software Calibration Customer optional

Identification

The product identification labels are attached to the controller housing next to the electrical interface of the pump. The pump hardware part and serial numbers are located on the upper label. The lower label identifies the Programmed Assembly number and the associated control software as the pump leaves the manufacturing facility. The EMP service tool can be used to confirm the pump software should calibration changes be required and new identification tags issued.

Label Details

Number

Assembly Number or Customer Part Number

Number

information

Page 9

Performance

Flo w -vs- St at ic Pressure Rise

WP29 12 volt Pump

0 5 10 15 20 25 30

Flow (gpm)

Pump Rise (psi)

14V Ful l 4000 3500

3000

2500

2000

1500 1000

Static Pressure Rise -vs- Flow

WP29 - 24 volt pump

0 5 10 15 20 25 30 35

Flow (gpm)

Pump Rise (psi)

WP29 24V (1000) WP29 24V (2000) WP29 24V (3000) WP29 24V (4000) WP29 24V (4500) WP29 24V (max spee d )

WP32 and WP29 -12V

WP32 and WP29 -24V

Performance

Pump Performance Curves

The pump performance curves shown in the illustrations below outline the maximum capability of the pump at maximum speed 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.

Page 10

Limitations

Debris in weep hole region

Pump Limitations

Temperatures

Table 1: Temperature Limitations

Maximum Fluid and Ambient Operating Temp Minimum Fluid and Ambient Operating Temp Maximum Ambient Storage Temp Minimum Ambient Storage Temp

* If the intended application fluid temperature exceeds 95°C, installation must be

reviewed and approved by EMP to ensure warranty coverage. See Appendix A for the Installation Approval checklist.

203°F (95°C)*

-40°F (-40°C)

257°F (125°C)

-40°F (-40°C)

NOTE: Over-temperat ur e Pr otection

If the internal electronics operating temperature exceeds 266°F (130°C) the pump will shut off and stay off until the

temperature drops to 257 electronics temperature threshold.

F (125°C). At 95°C fluid temperature the pump controller is operating near the 130°C

Vibration

Vibration exceeding the EMPTS009 profile can shorten pump life, potentially leading to PCB and motor shaft failures. If you are unsure of your vibration profile for a given installation please contact EMP to ensure warranty coverage.

Environment

Environment cleanliness is crucial to pump life. The WP29 and WP32 are certified with an IP67 rating but debris collection in the weep pocket can lead to premature seal failure (See figure below). Shielding may be required to ensure debris does not enter the weep hole. If you have any questions regarding your installation contact EMP to ensure warranty coverage.

Orientation

Each pump part number has a specified and approved orientation. If the pump is not properly installed several failure modes could potentially result. Please reference the Pump Orientation section of this document for installation guidelines. If you have any questions regarding pump orientation please contact EMP to ensure warranty coverage

Page 11

Limitations

WP29 Pump Inlet Pressur e

-10

-8

-6

-4

-2

0 1000 2000 3000 4000 5000

WP29 Pump Spee d ( r pm )

Pump Inlet Pressur e ( psi )

Inlet A Inlet B Inlet C LIMIT

Operation in this Range

WP32 and WP29 –Pump Inlet Pressure

Inlet and Outlet Pressures

Inlet Pressure/Configuration

• The WP29 and WP32 pumps must maintain an inlet pressure greater than -5 psi (-35kPa gauge) at the set WP29 and WP32 operating speed under all operating conditions

Is Not Allowed

In the WP29 and WP32 Pump Inlet Pressure Map, three inlet configurations are illustrated. “Inlet A” configuration represents an inlet that is very restrictive, and any pump operation above 3000 pump rpm will violate the minimum inlet pressure requirement. The configuration will be forced to have a 3000 rpm pump speed limit. “Inlet B” is also restrictive, and will require the WP29 and WP32 pump speeds to be limited to 3500 rpm, where “Inlet C” remains in the safe operating zone for all measured pump speeds and has no special limitations.

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 result of the motor controller protecting the electronics from a condition where excessive heat may build up in the controller.

Page 12

Limitations

Fluid Level

CAUTION: DO NOT RUN THE PUMP WITHOUT FLUID PRESENT. IF RUN DRY EVEN FOR A SHORT

PERIOD THE SEAL WILL BE DAMAGED.

Approved Coolants

Heavy Duty Engines using Fully Formulated Coolant: Reference ASTM D6210 -10 for coolant quality and maintenance schedules. Test method references are listed in this specification

Light Duty Partial Formulated Coolant: Reference ASTM D3306 for coolant quality and maintenance schedules.

Based on field testing and experience, the WP29 and WP32 are compatible with the following coolant types:

1. Ethylene Glycol

2. HOAT ( Hybrid Organic Acid Technology)

3. OAT (Organic Acid Technology)

4. Propylene Glycol

NOTE: - Use distilled water t o dilute c oolant or use pre-mix coolant

Supplementary Coolant Additives (SCA)

Coolant additives are allowed with the WP29 and WP32 water pump. The additive must be compatible with the base coolant and all contact surfaces of the pump. The additive concentration must be within the additive manufacturer’s specification. Damage to the WP29 and WP32 or the system will not be warranted if the additive is not compatible with the base coolant or the concentration is outside manufacturer recommendations.

CAUTION: CONTACT CUSTOMER SERVICE TO VERIFY THAT COOLANTS NOT LISTED ABOV E ARE

COMPATIBLE WITH PUMP COMPONENTS AND COMPLETE THE INSTALLATION APPROVAL FORM. WHEN USING A COOLANT THAT IS NOT APPROVED, THE INSTALLATION MUST BE EMP APPROVED

CAUTION: USE OF “STOP LEAK” STYLE SYSTEM ADDITIVES ARE NOT APPROVED CAUTION: MIXING OF COOLANTS CAN CAUSE PROBLEMS WITH THE COOLING SYSTEM. FLUIDS CAN

INTERACT RESULTING IN DAMAGE TO THE COOLI N G SYST EM AN D PU M P

Page 13

Plumbing

Outlet

Inlet

Plumbing

Recommended Plumbing

Pump Inlet must be plumbed using 25mm (1.0 inch) diameter hose and/or thin walled tubing from the fluid supply to the pump inlet. A restriction in the inlet plumbing is allowed as long as the flow diameter is not less than 17mm (0.75 inch) and does not exceed 25mm (1.0 inch) in lengt h.

Deviations from the Recommended Plumbing must meet the Inlet Requirements and be approved by

EMP Engineering. Please contact EMP customer service for installation review.

Mounting Screws

Mounting screws used should be M8 x 1.25 screws (qty=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 (20N-m).

CAUTION: THE MOUNTING HOLES ARE TAPPED TO A DEPTH OF 0.59 INCHES (15MM). BE AWARE OF

THE BRACKET THICKNESS WHEN SELECTING THE FASTENER LENGTH TO ENSURE THAT THE FASTENER WILL NOT BOTTOM OUT IN THE PUMP HOUSING.

Hose Clamps

When making the inlet and outlet hose connections to the pump it is strongly recommended to use SAE20CT worm drive type hose clamps. Torque worm drive clamps to 45 in-lbs per SAE J1508. Spring type c lamps are not recommended.

Page 14

Electrical

12V Pump

Parameter

Min

Nom

Max

Units

Vin – Operating

9.0

13.5

Operating current

- 25

(1)(2)

Ignition off current

- - 300

µA

Motor off current

Inrush current

- - 205

(3)

Inrush current duratio n

- - 270

µS

24V Pump

Parameter

Min

Nom

Max

Units

Vin – Operating

27.0

Operating current

- - 15

(1)(2)

Ignition off current

- - 300

µA

Motor off current

Inrush current

- - 370

(3)

Inrush current duratio n

- - 250

µS

Electrical Specifications and Requireme nts

Vehicle Battery Parameters

(1): Peak current is based on the software current limit. 25 amps is the standard current limit for a 12V pump and 15 amps is the standard current limit for a 24V pump for serial numbers > 07065826. (2): The pump shuts down when the i nternal controller temperatures reaches 130˚C at this point the pump will stop running until the internal controller temperature drops below 125˚C. Once t he safe value is reached, the pump will restart. No ignition cycle is required to restart the pump. (3): The inrush current occurs when the controller first receives the required voltage on the ignit ion pin. This current inrush is due to the charging of the bulk capacitors in the controller. The inrush current numbers are worst case. They were measured with a battery as the source with a harness that was 3ft in length (very low source impedance). Anything done in the application to increase the source impedance will have a significant (downward) impact on these numbers. This current is not generated every t im e the motor is started, but only when the igniti on line is first applied.

Vehicle Ignition Parameters

Parameter Min Nom Max Unit

Vin 9 13.5 or 27 32 V IGN Current (13.5v) IGN Current (27.5v)

- 2.5 - mA

- 4 - mA

Vin – Low (sleep) -50 0 1 V

Page 15

Schematics

NOTE:

Electrical

1 – CANH 2 – CAN SHIELD 3 – SERIAL GND 4 – SERIAL TX 5 – SERIAL RX 6 – CANL

These represent the controller connectors – not the mating harness

connectors.

1 – TEMP INPUT OR CAN ADDRESS 2 – GND 3 – BATT 4 - IGNITION

NOTE: Addressing and motor status message information can be found in our

J1939 Motor Control Document, 9980010068

Controller Connectors

Mating Connectors

The mating connectors and pins are available from EMP in kit #3170001077 for the 6 pin and #3170001078 for the 4 pin connector.

IF CAN OR SERIAL TTL CONTROL IS NOT USED THE 6 PIN DTM CONNECTOR MUST BE BLOCKED OFF TO

PREVENT ENTRY OF WATER OR DIRT WHICH WILL RESULT IN DAMAGE TO THE PUMP. A BLOCK OFF PLUG, EMP P/N 3250001030 CAN BE PURCHASED.

Sample Wiring Schematic

Page 16

Electrical

Wires pulling on connectors can

event

Wire routing provides a path for water to flow

Drip loop collects water and sheds it away

Wiring

Wire Sizing

- For complete connector body sealing the ignition wire should be 16ga minimum and the power and ground wires should be 12ga minimum

Recommended Wiring Practices

- Wiring or electrical harness must not rub on sharp edges.

- The electrical harness should not be stressed at connections (see Figure below)

- Incorporate Drip Loops into wiring designs (see Figure below). The pump connectors are environmentally sealed. However, good wire management can help ensure a good seal over the life of the product

down into connector

compromise the connector body seal and possibly create a water intrusion

- The voltage drop between the battery and the fan 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.

- Wiring or electrical harness should be supported at least every 18" to 20".

- To avoid possible fire or shock, do not pinch any wiring or electrical harnesses.

from connectors

- The use of Dielectric Grease such as Dow Corning DC-4 is acceptable as long as the connection is mated directly after grease application to prevent dirt from being captured by the grease

Page 17

Orientation

0°

-5°Nom

-15°

0° Nom

10°

-10°

0°

-5°Nom

-15°

Installation

Orientation Specific

For orientation specific pumps, acceptable pump orientations are tied to the individual pump part numbers. The part number includes the motor stator for the appropriate voltage, the controller circuit board, and the vent port configuration.

Vertical Controller Ori e nt a ti on

Part numbers for this orientation include: 1030002275, 1030002278, 1030002280, 1030002283, 1030002285, 1030002287, 1030085013, 1030085016, 1030085018, 1030085019, 1030085021, 1030085023

10°

0° Nom

Horizontal Controll e r Or ientation

Part numbers for this orientation include: 1030002276, 1030002277, 1030002279, 1030002284, 1030002286, 1030002288, 1030085014, 1030085015, 1030085017, 1030085020, 1030085022, 1030085024

Page 18

Orientation

Not Acceptable Orientation

Dual Orientation

Part Numbers Include: 1030002225, 1030002228, 1030002229, 1030002230, 1030002231, 1030002232, 1030002237, 1030002247 thru 1030002251, 1030085001 thru 1030085012

The Dual Orientation pumps cannot be mounted at any arbitrary angle (i.e. 45 deg off axis). Standard Service pumps can use either the Vertical or Horizontal Orientations listed on the previous page.

Incorrect Pump Orientation and Reasons

The WP29 and WP32 contain a mechanical seal; 0.1cc/hr may weep past the seal as a part of normal operation. To properly collect the weepage pump orientation is important. Too steep of an angle will not allow the fluid to collect in the weep pocket and evaporate off and the pump may appear to be leaking when in fact it is operating as designed. An incorrect mounting angle may also result in too much fluid being retained in the weep pocket resulting in bearing contamination and reduced service life.

No Weep Collection

Seal Life

Water in Connectors

Bearing Life

Page 19

Physical Inspection

CAUTION: DO NOT RUN THE PUMP WITHOUT FLUID PRESENT. IF RUN DR Y EVEN FOR A SHORT

PERIOD THE SEAL WILL BE DAMAGED.

1. Make sure the weep hole ports are not clogged with debris. If weep holes are plugged then open them up.

Weep Hole Ports

2. While the pump is connected to the bus, remove the 6 pin plug and connect the TTL adapt er and turn the bus and heating switches "on" (to enable pump).

a. 24V power and IGN must be supplied to pump or it will not connect to the service tool. b. Use EMPower Connect™ Service Tool to verify that the pump is on and running at

correct speed.

3. Evaluate the pump for abnor mal noi ses dur i n g operati o n. This is a subjective evaluation, vibration is not grinding; the user is looking for a noticeable bearing noise.

4. Observe the pump and area for leaking coolant. Fluid pouri ng out of the weep hol e w ould indicate a failed mechanical seal. Dampness around the weep pocket is acceptable.

NOTE:

COOLANT MAY BE SEEN OUTSIDE THE EMP WP29 ELECTRIC WATER PUMP. Mechanical Seal

design requires fluid between the shaft and the seal material. This fluid vaporizes and passes the seal, venting through the weep collection pocket. As the seal wears in, the amount of venting decreases but never to zero. In properly oriented pumps, the vapor will harmlessly evaporate unless the outside surfaces are cool enough to condense the vapors, which may result in a small volume of coolant visible on the exterior of the weep holes There are two weep holes that vent from the same cavity. One will be capped with a solid plug, the other with a cap with two holes. If the pump seals are leaking excessively, fluid will come through the holes.

Acceptable Leakage

Depending on pump installation orientation, pumps may show up to 10 cc external leakage during the first 100 hours. In the preferred orientation, about half this amount may have external leakage. 10 cc coolant will make a small puddle approximately 4 inches across on a flat surface.

Page 20

Troubleshooting

Verify pin location

Check pump inlet for trapped debris

address is being used.

ump bearings are making a grinding noise

• Replace pump

• Replace pump. No action is required by

leakage as described

Troubleshooting

Symptom Check

Pump not running.

Pump is running but not pumping fluid.

No CAN communication and/or pump not responding to CAN commands

P when running

• Check electrical connections

• Check ignition wire

• Check if ignition wire is “on”

•

• Check system fluid level

• Check for tubing restrictions (kinks)

• Make sure pump is primed

• Check for collapsed inlet or outlet hose

•

• Check communication harness wiring.

• Verify that CAN messages are being

transmitted in the proper formats (see online Technical Guide or contact EMP Technical Support for C AN mess ag e details).

• Verify that the proper component CAN

Pump is leaking excessively while running

EMPower Connect™ Service Tool

Monitoring operation and manual control of the pump can be accomplished using the service tool EMPower Connect which is part of the EMP Service Suite available at no cost on our website at:

http://www.emp-corp.com/support/downloads/ . To use EMPower Connect download and install on

your PC. If the pump is being run standalone you will also need an interface cable from the 6 pin Deutsch connector on the pump and an EMP USB/TTL converter. Both are available as a kit P/N

7500038001. If the pump is on a J1939 CAN bus EMPower Connect™ can be run using a Data Link Adapter (DLA) to interface to the CAN bus. A user guide for EMPower Connect™ can be found here:

http://www.emp-corp.com/support/documents/

customers for pumps ex hi bi ti ng acceptable

Page 21

Appendix A, WP29 and WP32 Testing

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 Voltage

Circuit Flow

Optional

Ensure Flow meter does the system.

Append ix A, WP29 and WP32 Installation Testing

The information provided in this document supplements the Installation Approval document and provides detailed information for service tool use with the WP29 and WP32. The information within this document may be helpful in developing unique system calibrations and mapping the operation of the cooling system.

Equipment Required for WP29 and WP32 Data Collection

1. Computer with the EMPower Connect service tool software installed.

2. Computer Interface Hardware with the WP29 and WP32

a. Using DLA: EMP Harness 3180001080 (may need power for DLA) b. Using an EMP TTL: Service Tool EMP Kit # 7500038001

3. Data Acquisition Equipment Capabilities:

Pump Current Measurement,

not generate a restriction in

4. For inlet pressure measured within one inch of the pump inlet, a special test pump with an

instrumented inlet is available from EMP for installation approval testing. Contact EMP Engineering for access to the test pump (shown below).

Page 22

Appendix A, WP29 and WP32 Testing

Inlet Pressure Measurement Test Procedure

1. Install Instrumented WP29 and WP32 into the system.

a. If a non-instrumented WP29 and WP32 is to be used with an external 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 selecting F3 or the F3-Dash button on the service tool banner.

This will provide the following screen for the component control.

Page 23

Appendix A, WP29 and WP32 Testing

5. To manually control the WP29 and WP32 pump speed:

Step 1 Select “Manual Control” button Step 2 Select “Motor Enable” button Step 3 Enter pump test point speed Press the enter button Step 4 Record Test Data on the Installation Data Sheet Step 5 Adjust pump speed for the next data point and record test

data. Repeat step5 until matrix is complete. Step 6 Select “Manual Control” button to return to normal

operation. Motor Enable and Reverse will be grey as shown in the im age.

6. Record the requested test information in the data sheets below.

Page 24

Appendix A, WP29 and WP32 Testing

Customer Calibrations

Value

LV_MOTOR_RPM_MIN

LV_MOTOR_RPM_MAX

LV_MOTOR_MAX_CURRENT

LV_MOTOR_RPM_DEFAULT

LV_CAN_ADDRESS

LV_CAN_FUNCTION

LV_CAN_MSG_TIMEOUT

LV_CAN_BASE ADDRESS

LV_POWER_SHUTDOWN_TIME

LV_TK_FAN_SPEED_SETPOINT

LV_TK_FAN_TIME_REVERSAL

LV_TK_FAN_REVERSAL_INTERVAL

LV_TK_FAN_REVERSE_AT_START

LV_TK_FAN_TEMP_MIN

LV_TK_FAN_TEMP_MAX

LV_TK_FAN_TEMP_HYST

LV_TK_FAN_TEMP_BINS

Test Data Log Sheet

Installation Description

Pump Hardware & Software Numbers (Label) Fluid Type Unit or Vehicle Description and # Coolant Type Evaluation Date Evaluation Location Evaluator Contact Information

NOTE:

Calibration Tab, View Calibrations

Controller Settings from EMPower Connect service tool

Page 25

Appendix A, WP29 and WP32 Testing

Installation Description Test Configuration

Special Conditions:

Test Data Log Pump Speed (rpm) 0 1000 2000 3000 3500 4000 4300 4600

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 coolant 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 install ati on regis tra tion

information.

Page 26

Appendix B, EMPower Connect Service Tool

Installation Approval #

Date Submitted

Reviewer

Approval Date

Approval Signature

Comments

Organization

Street Pump Hardware Number

City

State/Prov Pump Hardware Serial Number

Country

Zip Code Pump Programmed Assembly (PA) Number

Contact

Phone

Requestor Signature

Submit Completed Forms to:

Appendix B, WP29 and WP32 Installation Approval Registration and Check Sheet

To be Completed by EMP

EMP

2701 North 30th Street

Escanaba, Michigan 49829

Phone: 906-789-7497

www.emp-corp.com

[email protected]

To Be Completed By Customer/Reviewer

Product Information

Installation Description, (Vehicle Type, Fluid Type, Mounting Location, Flow Requirements)

I certify that the pump will be used in as described in this installation approval request. I understand that any deviation from use as de sc r ibed her e may void the warranty on the pump.

Requestor Name Request Date

Page 27

Appendix B, EMPower Connect Service Tool

Input Met?

Specifications -

Is the maximum system fluid temperature (at the pump

Specifications -

Is the maximum ambient temperature less than or

Specifications -

equal to -40°C?

Specifications -

Is the application vibration enveloped by the EMPTS009

Specifications -

the pump mounted)?

Specifications -

the range of operating speeds?

Specifications -

Is the pump located where there is a minimum 13mm

Specifications -

Is the pump located away from external heat sources and direct road spray?

Specifications -

Specifications Specifications -

Specifications -

Are the power and ground wires a minimum of 12 AWG wire?

Product Installation Questionnaire

Reference

Section

Performance

Limitations

Limitations Specifications -

Limitations

Input Requirement

Do the flow and pressure curves match the system requirements?

inlet) less than or equal to 95°C?

equal to 95°C? Is the minimum system fluid temperature (at the pump inlet) greater than or equal to -40°C?

Is the minimum ambient temperature greater than or

profile? Is the pump's mounting bracket .187" thick or greater? Does the bracket natural frequency exceed 150 Hz (with

Are any bracket resonances or other audible abnormalities observed when the pump is run through

Yes

Reference Document(s)

and/or

Comments

Limitations

Approved Fluids

Electrical Specifications -

Electrical

(1/2 inch) clearance to ensure no rubbing or interference?

If pump is exposed to external heat and road spray, is proper shielding in place to protect the pump?

If the pump is exposed to road spray, is the correct pump orientation (horizontal/vertical) and part number being used (severe service)? Is the system fluid on the approved fluids list? Provide fluid information and spec sheet.

Is the proper shaft material selected for the fluid used in the application (stainless steel vs carbon steel)

Does the application meet the voltage and current requirements Is there a fluid level warning and/or switch to prevent dry operation of the pump? List the type of system used

Page 28

Appendix B, EMPower Connect Service Tool

Input Met?

Specifications -

Is the ignition (key switch power) fused from the source

ignition source.

Specifications Electrical

Specifications -

If the pump is CAN Controlled, is the CAN harness

Specifications -

address, CAN timeout, baud rate, etc)?

Specifications -

Are electrical cables supported to prevent wear and abrasion to the cables?

Installation -

Is there a feature on the pump mounting structure to

Installation -

Are the hoses/tubes supported to reduce the risk of rubbing?

Installation -

Is the WP29 and WP32 inlet plumbing “downhill” from

Reference

Section

Electrical

Specifications Electrical

Electrical

Input Requirement

Is the positive power wire fused at 30 amps within 6

Yes

inches of the voltage source?

or was an additional 5 amp fuse added to the ignition wire within 6 inches of the ignition source? Identify

Is the Ignition wire a minimum of 16 AWG?

Is the power connected directly to the battery and the wake/sleep of the pump controlled by the enable signal? This is required for proper history and fault data storage. If the pump is not CAN controlled, is the 6 pin connector capped and contain all 6 cavity plugs?

potted and are provisions made to seal the shield wire?

If the pump is CAN Controlled, is the pump PA # properly specified for J1939 communication (J1939

Reference Document(s)

and/or

Comments

Electrical

Orientation

Installation Plumbing

Plumbing

Plumbing Installation -

Plumbing

Power and Plug installed and locked in position, no stress on the wires at connectors?

Are electrical cables shielded if within 6 inches of an external heat source?

Is the pump left to right angular orientation 5° to 15° downward to allow proper weep hole drainage?

Is the pump front to back angular orientation ±10° to allow proper weep hole drainage?

collect the small amount of weep that may escape the pump? Are the inlet and outlet hoses aligned and supported to reduce loading on the pump and bracket?

Is the WP29 and WP32 inlet plumbing one inch internal diameter from the coolant source? Are there 2-3 diameters of straight plumbing directly before the inlet of the WP29 and WP32?

Plumbing

the coolant source?

Page 29

Appendix B, EMPower Connect Service Tool

Input Met?

Installation -

Is the WP29 and WP32 more than 6 inches below the low fluid level?

Installation -

Are proper fasteners M8x1.25 used with lock washers and flat washers?

Installation -

Have the environmental limitations and the installation

Please describe the systems reaction to a WP29 and

Reference

Section

Plumbing

Mounting

Mounting Installation -

Fault Codes

Input Requirement

Are there any elevated areas in the inlet supply? NOTE: Areas where air can be trapped and prevent coolant flow to the pump. The WP29 and WP32 is not a

self-priming pump.

Is the inlet pressure greater than -5psig at maximum operating speed? Are there any filters or soft plumbing that could increase inlet restriction over time?

Do the fasteners have 12.7±1 mm (0.5±0.05 inch) engagement into the pump? NOTE: Mounting holes are threaded to 15mm (0.59 inch) depth. Are the fasteners torqued to the 20±2 Nm (15±1.5 ftlbs) specification? Are any J1939 feedback parameters other than motor speed being used for system diagnostics?

Yes

Reference Document(s)

and/or

Comments

Requirements

requirements outlined in 9970002273 been reviewed and agreed to?

WP32 fault.

(e.g. immediate stop, reduced performance, limited

time to operate, system fault code etc..)

If CAN controlled list the CAN messages used for

diagnostics

Page 30

Engineered Machined Products Inc.

2701 North 30th Street

Escanaba, Michigan 49829

Phone: 906-789-7497

www.emp-corp.com

[email protected]