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EMP OP80 Installation And Operation Manual

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Installation and Operation Manual
Rev
Rev By
C
ME
D
ME
9970115018 Rev. D – 06/30/2021
OP80 Electric Oil Pump
This manual is effective for aftermarket and OEM
installations of the following part numbers:
Base Part Number
1010115XXX
Date
7/29/20
Revisions
6/30/21
Revisions
© 2019 EMP, Inc.
Description of Change
Approved By
ECN6044
ECN6236
1

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  • Page 1 Installation and Operation Manual OP80 Electric Oil Pump This manual is effective for aftermarket and OEM installations of the following part numbers: Base Part Number 1010115XXX Rev By Date Description of Change Approved By 7/29/20 Revisions ECN6044 6/30/21 Revisions ECN6236 9970115018 Rev.

  • Page 2: Product Overview

    The OP80 pump is capable of delivering up to 8 gal/min (30 L/min) of oil flow. It is capable of operating at system pressures up to 80 psi (5.5 Bar). This performance allows the pump to handle a variety of fluid transfer applications.

  • Page 3: Table Of Contents

    Warnings, Cautions and Notes ........................5 Definition of Terms ............................5 Product Safety Warnings ........................... 6 Identification ..............................7 EMP Oil Pump Model Codes .......................... 8 Technical Information ............................9 Operation ............................... 9 Specifications ..............................9 Dimensional and Mounting Details ....................... 10 Sample Performance Chart ..........................

  • Page 4: Introduction

    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.

  • Page 5: About This Document

    EMP-Link ..EMP Based Proprietary Serial Data Bus Ignition Enable ..Signal that commands the controller to turn on/wake-up OP80 ..... Oil Pump with Integral Controller and EMP- Link or PWM Communications OP80C ..Oil Pump with Integral Controller and J1939 CAN Communications or Thermistor Input...

  • Page 6: Product Safety Warnings

    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.

  • Page 7: Identification

    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.

  • Page 8: Emp Oil Pump Model Codes

    ––––––––––––––––––––––– ––––––––––––––––––––––– ––––––––––––––––––––––– OP80-24V-EA-L = Oil Pump. Single stage, 8.0 gpm pressure, on/off/PWM communication, 24 Volt External Mount at 0 degrees, no relief valve, uses PWM Low input for commands. NOTE: Not every option combination is available. NOTE: All current pump models are optimized for use with lighter weight oils like ATF. Performance will be reduced for heavier weight oils.

  • Page 9: Technical Information

    Technical Information Technical Information Operation Connector, operation, and wiring information are in the appendices, depending on the pump model.  Model OP80 pumps are explained in Appendix A, Operation Manual R20L Controller Board.  Model OP80C pumps are explained in Appendix B, Operation Manual R20C Controller Board.

  • Page 10: Dimensional And Mounting Details

    Technical Information Dimensional and Mounting Details NOTE: Dimensions are given in millimeters. © 2019 EMP, Inc.

  • Page 11: Sample Performance Chart

    350 watts which is half that for a 28V power supply. The reduced power will also directly impact performance at lower temperatures and for heavier weight oils. Figure 1 – 25 °C Sample Performance Chart © 2019 EMP, Inc.
  • Page 12 Technical Information Figure 2 – 100 °C Sample Performance Chart Figure 3 – 25 °C vs 100 °C Sample Performance Chart © 2019 EMP, Inc.

  • Page 13: Installation

    (suction) should be kept as short as possible. Avoid restrictions such as sharp bends and undersized fittings in lines. • • Avoid routing hoses/lines in areas that would cause chafing. All hoses should be secured to prevent rubbing against any surfaces. © 2019 EMP, Inc.

  • Page 14: Wiring Practices

    • The maximum current draw for the OP80 pump is 25 amps. The actual pump current draw varies with oil viscosity and the pressure required to pump the oil through the system. It is recommended to install a properly sized fuse, not less than 30A on the power supply line to protect installed wiring.

  • Page 15: Fluids Fill

    Is the ignition enable on a switched source and not tied to power? Installation Review Checklist To determine if the oil pump was successfully installed, reference the Installation Review Checklist for EMP Oil Pumps, document number 9890094024. This document can be found on the EMP website by searching for the document number.

  • Page 16: Routine Maintenance

    Low fluid level. • Incompatible fluid. • • Worn or damaged pumping gear. Low flow rate Clogged suction • screen/strainer. • Inlet circuit leak. Incompatible fluid. • Worn or damaged pumping • gear. Low supply voltage. • © 2019 EMP, Inc.

  • Page 17: Operation Manual R20L Controller Board

    Appendix A Appendix A Operation Manual R20L Controller Board © 2019 EMP, Inc.

  • Page 18: Operation Manual R20C Controller Board

    Operation Manual R20L Controller Board Components FIL11 Fan OP3530 Oil Pump OP40 Oil Pump OP80 Oil Pump WP120L Water Pump Rev By Date Description of Change Approved By 7/6/20 Revisions ECN5959 5/10/21 Revisions ECN6234 9970039144 Rev. E – 05/10/2021 © 2019 EMP, Inc.
  • Page 19 Service@emp-corp.com 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.
  • Page 20 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™...

  • Page 21: Introduction

    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.

  • Page 22: About This 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.

  • Page 23: Product Safety Warnings

    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.

  • Page 24: Power Specification

    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 Units 13.5 or 27 Ignition current (13.5V) Ignition current (27.5V) – Low (sleep) © 2019 EMP, Inc.

  • Page 25: Component Connector

    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 Wire Size and Color service kit drawing is available on the EMP website 16 AWG Black/Tan obtained www.emp- 16 AWG Black/Yellow corp.com/support/documents...

  • Page 26: Electrical Connections

    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. NOTE: For assistance with component calibrations and settings, please contact EMP Technical Service at service@emp-corp.com and provide a serial number for the part in question.

  • Page 27: Pwm Variable Speed Control

    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...
  • Page 28 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. © 2019 EMP, Inc.
  • Page 29 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. ������������ = 24 ∗ �������� ���� ������������ ������������ = 24 ∗ 0.000625 ������������ = 4000 © 2019 EMP, Inc.

  • Page 30: Emp-Link Control

    EMP-Link Control EMP-Link Control On EMP Systems controlled via a system controller, µTMC or TMC, R20L Purpose Address components are controlled by the system controller via EMP-Link communication. Plugged EMP-Link is an EMP proprietary communication protocol used for component Ignition enable communication on EMP thermal systems.

  • Page 31: Diagnostic Outputs

    Diagnostic Outputs/Service Tool 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.

  • Page 32: Service Parts Replacement

    Cut/remove any zip ties that are securing the place using a compatible crimper. component to the system. Cut the replacement harness wires to match the Disconnect the component connector from the staggered cuts made on the component wires main system harness connector. © 2019 EMP, Inc.
  • Page 33 17. Replace any zip ties cut in step 1. you will have to repeat the instructions and install a new Molex butt connector, as these types of butt connectors are one use only. © 2019 EMP, Inc.
  • Page 34 Appendix B Appendix B Operation Manual R20C Controller Board © 2019 EMP, Inc.
  • Page 35 R20C Controller Board Components FIC11 Fan OP3530C Oil Pump OP40C Oil Pump OP80C Oil Pump WP120 Water Pump Rev By Date Description of Change Approved By 7/6/20 Revisions ECN5959 5/10/21 Revisions ECN6234 9970039145 Rev. F – 05/10/2021 © 2019 EMP, Inc.
  • Page 36 Service@emp-corp.com 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.
  • Page 37 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 © 2019 EMP, Inc.

  • Page 38: Introduction

    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.

  • Page 39: About This Document

    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. © 2019 EMP, Inc.

  • Page 40: Product Safety Warnings

    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.

  • Page 41: Power Specification

    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 Units 13.5 or 27 Ignition current (13.5V) Ignition current (27.5V) – Low (sleep) © 2019 EMP, Inc.

  • Page 42: Component Connector

    Plugged 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...

  • Page 43: Electrical Connections

    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.

  • Page 44: Can Control

    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.
  • Page 45 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.
  • Page 46 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).

  • Page 47: Temperature Input Control

    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.

  • Page 48: Diagnostic Outputs

    4.2 of EMP document 9980001068. EMPower Connect™ Service Tool EMP Service Suite is available at no cost on the 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.

  • Page 49: Service Parts Replacement

    Terminal – Apex 2.8mm, F, 18–20 AWG, Tin Plated 3210106070 Terminal – Apex 2.8mm, F, 14–16 AWG Tin Plated 3250106072 Plug – Apex 2.8mm Gray 3180106119 Cable Asy, R20CT, Apex Replacement 3250036079 Molex Butt Connector 16–14 AWG 3250002166 Molex Butt Connector 12–10 AWG © 2019 EMP, Inc.
  • Page 50 Service Parts Replacement 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.
  • Page 51 Product Warranty Registration Form Product Warranty Registration Form © 2019 EMP, Inc.
  • Page 52 Product Type (Complete one form per Electric Water Pump product type. For complete thermal Individual Fan Individual system assemblies you do not need to Controller register each assembled fan/controller/ EMP Alternator pump) Oil Pump OilMate System Other Thermal System - # of Fans Model Purchased...
  • Page 53 Vehicle Information Serial, Part, and Model Number are Located on the EMP Product Label Fleet ID # Vehicle Make/Model Vehicle Model Year Vehicle Identification Number (VIN) Vehicle Miles/Hours at Installation If New System, Alternator Serial Number Notes Contact EMP Mail/Fax/E-Mail Completed Registration Forms to:...

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