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Appendix B

© 2019 EMP, Inc.

18

Appendix B

Operation Manual R20C Controller Board

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Summary of Contents for OP80

Page 1: ...isions ECN6044 D ME 6 30 21 Revisions ECN6236 9970115018 Rev D 06 30 2021 2019 EMP Inc 1 Installation and Operation Manual OP80 Electric Oil Pump This manual is effective for aftermarket and OEM insta...

Page 2: ...eatures a brushless DC motor with an integrated motor drive controller This pump is available in both 12 and 24 VDC models The OP80 pump is capable of delivering up to 8 gal min 30 L min of oil flow I...

Page 3: ...EMP Oil Pump Model Codes 8 Technical Information 9 Operation 9 Specifications 9 Dimensional and Mounting Details 10 Sample Performance Chart 11 Installation 13 Locations Orientations 13 Plumbing Consi...

Page 4: ...ll 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 ensu...

Page 5: ...sonal 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...

Page 6: ...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 sy...

Page 7: ...e 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 en...

Page 8: ...10 OEM Omit if n a 3 Pressure Flow Rate In 0 1 gallons per minute 30 3 0 gpm 11 4 lpm 40 4 0 gpm 15 1 lpm 80 8 0 gpm 30 3 lpm 7 Orientation degrees A 0 B 90 C 180 D 270 11 Certification Omit if n a 4...

Page 9: ...V Theoretical Displacement 0 468 in3 rev 7 67 cm3 rev Flow Capacity Maximum 8 0 gal min 30 L min Operating Pressure Maximum 80 psi 5 5 Bar Operating Temperature Maximum Air 203 F 95 C Operating Temper...

Page 10: ...Technical Information 2019 EMP Inc 10 Dimensional and Mounting Details NOTE Dimensions are given in millimeters...

Page 11: ...voltage of 28 Vdc Figure 3 illustrates the difference in flow versus power consumption between 25 C and 100 C temperature settings The actual performance of the pump will vary from application to app...

Page 12: ...Technical Information 2019 EMP Inc 12 Figure 2 100 C Sample Performance Chart Figure 3 25 C vs 100 C Sample Performance Chart...

Page 13: ...13mm 1 2 of clearance to ensure there is no rubbing or interference during operation Securely attach pump to frame or mounting bracket by using 4 M8 1 25 fasteners The mounting holes are tapped to a...

Page 14: ...on the power supply line to protect installed wiring Although the pump connector and mating connector are environmentally sealed care must still be taken to prevent water from pooling up on the pump c...

Page 15: ...For new pumps pour oil into the pump discharge port to wet the pumping element 2 Use care to avoid contaminating oil with debris when working on the system or pump Final Item Checklist Are all hoses...

Page 16: ...rect supply voltage Blown fuse Electrical connection issue Pumping gear seized with debris Problem with ignition switch Pump not running at commanded speed This may be normal operation due to the syst...

Page 17: ...Appendix A 2019 EMP Inc 17 Appendix A Operation Manual R20L Controller Board...

Page 18: ...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 OP3530 Oil Pump OP40 Oil...

Page 19: ...l at any time without notice 2019 EMP Inc 2 Engineered Machined Products Inc 2701 North 30th Street Escanaba MI USA 49829 Phone 1 906 789 7497 www emp corp com Service emp corp com Product Overview Th...

Page 20: ...y 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 Ap...

Page 21: ...ty 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...

Page 22: ...OTE 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 th...

Page 23: ...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 sy...

Page 24: ...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 drop...

Page 25: ...rical 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 e...

Page 26: ...n 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...

Page 27: ...y 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...

Page 28: ...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 Max rpm normally reserved for rev...

Page 29: ...ller See the example schematic Tachometer output represents component speed according to the following formula Tachometer Output Parameters Parameter Min Nom Max Units Vol No Load 0 V V Pull Up 32 V I...

Page 30: ...tem 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 inf...

Page 31: ...ll 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 Win...

Page 32: ...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 bod...

Page 33: ...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...

Page 34: ...Appendix B 2019 EMP Inc 18 Appendix B Operation Manual R20C Controller Board...

Page 35: ...pproved 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 OP3530C Oil Pump OP40C Oi...

Page 36: ...ervice 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...

Page 37: ...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 Exa...

Page 38: ...ty 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...

Page 39: ...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 do...

Page 40: ...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 sy...

Page 41: ...ion 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 de...

Page 42: ...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...

Page 43: ...equire 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 A...

Page 44: ...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 statu...

Page 45: ...ports 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 Message...

Page 46: ...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...

Page 47: ...perature 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 prog...

Page 48: ...l 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 h...

Page 49: ...r 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 compon...

Page 50: ...arried 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 wi...

Page 51: ...Product Warranty Registration Form 2019 EMP Inc 19 Product Warranty Registration Form...

Page 52: ...t Information Product Type Complete one form per product type For complete thermal system assemblies you do not need to register each assembled fan controller pump Electric Water Pump Individual Fan I...

Page 53: ...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 EMPAdv...

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