electric coolant pump ecp 160 installation manual · electric coolant pump ecp 160 5 technical data...

Electric Coolant Pump ECP 160Installation Manual

V 1.0 1/23/2019

Electric Coolant Pump ECP 160 Table of contents | en 3

Bosch Engineering GmbH Installation Manual 11.04.2018 | V 1.0 |

Table of contents1 Getting started 42 Technical Data 53 Installation 83.1 Installation Electronic 83.2 Installation Pump 84 Usage 95 Troubleshooting/Frequently asked Questions 106 Vibration Profile 117 Requirements for the coolant 128 Requirements for the intake air 139 Disposal 14

4 en | Getting started Electric Coolant Pump ECP 160

11.04.2018 | V 1.0 | Installation Manual Bosch Engineering GmbH

1 Getting startedDisclaimerDue to continuous enhancements we reserve the rights to change illustrations, photos ortechnical data within this manual. Please retain this manual for your records.

Before startingBefore starting your engine for the first time, install the complete software. Bosch Motorsportsoftware is developed for Windows operation systems. Read the manual carefully and followthe application hints step by step. Don’t hesitate to contact us. Contact data can be found onthe backside of this document.

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Caution!Risk of injury if using the ECP 160 inappropriately.Use the ECP 160 only as intended in this manual. Any maintenance or repair must beperformed by authorized and qualified personnel approved by Bosch Motorsport.

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Caution!Risk of injury if using the ECP 160 with uncertified combinations and accessoriesOperation of the ECP 160 is only certified with the combinations and accessories that arespecified in this manual. The use of variant combinations, accessories and other devicesoutside the scope of this manual is only permitted when they have been determined to becompliant from a performance and safety standpoint by a representative from BoschMotorsport.

Notice!For professionals only.The Bosch Motorsport ECP 160 was developed for use by professionals and requires in depthknowledge of automobile technology and experience in motorsport. Using the system doesnot come without its risks.It is the duty of the customer to use the system for motor racing purposes only and not onpublic roads. We accept no responsibility for the reliability of the system on public roads. Inthe event that the system is used on public roads, we shall not be held responsible or liablefor damages.

Notice!Drive-by-wire systemsFor systems with drive-by-wire additional safety provisions apply. For details please refer tothe document „Safety Instructions for Drive-by-Wire Systems in Motorsport Applications“.

Electric Coolant Pump ECP 160 Technical Data | en 5


2 Technical DataThe Bosch ECP 160 coolant pump features a PWM controlled BLDC motor. Its main purposeare coolant systems. The supply voltage is 12 V.

Application

Max. differential pressure (el. limited) <2.4 bar (g)

Delivery rate at 22°C 160 l/min at 1.5 bar (g) (690 W)

Max. delivery rate <240 l/min

Max. coolant temperature 135°C

Max. ambient temperature 85°C

Max. vibration Pump Unit and Electronic Box See Vibration Profile 1 on our homepage

Max. dry run time (new condition) < 30 s

Duration for pressure build up < 1,000 ms (from 0 to 160 l/min at 1.5 bar (g)at T_coolant = 95°C)

Coolant compatibility Automotive coolant fluids

Mechanical Data

Size Pump Unit 105 x 90 x 95 mm

Size Electronic Box 110 x 97 x 45 mm

Weight Pump Unit 445 g

Weight Electronic Box 481 g

Weight total 926 g

Protection Classification Pump Unit IP55

Protection Classification Electronic Box IP67

Housing Pump Unit and Electronic Box Aluminum

Intake side Wiggins clamps 1 ¼”

Pressure side Wiggins clamps 1 ¼”

Periodically service after 100 operating hours – Maintenance of Pump Unit– See also maintenance list

Periodically service after 200 operating hoursor after 2 years

– Functional test of Electronics– See also maintenance list

Electrical Data

Supply voltage 9 to 18 V DC

Load current 51.1 A at 13,500 rpm and 1.5 bar (g); 160 l/min (see diagrams)

Max. current 62 A

Max. released short-term power (el. limited) 750 W

6 en | Technical Data Electric Coolant Pump ECP 160


Speed control PWM

Characteristic

Surface coating Anodization

Color Black

Fluid filtering Possible both sides

Pressure

Flow rate l/min

Pump speed1/min

0 50 100 150 200 250

5,000 327 281 mbar

6,000 484 438 160

7,000 653 623 341

8,000 843 825 519 84

9,000 1045 1051 764 311

10,000 1308 1312 1040 594 0

11,000 1547 1593 1330 869 266

12,000 1846 1905 1651 1130 603

13,000 2168 2267 2022 1495 940 144

14,000 2502 2546 2240 1688 1193 524

Electric Coolant Pump ECP 160 Technical Data | en 7


Power Consumption

Flow rate l/min

Pump speed 1/min 0 50 100 150 200 250

5,000 43 54 34 W at 13.5 V DC

6,000 64 80 66

7,000 91 112 109

8,000 127 151 156 104

9,000 168 209 225 177

10,000 230 276 311 275 143

11,000 293 358 408 389 282

12,000 380 462 528 506 431

13,000 481 591 686 682 605 384

14,000 613 707 781 787 759 626

8 en | Installation Electric Coolant Pump ECP 160


3 InstallationThe ECP 160 is designed for easy installation and fast swaps. To ensure a smooth run and along lifespan of the product the following requirements have to be met.

3.1 Installation ElectronicThe electronics require supply air for certain loads and ambient temperatures. Minimum airspeed 5 m/s to ensure safe operation.

3.2 Installation Pump– Mount the whole pump assembly rigidly. Rubber dampers may help to prevent long-term

damages caused by vibration.– First, fix the pump, then the coolant and air connectors.– Use two M5 screws (A) and the support on the motor side (B).

Pressure nozzle

Suction nozzle

(A)

(A)

(B)

– The support (B) assists in absorbing the radial vibration stresses. The hole should have adiameter of 23.5 mm.

– The water should drain and the place of installation should be chosen accordingly. Thecooling fins of the electronic must be protected against sludge and must not becomeclogged. Don’t cover the cooling fins.

– An optimal air convection around the electrical motor and electronics, as well as thecables, helps to guarantee smaller load currents and a longer life of the component.

– Mount the whole pump assembly either horizontally or vertically (referred to thelongitudinal axis of the motor).

– The suction nozzle must not be positioned downwards.

– If properly positioned, the pump will deaerate itself after short usage. Nevertheless, makesure that no air can get into the pump element.

– The flanges of the coolant circuit quick couplings must not be subjected to tensile-compression forces during operation.

– The pipe/hose connection must be mounted in such a way that the coupling connectionelements can take over the task of vibration decoupling.

Electric Coolant Pump ECP 160 Usage | en 9


4 Usage– The pump may only be operated in accordance with the specification.– The system must be completely vented and must not be switched on without coolant.– The pump must be completely flooded and must not be used for priming.– Before vibrations can occur, the pump must run at a minimum speed.– If the pump is mounted on the combustion engine, it must be switched on and run before

starting. This sequence protects the bearing.

10 en | Troubleshooting/Frequently asked Questions Electric Coolant Pump ECP 160


5 Troubleshooting/Frequently asked Questions– Hydraulic and electrical power deviations of up to 5 percent from the data sheet are

possible due to the design.– A leakage of up to 2 ml per hour is possible due to the design and no cause for concern.– A sufficiently powerful power supply unit must be used for testing outside a vehicle.

Recommended output power: more than 3.000 watts.– Sufficient cooling according to specification must be provided for testing outside a

vehicle.– Permanent application of system pressure outside of normal use is not permitted.– If a secondary casing pump overflows the ECP 160 pump at the test bench, this can lead

to starting difficulties for the ECP 160 pump.– PWM signal: we recommend to use a push/pull power amplifier. With a low side switch

you could use the internal pullup.– All plugs / cables may only be disconnected when the pump is stopped and the

electronics are de-energized.– Cleaning:

– High pressure cleaning and compressed air are not permitted, do not use aggressivecleaning agents (brake cleaner, etc ...).

– Cleaning with warm water, mild soap and brush is recommended. All entrances andexits must be closed.

– Overtemperature behavior:– The electronics automatically reduces the power when the permissible temperature

is exceeded until the permissible temperature/power ranges level off.

Electric Coolant Pump ECP 160 Vibration Profile | en 11


6 Vibration ProfileBroadband noise: 8h/direction

Frequency (Hz) Acceleration density (m/s2)2/Hz

20 50.4

55 26.0

180 1.0

300 1.0

360 0.56

1,000 0.6

2,000 0.6

Effective value aEff 55.4 m/s2

Sine: 8h/direction

Frequency (Hz) Acceleration peak (m/s2)

100 50

180 200

250 200

350 60

2,000 60

12 en | Requirements for the coolant Electric Coolant Pump ECP 160


7 Requirements for the coolantThe coolant system may only be filled in the cleaned state and connected to the pump. Nocore sand, other production residues or contamination of the pump may be supplied. Thepump may only be operated with commercially available coolants. Bosch Motorsport can’tissue a release. The chemical resistance must be proven in own tests.

Electric Coolant Pump ECP 160 Requirements for the intake air | en 13


8 Requirements for the intake airIf the pump is operated in a dirty environment, clean intake air must be provided. The intakeair particles must be less than 0.1 mm. The pump has only low intake effect and must not beobstructed by fine filters during operation.Do not cover the air outputs.

Air intake

Air output

Air output

Air output

14 en | Disposal Electric Coolant Pump ECP 160


9 DisposalHardware, accessories and packaging should be sorted for recycling in an environment-friendlymanner.Do not dispose of this electronic device in your household waste.Waste electronic equipment must be disposed of properly according to Electrical andElectronics Act (ElektroG) and the European WEE directive.

Bosch Engineering GmbHMotorsportRobert-Bosch-Allee 174232 AbstattGermanywww.bosch-motorsport.com© Bosch Engineering GmbH, 2018

electric coolant pump ecp 160 installation manual · electric coolant pump ecp 160 5 technical data...

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