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EMP WP120 12V - User Manual

EMP WP120 12V
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Date
Description of Change
Approved By
A
ME
5/17/21
New Release
ECN6212
9970137016 Rev. A – 05/17/2021 © 2021 EMP Inc. 1
Quick Start Guide
WP120 Electric Water Pump
This manual is effective for consumer installations
of EMP WP120 water pumps. OEM installers must
contact EMP for production requirements.

Questions and Answers

Summary

Product Overview

Introduction

Purpose of the Guide

Explains the guide's aim to present pump dimensions, electrical specs, coolant guidelines, plumbing, mounting, and maintenance.

Service Technician Responsibilities

Emphasizes understanding safety messages and using caution during service work for safe operation.

Liability Disclaimer

States EMP cannot anticipate all hazards and users must ensure safety of chosen procedures.

Additional Information

Provides EMP website URLs for support documents, service bulletins, and customer registration.

Technical Help

Offers contact information for EMP Customer Service for technical assistance via phone or email.

Warnings, Cautions and Notes

Details the styling and purpose of WARNING, CAUTION, and NOTE headings used in the document.

Definition of Terms

Defines key terms like CAN, EMPower Connect™ Service Tool, Ignition Enable, and rpm.

Product Safety Warnings

General Safety Precautions

Covers essential safety practices including hazard awareness, equipment securing, electrical safety, pressure systems, ventilation, fire safety, and tool removal.

Specifications

Performance Specifications

Details maximum/minimum operating temperatures and motor speed for the pump models.

Mechanical Specifications

Outlines component construction material and weight for the pump.

Electrical Specifications

Lists input voltage, maximum operating current draw, and thermal protection features.

Dimensions and Bolt Spacing

Provides detailed diagrams with measurements for pump dimensions and mounting hole locations.

Material Listing and Operating Limits

Material Listing of Parts

Lists external and fluid contacting parts with their materials and indicates if they contact fluid.

Operating Limits

Specifies temperature limitations for fluid and ambient operating and storage conditions.

Identification and Product Labels

Component Identification Information

Explains where to find serial information on the product label for tracing configuration, calibration, and manufacturing data.

EMP Water Pump Model Codes

Model Code Breakdown

Details the structure and meaning of each segment in the WP120 pump model designation.

Installation Guidelines

Environmental Considerations

Highlights the importance of environment cleanliness and the pump's submersible nature.

Pump Orientation

Shows diagrams illustrating the standard orientation and preferred angles for pump installation.

Plumbing Requirements

Specifies the required hose diameter for the inlet and cautions about air trapping and seal damage.

System Fill and Fluid Requirements

Hose Clamp Recommendations

Recommends SAE20CT worm drive hose clamps and specifies torque, advising against spring clamps.

System Fill Procedure

Provides step-by-step instructions and cautions for filling the cooling system and pump to avoid dry running and air locks.

Approved Fluids

Lists acceptable coolant standards, advises on silicate/phosphate content, and emphasizes customer verification of compatibility.

Wiring and Connectors

Recommended Wiring Practices

Outlines best practices for routing, securing, and protecting wiring harnesses to prevent damage and hazards.

Electrical Connections Overview

Explains the power input and ignition enable signal, including wiring and fusing recommendations.

10-way Component Connector

Details the pinout and wire colors for the male Apex 2.8mm sealed connector.

10-way Mating Connector

Provides part numbers for the female Apex 2.8mm sealed mating connector and its components.

10-way On;Off Single Speed Control

Connector Pinout and Purpose

Lists the function of each pin in the 10-way connector for single-speed control.

Single Speed Operation

Describes how the pump operates in single speed mode with power and ignition, and mentions the 'Power Hold' option.

7-way Connector Information

7-way Component Connector Details

Shows the pinout and wire colors for the male Delphi Metripack 150/480 sealed connector.

7-way Mating Connector Details

Provides part numbers for the female Delphi Metripack 150/480 sealed mating connector and its components.

7-way Connector Greasing

Instructs on applying dielectric grease to electrical connectors and lists reference quantities.

7-way On;Off Single Speed Control

Connector Pinout and Purpose

Lists the function of each pin in the 7-way connector for single-speed control.

Single Speed Operation

Describes pump operation in single speed mode with power and ignition, and notes on PWM/TACH_OUT.

Routine Maintenance

Maintenance Schedule and Actions

Outlines checks for fluid levels, cooling system, exterior inspection, and electrical connections at different frequencies.

Physical Inspection Checklist

Details specific checks for weep hole condition and wiring integrity during physical inspection.

EMPower Connect Service Tool

Service Tool Overview

Introduces the EMPower Connect software for monitoring, manual control, and data collection.

Diagnostic Outputs and Usage

Explains how to gather operational and diagnostic information for WP120 (CAN) and WP120L (PWM) models.

Troubleshooting Guide

Pump Not Running Issues

Lists checks for electrical connections, ignition enable, and system fluid level for non-operational pumps.

Pump Not Pumping Fluid Issues

Provides checks for system fluid, tubing, priming, inlet for debris, and hose condition when pump is running but not moving fluid.

CAN Communication Issues

Guides on checking communication harness, CAN message formats, and component CAN address for communication failures.

Water Pump Seal Leak

Recommends verifying coolant level, selection, maintenance records, and system aeration for seal leak issues.

Excessive Noise Issues

Suggests checking for cavitation, low inlet pressure, trapped debris, and plumbing restrictions causing noise.

Overview

The EMP WP120 Electric Water Pump is an electrically powered fluid pump designed for consumer installations. It is available in both 12-volt DC and 24-volt DC configurations, utilizing a stainless-steel shaft for fluid compatibility. Proper installation is crucial to ensure optimal performance and reliability, while also minimizing the risk of damage to other system components.

Key Technical Specifications:

  • Voltage Configurations: 12V DC (9-16 V DC nominal 14V) and 24V DC (18-32 V DC nominal 28V).
  • Operating Temperature Range: Maximum 203 °F (95 °C), Minimum -40 °F (-40 °C).
  • Motor Speed Range: Maximum 5500 rpm, Minimum 1000 rpm.
  • Operating Current Draw Maximum: 27.5 A for 12V, 22 A for 24V.
  • Thermal Protection: Features auto self-protect rpm rollback to prevent overheating. The motor speed will derate when the internal controller temperature reaches a calibrated threshold, continuing until the temperature drops to a safe value.
  • Component Construction: Cast Aluminum.
  • Component Weight: 6.2 lbs (2.8 kg).
  • Dimensions: Inlet and outlet connections require a 1-inch (25.4 mm) inside diameter hose. The overall length is approximately 7.43 inches (188.72 mm), with a width of 5.09 inches (129.29 mm) and a height of 7.16 inches (181.86 mm) from the mounting surface. Mounting is via four M8-1.25, 15mm deep bolt holes.
  • Fluid Contacting Materials: Includes HS6 AISi10Mg for housing and volute, 304 Stainless Steel for impeller, SAE 440 Stainless Steel for shaft, Carbon/Silicon Carbide for water seal faces, AISI 304 for water seal stamping, HNBR for bellows/cup, and AISI 302 for spring.

Usage Features:

  • Fluid Compatibility: The pump is designed to be compatible with a variety of fluids. For optimal pump seal life, Organic Acid Technology (OAT) coolants that are silicate and phosphate-free are recommended. Fluids must conform to ASTM D6210-10 or ASTM D3306. The use of "Stop Leak" or radiator cleaner style system additives is not approved. Distilled water should be used to dilute coolant or pre-mix coolant.
  • Submersible Design: The WP120 is fully submersible, though shielding may be required to prevent debris from entering the weep hole.
  • Orientation Specific: The pump must be installed according to EMP guidelines regarding orientation to ensure proper function.
  • Electrical Connections: The pump can be controlled in an on/off, single-speed manner. An "Ignition Enable" signal, drawing less than 10 mA, initiates operation. This signal can be wired to a vehicle ignition, PLC output, manual switch, or thermal switch. EMP also offers a "Power Hold" option to allow post-shutdown cooling.
  • Wiring Practices: Recommended wiring practices include ensuring harnesses do not rub on sharp edges or hot surfaces, are not stressed at connections, and are supported every 12-18 inches. Voltage drop between the battery and pump should not exceed 5% of the rated battery voltage.
  • Diagnostic Capabilities: The EMPower Connect™ service tool (available via Windows PC software) allows users to monitor operation, manually control the component, and collect history data. For CAN-based WP120 pumps, a breakout harness (3170073176) and an RP1210 compatible data link adapter are used. For PWM-based WP120L pumps, a different breakout harness (3180036020) and an EMP TTL/EMP-Link data link adapter (3640036049) are used. Status messages for WP120 are broadcast over CAN.

Maintenance Features:

  • System Fill Procedure: Critical for preventing seal damage from dry running. The system must be filled with fluid, ensuring no air pockets, before electrical connections are made. The pump should be run at 4600 rpm to purge air, and fluid levels topped off. Input power should be monitored (above 200W at 4600 rpm) to verify fluid movement.
  • Hose Clamps: SAE20CT worm drive type hose clamps are recommended for inlet and outlet connections, torqued to 45 in-lbs per SAE J1508. Spring type clamps are not recommended.
  • Routine Inspections:
    • When checking/filling vehicle fluids: Ensure correct fluid levels to prevent pump seal failure.
    • Every engine oil change/major vehicle service interval: Inspect the cooling system for leaks, sample coolant, and check coolant quality. Refer to Service Bulletin Electric Water Pump Inspection and Diagnostic Procedures (9910085143) before pump removal.
    • Every three months or more often (harsh conditions): Visually inspect the pump exterior, ensuring weep holes are not clogged. Check wires for wear or frayed insulation, and ensure all electrical connections are tight.
    • Annually (and after any service): Ensure connections are tightened to proper torque, all wires and pin connections are intact, and the support structure is free of damage or loose hardware.
  • Weep Hole Maintenance: Ensure the weep hole port is not clogged with debris. If plugged, it should be opened.
  • Connector Greasing: Dielectric grease should be applied to each harness side electrical connector. Refer to Service Bulletin Approved Grease (9910039075) for approved products and specified grease amounts (e.g., 1.25g for Delphi 7-Way Connector). All cavities in mating connectors must be terminated or plugged to prevent moisture ingress.
  • Troubleshooting Guide: The manual provides a troubleshooting section for common issues such as the pump not running, running but not pumping fluid, CAN communication issues, suspected water pump seal leaks, and excessive noise. This includes checks for electrical connections, fluid levels, tubing restrictions, air locks, collapsed hoses, trapped debris, and cavitation.

EMP WP120 12V Specifications

General IconGeneral
BrandEMP
ModelWP120 12V
CategoryWater Pump
LanguageEnglish

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