Bosch ECP 160 Bedienungsanleitung

Electric Coolant Pump ECP 160

Installation Manual

V 1.0 6/4/2018

Electric Coolant Pump ECP 160 Table of contents | en 3

Bosch Engineering GmbH Installation Manual 11.04.2018 | V 1.0 |

Table of contents

1Getting started 4

2Technical Data 5

3Installation 9

3.1 Installation Electronic 9

3.2 Installation Pump 9

4Usage 10

5Troubleshooting/Frequently asked Questions 11

6Vibration Profile 12

7Requirements for the coolant 13

8Requirements for the intake air 14

9Disposal 15

4en | Getting started Electric Coolant Pump ECP 160

11.04.2018 | V 1.0 | Installation Manual Bosch Engineering GmbH

1 Getting started

Disclaimer

Due to continuous enhancements we reserve the rights to change illustrations, photos or

technical data within this manual. Please retain this manual for your records.

Before starting

Before starting your engine for the first time, install the complete software. Bosch Motorsport

software is developed for Windows operation systems. Read the manual carefully and follow

the application hints step by step. Don’t hesitate to contact us. Contact data can be found on

the backside of this document.

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 be

performed by authorized and qualified personnel approved by Bosch Motorsport.

Caution!

Risk of injury if using the ECP 160 with uncertified combinations and accessories

Operation of the ECP 160 is only certified with the combinations and accessories that are

specified in this manual. The use of variant combinations, accessories and other devices

outside the scope of this manual is only permitted when they have been determined to be

compliant from a performance and safety standpoint by a representative from Bosch

Motorsport.

Notice!

For professionals only.

The Bosch Motorsport ECP 160 was developed for use by professionals and requires in depth

knowledge of automobile technology and experience in motorsport. Using the system does

not come without its risks.

It is the duty of the customer to use the system for motor racing purposes only and not on

public roads. We accept no responsibility for the reliability of the system on public roads. In

the event that the system is used on public roads, we shall not be held responsible or liable

for damages.

Notice!

Drive-by-wire systems

For systems with drive-by-wire additional safety provisions apply. For details please refer to

the document „Safety Instructions for Drive-by-Wire Systems in Motorsport Applications“.

Electric Coolant Pump ECP 160 Technical Data | en 5

Bosch Engineering GmbH Installation Manual 11.04.2018 | V 1.0 |

2 Technical Data

The Bosch ECP 160 coolant pump features a PWM controlled BLDC motor. Its main purpose

are 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 < 30 s

Duration for pressure build up < 1000 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 hours

or 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

6en | Technical Data Electric Coolant Pump ECP 160

11.04.2018 | V 1.0 | Installation Manual Bosch Engineering GmbH

Speed control PWM

Characteristic

Surface coating Anodization

Color Black

Fluid filtering Possible both sides

Pressure

500

1000

1500

2000

2500

3000

6 0 0 0 7 0 0 0 8 0 0 0 9 0 0 0 1 0 0 0 0 1 1 0 0 0 1 2 0 0 0 1 3 0 0 0 1 4 0 0 0

PRESSURE [mbar]

PUMP SPEED [1/MIN]

0 l/min 50 l/min 100 l/min

150 l/min 200 l/min 250 l/min

Flow rate l/min

Pump speed

1/min

0 50 100 150 200 250

6,000 500 410 110 mbar

7,000 670 600 300

8,000 870 810 500 50

9,000 1,080 1,040 740 300

10,000 1,300 1,280 1,000 570

11,000 1,550 1,570 1,290 850 240

12,000 1,820 1,870 1,620 1,120 530

13,000 2,140 2,230 1,990 1,460 900 40

14,000 2,470 2,600 2,370 1,830 1,250 430

Electric Coolant Pump ECP 160 Technical Data | en 7

Bosch Engineering GmbH Installation Manual 11.04.2018 | V 1.0 |

Power Consumption

100

200

300

400

500

600

700

800

900

6 0 0 0 7 0 0 0 8 0 0 0 9 0 0 0 1 0 0 0 0 1 1 0 0 0 1 2 0 0 0 1 3 0 0 0 1 4 0 0 0

POWER CONSUMPTION [W]

PUMP SPEED [1/MIN]

0 l/min 50 l/min 100 l/min

150 l/min 200 l/min 250 l/min

Flow rate l/min

Pump speed 1/min 0 50 100 150 200 250

6,000 72 85 74 W at

13.5V DC

7,000 100 119 115

8,000 136 159 164 120

9,000 167 200 219 183

10,000 209 263 294 267

11,000 271 344 382 365 271

12,000 342 432 487 473 394

13,000 431 550 623 625 563 359

14,000 535 678 772 806 745 562

Connectors and Wires

Pin A 12 V DC

Pin B GND

12 V electrical connector Souriau 8 STA 0-16-75PN 251 (red)

PWM-Signal Souriau 8 STA 2-02-05PN (red)

Pin 1 Free

Pin 2 GND

Pin 3 Signal PWM

8en | Technical Data Electric Coolant Pump ECP 160

11.04.2018 | V 1.0 | Installation Manual Bosch Engineering GmbH

Pin 4 Free

Pin 5 Free

Mechanical connector intake side Wiggins clamps W994-20D 1 ¼”

Wiggins welding flange W903-B20D 1 ¼”

Wiggins connecting sleeve W908-20D 1 ¼”

Mechanical connector pressure side Wiggins clamps W994-20D 1 ¼”

Wiggins welding flange W903-B20D 1 ¼”

Wiggins connecting sleeve W908-20D 1 ¼”

Cable length 500 mm

(1,000 or 1,600 mm opt.)

Air intake (for dirty environment) 19 mm hose support

PWM Signal

Frequency 250 Hz

Voltage Ulow 0 to 0.8 V; Uhigh 3.3 to 18 V

Type of Operation T_on/ Duty Cycle Rotation Speed

Not defined 0 to 0.499 ms / 0 % -

Stop motor 0.5 to 1.0 ms /

0 to 25 %

0 %

First commutation, not

permitted for usage

1.0 to 1.33 ms /

25 to 33 %

0 %

Operation width 1.33 to 2.0 ms /

33 to 50 %

33 to 100 %

Maximum speed 2.0 to 2.5 ms /

50 to 62.5 %

100 %

Not defined 2.501 to 4.0 ms /

62.5 to 100 %

Electric Coolant Pump ECP 160 Installation | en 9

Bosch Engineering GmbH Installation Manual 11.04.2018 | V 1.0 |

3 Installation

The ECP 160 is designed for easy installation and fast swaps. To ensure a smooth run and a

long lifespan of the product the following requirements have to be met.

3.1 Installation Electronic

The electronics require supply air for certain loads and ambient temperatures. Minimum air

speed 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)

(B)

– The support (B) assists in absorbing the radial vibration stresses. The hole should have a

diameter of 23.5 mm.

– The water should drain and the place of installation should be chosen accordingly. The

cooling fins of the electronic must be protected against sludge and must not become

clogged. Don’t cover the cooling fins.

– An optimal air convection around the electrical motor and electronics, as well as the

cables, helps to guarantee smaller load currents and a longer life of the component.

– Mount the whole pump assembly either horizontally or vertically (referred to the

longitudinal axis of the motor).

– The suction nozzle must not be positioned downwards.

– If properly positioned, the pump will deaerate itself after short usage. Nevertheless, make

sure 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 connection

elements can take over the task of vibration decoupling.

10 en | Usage Electric Coolant Pump ECP 160

11.04.2018 | V 1.0 | Installation Manual Bosch Engineering GmbH

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.

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