Electric Coolant Pump ECP 160

The Bosch ECP 160 coolant pump features a PWM controlled BLDC motor. Its main purpose are coolant systems. The supply voltage is 12 V.

Features

  • > 160 l/min at 1.5 bar (g)
  • 926 g (Pump Unit + Electronic Box)
  • Brushless motor
  • PWM speed controlled
  • Spiral housing additive manufactured

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 from 0 to 160 l/min at 1.5 bar (g) at T_coolant = 95°C

< 1000 ms with pwm-control

Duration for speed build up from 0 to 14,000 rpm at 1.5 bar (g) at T_coolant = 95°C

ECP 160 : not available

ECP 160 EVO : <4500 ms with RPM-control

Coolant compatibility

Automotive coolant fluids

Technical Specifications

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

Speed control

ECP 160 : with pwm-control

ECP 160 EVO : with pwm- & RPM-control,
CAN communication

CAN ECP 160 EVO

Parallel connection between ECU and pump electronics

ECP COMMAND ECP 160 EVO

The controller stores the last plausible transferred value in a non-volatile memory. This value is used in the event of a signal break.

Functional Data

PWM Input frequency

250 Hz

PWM Input duty cycle

Interpreted as time duration of the high level signal

ECP 160

1,330 µs (33 %) = 0 rpm, 1st commutation
1,331 µs (33 %) = 0 % rpm
2,000 µs (50 %) = 100 % rpm
2,500 µs (62,5 %) = 100 % rpm

Values below 1,330 µs and above 2,501 µs are estimated as implausible. Pump will standstill in this case.

ECP 160 EVO

1,468 µs (36.7 %) = 0% rpm
3,600 µs (90 %) = 100 % rpm

Values below 1,468 µs and above 3,600 µs are estimated as implausible. Pump will standstill in this case.

Operation label:

SpeedSetPointMode:
ID1 (CAN-Message 1)
- Mode selection between pwm-signal or rpm control
- 0=SetModeHWPwmUs

pwmPumpSpeedSet:
- ID1 (CAN-Message 1)
- precontrol pwm value in µs

Speed control ECP 160 EVO

Integrated closed loop control for the pump speed

Operation label:
SpeedSetPointMode:
- ID1 (CAN-Message 1)
- Mode selection between pwm-signal or rpm control
- 1=SetModeRpmCtrl

nPumpSpeedSet:
- ID1 (CAN-Message 1)
- demanded rpm value in rpm

nPumpMaxSpeed:
- ID1 (CAN-Message 1)
- demanded rpm value in rpm

Fail Safe Mode ECP 160

1,000 µs (25 %) = 0 rpm
1,330 µs (33 %) = 0 rpm, 1st commutation
1,331 µs (33 %) = 0 % rpm
2,000 µs (50 %) = 100 % rpm
2,500 µs (62.5 %) = 100 % rpm
2,501 µs (62.5 %) = implausible, 0 rpm
4,000 µs (100 %) = implausible, 0 rpm

ECU 160 EVO

Self-reliantly detected missing CAN signal, In case of disconnected CAN line hardware serves PWM as a backup signal.

The pump continues running until the next plausible CAN-signal (or a PWM value). In the event that there is no plausible signal after a power interruption, the pump will start with the last stored fail-safe value and continues running endless.

Debounce time:
- 10 seconds after power on
- 5 seconds during operation

Allowable pump overrun time if CAN and PWM-signal are not available: 1 second

Parameter value
0 µs
1 to 1,467 µs
1,468 to 3,600 µs
3,601 to 4,000 µs

Operation
No operation, pump speed 0 rpm
Non plausible, pump speed 0 rpm
Pump runs according to desired value
Non plausible, pump speed 0 rpm

 

Operation label:

FailSafeMode:
ID1 (CAN-Message 1)
fail-safe value defined in µs

FailSafeSetPointMode:
ID1 (CAN-Message 1)
0=discard (PWM)
1=rpm related

Motor Status ECP160_EVO

Indicated value:

uMotorPowerSupply
ID2 (CAN-Message 2)
power supply motor [V]

MotorPower
ID2 (CAN-Message 2)
Motor power [W]

nMeasuredPumpSpeed
ID2 (CAN-Message 2)
Motor speed [rpm]

Electrical Status ECP160_EVO

Indicated value:

SoftVersion
ID3 (CAN-Message 3)
firmware number in use

tElectronicBoardTemp
ID3 (CAN-Message 3)
temperature electronic board [°C]

uElecPowerSupply
ID3 (CAN-Message 3)
power supply electronic board [V]

HWpwm
ID3 (CAN-Message 3)
gathered hardware pwm signal [µs]

DiagPumpIdling
ID3 (CAN-Message 3)
pump detected as idling,- as empty

DiagPumpBlocked
ID3 (CAN-Message 3)
pump detected as blocked

DiagRedPowerHighPower
ID3 (CAN-Message 3)
Power reduction due to high torque

DiagRedPowerTempStage
ID3 (CAN-Message 3)
Power reduction due to high power stage temperature

CAN ECP160_EVO

Speed: 1Mbaud
Rate: 100ms
Order: little endian
ID1 (CAN-Message 1) 0x360
ID2 (CAN-Message 2) 0x370
ID3 (CAN-Message 3) 0x371

Possible modifications:
CAN-Message identifiers 1-3
on request (0x000 … 07FF),

 

 

Characteristic

Surface coating

Anodization

Color

Black

Fluid filtering

Possible both sides

Pressure

 

Flow rate l/min

Pump speed 1/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

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

Connectors and Wires

Pin A

Power Supply

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

Not connected (NC)

Pin 2

GND

Pin 3

Signal PWM

Pin 4

Not connected (NC)

Pin 5

Not connected (NC)

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

Air intake

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 %

-

Ordering Information

Electric Coolant Pump ECP 160

Incl. Pump Unit and Electronic Box

Order number: F 02U V02 499-02

Electronic Box

Order number: F 02U V02 500-01

Pump Unit

Order number: F 02U V02 501-02

Accessories

Connector Souriau 8STA616-75SN

Order number: F 02U 004 556-01

Connector Souriau 8STA602-05SN

Order number: F 02U 004 678-01

Wiggins connectors

One set for one pump:

2 x clamp

2 x welding flange

2 x connecting sleeve

4 x O-Ring

Order number: F 02U V02 502-01

Clamp

Order number: F 02U 004 503-01

Welding flange

Order number: F 02U 004 504-01

Connecting sleeve

Order number: F 02U 004 502-01

O-Ring

Order number: F 02U 004 506-01

Dimensions

Pump Unit
Electronic Box

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