Bosch ECP 160 User manual

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
0
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
0
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)
(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.

Electric Coolant Pump ECP 160 Troubleshooting/Frequently asked Questions | en 11
Bosch Engineering GmbH Installation Manual 11.04.2018 | V 1.0 |
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.
– Cleaning:
– High pressure cleaning and compressed air are not permitted, do not use aggressive
cleaning agents (brake cleaner, etc ...).
– Cleaning with warm water, mild soap and brush is recommended. All entrances and
exits 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.

12 en | Vibration Profile Electric Coolant Pump ECP 160
11.04.2018 | V 1.0 | Installation Manual Bosch Engineering GmbH
6 Vibration Profile
Broadband 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

Electric Coolant Pump ECP 160 Requirements for the coolant | en 13
Bosch Engineering GmbH Installation Manual 11.04.2018 | V 1.0 |
7 Requirements for the coolant
The coolant system may only be filled in the cleaned state and connected to the pump. No
core sand, other production residues or contamination of the pump may be supplied. The
pump may only be operated with commercially available coolants. Bosch Motorsport can’t
issue a release. The chemical resistance must be proven in own tests.

14 en | Requirements for the intake air Electric Coolant Pump ECP 160
11.04.2018 | V 1.0 | Installation Manual Bosch Engineering GmbH
8 Requirements for the intake air
If the pump is operated in a dirty environment, clean intake air must be provided. The intake
air particles must be less than 0.1 mm. The pump has only low intake effect and must not be
obstructed by fine filters during operation.
Do not cover the air outputs.
Air intake
Air output
Air output
Air output

Electric Coolant Pump ECP 160 Disposal | en 15
Bosch Engineering GmbH Installation Manual 11.04.2018 | V 1.0 |
9 Disposal
Hardware, accessories and packaging should be sorted for recycling in an environment-friendly
manner.
Do not dispose of this electronic device in your household waste.
Waste electronic equipment must be disposed of properly according to Electrical and
Electronics Act (ElektroG) and the European WEE directive.

Bosch Engineering GmbH
Motorsport
Robert-Bosch-Allee 1
74232 Abstatt
Germany
www.bosch-motorsport.com
© Bosch Engineering GmbH, 2018