EMP TK1 Manual

Rev
Rev By
Date
Description of Change
Approved By
B
ME
4/29/21
Revisions
ECN7265
C
ME
5/19/22
Revisions
ECN7627
9970023081 Rev. C – 05/19/2022 © 2021 EMP, Inc. 1
Installation and Service Manual
TK1 Thermal Systems with
FIC11 or FIL11 Fans
This installation manual is effective for aftermarket
installations of the following part numbers:
Part Number
2020023067
2020023076
2020023071
2020023077
2020023074
2020023078
2020023075
2020023079

Product Overview
The information contained in this manual is updated periodically. While great care is taken in compiling the information contained in this manual, Engineered
Machined Products, Inc. cannot assume liability for losses of any nature arising from any errors and/or omissions.
The information and specifications contained throughout this manual are up to date at the time of publication. Engineered Machined Products, Inc. reserves
the right to change the content of this manual at any time without notice.
© 2021 EMP, Inc. 2
Engineered Machined Products Inc.
2701 North 30th Street
Escanaba, Michigan 49829
Phone: [phone]
www.emp-corp.com
[e-mail]
Product Overview
The EMP TK1 thermal system is designed to provide auxiliary cooling for water-glycol cooled systems.
The EMP TK1 thermal system can also be applied to any water, glycol, or other fluid system with similar hydraulic
properties for the purpose of cooling the auxiliary system.
The fan type, voltage and airflow direction are shown on the fan product label.

Table of Contents
© 2021 EMP, Inc. 3
Table of Contents
Product Overview ..............................................................................................................................................2
Introduction........................................................................................................................................................4
Purpose .........................................................................................................................................................4
Service Technician Responsibilities ...............................................................................................................4
Liability Disclaimer .........................................................................................................................................4
More Information............................................................................................................................................4
Routine Maintenance .....................................................................................................................................4
Technical Help ...............................................................................................................................................4
Warranty ........................................................................................................................................................4
About This Document ........................................................................................................................................5
Warnings, Cautions and Notes.......................................................................................................................5
Definition of Terms.........................................................................................................................................5
Product Safety Warnings ...................................................................................................................................6
Theory of Operation...........................................................................................................................................7
Operation .......................................................................................................................................................7
Power.............................................................................................................................................................7
Heat Rejection ...............................................................................................................................................8
Plumbing Schematics ......................................................................................................................................10
Electronics Cooling – Low Temperature Applications................................................................................... 10
Auxiliary Engine Cooling – High Temperature Applications .......................................................................... 10
Electrical Schematics ......................................................................................................................................10
System Installation ..........................................................................................................................................11
Heat Exchanger and Fan Orientation ........................................................................................................... 11
Harness Management..................................................................................................................................11
Auxiliary Engine Cooling Installation................................................................................................................12
Location .......................................................................................................................................................12
Installation for larger displacement engines with high coolant flow from engine water pump ........................ 12
Installation for smaller displacement engines with lower coolant flow from engine water pump.................... 12
Auxiliary Electronics Cooling Installation.......................................................................................................... 13
Location .......................................................................................................................................................13
Installation....................................................................................................................................................13
Service Parts Replacement .............................................................................................................................14
Connector Greasing .....................................................................................................................................14
FIC11/FIL11 Fan..........................................................................................................................................15
Shroud .........................................................................................................................................................16
Heat Exchanger ...........................................................................................................................................17
Troubleshooting...............................................................................................................................................18
Final Items.......................................................................................................................................................19
Product Warranty Registration Form................................................................................................................ 20

Introduction
© 2021 EMP, Inc. 4
Introduction
Purpose
The purpose of the Service Manual is to present information and procedures required to properly service and
maintain your cooling system.
Service Technician Responsibilities
Ensure that all safety messages and information messages are read and understood before installation,
maintenance, or repairs are performed. It is important to use caution when service work is performed. Knowledge
of impacted systems and their operation are important before the removal or disassembly of any component.
Liability Disclaimer
EMP cannot anticipate every possible circumstance that might involve a potential hazard. The safety messages
in this document, in related manuals, and on the product are therefore not all inclusive. If a tool, procedure, work
method, or operating technique that is not specifically recommended by EMP is used, you must satisfy yourself
that it is safe for you and for others. You should ensure that the product will not be damaged or be made unsafe
by the operation, maintenance, or repair procedures that you choose.
More Information
Documents and software referenced in this manual are available for download from the support section of the
EMP website, https://www.emp-corp.com/support/.
Routine Maintenance
Routine maintenance schedule and procedures are outlined in service bulletin 9910039031.
Technical Help
Contact EMP Technical Service for technical help at [phone] or [e-mail].
Warranty
Mail, Fax, or Email the completed warranty registration form at the end of the document to:
EMP Advanced Development, LLC
2701 North 30th Street
Escanaba, MI, USA 49829
FAX# [phone]
[e-mail]

About This Document
© 2021 EMP, Inc. 5
About This Document
Warnings, Cautions and Notes
Two headings are used in this document to stress your safety and safe operation of the system. They are styled
with a graphic bullet and bold, uppercase text: WARNING and CAUTION. Warnings highlight risks to
personnel — hazards, unsafe conditions and practices that can result in personal injury or death. Cautions
indicate conditions or practices that can cause damage to components, systems, or other equipment.
A third heading, styled as NOTE, calls attention to additional information about components and procedures
discussed in the document.
Definition of Terms
CAN .............. Controller area network.
CAN Control................Fan motor speed controlled by CAN messages.
EMP-Link Control .......Fan motor speed controlled by EMP-Link messages (for use with EMP system
controllers).
FIC11 ............ 11” fan with CAN communication.
FIL11............. 11” fan with EMP-Link communication.
On/Off Control..........Fan runs when ignition enable signal is present.
PWM Control ............Fan motor speed controlled by PWM signal input.
Temperature Input Control.............Fan controller monitors thermistor input and controls fan motor to a
corresponding calibrated speed.
!
!

Product Safety Warnings
© 2021 EMP, Inc. 6
Product Safety Warnings
WARNING: EMP cannot anticipate every possible circumstance that might involve a potential
hazard. The safety messages in this document, in related manuals, and on the product are
therefore not all inclusive. If a tool, procedure, work method, or operating technique that is not
specifically recommended by EMP is used, you must satisfy yourself that it is safe for you and for
others. You should ensure that the product will not be damaged or be made unsafe by the
operation, maintenance, or repair procedures that you choose.
WARNING: Ensure that all safety messages and information messages are read and
understood before installation, maintenance, or repairs are performed. It is important to use
caution when service work is performed. Knowledge of impacted systems and their operation are
important before the removal or disassembly of any component.
WARNING: Make sure the equipment cannot move before doing any work or diagnostic
procedures on the EMP component, system, or vehicle.
WARNING: When working near electric components, ensure they cannot activate
unexpectedly. Remove power or utilize lock out switches.
WARNING: Use extreme caution when working on systems under pressure (i.e. coolant,
hydraulic fluids, air, fire suppression, etc.).
WARNING: Make sure the work area is ventilated and well lit.
WARNING: Make sure charged fire extinguishers are in the work area.
WARNING: Reinstall all safety guards, shields and covers.
WARNING: Make sure all tools, parts and service equipment are removed from the work
area.
WARNING: Ensure that all system power and ground connection points are torqued to EMP
and/or OEM specifications to prevent system damage. Failure to follow specified torque
requirements can result in loose connections which can damage electronic components and will
void EMP warranty.
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!
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Theory of Operation
© 2021 EMP, Inc. 7
Theory of Operation
NOTE: For exact controller parameters, Contact EMP Technical Service with the serial number of
the component.
Operation
FIC11 systems support on/off, CAN and temperature input control.
FIL11 systems support on/off, PWM and EMP-Link control.
For more information about interfacing with the fan, refer to Service and Installation Manual 11 Inch Axial Fan
Assembly, EMP document 9980036021.
Power
1. Ignition enable signal required
•For 12V system, 9–16 volts.
•For 24V system, 18–32 volts.
•Maximum 5 amps.
•5-amp fuse should be installed on ignition enable line.
2. System (fan) power must be fused at 30 amps.

Theory of Operation
© 2021 EMP, Inc. 8
Heat Rejection
NOTE: Heat rejection curves are for systems with EMP fans.
Inlet Temperature Differential (ITD) = (fluid temperature into cooler - air temperature into cooler)
The performance of the system can vary ±10%.
No external system restriction or airflow recirculation represented in test data. The system must be validated in
the application to determine the affect additional system restriction and airflow recirculation have on
performance.
4000 rpm is the maximum speed setting on 12V TK1.
4600 rpm is the maximum speed setting on 24V TK1.
Depending on ambient conditions and duty cycles, cooler performance exceeding 4600 rpm can be achieved
with 24V systems. Contact EMP to discuss these special cases.
The test results are for fans in puller configuration. Contact EMP for pusher configuration data.
11” Fan Speed
Air Flow Rate (SCFM)
4000
1000
4500
1250
5000
1500
5500
1750
TK1 Heat Exchanger - Corrected Coolant Side Heat Rejection
40F ITD, 50/50 Water/Glycol
EMP Calorimeter - 3/9/2007
0
2
4
6
8
10
12
0200 400 600 800 1000 1200 1400 1600 1800 2000
Air Flow Rate (SCFM)
Heat Rejection (kW)
19.9 GPM
15.0 GPM
10.0 GPM
5.2 GPM

Theory of Operation
© 2021 EMP, Inc. 9
TK1 Heat Exchanger - Coolant Side Restriction
140F Inlet Coolant Temp, 50/50 Water/Glycol
EMP Calorimeter - 3/9/2007
0
0.5
1
1.5
2
2.5
0 5 10 15 20 25
Coolant Flow Rate (GPM)
Coolant Side Restriction (psi)
Coolant Side Restriction

Plumbing/Electrical Schematics
© 2021 EMP, Inc. 10
Plumbing Schematics
Electronics Cooling – Low
Temperature Applications
NOTE: Thermistor for low temperature
applications is to be located on the outlet
side of the TK1.
NOTE: A vented surge tank suitable for use
in electronics cooling circuits is available
from EMP, part number 1370023082.
text
TK1
Thermistor
Inlet
Outlet
Water Pump
Electronics
Surge
Tank
Air Vent
Vented
Vented Auxiliary System Schematic
text
TK1
Thermistor
Inlet
Outlet
Water Pump
Electronics
Degas
bottle
Non-Vented Auxiliary System Schematic
Auxiliary Engine Cooling – High
Temperature Applications
NOTE: Thermistor for high temperature
applications is to be located on the inlet side
of the TK1.
text
Engine
Radiator Thermostat
Engine
Pump
TK1
Thermistor
Inlet Outlet
Water pump
(Optional)
Auxiliary Engine Cooling – High Displacement Engine
Schematic
NOTE: Secondary cooling schematic shows
system plumbed into the vehicle cooling
system in parallel to the main cooling system
for large displacement engines.
text
Engine
Radiator Thermostat
Engine
Pump
TK1
Thermistor
Inlet
Outlet
Water pump
(Required)
Auxiliary Engine Cooling – Low Displacement Engine
Schematic
NOTE: Secondary cooling schematic shows
system plumbed into the vehicle cooling
system in parallel to the upper radiator hose
for low displacement engines.
Electrical Schematics
Refer to the application examples in Service and Installation Manual 11 Inch Axial Fan Assembly for electrical
wiring schematics.