Emp Op80 User manual

Rev

Rev By

Date

Description of Change

Approved By

7/29/20

Revisions

ECN6044

6/30/21

Revisions

ECN6236

Installation and Operation Manual

OP80 Electric Oil Pump

This manual is effective for aftermarket and OEM

installations of the following part numbers:

Base Part Number

1010115XXX

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.

Engineered Machined Products Inc.

2701 North 30th Street

Escanaba, MI, USA 49829

Phone: +1 (906) 789-7497

www.emp-corp.com

Service@emp-corp.com

Product Overview

Thank you for purchasing the EMP OP80 electric oil pump. Please read through this entire manual before

beginning any work on integrating and/or installing this pump. EMP cannot be held responsible for any specific

use or misuse of this product. The purpose of this manual is to assist you in installing, operating, and maintaining

your OP80 electric oil pump.

Your oil pump is an electronically controlled positive displacement gear pump. The OP80 oil pump features a

brushless DC motor with an integrated motor drive controller. This pump is available in both 12 and 24 VDC

models.

The OP80 pump is capable of delivering up to 8 gal/min (30 L/min) of oil flow. It is capable of operating at system

pressures up to 80 psi (5.5 Bar). This performance allows the pump to handle a variety of fluid transfer

applications. These applications include those with use for motor oils, hydraulic fluids, transmission fluids, and

gear lubes. Current pump models have been optimized for lighter weight oils like ATF. Performance will be

reduced for heavier weight oils.

CAUTION:Do not use this pump for transferring any fluids other than those for which it was designed;

to do so may damage the pump and will void the warranty.

To assure the longest possible service life, it is important that you follow all guidelines as outlined in this manual.

It is challenging to address every possible installation type. EMP is always happy to help in assisting with the

integration or installation of this product. If you are in doubt about anything outlined in this manual, please contact

EMP technical service for assistance at service@emp-corp.com.

OEM Engineers: OEM installations must meet all EMP installation and use guidelines to ensure warranty

coverage. For review of your proposed implementation, contact service@emp-corp.com.

Table of Contents

Product Overview ..............................................................................................................................................2

Introduction........................................................................................................................................................4

Purpose .........................................................................................................................................................4

Service Technician Responsibilities ...............................................................................................................4

Liability Disclaimer .........................................................................................................................................4

Additional Information ....................................................................................................................................4

Technical Help ...............................................................................................................................................4

Warranty ........................................................................................................................................................4

About This Document ........................................................................................................................................5

Warnings, Cautions and Notes.......................................................................................................................5

Definition of Terms.........................................................................................................................................5

Product Safety Warnings ...................................................................................................................................6

Identification ......................................................................................................................................................7

EMP Oil Pump Model Codes..........................................................................................................................8

Technical Information ........................................................................................................................................9

Operation .......................................................................................................................................................9

Specifications.................................................................................................................................................9

Dimensional and Mounting Details ...............................................................................................................10

Sample Performance Chart..........................................................................................................................11

Installation .......................................................................................................................................................13

Locations/Orientations ................................................................................................................................. 13

Plumbing Considerations .............................................................................................................................13

Wiring Practices ...........................................................................................................................................14

Service Parts Replacement .............................................................................................................................14

Fluids Fill .........................................................................................................................................................15

Final Item Checklist .........................................................................................................................................15

Installation Review Checklist ...........................................................................................................................15

Routine Maintenance.......................................................................................................................................16

Troubleshooting...............................................................................................................................................16

Appendix A ......................................................................................................................................................17

Operation Manual R20L Controller Board ....................................................................................................17

Appendix B ......................................................................................................................................................18

Operation Manual R20C Controller Board....................................................................................................18

Product Warranty Registration Form................................................................................................................ 19

Introduction

Purpose

The purpose of the manual is to present information and procedures required to properly install, service, and

maintain your pump assembly.

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.

Additional Information

Access https://www.emp-corp.com/support/ for service software, service bulletins, service manuals, service

drawings, and other documents related to your installed EMP systems and components. First time users may

create a free customer login at http://www.emp-corp.com/account/register/.

Technical Help

Contact EMP Customer Service for technical help at +1 (906) 789-7497 or service@emp-corp.com.

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# +1 (906) 789-7825

warranty@emp-corp.com

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

EMP-Link...... EMP Based Proprietary Serial Data Bus

Ignition Enable.........Signal that commands the controller to turn on/wake-up

OP80 ............. Oil Pump with Integral Controller and EMP- Link or PWM Communications

OP80C .......... Oil Pump with Integral Controller and J1939 CAN Communications or Thermistor Input

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.

Identification

Each component is labeled with a model code, part number and serial number. The model code reflects hardware

configuration options of the component (see the next page). The part number is based on the combined hardware

and software configuration of the component. Each serial number is unique. Provide the component serial

number with all enquiries to EMP technical service, it is used trace the component hardware configuration,

software calibration, date of manufacture, and other manufacturing data.

Example Product Label

Identification

EMP Oil Pump Model Codes

Example: OP80-24V-EA-L

24V

[OEM]

[Cert]

[Suffix]

Component

OP = Oil Pump

Voltage

12V = 12 volt

24V = 24 volt

I/O

Omit if n/a

A = Address Input

C = Temperature Input

B = Address or Temp Input

(Specified in Calibration)

M = PWM High (modulated)

L = PWM Low (modulated)

–––––––––––––––––––––––

Scavenge Flow Rate

In 0.1 gallons per minute

35 = 3.5 gpm (13.2 lpm)

Omit for single stage pumps

Mounting

E = External Mount

C = Cartridge Mount 10

OEM

Omit if n/a

–––––––––––––––––––––––

Pressure Flow Rate

In 0.1 gallons per minute

30 = 3.0 gpm (11.4 lpm)

40 = 4.0 gpm (15.1 lpm)

80 = 8.0 gpm (30.3 lpm)

Orientation (degrees)

A = 0

B = 90

C = 180

D = 270

Certification

Omit if n/a

–––––––––––––––––––––––

Communication

C = CAN

Omit for on/off or PWM

Relief Valve Cracking

Pressure

Omit if n/a

Suffix

Omit if n/a

Denotes model variation

–––––––––––––––––––––––

OP80-24V-EA-L = Oil Pump. Single stage, 8.0 gpm pressure, on/off/PWM communication, 24 Volt External

Mount at 0 degrees, no relief valve, uses PWM Low input for commands.

NOTE: Not every option combination is available.

NOTE: All current pump models are optimized for use with lighter weight oils like ATF. Performance will be

reduced for heavier weight oils.

Technical Information

Operation

Connector, operation, and wiring information are in the appendices, depending on the pump model.

Model OP80 pumps are explained in Appendix A, Operation Manual R20L Controller Board.

Model OP80C pumps are explained in Appendix B, Operation Manual R20C Controller Board.

Specifications

*NOTE: Reference the pump performance charts for the typical performance capability of the oil pump

using a light weight oil.

NOTE: Performance will be reduced at lower operating temperatures when using lower voltage power

supplies and when using heavier weight oils.

Component Construction

Cast Aluminum

Performance

Model: 12V and 24V

Theoretical Displacement 0.468 in3/rev (7.67 cm3/rev)

Flow Capacity Maximum* 8.0 gal/min (30 L/min)

Operating Pressure Maximum* 80 psi (5.5 Bar)

Operating Temperature Maximum (Air) 203 °F (95 °C)

Operating Temperature Maximum (Oil) 212 °F (100 °C)

Operating Temperature Minimum 32 °F (0 °C)*

(*Sub-zero operation is application dependent)

Oil Viscosity Maximum ~5000 cSt

(Current models optimized for lighter weight oils like ATF)

Motor Speed Maximum 5000 rpm

Motor Speed Minimum 500 rpm

Motor Speed Default

4000 rpm (configurable)

Mechanical Connections

Model: 12V and 24V

Suction SAE STOR -10 (7/8-14 UNF-2B)

Discharge SAE STOR -8 (3/4-16 UNF-2B)

Weight

Model: 12V and 24V

Component Weight 9.5 lbs (4.3 kg)

Electrical

Model: 12V

Model: 24V

Input Voltage 9–16 V DC (14 V nominal) 18–32 V DC (28 V nominal)

Operating Current Draw Maximum

25 A

Thermal Protection Auto self-protect shutdown Auto self-protect shutdown

Technical Information

Dimensional and Mounting Details

NOTE:Dimensions are given in millimeters.

Technical Information

Sample Performance Chart

The curves shown in Figure 1, Figure 2, and Figure 3 outline the typical performance capability of the oil pump

using a light weight oil. As can be seen, pump flow capacity increases with increasing pump speed. Power

consumption increases with increasing pump speed and increasing discharge pressure.

NOTE: All current pump models have been optimized for use with lighter weight oils like ATF. Performance

will be reduced for heavier weight oils.

NOTE: The sample performance charts (Figure 1 and Figure 2) were taken using automatic transmission

fluid (Dexron VI) heated to 25 °C and 100 °C, respectively, with an input voltage of 28 Vdc. Figure 3

illustrates the difference in flow versus power consumption between 25 °C and 100 °C temperature settings.

The actual performance of the pump will vary from application to application. The power required to pump

will increase as the oil temperature is reduced and/or for the use of heavier weight oils. Power consumption

will increase with increasing oil viscosity, and will decrease with decreasing oil viscosity. The integrated

motor drive controller will limit the current draw to a maximum of 25 amps. Because of this the maximum

power allowable will be voltage dependent. For example, using a 14V power supply will yield a maximum

pump power of 350 watts which is half that for a 28V power supply. The reduced power will also directly

impact performance at lower temperatures and for heavier weight oils.

Figure 1 – 25 °C Sample Performance Chart

Technical Information

Figure 2 – 100 °C Sample Performance Chart

Figure 3 – 25 °C vs 100 °C Sample Performance Chart

Installation

WARNING: To avoid serious personal injury, possible death, or damage to the vehicle, disconnect the

power supply, main negative battery cable, and/or switch off the battery disconnect switch before

installation or servicing. When working on or near the electric components, ensure battery power is off or

lock out vehicle ignition, so the system cannot activate unexpectedly.

WARNING: To avoid burn injuries, allow time for the engine to cool to a safe working temperature

before removing or installing any components.

CAUTION: To avoid potential damage to the wiring and/or hoses, route all wires and hoses away from

any sharp edges, moving objects, and heat sources.

CAUTION: All wires should be secured every 12–18 inches and anywhere motion could result in wires

rubbing against any other surface. All zip ties must be placed over wire loom/convoluted tubing and not

over bare wires.

Locations/Orientations

•Operating temperature limits must be considered during installation.

•Whenever possible, the pump should be mounted with the wires facing down. Although the pump will run in

any orientation, it is preferred that the pump be mounted in the horizontal orientation. If the pump must be

mounted in a vertical orientation, the wire routing will need to be adjusted. Reference the Wiring Practices

section.

•Select a mounting location as close as possible to the oil supply.

•Ensure there is a minimum of 13mm (1/2”) of clearance to ensure there is no rubbing or interference during

operation.

•Securely attach pump to frame or mounting bracket by using (4) M8-1.25 fasteners. The mounting holes are

tapped to a depth of 16mm. Be aware of the bracket thickness when selecting the fastener length to ensure

a minimum thread engagement of 12mm while not bottoming out in the pump housing. Tighten fasteners to

a torque of 20 N m.

Plumbing Considerations

•Before first usage, it is good practice to pour oil into the pump discharge ports to wet the pumping element.

This will aid in priming of the pump.

CAUTION: Extended running without oil may damage the pump.

The pump interface includes two inlet (suction) ports and two outlet (discharge) ports. Note the discharge ports

are identified with the letter “P”. All ports are SAE J1926-1 straight thread O-ring ports. The suction ports are

size SAE-10 (7/8-14 UNF-2B) and the discharge ports are size SAE-8 (3/4-16 UNF-2B).

•This pump is equipped with flexible porting options. Select and connect one suction port and one discharge

port with the supply and delivery lines, respectively. The remaining two unused ports should then be plugged

with an appropriate fitting.

NOTE:All pump connections rely on an O-ring sealing method, do not use thread sealant or tape.

•For optimal performance, it is recommended that hose or lines be no smaller than 3/4” I.D. The supply hose

(suction) should be kept as short as possible.

•Avoid restrictions such as sharp bends and undersized fittings in lines.

•Avoid routing hoses/lines in areas that would cause chafing. All hoses should be secured to prevent rubbing

against any surfaces.

Installation/Service Parts Replacement

•Ensure all fittings, lines, and hoses are selected based on appropriate ratings for the application

(temperature, pressure, fluid type, etc.).

•It is recommended that the fluid quality meets ISO cleanliness code 20/18/15. This is representative of the

nominal filtration of 20 microns or better.

•It is recommended that a strainer on the suction side of the pump be used. The strainer will keep foreign

matter from entering the pump and reduce the risk of the pumping element seizing up. The strainer mesh

size should be large enough so that it does not cause excessive pressure drop, but fine enough to protect

the pump.

Wiring Practices

NOTE: The use of dielectric grease, such as Dow Corning DC-4, is acceptable as long as the connection is

mated directly after grease application to prevent dirt from being captured by the grease.

•For proper controller operation, the ignition enable line must not be tied to power. It must be supplied from a

separate DC switched source which allows the pump to be turned off before power is removed. Failure to do

so prevents the controller from going through its normal shutdown routine and results in a failure to save

history and diagnostic data.

•The maximum current draw for the OP80 pump is 25 amps. The actual pump current draw varies with oil

viscosity and the pressure required to pump the oil through the system. It is recommended to install a properly

sized fuse, not less than 30A on the power supply line to protect installed wiring.

•Although the pump connector and mating connector are environmentally sealed, care must still be taken to

prevent water from pooling up on the pump connector or the sealing grommet on the pump motor housing.

This can be achieved through proper wire harness routing.

•Route motor lead harness down and away from the pump sealing grommet. Ensure that there is a minimum

of approximately 1.5 inches (38 mm) of straight wire length exiting the sealing grommet prior to changing

wire routing directions.

•Care should be taken to ensure no stress or strain is placed on the interface between the wires and the

connectors else the sealing mechanism could be compromised.

•It is good practice to incorporate drip loops into the wire routing design. Always ensure the connectors are

not located in the bottom of the loop as the water runs off at the lowest point in the harness.

•It is recommended that the pump connector(s) are oriented so that water flows down and past the connectors.

This will prevent water from pooling on the seal between the mating connectors.

•The voltage drop between the battery or power supply and the pump should not exceed 5% of the rated

voltage. This should be verified at the pump’s maximum current draw once all electrical connections are

completed. Systems with excessive voltage drops will yield reduced pump performance.

Service Parts Replacement

The pump does not contain any serviceable components, except for the connectors. For instructions on how to

replace the connectors, reference the Service Parts Replacement section in Appendix A for the R20L connector

and Appendix B for the R20C connectors.

Fluids Fill/Final Item Checklist/Installation Review Checklist

Fluids Fill

CAUTION:Do not use this pump for transferring any fluids other than those for which it was designed;

to do so may damage the pump and will void the warranty.

System fill instructions must be developed, documented, and verified by the system integrator. OEM integrators

must communicate these procedures to the end customer in their maintenance documentation.

Follow these instructions each time the system is drained:

1. Caution must be taken to ensure the system is refilled properly to ensure effective priming of the pump

(For new pumps, pour oil into the pump discharge port to wet the pumping element.).

2. Use care to avoid contaminating oil with debris when working on the system or pump.

Final Item Checklist

•Are all hoses, fittings, and lines appropriately sized?

•Are the oil supply and delivery lines to and from the pump securely fastened?

•Is the pump supplied with the appropriate voltage?

•Is the pump securely mounted?

•Are all wires and/or hoses routed away from sharp edges, moving objects, and heat sources?

•Is the ignition enable on a switched source and not tied to power?

Installation Review Checklist

To determine if the oil pump was successfully installed, reference the Installation Review Checklist for EMP Oil

Pumps, document number 9890094024. This document can be found on the EMP website by searching for the

document number.

Routine Maintenance/Troubleshooting

Routine Maintenance

Frequency

Action

When

checking/filling

vehicle fluids

Ensure fluid levels are correct.

Every oil change

Inspect system for leaks.

If a leak is suspected, before

removing the pump, clean the

area to properly locate the leak

source.

Sample oil and check to ensure

oil meets recommended oil

cleanliness (ISO 20/18/15).

Every three

months or more

often if conditions

are harsh

Visually inspect exterior of pump

for evidence of leaks or damage.

Check wires for wear or frayed

insulation. Ensure all electrical

connections are tight.

Annually

Ensure plumping connections are

tightened to proper torque rating.

Ensure all wires and pin

connections are intact. Inspect

support structure for any damage

or loose hardware.

Troubleshooting

Symptom

Probable Cause

Pump will not run

•Incorrect supply voltage.

•Blown fuse.

•Electrical connection issue.

•Pumping gear seized with

debris.

•Problem with ignition switch.

Pump not

running at

commanded

speed

•This may be normal operation

due to the system design. An

application that has a high

downstream circuit flow

restriction and/or a low fluid

operating temp (increased

fluid viscosity) will result in a

pump reaching its electrical

current limit and will thus roll

back its speed to not exceed

this limit. This speed limitation

is a result of the motor

controller protecting the

electronics from a condition

where excessive heat may

build up in the controller. For

pumps on CAN, the controller

will always provide a status

reason why the motor is not

at commanded speed.

•Using heavier weight oil.

Pump won’t

prime

•

Clogged suction

screen/strainer.

•Inlet circuit leak.

•Outlet circuit is blocked.

•Low fluid level.

•Incompatible fluid.

•Worn or damaged pumping

gear.

Low flow rate

•Clogged suction

screen/strainer.

•Inlet circuit leak.

•Incompatible fluid.

•Worn or damaged pumping

gear.

•Low supply voltage.

Appendix A

Operation Manual R20L Controller Board

Rev

Rev By

Date

Description of Change

Approved By

7/6/20

Revisions

ECN5959

5/10/21

Revisions

ECN6234

Operation Manual

R20L Controller Board

Components

FIL11 Fan

OP3530 Oil Pump

OP40 Oil Pump

OP80 Oil Pump

WP120L Water Pump

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.

Engineered Machined Products, Inc.

2701 North 30th Street

Escanaba, MI, USA 49829

Phone: +1 (906) 789-7497

www.emp-corp.com

Service@emp-corp.com

Product Overview

The R20L controller is used for brushless motor control in EMP fans and pumps. Components are available with

on/off control, PWM speed control, and EMP-Link control (for use with EMP system controllers).

This manual provides information on electrical specifications, connectors, component applications and

troubleshooting.

For assistance with component calibrations and settings, please contact EMP Technical Service at

service@emp-corp.com and provide a serial number for the part in question.