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CM100HP High Power manual ‖ EN, SV

CM100HP High Power manual ‖ EN, SV
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CM100HP High Power manual ‖ EN, SV

Product catalog summary
Introduction
The document serves as the instruction manual for the CM100HP DC Driven Circulation Pump, suitable for marine and automotive applications. It features a high-quality brushless motor, designed for heating and cooling systems in buses, trains, and large boats.
Specifications
The pump is a centrifugal type requiring priming, equipped with a magnetic drive and brushless motor for durability and continuous operation. It operates over a wide temperature range and includes thermal overload protection, automatic speed regulation during overheating, and safeguards against incorrect polarity and locked rotor conditions. It complies with various EMC standards.
Technical Description
Key components include an aluminum pump housing, PPS GF impeller, and stainless steel shaft. The motor is a permanent magnet brushless type with integrated electronics, housed in anodized aluminum.
Installation
The pump should be installed to remain filled with liquid, ideally positioned low within a closed system. It should not run dry for more than 25 minutes to prevent damage. Full hose diameter should be used on the inlet side to avoid cavitation.
Electrical Installation
The nominal voltage is 27.2V DC, with an operational range of 16-32V. The motor has a current limit of 17.5A and requires appropriate cable sizes. The pump includes built-in protection against incorrect polarity and voltage transients.
Operational Features
The pump features temperature limitation that reduces speed during overheating and automatically restarts when temperatures normalize. It also has low voltage protection, shutting off below 13V and restarting at 15V.
Testing and Compliance
The pump has been tested for vibration and mechanical shock according to ISO standards and salt spray testing according to IEC standards.
Specifications
The document details specifications for the CM100HP AL-1BL pump with two variants: D25 and D38, including dimensions and component descriptions. The pump operates at 27.2V and is designed for marine and automotive applications.
Dimensions
For the CM100HP AL-1BL D25, key dimensions include a diameter of 25 mm and a cable length of 500 ± 10 mm. The D38 variant has a diameter of 38 mm with similar cable specifications. Detailed measurements for various parts are provided.
Components
The document lists components with position numbers, descriptions, and comments. Key components include the motor, magnet housing, impeller, intermediate part, pump housing, O-rings, screws, and a complete bracket, specified with material and size details.
Procedures and Recommendations
The document emphasizes confirming design features, materials, and dimensional data in writing before reliance. It advises contacting local sales representatives for product availability and further information.
Customer Support
Contact information for customer service and support is provided for regions including Sweden, the US, and Australia. The document encourages visiting the Johnson Pump Marine website for more information on worldwide locations, approvals, and certifications.
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Catalog excerpts

CM100HP High Power manual ‖ EN, SV-1

DC Driven Circulation Pump CM100HP H I G H Q UA L I T Y B R U S H L E S S M OTO R C I R C U L AT I O N P U M P S F O R M A R I N E & AU TO M OT I V E A P P L I CAT I O N S

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CM100HP High Power manual ‖ EN, SV-3

Cirkulationspump CM100HP Typiska användningsområden Cirkulation i värme- och kylsystem för bussar, tåg och större båtar etc. Allroundpump där självsugningsförmåga ej krävs. Egenskaper • Centrifugalpump (kräver tillrinning) • Magnetdrivning (ingen axeltätning) • Borstlös motor • Lång livslängd • Konstruerad för kontinuerlig drift • Stort temperaturområde • Inbyggt termiskt överbelastningsskydd • Derating, automatisk varvtalsreglering i samband med överhettning • Varvtalsreglering • Utgående signal för registrering av varvtal • Skydd mot felaktig polaritetsanslutning • Skydd vid låst rotor • Strömbegränsning...

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CM100HP High Power manual ‖ EN, SV-4

> Svenska Installation • CM-pumpar är normalsugande centrifugalpumpar och skall monteras så att den alltid är fylld med vätska. • I ett slutet system placeras pumpen lågt. • Pumpen skall ej köras torr, även om den tål en kortare tids torrkörning. • Max torrkörning 25 min. Efter 25 min. utan vätska slår pumpen ifrån. • Vid torrkörning kan oljud förekomma. • Undvik torrkörning då det alltid medför ökat slitage. • Använd alltid full slangdiameter på inloppssidan. Reducerad slangdiameter på inloppet innebär lägre prestanda och risk för kavitation, vilket kan skada pumpen. • Pumpen har medurs rotationsriktning,...

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CM100HP High Power manual ‖ EN, SV-5

> Svenska Systemtryck -0,2 till 2,5 bar vid +100 °C. Motor och elektronik har ett inbyggt skydd mot anslutning till felaktig polaritet. Livslängd Motorn är konstruerad för en livslängd 40.000 h vid nominell spänning och med en omgivningstemperatur på +40 °C. För att starta pumpen matas nominell spänning på röd (+) och svart (-) kabel samt på vit kabel >2V – 32V. Elektrisk installation Nominell spänning 27,2V DC, mätt vid motorns kabelanslutning. Spänningsintervall: 16 – 32 V Motorn klarar förhöjd spänning eller förhöjd omgivningstemperatur inom ovan angivna gränser men båda påverkar livslängden...

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CM100HP High Power manual ‖ EN, SV-6

> Svenska Tre anslutningsalternativ 1. Trekabelanslutning • Anslut röd och vit kabel till plus pol (+). • Anslut svart kabel till minus pol (-). • Varvtalssignal är tillgänglig i blå kabel 12 ppr (pulser per varv), 0 – 5V. • Pumpen kommer ständigt att gå med fullt varvtal. • Varvtalsstyrning endast möjlig genom variation av inspänningen, 16 – 32V. Pumpen startas då styrspänningen Vin mellan svart kabel (-) och vit kontrollkabel är >2V. Vid spänningen <2V stoppar motorn och går till sleep mode. Strömförbrukningen vid sleep mode är 6,5 mA. Motorns varvtal kan varieras via Vin med spänningar >2V...

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CM100HP High Power manual ‖ EN, SV-7

För att starta pumpen matas nominell spänning på röd (+) och svart (-) kabel samt >2 V – 32V på vit kabel. Analog varvtalsreglering • Vin, Vit styrkabel. Vin 0-10V DC. • 0 till <2V: Ingen funktion, sleep mode. • ≥2 till 9,5V: Pumpen arbetar med konstant varvtal, 2500 – 5750 rpm. Exempel: 6 Vin; 400*4 (6-2)+2500=4100 rpm (se Figur 8, Speed Map, sid 15) 10 till 32V, pumpen arbetar med fullt varvtal. Styreffekt via Vin ca 400 rpm/V. Varvtalsreglering med PWM (Puls Width Modulation) • • Motorn slår automatiskt ifrån då den uppnår skadlig temperatur. Pumpen startar åter då temperaturen har sjunkit...

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CM100HP High Power manual ‖ EN, SV-8

> Svenska Genomförda verifikationstester • Pump/motorenhet vibrationstestad enl. ISO 16750-3; punkt 4.1.2.7 Test VII ”Commercial vehicle, sprung masses”. • Pump/motorenhet testad för mekanisk chock enl. ISO 16750-3; punkt 4.2.2 “Test for devices on rigid points on body and on frame”. • Pump/motorenhet med fot möter vibrationskraven enl. ISO 16750-3; punkt 4.1.2.7 Test VII ”Commercial vehicle, sprung masses”. • Salt spray test enl. IEC 60068-2-52, Serverity 5 enl. ISO 16750-4, Annex A Kod E; “Mounting under body/weel housing, sprung masses”. 28 dygn. • EMC (se Radioavstörning sid. 3) • Kapslingsgrad...

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CM100HP High Power manual ‖ EN, SV-9

> Svenska Figur 5. Temperaturbegränsningar före automatisk varvtalsbegränsning startar

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CM100HP High Power manual ‖ EN, SV-10

Circulation Pump CM100HP Typical applications Circulation in heating and cooling system for buses, trains and boats, etc. All-around pump wherever selfpriming is not essential. Features • Centrifugal pump (must be primed) • Magnetic drive (no shaft seal/ mechanical seal) • Brushless motor • Long service life • Designed for continuous duty • Wide temperature range • Built-in thermal overload protection • Derating, automatic speed control at overheating • Speed control • Tacho out signal • Reversed polarity protection • Locked-rotor protection • Current limitation • Low voltage protection • Dry...

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CM100HP High Power manual ‖ EN, SV-11

> English Installation recommendations • The CM-series pumps are normalpriming centrifugal pumps and should be mounted in a manner that ensures that they are always flooded or else they should be primed before being switched on. In a closed system the pump should be placed at a low point. • The pump should not be run dry, even if it withstands a shorter time of dry running. Max dry running 25 minutes. If the pump is run dry, noise may occur. • Avoid dry running because it will always cause increased wear. • Use full hose diameter at the pump inlet. Reduced hose diameter at inlet gives reduced...

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