EKP Active Cooling

[KClemente]

Since the popular topic right now is fueling, anyone else try adding active cooling to their EKP's? According to this thread EKP Fuel Module Overheating adding a 40x10mm fan and a small heatsink made the ekp go from "untouchable" to "nicely warm". For basically a couple bucks, this is a good idea. I haven't taken off the side bolster in a while so I don't know about spacing so a relocation may be necessary.

 

[The Banshee]

If somone would make an EKP cooling kit it would sell like crazy. Like many others I have had this problem since installing a single 450 Walboro. I could just spend 800 bucks and get the BPM4 but then I worry about melting the top hats on the fuel buckets. This seems like such a simple solution to a long time PITA problem.

 

[b4llistic]

EDIT: Thanks your finding and reading my post. Unfortunately, Spoolstreet is no longer a neutral platform where we can have honest discussions on subjects and products freely.
For this reason I have deleted all information I posted on the forums.

 

[fmorelli]

Nice. Do we know the component that specifically gets hot? If a flat IC, I might like a peltier junction. Low speed fan should work, amperage draw should be little. Kind of sucks pulling power at the EPK harness, but probably negligible?

I'm about to do some trunk wiring. Finding ignition on is not so easy in the trunk. Turns out exhaust flap we all get rid of is ign on power by the tail lights (different places depending on which N54 bodied car you have) but nice clean harness with 10 amps and one can do a factory plug and be clean.

Please let us know how you proceed.

Filippo

 

[NoGuru]

Where is the location of the EKP? I think I could make this in a few minutes.

 

[NoGuru]

Never mind, found it, and added passive cooling to it. I'm debating if it needs active cooling and if it does, were to up the power from.

But I think passive should be fine. Might just drill some holes to release the hot air.

 

[MoistNapkin]

If somone would make an EKP cooling kit it would sell like crazy. Like many others I have had this problem since installing a single 450 Walboro. I could just spend 800 bucks and get the BPM4 but then I worry about melting the top hats on the fuel buckets. This seems like such a simple solution to a long time PITA problem.

Dont worry about the top hat my friend. I have two bosch044's with Bpm4. They run 13 amps each and the top hat has gained zero heat. I took the fuel level sensor out and ran both pumps through the top hat.

 

[S54ca]

From the images above, I believe the pink sheet sandwiched between the PCBA and aluminum base plate is a thermally conductive gap pad. If correct, then the hot devices are on the bottom of the board (likely the gate driver and power MOSFET's).

Replacing the gap pad with a more thermally conductive one should have a significant effect on the unit's T-rise.

 

[NoGuru]

My heat sinks were too big so I put smaller ones on and did active cooling anyway. I used a 40mm 12v fan and spliced into the power and ground for the fuel pump.

 

[hardparker]

I like the peltier option because you can make it remote. Peltier on the EKP, with tubing to active cooling on the heat exchanger elsewhere.

 

[KClemente]

So another question regarding the EKP, it's usually heat that kills them correct? Do you guys think if we put a real good active cooling solution, maybe we can run a dual pump setup off of the EKP? Gonna look for my laser thermometer and take some temperature readings and get a delta between no cooling and active cooling.

The goal is to run two Walbro 535's (single 450 currently), but if it comes to it, I don't mind running one to a hobbs switch.

 

[derekgates]

Is this a problem for stock fueling or corn?

 

[b4llistic]

EDIT: Thanks your finding and reading my post. Unfortunately, Spoolstreet is no longer a neutral platform where we can have honest discussions on subjects and products freely.
For this reason I have deleted all information I posted on the forums.

 

[typedRew]

My heat sinks were too big so I put smaller ones on and did active cooling anyway. I used a 40mm 12v fan and spliced into the power and ground for the fuel pump.

when can i come over and do this too? lol

 

[NoGuru]

when can i come over and do this too? lol

As soon as quarantine is lifted. It's super easy. I think I could do this in about 30 minutes.

I haven't put the seat back yet to see if it all fits. I may have to 3D print a cover for the fan.

 

[NoGuru]

Does anyone have an EKP that has died or knows what part of the EKP dies when it pulls to may amps?

My thoughts were to see if I can solder an upgraded part in place of the one that dies. Run a Walbro 525 and see if it will work.

 

[MRC-5.56]

There are 2 chips on the EKPM board. The computing chip and the voltage regulating chip. The last one can get pretty hot. It's the chip that has the blue heatsink added.
Normally this chip is cooled through the bottom of the board with a piece of pink heat conducting tape to the mounting plate, and the mounting plate conducts to the car's mounting position.
This works fine for stock operation but with a lpfp pump upgrade, more current gets pulled through the chip and this heats it up.
This heat up leads to higher wear and higher risk of the EKPM shutting down. If your lucky, this means no fuel pressure until it is cooled down.

The lpfp is controlled through PWM. This means the current is always 12v but given in pulses. More pulses = more fuel pumping action.
Temperature variations kill electronics. Your best bet is to keep it as stable as possible. For this reason I have connected a Noctua fan (non-PWM) to the wires that lead to the fuel pump itsself (small black connector wires). This results in low fanspeed at low operation and higher fanspeed at high operation.
Drill some holes in the top and sides of the black plastic to make some airflow possible.
These little fans barely use any power so i'm not worried about current draw in any way.

Is there enough room under the rear seat panel that gets removed to access the EKPM to take advantage of the airflow? Does being sandwiched between the chassis and cushion contribute to the heat? I wonder if relocating the EKPM to the trunk would aid in keeping it cool?

 

[KClemente]

Is there enough room under the rear seat panel that gets removed to access the EKPM to take advantage of the airflow? Does being sandwiched between the chassis and cushion contribute to the heat? I wonder if relocating the EKPM to the trunk would aid in keeping it cool?

Yeah there is virtually no negative space between the ekp and the side bolster. So on a hot sunny day, your ekp already has a headstart on overheating. Ill probably relocate mine to the trunk someday and upgrade the fuel pump wires to a thicker gauge.

 

[fmorelli]

Z4 guys have tons of room - it's in the trunk, passenger-side wheel well. I have a couple EKPM's to do, so ordered up some heat sinks, thermal adhesive, and fans.

Filippo

 

[kcorrie4]

My heat sinks were too big so I put smaller ones on and did active cooling anyway. I used a 40mm 12v fan and spliced into the power and ground for the fuel pump.

Could you please provide detail on how you get power to the fan? No one seems to have any guide on how exactly to do it.