Tecomotive - tinyCWA – User Manual

Tecomotive - tinyCWA – User Manual
Tecomotive - tinyCWA – User Manual
Operation
Overview
When activated the controller is measuring the coolant temperature and
the rate of increase with the connected temperature sensor. With this data
it then calculates the appropriate water flow and sends a signal to the
pump where the internal pump electronics then set it to the right speed.
This way you will always have the right pump speed for any circumstances.
Contents
-
tinyCWA controller
Fuse holder
Fuses (15A/30A)
Connector 8 pin (controller)
Connector 4 pin (water pump)
Connector 2 pin (temperature sensor)
Temperature sensor M12x1.5
Set of screws (controller mounting) (see next page)
Introduction
The Pierburg CWA200 was the first
electronic water pump for line production
introduced by BMW in 2004. They are now
widely available in used cars and the
aftermarket and got many advantages over
conventional mechanical pumps. Some of
which are the freedom of installation and the independence of engine
revolutions. Also the pumps are very well built and with its brushless
canned motor they are practical maintenance free.
The “tinyCWA” controller can control the pump in the appropriate manner.
Page 1 of 14
Features
-
Simple to set up with only one rotary switch
Choose your favorite target temperature in six steps
from 75°C to 100°C (167°F to 212°F)
LED display shows the current pump speed or rough coolant
temperature
Compact and robust anodized aluminum case
Relay output for the radiator fan (recommend to use)
Delayed shutdown of the pump and the fan after ignition turned off
Manually control the pump speed (e.g. for bleeding or testing)
Installation
Connection
Installation drawing scale 1:1
We made the connection as easy and intuitive as possible. So in general
that means that the same color cables are meant to connect to each other.
A detailed connection diagram can be found on the last page.
After you installed all the wires you can then plug in all the connectors.
Even though the CWA200 is electronically regulated to a maximum load of
15 ampere you should always use the fuse / fuse holder that comes with
the kit.
Connector: Controller (8 pin)
Info: If you do not want to use the
delayed shutdown function you can
connect the red wire (pin 2) to the
ignition switch, too.
Changing the screws
To mount the controller on a front panel you can
change the four case screws (M3) to the longer
ones which come with the kit.
Please only change one at the time. There are little
spacers inside the case which can get out of place without the screw.
(See the picture at the last page)
Of course the controller can be mounted anyway you like. (E.g. with double
sided tape or zip ties …)
Page 2 of 14
Attention: The radiator fan relay output
can only handle a maximum of 0.6 amps!
(That means a minimum of 25 ohms coil resistance)
PIN
Color
Connection
1
Black
Ground GND 2
Red
Battery +
3
Yellow
Ignition key +
4
Black
Additional ground GND for temperature sensor
5
Orange
Signal wire temperature sensor
6
Blue
Radiator fan relay output
7
Grey / Red
Signal wire water pump
8 Grey / Black
Ground wire water pump
Connector: Water pump (4 pin)
Water pump installation
Info: If you do not want to use the delayed
shutdown function you can connect the red
wire (pin 1) via an ignition switched relay.
In and outlet of the pump are shown
in the picture.
To get a decent coolant circulation
the pump should suck the water out
of the bottom radiator port and then
pump it back into the engine.
Also it is recommended to mount the
pump as low as possible.
Attention: The main
current flows through
pin 1 and pin 4.
(CWA200 15 amps / CWA400 30 amps)
Please only use wires which are able to handle the current!
PIN
Color
Connection
1
Red
Battery +
2
Grey / Red
Signal wire from controller
3 Grey / Black Ground wire from controller
4
Black
Ground GND
Connector: Temperature sensor (2 pin)
PIN Color
Connection
1 Orange
Signal
2
Black Ground GND
Attention: Please only mount the pump with appropriate rubber dampers
because high vibration can damage the internal electronics!
Placing the temperature sensor
The temperature sensor is a normal Bosch type NTC used in
many European line production cars. It’s got an M12x1.5
thread and a copper ring for proper sealing.
Attention: You should position the sensor at the hottest
place of your cooling system.
If you use a thermostat the sensor has to be placed in the
“small” cycle!
If you want to bring the pump up to a standstill you should position the
sensor in a place where the coolant always gets hot even without the pump
running.
(In normal operation this is not possible. See the advanced settings for
this.)
Page 3 of 14
Use a thermostat or not?
Tips and Tricks
It is possible to use the pump / controller in combination with or without an
ordinary mechanical thermostat.
It might be a good idea to rethink the whole cooling system while updating
it to the new pump.
Many mechanical parts are not necessary anymore and perhaps could be
removed or replaced.
If you use one just make sure you set the controllers target temperature as
close as possible to the opening temperature of the thermostat.
(Of course you can play with the target temperature a little for eventually
better cooling results.)
A cooling system with a thermostat can benefit from an even shorter
warm-up time and a more exact actual temperature.
A system without one on the other hand got fewer mechanical losses but
the actual temperature can vary a bit more from the target you set.
Removing the old mechanical water pump
Normally you would replace the old mechanical pump for the new one.
So it is a good idea to remove the old one completely to lower the
mechanical losses in your cooling system.
Sometimes it is not so easy to do that because of the way the belt drive was
designed on your particular engine.
In this case you can help yourself by simply removing the impeller of your
old pump and putting it back in place to use it as a simple pulley.
Of course you can use the new pump / controller in conjunction with the
old mechanical one. This way the electrical one will act as a booster pump if
the target temperature was set right.
Page 4 of 14
Even a complete new way how or in what direction the cooling flows
through the engine is possible.
Basic settings
The controller is preprogrammed in a way that should work for most of the
cars right out of the box.
The only things you need to decide is what target temperature and
program you want to run. (See the list beside)
Turn the rotary switch to the associated character. Done.
Using the rotary switch
Right in the center of the controller’s front panel you’ll find the rotary
switch. By turning it to a specific character you are able to set up all the
things the controller can do.
The character that points to the bottom is the currently selected one.
(You will see a little white dot by looking closely.)
Also it helps to use a little screwdriver for turning.
Rotary switch position’s
You can turn the switch to 16 different positions. Every one of them stands
for a different program / target temperature.
Just choose the one that’s best for your application from the following list.
If you don’t know what target temperature would be the best for your
engine, just choose one which is roughly the same as the opening
temperature of the engines thermostat.
Page 5 of 14
Program list
Pos.
Mode
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
Test mode
Test mode
Test mode
Test mode
Normal mode
Normal mode
Normal mode
Normal mode
Normal mode
Normal mode
Pulsed mode
Pulsed mode
Pulsed mode
Pulsed mode
Pulsed mode
Pulsed mode
Target
Temperature
75°C / 167°F
80°C / 176°F
85°C / 185°F
90°C / 194°F
95°C / 203°F
100°C / 212°F
75°C / 167°F
80°C / 176°F
85°C / 185°F
90°C / 194°F
95°C / 203°F
100°C / 212°F
Description
Pump Off / Fan Off
Pump to min. rev. / Fan Off
Pump to 50% / Fan Off
Pump to 100% / Fan On
At 5° Celsius over target the
radiator fan will come on.
The controlled temperature
range is plus minus 5°C / 9°F
from the current target
temperature.
The controller will exit the
warm up mode at 10°C under
target.
General Information
In contrast to most stock systems the controller uses the cooling fan not
only as an emergency but actively and early.
This is intended and strongly recommended to use.
If you turn the engine off while the coolant temperature is in the controlled
range, the controller will perform a delayed shutdown of the pump and fan.
This is a two-step process that runs for a maximum of two minutes.
You find more information on this under “Advanced settings / Delayed
shutdown” later in this manual.
The Test mode
There is no active pump / temperature regulation in this mode.
With the ignition key on, the controller will set the pump to a certain speed
and will hold that until the ignition is turned back off.
This mode can be used for e.g. the first tests or bleeding purposes.
Rotary switch:




„0“ – The pump and the radiator fan are switched off.
„1“ – The pump will run with the setup minimum pump value.
(see „ Advanced settings / Minimum pump value“)
The radiator fan is turned off.
„2“ – The pump will run at 50%
The radiator fan is turned off.
„3“ – The pump will run at full speed.
The radiator fan is turned on.
The Normal mode
In warm up condition (target minus 10°C / 18°F) the controller will run the
pump with the setup minimum pump value.
(See “Advanced settings / Minimum pump value” for this.)
Once the coolant temperature reaches the controlled range (target plus
minus 5°C / 9°F), the controller will regulate the pump speed / temperature
dynamically.
This mode is mostly suitable for use with a mechanical thermostat.
Page 6 of 14
There are six different target temperatures to choose from:






„4“ – Target temperature 75°C or 167°F
„5“ – Target temperature 80°C or 176°F
„6“ – Target temperature 85°C or 185°F
„7“ – Target temperature 90°C or 194°F
„8“ – Target temperature 95°C or 203°F
„9“ – Target temperature 100°C or 212°F
The Pulsed mode
The only thing that differs here in this mode is the way the warm-up phase
is handled.
If the engine is cold, the controller will change the speed of the pump
between the minimum pump value and another even lower value called
“Pulse speed” in a timed cycle.
(See the chapters “Minimum pump value” and “Pulse speed” in the
“Advanced settings” passage for more information on this.)
This way the engine will warm-up much faster as in Normal mode.
Therefore this mode is better suited for cooling systems without a
mechanical thermostat.
Once the warm-up phase is complete the controller will regulate the pump
speed / temperature dynamically just as in the Normal mode.
There are six different target temperatures to choose from:






„A“ – Target temperature 75°C or 167°F
„B“ – Target temperature 80°C or 176°F
„C“ – Target temperature 85°C or 185°F
„D“ – Target temperature 90°C or 194°F
„E“ – Target temperature 95°C or 203°F
„F“ – Target temperature 100°C or 212°F
Info: Of course you can use this mode for cooling systems with a
thermostat, too. But the time the pump spends at “Pulse speed” could be a
bit to long for this. So it might be a good idea to lower the value a bit.
(See “Advanced settings / Pulse mode off-time” for more information on
this.)
Advanced settings
If the preset values the controller is using are not suitable for your
application you are able to change the important ones with some advanced
setup procedures.
The controller will then store all the changes to its onboard memory so that
they are safe even if it loses power.
The Setup procedure
To change any of the advanced settings you have to put in a four digit code
under a certain condition with the rotary switch.
The code uses the numbers 0 – 4 – 2 – … followed by a fourth digit that
represents one of the following settings.
Setting / Code:








Page 7 of 14
0 – 4 – 2 – 0 >> Changes the minimum pump value
0 – 4 – 2 – 3 >> Switches the LED display
0 – 4 – 2 – 6 >> Switches the delayed shutdown feature on or off
0 – 4 – 2 – 9 >> Switches the boost feature on or off
0 – 4 – 2 – C >> Changes the “On-time” the Pulsed mode uses
0 – 4 – 2 – D >> Changes the “Off-time” the Pulsed mode uses
0 – 4 – 2 – E >> Changes the “Pulse speed” the Pulsed mode uses
0 – 4 – 2 – F >> Reset to factory settings
The Setup procedure step by step:
1. Disconnect the main battery connection from the controller. (e.g.
by pulling the controllers plug)
2. Turn the rotary switch to the first digit of the code „0“.
3. Reconnect the main battery connection to the controller.
a. The LED in the middle lights up.
4. Turn the rotary switch to the second digit of the code „4“.
a. You got a 10 second time window to do so.
b. After those 10 seconds another LED will light up.
5. Turn the rotary switch to the third digit of the code „2“.
a. You got a 10 second time window to do so.
b. After those 10 seconds a third LED will light up.
6. Turn the rotary switch to the forth digit of the code „0-F“.
a. You got a 10 second time window to do so.
b. After those 10 seconds the LED’s are going to flash once.
7. Now you have to turn the rotary switch to the new value of that
particular setting. (You find a description of that in the relevant
chapter in this manual)
a. You got a 20 second time window to change the setting.
b. After those 20 seconds the LED’s will flash several times to
show you that the new value was saved correctly.
c. Afterwards the controller goes into normal operation.
Info: The ignition key does not have to be turned on for this.
Tipp: If you plan on changing many settings you should consider putting a
simple on off switch between the battery wire of the controllers plug and
your actually battery + line.
Page 8 of 14
Tipp: Write down the 4 digit code followed by the new settings value you
want to change.
This way you have a nice readable 5 digit code for each change.
Minimum pump value – Code „0“
In this setting you can change the minimum speed of the pump the
controller will allow.
The factory setting here is 1400 revolutions or about 35 liters per minute
(555 gallons per hour) which is roughly the same a mechanical pump would
perform if the engine is in idle. (The numbers apply only to the CWA200)
The pump itself (CWA200) is able to deal with speeds from 18 up to 4500
revolutions per minute. This relates to a flow rate from 0.5 to 116 liters per
minute or 8 to 1839 gallons per hour.
Keep in mind that there should always be enough flow so the temperature
sensor is able to measure the coolant temperature correctly.
The right amount auf minimum flow is tricky to find out. Feel free to
experiment a little with this setting but always observe the actual
temperature.
You can damage your engine permanently if it gets to hot!
Possible settings: (CWA200)
In step 7 of the setup
procedure, just choose one of
the settings beside.
E.g.: If you want to change the
setting to 600 rpm
the 5 digit code is:
“0” – “4” – “2” – “0” – “3”
(0420 for this menu and 3 for
the new setting)
Rotary switch
position
0
1
2
3
4
5
6
7
8
9
rpm
18
150
340
600
1000
1500
2000
2600
3300
4000
l/min gal/h
0,5
4
9
15
25
38
52
67
91
104
8
63
143
238
396
602
824
1062
1442
1648
There is a seven LED display right above the rotary switch.
In factory setting this will show you the actual speed of the pump.
However you are able to change this so it shows you the rough coolant
temperature in 7°C (~13°F) steps from 60°C (140°F) to 102°C (~216°F).
Rotary switch
position
0
1
LED Display
Speed of the pump
Coolant temperature
E.g.: If you want to change the display to show the coolant temperature.
The 5 digit code is: “0” – “4” – “2” – “3” – “1”
(0423 for this menu and 1 for the new setting)
Page 9 of 14
After the ignition key is turned off the controller will check the coolant
temperature once again. If it is still in the controlled range the delayed
shutdown mode will kick in.
This mode is divided in two steps of one minute each.
In the first minute the pump will go to its full speed and the radiator fan will
come on.
In the second step the pump speed is reduced to about 50% and the
radiator fan is turned off again.
After that or if the coolant temperature falls down below the controlled
range, the delayed shutdown feature will quit and the controller / pump
will go into standby mode.
LED Display – Code „3“
In step 7 of the setup
procedure, just choose
one of the settings
beside.
Delayed shutdown – Code „6“
If you don’t need or want this feature you can deactivate it.
By doing so, the controller / pump will go directly into standby mode if the
ignition key is turned off.
In step 7 of the setup
procedure, just choose
one of settings beside.
Rotary switch
position
0
1
E.g.: If you want to deactivate the delayed shutdown
the 5 digit code is: “0” – “4” – “2” – “6” – “0”
(0426 for this menu and 0 for the new setting)
Delayed
shutdown
Off
On
Boost Feature – Code „9“
Pulsed mode Ontime – Code „C“
To calculate the optimal pump speed the controller is measuring not only
the current coolant temperature but also looks at how fast the
temperature is rising.
The Pulsed mode is explained on page 6 of this manual.
If the temperature rises too fast to counteract with the normal control
algorithm the controller will boost the pumps speed to its maximum in
order to get it under control.
But in some few cases this can cause a saw tooth like effect where the
pumps speed is quickly changing from high to low and back again.
If this happens you should deactivate this feature to take it easy on the
pumps life span.
In step 7 of the setup
procedure, just choose
one of the settings
beside.
The factory setting here is about 3 seconds to circulate the coolant just
enough for a quick but safe warm-up.
If this setting doesn’t work for you, you can of course change it.
Possible settings:
Rotary switch
position
0
1
Boost feature
E.g.: If you want to deactivate the Boost feature
the 5 digit code is: “0” – “4” – “2” – “9” – “0”
(0429 for this menu and 0 for the new setting)
The factory setting here is “On”.
Page 10 of 14
The “Ontime” describes how long the controller will hold the “Minimum
pump value” in the Pulsed mode warm-up cycle.
Off
On
In step 7 of the setup procedure,
just choose one of the settings beside.
E.g.: If you want to change
the Ontime to 10 seconds
the 5 digit code is:
“0” – “4” – “2” – “C” – “2”
(042C for this menu and 2 for the new setting)
Rotary switch
position
0
1
2
3
4
5
6
7
8
9
Ontime in
seconds
3
5
10
15
20
25
30
35
40
45
Pulsed mode Offtime – Code „D“
Pulse speed – Code „E“
The Pulsed mode is explained on page 6 of this manual.
The Pulsed mode is explained on page 6 of this manual.
The “Offtime” describes how long the controller will hold the “Pulse speed”
in the Pulsed mode warm-up cycle.
The “Pulse speed” is the pump speed the controller will set in the “Offtime”
cycle of the Pulsed mode warm-up.
The factory setting here is about 30 seconds to circulate the coolant just
enough for a quick but safe warm-up.
If this setting doesn’t work for you, you can of course change it.
The factory setting here is about 280 revolutions or 7 liters per minute to
ensure a quick and safe warm-up. (That’s about 111 gallons per hour.)
Possible settings:
In step 7 of the setup procedure,
just choose one of the settings beside.
E.g.: If you want to change
the Ontime to 10 seconds
the 5 digit code is:
“0” – “4” – “2” – “D” – “2”
(042D for this menu and 2 for the new
setting)
Rotary switch
position
0
1
2
3
4
5
6
7
8
9
Offtime in
seconds
3
5
10
15
20
25
30
35
40
45
Possible settings: (CWA200)
In step 7 of the setup
procedure, just choose
one of the settings beside.
E.g.: If you want to change
the Pulse speed
to 600 rpm
the 5 digit code is:
“0” – “4” – “2” – “E” – “3”
(042E for this menu and 3 for
the new setting)
Rotary switch
position
0
1
2
3
4
5
6
7
8
9
D
rpm
18
150
340
600
1000
1500
2000
2600
3300
4000
Pump OFF
l/min gal/h
0,5
4
9
15
25
38
52
67
91
104
0
8
63
143
238
396
602
824
1062
1442
1648
0
!!! Attention !!!
It is possible to get the pump to a complete stand still with the “D” setting.
In this case there will be no coolant flow whatsoever, the sensor will only be
able to measure the temperature at the spot it’s sits in and the possibility
for building hot spots in the cooling system is very high!
You should only use this setting if you know what you’re doing! We cannot
be held liable for any damages on your car, engine or whatsoever!
Page 11 of 14
Reset to factory settings – Code „F“
Specifications Controller
You can always reset the whole controller to its factory settings.
Name:
Tecomotive „tinyCWA“
In step 7 of the setup procedure, just choose the “1” for this.
The controller will then overwrite all the previous settings with the ones in
the table below.
Dimensions:
51x51x13mm (without connector)
51x51x24mm (with connector)
Operating voltage:
8 to 16 Volts
So the 5 digit code for this is:
“0” – “4” – “2” – “F” – “1”
(042F for this menu and 1 for the reset)
Current consumption: max. 20mA
about 1.5mA in Standby mode
Factory settings:
Temperature range:
-40°C to +100°C (-40°F to +212°F)
Weight:
about 40 grams (1.4 ounces)
Name
Minimum pump value
LED Display
Delayed shutdown
Boost feature
Pulsed mode Ontime
Pulsed mode Offtime
Pulse speed
Page 12 of 14
Setting
1400rpm (35 l/min / 555 gal/h)
Displays the speed of the pump
Delayed shutdown activated
Boost feature activated
3 seconds
30 seconds
280rpm ( 7 l/min / 111 gal/h)
Specifications Water pump
Name:
Pierburg „CWA200“
Dimensions:
100x125x175mm
Example part numbers:
Pierburg:
7.00294.17.0
Operating voltage:
8 to 16 Volts
Current consumption: max. 15A
0,2mA in Standby mode
BMW:
11 51 7 586 925
Speed:
Pump pressure:
Volume flow:
Temperature range:
BMW old:
11 51 7 563 183
11 51 7 546 994
11 51 7 521 584
11 51 7 545 201
18 to 4500rpm
0.45 bar
116 l/min
-40°C to +140°C
-40°F to +284°F
Safety notes
Disclaimer
Don’t lay cables or connectors in areas which are exposed to spray water.
The installation should only be done by experienced or special trained
personnel with the necessary knowledge.
We cannot be held liable for any damages on your car, engine or the
product itself!
Don’t mount the wires / sensor in areas which are exposed to moving or
rotating parts.
General notes
Before you plug in the devices make sure all the cables are wired correctly!
The installation needs special automotive and electrical knowledge.
Improper connection and use can damage your car, the engine or the
product itself.
Installation
Before you start with the installation disconnect the cars battery to prevent
any unintentional short circuits.
Pay attention to any potential safety notes from your car manufacturer.
(E.g. regarding airbags, alarm systems, ECU’s or immobilizers)
Avoid smoking, fire, flying sparks or static electricity charges.
Be careful not to damage any parts (e.g. battery, wires, hoses…) while
drilling holes.
Page 13 of 14
Operation
Any modifications on your car could be against the law.
It is your responsibility to get all the necessary information and permissions
to drive the car legally.
If you drive your car without proper legality and permissions you could lose
your insurance coverage and could be committing a criminal offence.
Current consumption over longer periods of time
The devices are consuming a little bit of current even in standby mode.
If you don’t use them over a longer period of time it is recommended to
disconnect them entirely to not damage the cars battery.
Application
The device described in this manual is only tested with the water pump
“CWA200” made by the “Pierburg Pump Technology GmbH” which is
available at the replacement department of the “BMW AG”.
A functional guarantee can only be given by using this product.
Wiring diagram
Page 14 of 14
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