Tecomotive - tinyCWA - User Manual Charge Cooler Special

Tecomotive - tinyCWA - User Manual Charge Cooler Special
Tecomotive - tinyCWA - User Manual
Charge Cooler Special
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
Features
-
-
tinyCWA controller
Fuse holder
Fuses (7.5A/15A/30A)
Connector 8 pin (controller)
Connector 3 or 4 pin (water pump)
Connector 2 pin (temperature sensor)
Temperature sensor M8 or M12
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 and others 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.
The “tinyCWA” controller can control all CWA type pumps in the
appropriate manner.
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Simple to set up with only one rotary switch
Choose your favorite target temperature in twelve steps
from 0°C to 55°C
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 in Millimeters
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 …)
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Attention: The radiator fan relay output
can only handle a maximum of 0.6 amps!
(That means a minimum of 25 ohms coil resistance)
PI
N
1
2
3
4
5
6
7
8
Color
Connection
Black
Red
Yellow
Black
Orange
Blue
Grey / Red
Grey / Black
Ground GND Battery +
Ignition key +
Additional ground GND for temperature sensor
Signal wire temperature sensor
Radiator fan relay output
Signal wire water pump
Ground wire water pump
CWA200 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/intercooler.
Also it is recommended to mount the
pump as low as possible.
Attention: The main
current flows through
pin 1 and pin 4.
Fuses:
(CWA50 7.5 amps / CWA200 15 amps / CWA400 30 amps)
Please only use wires which are able to handle the current!
PI
N
1
2
3
4
Color
Connection
Red
Grey / Red
Grey / Black
Black
Battery +
Signal wire from controller
Ground wire from controller
Ground GND
Connector: Temperature sensor (2 pin)
PIN
1
2
Page 3 of 13
Color
Orange
Black
Connection
Signal
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.
(M8 Sensor for the CWA50 kit)
Attention: You should position the sensor at the hottest
place of your cooling system.
Basic settings
The controller is pre-programmed 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.
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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
Normal mode
Normal mode
Normal mode
Normal mode
Normal mode
Normal mode
Target
Temperature
0°C
5°C
10°C
15°C
20°C
25°C
30°C
35°C
40°C
45°C
50°C
55°C
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.
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.
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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:





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 – F >> Reset to factory settings
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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.
Tip: 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.
Tip: Write down the 4 digit code followed by the new settings value.
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.
(CWA200) The factory setting here is 600 revolutions or about 15 liters per
minute. The pump itself 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
Page 7 of 13
Rotary switch
position
0
1
2
3
4
5
6
7
8
9
rpm
l/min
gal/h
18
150
340
600
1000
1500
2000
2600
3300
4000
0,5
4
9
15
25
38
52
67
91
104
8
63
143
238
396
602
824
1062
1442
1648
the new setting)
LED Display – Code „3“
There is a seven LED display right above the rotary switch.
In factory setting this will show you the measured temperature.
(Six °C stepsize, first LED lights up at 6°C)
However you are able to change this so it shows you the actual pump
speed.
In step 7 of the setup
procedure, just choose one of
the settings beside.
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)
Delayed shutdown – Code „6“
Boost Feature – Code „9“
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.
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.
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.
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.
Rotary switch
Boost feature
In step 7 of the setup procedure,
position
just choose one of the settings
0
Off
beside.
1
On
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.
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)
Page 8 of 13
Delayed
shutdown
Off
On
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”.
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
Setting
600rpm (15 l/min) (CWA200)
Displays the temperature
Delayed shutdown activated
Boost feature activated
Specifications Water pump
Name:
Pierburg „CWA200“
Dimensions:
100x125x175mm
Operating voltage:
8 to 16 Volts
Current consumption: max. 15A
0,2mA in Standby mode
Speed:
Pump pressure:
Volume flow:
Temperature range:
Page 9 of 13
18 to 4500rpm
0.45 bar
116 l/min
-40°C to +140°C
-40°F to +284°F
Example part numbers:
Pierburg:
7.00294.17.0
BMW:
11 51 7 586 925
BMW old:
11 51 7 563 183
11 51 7 546 994
11 51 7 521 584
11 51 7 545 201
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 10 of 13
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 diagrams
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