Tecomotive - tinyCWA - User Manual Charge Cooler Special
Contents
1. Connector Temperature sensor 2 pin mm Attention You should position the sensor at the hottest place of your cooling system PIN Color Connection 2 Black Ground GND Page 3 of 13 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 Page 4 of 13 Program list Pos Mode Target Description Temperature 0 Testmode PumpOff Fan Off 1 Testmode Pump to min rev Fan Off2. ugr ugn upr uq Current consumption max 20mA 042F for this menu and 1 for the reset about 1 5mA in Standby mode Factory settings Temperature range 40 C to 100 C 40 F to 212 F Name Setting ee i i seme cies Minimum pump value 600rpm 15 l min CWA200 LED Display Displays the temperature Delayed shutdown Delayed shutdown activated Specifications Water pump Example part numbers Boost feature Boost feature activated Name Pierburg CWA200 Pierburg 7 00294 17 0 Dimensions 100x125x175mm BMW Operating voltage 8 to 16 Volts 11517586 925 Current consumption max 15A 0 2mA in Standby mode BMW old 1151 7 563 183 Speed 18 to 4500rpm 11517546994 Pump pressure 0 45 bar 11517521584 Volume flow 116 l min 11517545 201 Temperature range 40 C to 140 C 40 F to 284 F Page 9 of 13 Safety notes Disclaimer 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 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 t
3. aN9 12V Page 11 of 13 GND lt lt battery 12V lt lt switched 12V lt lt o a oN o aN9 12V Page 12 of 13 as Grey Black er En haa Orange rary Grey Red CWASO 4 Pin BMW Version i 1 Ground 2 Signal Ground 3 Signal Positive 4 Battery GND lt lt Black battery 12V lt lt switched 12V lt lt aa Yellow o Black as Orange es EE a A Grey Red not needed S ove CWASO 3 Pin Audi Version 3 GND ia 3 2 Signal Positive 2 Sen 12V 1 Battery Page 13 of 13
4. 2 Testmode Pump to 50 Fan Off 3 Testmode Pump to 100 Fan On 4 Normalmode O C 6 Normalmode 10 C At 5 Celsius over target the radiator fan will come on 8 Normalmode 20 C 9 Normalmode 25 C _ The controlled temperature range is plus minus 5 C 9 F B Normalmode 35 C from the current target temperature D Normalmode 45 C 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 e 0 The pump and the radiator fan are switched off e 1 The pump will run with the setup minimum pump value see Advanced settings Minimum pump value The radiator fan is turned off e 2 The pump will run at 50
5. The radiator fan is turned off e 2 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 Page 5 of 13 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 4 2 0 gt gt Changes the minimum pump value 4 2 3 gt gt Switches the LED display 4 2 6 gt gt Switches the delayed shutdown feature on or off 4 2 9 gt gt Switches the boost feature on or off 4 2 F gt gt Reset to factory settings J O O OOO Page 6 of 13 The Setup procedure step by step 1 Disconnect the main battery connecti
6. Tecomotive tinyCWA User Manual Operation Charge Cooler Special 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 Overview ki O l This way you will always have the right pump speed for any circumstances i n Contents j __ lecOmotive Features tinyCWA controller LED display shows the current pump speed or rough coolant PMA Ia Simple to set up with only one rotary switch Fuse holder OR a Choose your favorite target temperature in twelve steps Fuses 7 5A 15A 30A r from 0 C to 55 C Connector 8 pin controller ZOO ia ee Connector 3 or 4 pin water pump Je _ 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 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
7. an only handle a maximum of 0 6 amps That means a minimum of 25 ohms coil resistance i Color Connection Ground GND 2 Red Battery Ignition key 4 Black Additional ground GND for temperature sensor 6 Blue Radiator fan relay output 8 Grey Black Ground wire water pump CWA200 Connector Water pump 4 pin Water pump installation Info If you do not want to use the delayed In and outlet of the pump are shown shutdown function you can connect the red in the picture wire pin 1 via an ignition switched relay To get a decent coolant circulation the pump should suck the water out of the AREAN I Dema bottom radiator port and then pump it current flows through back into the engine intercooler pin Land pin 4 Also it is recommended to mount the pump as low as possible Fuses CWA50 7 5 amps CWA200 15 amps CWA400 30 amps Attention Please only mount the pump with appropriate rubber dampers Please only use wires which are able to handle the current because high vibration can damage the internal electronics pl Color Connection Placing the temperature sensor 1 Red Battery Grey Red Signal wire from controller AX The temperature sensor is a normal Bosch type NTC used in Grey Black Ground wire from controller NIE many European line production cars It s got an M12x1 5 4 Black Ground GND J i A thread and a copper ring for proper sealing SS 7 MB Sensor for the CWASO kit
8. 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 Page 1 of 13 Installation Installation drawing in Millimeters Changing the screws axle To mount the controller on a front panel you can AED O change the four case screws M3 to the longer ones which come with the kit L 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 13 Connection 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 Attention The radiator fan relay output c
9. e to change this so it shows you the actual pump speed In step 7 of the setup R itch procedure just choose one of position O Speed of the pump 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 the settings beside Delayed shutdown Code 6 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 soeed 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 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 Rotary switch Delayed position shutdown o 0 ignition key is turned off In step 7 of the setup procedure just choose one of settings beside E g If you want to deactivate the delayed shutdown the 5 digit code is 0 4 2 6 0 0426 for th
10. is menu and 0 for the new setting Page 8 of 13 Boost Feature Code 9 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 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 In step 7 of the setup procedure position Boost feature n 0 o just choose one of the settings beside 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 Dimensions 51x51x13mm without connector The controller will then overwrite all the previous settings with the ones in 51x51x24mm with connector the table below Operating voltage 8 to 16 Volts So the 5 digit code for this is ug
11. o 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 Don t lay cables or connectors in areas which are exposed to spray water Don t mount the wires sensor in areas which are exposed to moving or rotating parts 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 GND lt lt Black oaea e S switched 12V lt lt A Yellow m E Orange Grey Red Grey Black
12. on 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 gota 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 gota 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 gota 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 gota 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 digi
13. t 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 ection PM Vein eth In step 7 of the setup position i8 o5 8 a ae procedure just choose one of 1 J10 4 63 the settings beside o 340 9 we E g If you want to change the E 38 B 4 1000 25 396 setting to 600 rpm the 5 digit code is 6 oo s2 824 o a I y 3 0420 for this menu and 3 for 8 3300 91 1442 9 4000 104 1648 Possible settings CWA200 Page 7 of 13 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 abl
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