SmartWire Installation Manual - PDF Format
Contents
1. SMARTWIRE INSTALLATION MANUAL Table of Contents MCE OGG IO th ssc MM YE A EM ERE TW Hie EE Rak e e TES 0 Smart e Packs COME ITS AR MAN RM A KY ME 1 TecnaicalS PES he 2 Becoming Familiar with the SmartWire lnstallation 3 ba e bee ez WA A Ree Sn nee ee GENE Seem EE EMEN LORS et DREN Ee eee IA 3 Examples elit Overview e alkali lies AS elleme sila tam dandini elisa 4 Sari W ie External Fedre S ll ml el n alla a a il a a Wastin b D Z 6 en AEC WV E MOUNU NO e 7 Smat WV re OMS CLIO dt ddr tl 8 PO Wey MINS N diciendo 8 Ground Supply Bm AO ADO BII iaa 8 a ra a a e A A A TE ee Ve ene 8 Elarela ti Geli ie all pulsos 9 OUTPUTS ane yi a Sal alm yal ny lem delim ada me el dm andan ll dll 9 Smart Wire 23 Pin Connector Pinout ccccscecoscoececcscoscaccsccecsecsccscaccsccscecseesceecesescescaecscescecscescescscescuscsens 10 SHAE Vy WSN VEIN E RNA EL EREM ats eet see E E E Ades a nce ea MC PE teed II PE A 11 Datalink Wire Sizer App shownonly nstandaloneapplicatons 12 Connector Requirements 23 Pin Amp Connectors sasuke el A a 13 A o em PRE SEE ent Pritt AR Pete MEN wR RE ee ARE EM AY YO MER ME MY Ree oe 13 Mr e e Re Me e ere Ye 13 TOMO a VK T EA e 13 1616 EC EI E ME A BE ee ne ee eC ee EE PRE PE AMR ee eee YENE 14 C OMe CIOL aran o e e e 15 Comiector Disassembly sist e ein Sealed ai ii yi edi y i d le l yi Da dei l ili r l 16 DOE2. LE ee ola lale ilanl molla Se E A 16 il A A A A AT 17 Sanet a e e bili A A a ed adie ll 17 kl 0 E a PP A ten Me e ae A e 17 FE UOT E e Geek alakali ie Gmail ck ebe eee hari kek ae emel 17 SONO e le ie ccs e l l ll Bn a d a ade le a eso 17 VY TG MEE VV e EE YE MA GN YY GE VD VE ME LE ME EN 18 mame bime L e b O E O RIA nel Mk A m A 20 Programming Manual Release A Dec061 1 Disclaimer Competition Systems Inc Racepak make no representations or warranties of any type with respect to the contents in this manual Competition Systems Inc Racepak disclaim any implied warranties or fitness for any particular purpose Competition Systems Inc Racepak is not liable for any errors contained within or for incidental or consequential damages in connection with the supply performance or use of the hardware and software or this manual Competition Systems Inc Racepak reserve the right to revise this installation and user manual at any time without obligation to notify any person of revisions Warranty Competition Systems Inc Racepak make every effort to insure our products and services are of the highest quality and standards It is our intention to maintain a mutually beneficial and cordial relationship with each and every customer Competition Systems Inc Racepak warrants all merchandise manufactured by Competition Systems Inc Racepak against defects in workmanship or material for a period of six months after the data of purchas
3. gt 0 s 9 w e Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com Channel Pin Chart Sorted by Pin Number PIN CH Type AMP MMM PIN CH Type AMP A 4 Output 20 E Bi 5 Output 20 me BB 22 Output 10 AB 0 1 Output 20 EN B3 7 Output 20 A5 13 Output 10 2 Output 20 15 Output 10 3 Output 20 12 Output 10 so Input Input a Input Input Input f nu MN Btg 12 Imput ground o NM B19 NA Ground ground a B20 On Off Shutdown B 2 Output m the Shutdown pin will turn off power to the Soren unit and all outputs Sorted by Channel Number CH Type PIN AMP E CH Type PIN AMP Input Ato E Output Be 20 Input A18 7 input Be 8 Output B6 20 Grounding the Shutdown pin will turn off power to the SmartWire unit and all outputs Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com 30402 Esperanza Rancho Santa Margarita California 92688 949 709 3303 www KALEPAK com
4. 05C 221 deni ch is bla mini Cross linked wires types 22 AWG SA i or Tefzel higher this ty expen 20 AwG NO Max FT meter nt capal Mis almost alway 18 AWG Max FT 4 AWG Max FT ano TEME Max tousea gara in doubt about the load go up a tapa affect the capaci ee and this includes if in 3 hot environment duration of id stranded vs NM ing Some aircraft Teflon wires have high strand count and are silver plated The 16 AWG NOT ME 2 awe HEND MEET have higher capacity then ir ical copper stranded wires Check ol SEIS for more info on wires AWG Brown and Sharpe gauges and the math 14 AWG ANDO Max FT 1 awc JEER Max FT e the calculator enter the Battery Voltage Maximum Required Current in Amps of the component and the Required Wire Length Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com KN 3 1 Connector Requirements 23 Pin Amp Connectors Wire Wire Selection The socket will accept wire ranging in size from 20 to 16 AWG and 1 5 mm Wire insulation diameter should be a minimum 1 7 mm maximum 2 7mm Smaller wire gauge can be used but will require careful preparation to correctly fit during the crimping process Wire Preparation Wire should be stripped approximately 2 5 1mm Care should be taken during the stripping process to ensure the wire conductor is not nicked scraped or cut Tooling The appropriate crimp pliers must be used to ensure a p
5. firmware version 17 or higher e G2X Pro firmware version 57 or higher If the PC does not meet the above firmware requirement contact Racepak for update details Portions of this manual will call out two installing programming types Standalone AND with a AN Data Recorder In Standalone mode all programming is performed via USB cable between the PC and the SmartWire unit When utilized with Racepak V Net sensors or in conjunction with a Racepak data recorder programming is performed via serial connection between the PC and the data recorder unit Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com fg pp Example Installation Overview In a standard switch device application power is routed to a switch with this switch controlling one device Depending on the device current Amperage requirement this switch controls a relay when triggered allows a large amount of current flow to the device Activating the device requires manually flipping a switch Switch y Water Pump Two Switches One for Water Pump Standard switch installation O ne for Fan Fuse One switch for each device oc Fuse Switch Switch on device on Basic SmartWire installation One switch for each device Two Switches ek i One for Water Pump ni Water P Switch on device on One for Fan Outputs ater Pump Monitors on both devices for e C
6. minimum 4 volts required Minimum trigger voltage requirement 4 Volts Voltages higher than 19 5 are not recommended Wire size 20 gauge wire as switch inputs do not require a large amount of current Outputs The SmartWire unit contains a total of 30 pins for output switching e 8 channels at 20 amp maximum e 22 channels at 10 amp maximum Each output is switched to battery power when its channel parameters are activated All channels have programmable logic control current limiting and overload protection settings Output channels can be wired in parallel to increase current but must be of same type 2 x 20Amp 40 Amp two 20Amp outputs to create a single 40Amp output or 2x 10 Amp 20 Amp two 10Amp outputs to create a single 20Amp output When output channels are wired in parallel special channel logic 1s required DO NOT wire channels of different output together i e do not connect a 20Amp with a 10Amp output When connecting to devices if the manufacturer of the device recommends the main power be connected to the main direct battery power follow the manufacturer s requirement and DO NOT connect items through the SmartWire Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com SmartWire 23 Pin Connector Pinout il EE Pin numbers are located on wire connector SmartWire unit is labeled A or B above each port N 9 ANA
7. of residual indentations Care should be taken to ensure that the wire insulation is not cut or broken during the crimping operation and to ensure that the insulation is not crimped into the wire barrel The ends of the insulation barrel shall be wrapped around the wire insulation leaving no sharp points to damage the rubber wire seal Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com Connector Assembly Retention Fingers J PAS _ NES p 5 SS PY CL Diaphragm Wedge Lock g Mating Seal Shown in Open Position l Verify the wedge lock is in the open position shown above 2 Insert socket and push in straight into the selected circuit cavity as far as it will go shown below 3 Gently pull back on socket wire to be sure the retention fingers are holding the socket ___ Retention Fingers Holding Contact Pull Back on Wire 4 After all wire sockets have been inserted the wedge lock must be closed to its locked position 5 Release the locking latches by squeezing them inward shown below ane a Y amy Fag Aho ae A Mig Y an eh 7 gt Squeeze Locking Latches to Seat Wedge Lock Both Sides Wedge Lock Flush with Housing emi y Jt Ss A I N Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com fg PR Connector Dis
8. output connections will be utilized Do not insert every socket in the connector unless a device will be connected See SmartWire Programming Manual for details Power Supply Main Stud Power is supplied to the Smart Wire unit using the main Battery Y stud on the unit The main power stud will be connected direct to the positive terminal on the battery In situations where a main power cut off switch is required the SmartWire main power should connect to switched side of the cut off switch to ensure power 1s removed from battery as per the rules Wire gauge to be based on maximum wire temperature and the accepted voltage drop for the application See wiring section NOTE The SmartWire is designed as a switching control unit The SmartWire unit is not designed as a main power feed for certain high current items These items include but not limited to ignition and electronic fuel systems Refer to device manual for power requirements AN If the manufacturer recommends the main power be connected to the main direct battery power follow the manufacturer s requirement and DO NOT connect items through the SmartWire Ground Supply Pin A19 A20 B19 A grounding path is supplied by the SmartWire unit using three individual terminals on the two main connectors Pins A19 A20 and B19 must be securely connected to the battery negative terminal or to a secure chassis ground Since each switched device connected to the SmartWire outputs wil
9. 12 13 14 a 5 16 17 18 19 20 21 22 23 i Table 1 Input Pins hardwired direct A Connector PIN Input Channel j i aa z NX J y gt E pe B Connector i AM PIN Input l Channel Defaulted Channel name in Qa software shown below aes SUT Inputs a 6 Table 2 20 Amp Output pins mp lt p ftutted Channel names in PIN Output AMP PIN Output AMP SO ftware shown below Channel Channel Table 3 10 Amp Output pins A Connector B Connector Defaulted Channel name in software shown below PIN Output AMP P cannes 9 21 10 SM1 Output 9 SM1 Output 10 SM1 Output 11 SM1 Output 12 SM1 Output 13 SM1 Output 14 SM1 Output 15 SM1 Output 16 SM1 Output 17 SM1 Output 18 SM1 Output 19 SM1 Output 20 SM1 Output 21 SM1 Output 22 SM1 Output 23 SM1 Output 24 SM1 Output 25 SM1 Output 26 SM1 Output 27 SM1 Output 26 SM1 Output 29 SM1 Output 30 PIN Output AMP P N amet 0 9 12 10 16 9 10 Table 4 Other A Connector B Connector Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com uh SmartWire Wiring The SmartWire unit is equipped with socket terminals and main connectors for the end user to assemble the harness connection to the main unit Typical harness wire gauge will be 16 24 AWG When wiring the Sm
10. Install only the main power and grounds on the SmartWire Connect SmartWire to PC using supplied USB cable Utilizing the SmartWire Programming Installation manual open the configuration file on PC Sync the configuration file with the SmartWire Name program and send each of input Hardwired direct inputs Smart Panel Smart Module and V ee ei e Net items can be programmed at this time if connected Or each can be programmed at a later date 7 Name program and send each of the outputs ensure correct Amperage rating for each device 8 Wire each of the inputs per programmed settings see Hardware Installation Manual 9 Wire each of the outputs per programmed settings see Hardware Installation Manual 10 Test each of the input and output settings Insure each circuit operates as intended Pre Install notes It is recommended to initially install the Main Power and Ground wires first in order to program AN each input and output Once programmed terminate and wire only the necessary connections Do not terminate every connection unless a device will be connected The SmartWire can be installed and used as a standalone unit i e not connected to a data A recorder or is compatible with the following Racepak Data Recorders e V300 firmware version 41 or higher e V300SD firmware version 22 or higher e V500 firmware version 56 or higher e 103 Logger Dash firmware version 15 or higher e 103 Display Only non logger Dash
11. Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com fg p SmartWire External Features Two 23 Pin Amp connectors for e Thirty Outputs Output to all vehicle devices requiring switched power e Twelve Hardwired Direct Inputs Inputs from switches and buttons e Three SmartWire Ground Main grounding for SmartWire unit e One Shutdown Pin Main power shutdown for Smart Wire when grounded Main Stud Main power for SmartWire from battery 11 5 volts minimum for typically operating USB Programming Port Used for programming when no V Net data recorder is connected Note Not used when SmartWire is utilized with a V Net Data recorder Programming will then be performed through the data recorder Switch Port Connection for External Switch Panels Modules if utilized Lights Power V Net Port e Red when powered Connection for V Net Status devices if utilized e Green when no fuses are blown e Red when a fuse is blown Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com k SmartWire Mounting LI Er gt x i 3 470 9 230 5 900 The most important consideration when mounting the Smart Wire unit is selecting the proper location Several issues were covered in the previous section regarding installation The following additional requirements should be taken into consideration 1 Choose a mount
12. ally provided with other Racepak sensor modules and devices To get the most out of the Racepak SmartWire unit it is highly recommended to thoroughly read the entire manual before installation and use of the Racepak SmartWire unit In addition test the SmartWire unit and settings functions before use The race track is not the place to determine something is not working properly k SmartWire Package Contents Smart Wire main unit Connector kit USB programming Cable Programming Software Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com KK 2 J Technical Specifications Output Capacity 125 Amps Current Consumption 180 mA typical operation lt 1 mA in shutdown mode Min Max Power Supply 8 20 Volts Operating Power Supply 12 16 volt automotive applications Inputs 12 hardwired direct voltage triggered gt 2 7V or ground triggered lt 2 5V Outputs 30 8 outputs 20 Amps 22 outputs 10Amps Response 3 0 milliseconds max Programming USB or via V Net when used with a V Net data recorder Dimensions Length 6 5 16 51 cm Width 5 5 13 97 cm Height 2 0 5 08 cm Weight 25 8 ounces 731 4 grams Note All current ratings are for 12 volt operation For 16 volt systems subtract 25 percent Connections e Two 23 pin Ampseal hardwired direct inputs outputs grounds and shutdown pin e One 1 4 x 20 Main Stud main power
13. artWire unit utilize the proper wire type for the application Wire 1s rated both on current and temperature Verify both the correct wire size and casings insulation based on current draw and location of wiring in the vehicle Below are common wire types e GPT wire SAE J1128 GPT e SXL SAE J1128 SXL e GXL SAE J1128 GXL e TXL SAE J1128 TXL e ETFE TEFZEL MIL22579 e PTFE TEFLON MIL22579 Teflon and or Tefzel are the preferred wire type for automotive application Higher quality Teflon or Tefzel wire utilize silver plated conductors General wire selection guidelines e The smaller the wire diameter the greater the resistance and thus lower current capability over a given length In most cases larger gauge wire can be utilized When in doubt as the load increases so should the wire gauge larger wire e Other factors can affect the load capacity of wire besides length o Environment Temperature o Duration of load o Stranded vs Solid wire o Wire plating e Higher capacity wiring utilizes silver plating with a higher strand count and as such will typically have a higher capacity when compared to copper stranded wires The actual maximum current capacity rating of a particular wire size 1s affected by the operating temperature of the wire Wire gauge should be chosen according to the wire temperature limit and acceptable voltage drop In most instances a 3 voltage drop is the recommended limit The temperature of t
14. assembly 1 Do not damage the connector during disassembly As shown below insert small screw driver between mating seal and one of the red wedge lock tabs 2 Gently pry open the wedge lock to the open position 3 While rotating the wire back and forth at least a 1 4 turn in each direction gently pull the wire until the wire socket is removed NOTE The wedge lock should never be removed from the housing for insertion or removal of the sockets Seal Plug All circuits are sealed by a diaphragm in the rubber wire seal During plug connector assembly the diaphragm is pierced as the contact passes through it Unused circuit cavities unless accidentally perforated will remain sealed A seal plug is available and designed to keep out contaminant if the diaphragm is pierced To install seal plug insert seal plug large end first into circuit cavity as far as it will go An insertion tool is not required See below Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com 7 J External Devices Starter Solenoid The starter solenoid in most cases will require a 20 Amp output In some cases the starter solenoid can draw greater than 20 Amps especially during extended cranking periods Due to the SmartWire design the output current can exceed the current fuse limitation for short periods of time typically lt 4 seconds Should the current exceed the fuse setting
15. ckMap View Settings Security Help EL Graph 4 SmartWire SmartWire 1 NS SM1 Output 6 NS SM1 Output 12 NS SM1 Output 18 NS SM1 Output 24 NS SM1 Output 30 Ns 3 l smi Output 1 NS SM1Output 7 NS SM1 Output 13 NS SM1 Output 19 NS SM1 Output 25 NS O SMA Switches N S SM1 Output 2 NS SM1 Output 8 NS SM1 Output 14 NS SM1 Output 20 NS SM1 Output 26 NS SP1 Switches _ N S SM1 Output 3 NS SM1 Output 9 NS SM1 Output 15 N S SM1 Output 21 NS SM1 Output 27 NS aa SM1 Output 4 NS SM1 Output 10 NS SM1 Output 16 NS SM1 Output 22 NS SM1 Output 28 N S te SM1 Output 5 NS SM1 Output 11 NS SM1 Output 17 NS SM1 Output 23 NS SM1 Output 29 N S ion Run Info Weather Gauge User Page 1 User Page 2 User Page 3 Video Video DER NE 52 mare e Plug A SmartWire Plug B Thi ri S ive D LENGTH TXL SAE J1128 TXL Extra thin insula Hey Automotive Cross link Wire rated 49F to 257F us ERS SHOWN BELOW IS THE MAX MENDE FOR EACH SIZE AT THE ABOVE INPUTTED REQUI OO SMALL OF Wi SXL GXL and TXL wires are oil gas acid and generally chemical proof One other note about wire type Teflon and Tefzel are generally very good OR SHOWN LENGTH wire but expensive Always check the ratings Teflon wires with a a temperature rati rar
16. e This watranty applies to the first retail purchaser and covers only those products exposed to normal use or service It does not apply to those products used for a purpose for which said products were not designed or which has been altered in any way that would be detrimental to the performance or life of the product or misapplication misuse negligence or accident Any part or product found to be defective after examination by Competition Systems Inc Racepak will be repaired or replaced Competition Systems Inc Racepak assumes no responsibility for diagnosis removal and or installation labor loss of vehicle use loss of time inconvenience or any other consequential expenses This warranty is in lieu of any other expressed or implied warranties including any implied warranty or merchantability or fitness and any other obligation on the part of Competition Systems Inc Racepak or selling dealer If you have any questions regarding warranty please contact customer service at Competition Systems Inc Racepak 949 709 5555 Introduction Solving the wiring complexity of a modern race car the Racepak SmartWire is a fully programmable power control module While traditional wiring provides control of vehicle electronic components through the routing of single or multi fuse relay and circuit breaker panels the Racepak SmartWire functions as a central command center for all vehicle wiring Based on Racepak s exclusive single cabl
17. e V Net technology the Racepak SmartWire unit is the electronic starting point with a direct main power connection from the vehicle battery to the SmartWire unit Each output 1s user defined both in function current requirement and current limit via a USB connection to the user s PC The design of the SmartWire unit will reduce overall installation weight clutter while contributing to a quicker reacting electronic system through the solid state switching design Manual activation can be achieved through the 12 hardwired direct inputs on the SmartWire unit or through the use of the optional Racepak SwitchPanel or SwitchModule units When utilized a single small cable is routed to the SwitchPanel SmartModule from the Racepak SmartWire unit reducing wiring clutter Users needing additional switch panel capabilities can easily expand through the use of an additional jumper cable to a second Racepak SwitchPanel SmartModule The Racepak V Net compatibility of the SmartWire unit insures a seamless integration with existing Racepak V Net equipped vehicles When connected with existing V Net equipment these items provide additional inputs control modules and instrumentation compared to when utilized as a standalone power control module This manual will guide by step through the installation setup and operation of the SmartWire unit During this process the manual may refer to system worksheets and individual instruction sheets origin
18. er When connected to a V Net data recorder each sensor can be utilized for on off function or logic control of each device connected to the SmartWire Optional Racepak Switch Panels or Switch Modules can also added and connected to the SmartWire for more inputs and or control Optional Switch Panel O A AA o ol o ol To Display Input To Data Voltage triggered switches Dash Recorder A e Optional Switch f e Module Ground triggered l switches Optional Optional Switch ve Inputs Panel Inputs Fuel Pump Sensor Input Water pump Fan Ground o gt W Switch port V Net port triggered o gt Switches O Solenoids SmartWire e Unit a lt a Outputs to gt additional Hardwired Inputs Outputs gt devices gt Voltage o O _ gt triggered Switches s O Battery Input Main stud Ground 3 wires Starter Solenoid Cut Off Ez Switch 0 EF gt Y Main Power from Battery or cut off switch i Battery V Net Data mE Recorder Note Most ignition and ECU systems require a direct main power connection This main power connection must go directly to the battery DO NOT connect the main power wire from these devices to the SmartWire outputs Each of these devices will also have a small wire requiring an ignition switched power source This small wire will connect to an output from the SmartWire Racepak 30402 Esperanza
19. for extended periods 1 e more than 5 10 seconds the output will be deactivated A re try setting is available for both time and number of retries see programming manual for further details Ignition Most ignition systems have two power inputs One is a main power feed for the system normally accompanied with a main ground feed and the other is a switched power designed for an ignition switched power source The SmartWire unit is not designed as a main power feed for the ignition unit The SmartWire is designed as a switching control unit the main power and ground wires from the ignition system should connect directly to the battery and ground ECU or EFI Most engine management or electronic fuel injection systems have two power inputs One is a main power feed for the system normally accompanied with a main ground feed and the other is a switched power designed for an ignition switched power source The SmartWire unit is not designed as a main power feed for the fuel injection system Since the SmartWire is designed as a switching control unit the main power and ground wires from the ignition system should connect directly to the battery and ground Solenoids When connecting the SmartWire to solenoids for items such as trans brake nitrous water injection etc insure the current draw of the solenoid does not exceed the maximum rating for the output When connecting to devices if the manufacturer of the device recommends the main p
20. he wire 1s affected by the ambient temperature air circulation current wire gauge the temperature of any surrounding wires and the covering sheath Wire gauge is based on maximum wire temperature and the accepted voltage drop for the application Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com A AMAA 2 Jh As a general rule the following charts can be utilized Shown values are the maximum recommended length in feet for each wire size at the shown current Amps When planning for both power and ground make sure the wire will support the total calculated length of both runs Max run in feet at 12 volts with a max 3 voltage drop 25C 77F Current Amperage O Max run in feet at 12 volts with a max 3 voltage drop 100C 212F Current Amperage AWG a si ai 21 is 10 08 mw as 97 11 98 66 49 Datalink Wire Sizer App shown only in standalone applications To aid in selecting the correct wire gauge the SmartWire configuration file contains a wire sizer app If you haven t done so yet install the Datalink software The wire sizer app 1s located in the Run Log area This can be found by opening the Datalink program Selecting gt File gt Open Car Configuration gt SmartWire gt Click OK View Organize Panes Locate SmartWire Plug Wire Sizer across the bottom of the window l0 x ink File Edit Telemetry Runlog Tra
21. ing location that allows easy access to the USB port and the main 23 pin wire connectors 2 Avoid mounting the SmartWire directly on or near a heat source on the floor near the exhaust system under the hood etc 3 Avoid mounting the SmartWire unit directly near the ignition box or any other electronic ignition components Maintain a minimum of 18 inches of clearance between the SmartWire unit and any of these type items 4 Choose a location that will allow easy routing of the interconnecting cables Care must be taken to prevent the cables from interfering with the driver safe operation of the vehicle any maintenance or repair services 5 Always mount the SmartWire using the four rubber shock isolators feet provided This will protect the unit from shock and vibration damage 6 Temperature The internal temperature should be checked to ensure no more than a 50 F difference between ambient and internal Internal Smart Wire unit temperature can be viewed in the DatalinkII software while connected to the PC Mounting hole size 1875 476cm The mount feet locations and correct positioning are shown above Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com fg y SmartWire Connections Before terminating the 23 pin connectors it is highly recommended that the DatalinkII software be installed and the SmartWire outputs are programmed This will dictate which
22. l have its own ground path the three connections will carry a low amount of current Each ground requires a minimum 18 gauge wire DO NOT connect the three wires together and run a single wire to ground Three separate correctly sized wires need to be connected to the battery negative post Shutdown Pin B20 A master shutdown 1s incorporated into the SmartWire unit which enables complete power cut off to both the main unit and all outputs When pin B20 is grounded all power between the main stud and the SmartWire will be completely terminated disabled When this function is enabled the Smart Wire unit will draw less than Milliamp of current The Smart Wire unit retains all program settings during this off period Once ground is removed from this pin the unit will resume normal operation Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com 9 gt Hardwired Direct Inputs The SmartWire unit contains 12 pins for direct switch inputs Using the DatalinkII software each input can be programmed to accept a voltage triggered input or a ground triggered input The trigger levels are e Ground Trigger Input is triggered active when the pin connection is grounded From open to a ground or from a voltage to ground e Voltage Trigger Input is triggered active when the pin connection has voltage applied From open to voltage or from a ground to voltage
23. or via direct or through the speed switch When the Park switch is on power will continue to the Relay When the park switch is off power is cutoff to the motor Relay Output SmartWire ome ES U o o O e ia m yo O ul so Home Park a Switch j 4 Direct Only available on output channel 19 one output one input When a direct method is required a reference channel must be selected in order to Park the wipers in the correct location Output channel 19 pin A17 has this ability when its Output Function is configured for Windshield Wiper This method is only available on output channel 19 pin A17 When set to this a Wiper Brake Control Channel becomes selectable This is the channel that will be referenced for the Park position Any input can be used although we will describe the use of a hardwired direct input Connect the Park switch as shown below The input channel settings need to be set appropriately ground triggered as shown below When the Park switch is in the home position the input channel will be grounded This will make the input channel true causing the wiper motor to stop Other inputs channels can be selected for use The input can be either a hardwired direct input or a V Net sensor input not requiring the use of the hardwired direct input Slow i Output 0 0 IS A s Wiper Y SmartWire e Motor O LA F Fast K Input o O Home e a Park O Switch
24. ower be AN connected to the main direct battery power follow the manufacturer s requirement and DO NOT connect items through the SmartWire Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com rj Windshield Wipers The SmartWire unit can operate windshield wiper motors within the following guidelines Most wiper motors have multiple speeds slow and fast The SmartWire cannot be connected to both fast and slow terminals at the same time due to voltage being generated by the internal windings of the wiper motor during operation NOTE The following methods are for common ground wiper assemblies For common positive wiper assemblies the methods would need to be adjusted accordingly 1 Utilizing the factory OEM controller The below method utilizes the vehicles factory wiper controller The SmartWire is used to supply power only to the factory controller The controller handles all wiper motor functions such as the intermittent and motor braking pa SmartWire Js wiper an Motor Factory ee Controller i e 7 Switches Y 3 Switch 2 Utilizing two switches one output Below method uses two external switches e One switch for supplying power to the wiper motor e One switch used to toggle the wiper speed The SmartWire supplies only the power The braking function for the wiper motor 1s handled between the use of the power swi
25. roper secure crimp designed for the 23 pin AMP connector Below are the part numbers for the correct crimper tool Racepak 800 XP CRIMPAMP Racepak AMP Automotive Crimp Tool Tyco 58529 1 PRO CRIMPER III Hand Tool with Die Assembly 58529 2 Extra SmartWire connector and pins are available for purchase Racepak 810 CN AMP23 1 connectors and 25 sockets The ends of the insulation barrel shall be wrapped around the wire insulation leaving no sharp points to damage the rubber wire seal Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com j _ Socket Crimping The sockets should be crimped and then inspected for conditions shown below Wire Strand Ends Must be Wire Barrel Shall be Closed at Seam with Visible in this Area No Strands Protruding or Showing Al pi Wire Strands and Insulation Shall Both be Visible Proper Crimping on wire insulation required for socket to insert correctly Incorrect End should be completely round Correct Completely round NOTE Wire stripping tool jaws may leave corrugated indentations on the surface of the wire insulation This is especially severe with cross linked polyethylene high temperature insulation If these indentations occur at the location of the wire seal leakage may result Insulation surface within 26 mm from the tip of the contact must be smooth and free
26. supply e One USB mini programming when utilized without a compatible data recorder e One Switch CAN bus connection for optional Switch Panel and or Switch Module e One V Net CAN bus connection for optional V Net sensors and or compatible data recorders Outputs are e Monitored for Current Voltage and Status e Protected via user settable limits for over current situations e Protected from short circuits and or thermal overload situations e Function programmable as o Constant On o Flash o Latch On o Single Pulse o Windshield Wiper only available on channel 19 e Time Delayed for On or Off e Outputs are controlled via any combinations of o Switchable inputs o Programmed logic operations Equal to Not Equal to Greater than Greater than or Equal to Less than Less than or Not Equal to o V Net attached sensors Temperatures Pressures RPM etc o Other Outputs Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com KN ehh Becoming Familiar with the SmartWire Installation This manual is designed to provide guidance through the hardware installation of the SmartWire unit Use of this manual along with the SmartWire Software Programming manual will provide complete installation and programming instructions Below 1s an overview of a typical installation and setup Utilizing the Smart Wire Software Programming manual install the DatalinkII software on PC
27. tch and the internal park switch Intermittent operation cannot be done since a single power supply is used Removal of this power source instead of using the on off switch will cause the wipers not to park in the correct position OO NANA Pay Output On On Off Slow e S Wi TQ Switch O f s martWire a A s Wipe Y i Motor z gt Speed gt EXE Off Switch perk a C Home m m Park o Switch j k pan AAA o Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com 9 J 3 Utilizing a relay two outputs Below method uses a single external switch and a relay This method provides the ability for intermittent operation Two SmartWire outputs are required for this method e One output controls a relay for intermittent operation e One output supplies power through the same relay for the main wiper motor power The braking function for the wiper motor is handled between the use of the power relay and the internal park switch Intermittent function 1s controlled by turning the relay off momentary The delay time setting can be determined by the end user and programmed on the output controlling the relay The other output is the main power feed for the motor When the relay is energized the power is fed to the motor via direct or through the speed switch When the relay is de energized power is fed through the park switch to the relay and then to the mot
28. urrent Amps e Voltage e Status on off blown fuse Hardwired Battery Input Inputs Option 1 SmartWire installation One switch for both devices SmartWire Unit Switch on both devices on Ones ir bah Outputs Water Pump Smart Wire can toggle both devices on off at 9 o set timer intervals Hardwired Monitors both devices for Input Battery Input e Current Amps e Voltage e Status on off blown fuse Option 2 SmartWire installation V Net to SmartWire M CA b One switch for manual override V Net sensor used Water for trigger V Net Input Temp V Net Port Module amp Sensor Switch on devices on regardless of temperature 5 5 P SmartWire input Y Unit Switch off SmartWire is programmed to One Switch for both automatically turn both devices on at user set Force both on Outputs Water Pump temperatures based on V Net input SmartWire can toggle both devices on off at set timer intervals gso Hardwired Input Battery Input Sensor failure SmartWire can be programmed to force devices on should temperature go outside sensor readable scale regardless of switch position Monitors both outputs devices for Current Amps e Voltage O Status on off blown fuse Racepak 30402 Esperanza Rancho Santa Margarita CA 92688 USA Phone 949 709 5555 Fax 949 709 5556 www racepak com fsp Option 3 SmartWire installation in conjunction with Racepak V Net data record
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