Tecomotive - tinyCWA – User Manual
Contents
1. 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 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 yovr 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 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 ugr ug apn ag Current consumption max 20mA 042F for this menu and 1 for the reset about 1 5mA in Standby mode Temperature range 40 C to 100 C 40 F to 212 F Factory settings Weight about 40 grams 1 4 ounces Setting Minimum pump value Specifications Water pump Name Pierburg CWA200 Example part2. 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 The radiator fan is turned off e 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 e 4 Target temperature 75 C or 167 F e 5 Target temperature 80 C or 176 F e 6 Target temperature 85 C or 185 F e 7 Target temperature 90 C or 194 F e 8 Target temperature 95 C or 203 F e 9
3. 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 e A Target temperature 75 C or 167 F e B Target temperature 80 C or 176 F e C Target temperature 85 C or 185 F e D Target temperature 90 C or 194 F e E Target temperature 95 C or 203 F e 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 Page 7 of 14 Advanced settings If the preset values the controller
4. can only handle a maximum of 0 6 amps That means a minimum of 25 ohms coil resistance PIN Color Connection Ground GND 2 Red Battery Ignition key 4 Black Additional ground GND for temperature sensor Signal wire temperature sensor 16 Bue Radiator fan relay output 8 Grey Black Ground wire water pump Connector Water pump 4 pin 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 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 Red Battery 2 Grey Red Signal wire from controller 3 Grey Black Ground wire from controller Ground GND Connector Temperature sensor 2 pin PIN Color Connection 1 Ground GND Page 3 of 14 Water pump installation 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 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 prod
5. 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 Tips and Tricks 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 Even a complete new way how or in what direction the cooling flows through the engine is possible GO NAMAN fecomotive 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 sta
6. LED will light up 5 Turn the rotary switch to the third digit of the code 2 a Yougota 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 Yougota 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 Yougota 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 number
7. 0 seconds the 5 digit code is O 4 2 C 2 Pulsed mode Offtime Code D 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 factory setting here is about 30 seconds to circulate the coolant just enough for a quick but safe warm up Pulse speed Code E The Pulsed mode is explained on page 6 of this manual 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 280 revolutions or 7 liters per minute to ensure a quick and safe warm up That s about 111 gallons per hour If this setting doesn t work for you you can of course change it Rotary switch Offtime in position seconds by 4 Possible settings CWA200 Rotar A y switch fenton PM Vmin al KO 48 o5 In step 7 of the setup Possible settings procedure just choose one of the settings beside 340 a gogo 5 30g 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 rom the 5 digit code is O 4 pee ng Ka E e NG 6 2000 52 824 8 3300 91 1442 042E for this menu and 3 for 9 4000 104 1648 5 PumpOrf 0o 0 the new setting
8. Tecomotive tinyCWA User Manual Overview ABA Contents mmr aaa o tinyCWA controller cy NN Fuse holder NO Fuses 15A 30A GO O Monge Connector 8 pin controller Ho ba Mie Connector 4 pin water pump nai 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 Operation 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 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 d
9. ing 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 In step 7 of the setup Rotary switch NG Boost feature procedure just choose position one of the settings Ce Off beside E g If you want to deactivate the Boost feature the 5 digit code is O 4 2 9 0 0429 for this menu and O for the new setting The factory setting here is On Page 10 of 14 Pulsed mode Ontime Code C The Pulsed mode is explained on page 6 of this manual The Ontime describes how long the controller will hold the Minimum pump value in the Pulsed mode warm up cycle 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 In step 7 of the setup procedure Rotary switch Ontime in position seconds 0 3 just choose one of the settings beside E g If you want to change the Ontime to 1
10. 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 gt gt Changes the minimum pump value 3 gt gt Switches the LED display 6 gt gt Switches the delayed shutdown feature on or off 9 gt gt Switches the boost feature on or off C gt gt Changes the On time the Pulsed mode uses D gt gt Changes the Off time the Pulsed mode uses E gt gt Changes the Pulse speed the Pulsed mode uses O O O O O O QO O A A A aA aA BR A gt aJa PEN ee PAG Zi 7 gen Re me ee ame NE 9a F gt gt 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 Turn the rotary switch to the first digit of the code 0 3 Reconnect the main battery connection to the controller a TheLEDin the middle lights up 4 Turn the rotary switch to the second digit of the code 4 a Yougota 10 second time window to do so b After those 10 seconds another
11. isplay 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 Installation drawing scale 1 1 Changing the screws E a 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 KAL 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 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
12. nds 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 Mode Target Description a re 0 Testmode Pump Off Fan Off KO AA 12 Testmode 13 Testmode 4 Normalmode 75 C 167 F At 5 Celsius over target the 16 Normalmode 85 C 185 F radiator fan will come on Pump to 50 Fan Off Pump to 100 Fan On 20 C 194 F 11 controlled temperat 8 Normalmode 95 C 203 F ahaa RAE he ee 3 Nera mde aor 2127F ne lus minus 3C Pulsed mode 75 C 167 F i temperature B Pulsed mode 80 C 176 F Pulsed mode a mi The controller will exit the D Pulsed mode 90 C 194 F Warm up mode at 10 C under Pulsed mode 95 C 203 F target Pulsed mode 100 C 212 F 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
13. numbers Bien lens a i daa 7 00294 17 0 Operating voltage 8 to 16 Volts Current consumption max 15A BMW 0 2mA in Standby mode 11 51 7 586 925 Speed 18 to 4500rpm BMW old Pump pressure 0 45 bar 11 51 7 563 183 Volume flow 116 l min 11 51 7 546 994 Temperature range 40 C to 140 C 11517521584 40 F to 284 F 11 51 7 545 201 Page 12 of 14 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 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 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 m
14. odifications 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 il l l Jal Mm Page 14 of 14
15. s 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 Rotary switch l min gal h sai a 118 05 8 In step 7 of the setup procedure just choose one of O 08 OB 2 40 9 143 U 3 600 15 238 the settings beside E g If you want to change the U 4 1000 25 396 6 2000 52 824 0420 for this menu and 3 for 8 3300 91 1442 9 4000 104 1648 setting to 600 rpm the 5 digit code is O a CE si Jes Ch o PES 3 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 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 In step 7 of the setup R itch l magi naka LED Display procedure just choose position one of the se
16. ttings O Speed ofthe pump beside 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 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 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 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 ignition key is turned off In step 7 of the setup procedure just choose Off one of settings beside E g If you want to deactivate the delayed shutdown the 5 digit code is O 4 2 6 0 0426 for this menu and O for the new setting Boost Feature Code 9 To calculate the optimal pump speed the controller is measur
17. uction cars It s got an M12x1 5 thread and a copper ring for proper sealing Attention You should position the sensor at the hottest yf 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 Use a thermostat or not It is possible to use the pump controller in combination with or without an ordinary mechanical thermostat 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
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