CLD - Coolant Level Detectors
EGT - Exhaust Gas Temperature
Temperature Probes
Pressure Senders

Using the Aux / Alarm / Relay Output

CLD - Coolant Level Detectors

All MadMan coolant level detectors weather built into the EMS unit or loose use the same electronic principle to detect the presence of coolant.
The detector measures the electrical capacitance of the coolant and can therefore be adjusted to cater for differing probe mounting positions and different cooling system environments (clean / dirty / slimy)
EMS units have a sensitivity function which can be used to compensate for variances in installations.

The brown wire is the CLD input on EMS units (Purple on CLD SA units). This wire is connected to the coolant liquid in one of two ways:

1. By using one of the supplied stainless steel screws screwed into a PLASTIC coolant header tank. This tank should be the main filling tank to the coolant system, have a pressure cap on and should empty completely if a coolant hose is removed from the engine. If this method is used, the header tank should be fitted with the second stainless steel screw (supplied) which should be earthed to the engine block. (grey wire in CLD SA) [Click here for an image]
2. By using a coolant adapter. A coolant adapter is an alluminium or copper pipe (purchased separately) which is fitted to the top coolant hose (leading to the radiator). This adapter has a stud fitted to it. The brown (for EMS) or Purple (for CLD SA) wire is connected to this stud. Water presence in the pipe is sensed by the unit. This pipe should be fitted close to the engine block. [click for image]

Note: On very rare circumstances it is not possible to electrically sense the coolant, in these situations a mechanical float level switch is used. The brown wire on the EMS (Purple on CLD SA) is connected to either of the leads on the float switch and the other lead is connected to EMS earth (Black) or purple (CLD SA). A 21mm hole is required for the float switch to be mounted.

EMS and EGT units have one EGT input channel. This channel can accept either a J or K type thermocouple. EMS and EGT units are preset for K type thermocouples.

MadMan makes and supplies it's own custom probes as follows:

TP 40 – 40mm x 6mm K type thermocouple probe with a 2.2 meter (7.2 ft) Stainless steel braided lead and a 1/8 NPT Brass Compression fitting

TP 60 – 60mm x 6 K type thermocouple probe with a 2.2 meter (7.2 ft) Stainless steel braided lead and a 1/8 NPT Brass Compression fitting.

The probe can be bent to suit the installation as long as the bend radius is at least 18mm. The sensing element of the probe is in the tip, the tube is filled with a ceramic powder and is solid.
Do not cut the braided lead as the wiring is in a fiberglass sheath and is very difficult to clean to reveal the conductors. Rahter tie up any excess cable in a figure 8 pattern and secure with a cable tie.
The conductors are very brittle - do not handle the indivisual strands too much - the connection is best done with a crimp connector.

Temperature Probes - Available from MadMan Dealers

EMS units have two temperature input channels.
They are able to use almost any brand temperature senders for coolant and oil temperature readings, however the EMS units have built in calibration for VDO 50-150 temperature senders permitting these to be used without any further user calibration.
Brand: VDO
Part Number : VDO 323/801/009/001c
Type: Temperature Sender 50-150 Deg C (122-302 Deg F)

Pressure Senders - Available from MadMan Dealers
The EMS unit has ONE pressure input channel - you can change the name tag of the input to suit the application.

Oil / Fuel /Aux Measurement

The EMS units are able to use almost any brand pressure senders for pressure readings, however the EMS units have built in calibrations for VDO pressure senders permitting these to be used without any fuirther user calibration.
Brand: VDO
Part Number: VDO 360/081/029/012
Type: Pressure Sender 0-10 Bar (0-145 Psi)

Turbo Boost

Turbo Boost can be montored using the VDO low pressure sender. The EMS unit will need to be setup to use this sender [Click here for setup instructions]
Brand: VDO
Part Number: VDO 360/081/032/025
Type: Pressure Sender 0-2 Bar (0-30 Psi)

This output has a dual function - in default mode it will enable a louder alarm buzzer to be fitted to the unit, however this output can also be used as a cooling fan control output or dual battery charge* output.
See the instruction manual for details on the setup.
When set up correctly the user can set upper and lower limits for the output to switch at - this enables an electric cooling fan to be switched on and off as needed depending on engine temperature. No more fan switches and wiring - the unit shows a "FAN ON" warning on the screen when the fan comes on.

* By connecting a small automotive relay to a larger high-current relay and setting a temperature cut-in of 60 degrees or there about, the user can have the unit connect a 2nd battery into the circuit when the engine has been running for a while. This prevents the alternator from charging two batteries immediately from cold start up and also disconnects the batteries when ignition is turned off. If the engine is warm then it will charge the batteries together, when cold it will charge the main battery first.

The output is active low - This means that when it is "on" the purple wire will provide an earth path for current.

• To use this output to drive a piezo buzzer (screemer) connect the red wire on the buzzer to +12V DC and the black wire to the purple EMS wire.
• To use this output to drive an automotive relay, connect any one of the relay coil wires to +12V DC and the other relay coil wire to the purple EMS wire.