cooling mist smart injection controller

8/8/2019 Cooling Mist Smart Injection Controller

1/16

Coolingmist Smart Injection DMS Controller

Technical Reference and Guide

FUNCTION INDEX

Overview..2

DMS PIN OUT 3

Connecting to the Controller ...4

Counters 1 and 2..5

RPM, MAF Frequency.. ..5

0-5V inputs 1-4 ...5

0-400 mv input.5

5 V output6

Virtual Outputs 1, 2, 3 ....6

Setting up your LEDS ....6

Ground outputs 1-5.7

Pulsing the outputs..7

Setting a delay on the outputs.....7

0-5V Output8

0-5V Grid....8

Clamp Output Feature.8

Optional Senders.9

Setting up EGT9

Setting up a failsafe...10

Activating the failsafe based on conditions...11

Things to know .12

Diagrams for Pre-Programmed System

Diesel High Flow Smart Injection ....13

Evolution M Boost + MAF and Failsafe ..14

Universal Boost + RPM and Failsafe ...15

Please take the time to read this entire document

before installing your product/kit. It is also important to

note that we are updating the documentation

daily/weekly with new examples and the latest

information. Software is also updated constantly with

new features. We will be putting the latest software

and flash on our website under our installation menu.

It is recommended that you check to see the date of

the new software release so you can get the latest fixes.

We recommend that you check back to our website to

see the latest details/features. Please read on to see

why we are your best choice. Your smart controller isnot programmed; this technical guide shows you the

concept of how to use the software.

PLEASE NOTE: If you already own a Smart Injection/DMS

controller and see that you dont have the same

features, please contact us for the latest flash/software.

Upgrades are free. We always update this with the

latest software functions so if you have an older unit it

may need flashed to use them. The current version is

1.09 released on 8/12/2008.


2/16

DMS Layout, Software Configuration. 2

There are 20 pins, each of these have different functions. There are 2 frequency inputs which can read

RPM, pulses, etc. There are 4 0-5V inputs, 1 mv input (EGT) a programmable 0-5V output, 5 on/off groun

outputs and 3 virtual outputs.. and much more. The pin out is below. All of the inputs and outputs can b

custom defined.

Its important to note that this document focuses almost exclusively on the elements of the smart

controller, how the controller works and what you can do with it. Due to the fact that there aremillions of applications we will give the basics of how the controller works. We have a 30 page PDF

which has many sample programs that you can get from the CD. Just click the SMART INJECTION

tab after installing the CD.

PLEASE READ ALL INSTRUCTIONS

CAREFULLY AND TEST YOUR UNIT

AFTER YOU PROGRAM IT.

Did you know your can save your MAP to a file so you can

easily import later if you change a setting? If you are in RUN

mode the button below will say EXPORT and you can

export to a file. If you are in Config mode it will say IMPORT

and you can import an existing file. Dont forget to click

SAVE


3/16

Smart injection has 20 pins that have various functions. Care must be taken not to damage the unit due to

mis-wiring. If you fry the unit due to mis-wiring, warranty will not be honored. On the controller you will see

a 1-10 label and 11-20 label, those will match the outputs you see below.

.

Pin Layout.

1: + 12 V Power (Switched ignition). Main System

Power. Always use the 1 amp fuse with this.

2: System Ground. Main System Ground

3: Aux 5 Volt Power. If you have a 5V device, you

can power it with this output. Use a relay if it uses

more than 1 AMP.

4: Gnd Output #1. Switchable ground output. You

can turn this on/off based on a single input or a

combination of upto 3 inputs. Use a relay if it uses

more than 1 AMP.


can turn this on/off based on a single input or acombination of upto 3 inputs. Use a relay if it uses

more than 1 AMP.




more than 1 AMP.




more than 1 AMP.

8: Gnd Output # 5. Switchable ground output. You



more than 1 AMP.

9: 0-5V out. Programmable 0-5V output.

10: Aux Ground. If you need to ground a device

you can use this. Make sure you use a relay if your

device uses more than 1 AMP.

11: 0-5V input #1. Any sensor that gives a 0-5V signal can be

used here. TPS, MAP, MAP are typical. We have Air Temp and

Water Temp probes as wel l. You can define the upper and lowelimits as well.

12: 0-5V input #2. Any sensor that gives a 0-5V signal can be used

here. TPS, MAP, MAP are typical. We have Air Temp and Water

Temp probes and EGT amplifiers as well. You can define the

upper and lower limits as well.

13: 0-5V Ground (optional). If your 0-5V sensor needs a ground

you can use this. If you are using a sensor from your vehicle, you

will not need to use this.



Temp probes as wel l. You can define the upper and lower limits a

well.



Temp probes as wel l. You can define the upper and lower limits a

well.

16: 0-5V Ground (optional). ). If your 0-5V sensor needs a ground

you can use this. If you are using a sensor from your vehicle, you

will not need to use this.

17: Millivolt input +. This is our Millivolt + input. Its a millivolt port

If you have a different sender that has a range anywhere

between 0 400 mV you can use this as well (you can user define

18: Millivolt Input . This is our Millivolt - input. Its a millivolt port. I

you have a different device that has a range between 0 400 mV

you can use this as well (you can user define).

19: Counter #1 Frequency (Square Wave) counter. Range of 2 h

to 20 Khz. RPM, MAF, etc.

20: Counter #2 Frequency (Square Wave) counter. Range of 2 h

to 20 Khz. RPM, MAF, etc.

VIRTUAL OUTPUTS:

Virtual Output #1

Virtual Output #2

Virtual Output #3

These outputs do not turn any devices on and do not have a pin attached

but they can be used to set a condition or a flag that you can reference in

any of your outputs, leds, etc. This will be detailed later.


4/16

Connect the software to Vari-Safe. In the file menu click controller>>>connect.

Make sure you have your serial cable OR USB> Serial converter and have connected to

your windows based laptop or desktop. For obvious reasons you must have 12V power

and ground to the Smart Controller.

Once you do that a new box will appear. This box contains the available ports on your

computer. You will need to choose the 1 that is assigned to your serial port. If you

dont know, you can guess, if you choose the right one, our system will respond. If no

ports show up, your computer is not setup correct. Choose the port and click Connect.

Choose your COM Port.

If your connected the controller version # will appear AND your computer will beupdating the update box. (See image above)

Configuring the software. 4

Click on the configuration button to put the system in

configuration mode. You must click this every time

you wan to make a change. If you dont click this,

you can View the configuration, but you cant change

it. Once you click the save button, the system

updates and you must click this button again if you

want to configure another input or output.

TIP: If your computer does not

have a serial port (9 pin RS232),

you will need to purchase a USB

to Serial Converter at your local

electronics store or on-line.


5/16

Counters 1 and 2 5

Counters #1 and #2 are designed to read the HZ of an input

This signal can be any hall effect signal, RPM/TACH or

FREQUENCY such as MAF . These can be custom sensors as

well. Once you are in config mode setup what you want.

you are doing RPM, choose 4, 6 or 8 cylinder. If you have

something other than a 4, 6 or 8, you can choose user defined

If you have a GM HZ MAF Sensor you can set the min and maxrange (200 to 2000 HZ) or any custom range you want. The

range of our high speed counters are 2 HZ to 20 KHZ. If you

decide to setup the counters, remember you are simply

reading the information into the Smart Controller. Later we

can activate an output based on the readings. We will show

you how to do this later on.

0-5 Volt Inputs 1-4

0-5V inputs 1-4 can read any sensor that gives a 0-5V reading. You can also g

a 12V input as well.

For example, if you have a MAP sensor that gives a 0-5V, you can set that up

You can do a user defined and set the MIN/MAX boost. If you dont know th

MIN/MAX, choose MAP from the dropdown box and it wi ll reference 0-5V.

You can use any sensor with a 0-5V output, this includes air temp senders, wa

temp sensors, flow sensors, etc. You can also use a 12V signal from somethin

such as a boost switch, pressure switch or throttle switch.

0-400 MV input

If you have a special sender that uses millivolts (some flow sensors

do) you can set any range between 0 and 400 MV. To use EGTplease purchase our EGT amplifier to use with your EGT probe.

Once you click the mv configuration button you get

options, in this case the person setting this up has a flo

sensor that gives a millivolts output from 30 MV to 160,

we set that range in the boxes


6/16

5V power output

Pin #3 on the smart controller is a dedicated 5V power supply. You cannot configure this, it

always has 5V. This is for low power devices. If your device draws more than 1 AMP use a

relay. You can use things such as a low level fluid switch, on/off switch, status monitor, boost

switch, air temp, water temp sender or any other low power device.

Virtual Outputs

What are Virtual Outputs and why do you need them? You may never use them but just in case we

have programmed them for you. The concept is simple, you can use these to setup a conditional

flag that you can reference on any of your outputs or leds.

We setup 2 conditions on virtual output 1.

You can setup as many as 3. In our case

configured the virtual output to be true if 0-

5V input #1 is between 2 and 5 and the MV

input is greater than 49. If those conditions

are true the value will be 1 otherwise it will be

zero. Later we will reference this in ground

output #1 to illustrate this simple concept.

The Pulse Output box has no effect on

virtual outputs, it only has an effect on real

digital outputs that we will discuss shortly.

Setting up the LEDS

In the above examples we have LED 3, 2 and 1 setup to do different things. LED 3 is going to blink fas

when the MAP sensor (0-5V input 1)>3. When the MAP sensor =5 it will be solid. All other times will be

off. LED 2 is setup to blink slow when the 0-5V output is less than 1 and will be solid (ON) when the 0-5V

greater than 4.5V. LED #1 will be off when Virtual Output #1 is off and will go solid (ON) when the Virtu

Output #1 conditions are all true.


7/16


8/16

0-5 Volt Output. 8 X 8 Grid 8

The example to the left sets up a 0-5V output based

on a single input. In this case we are using frequenc

as the input. The input1 MIN (250 in this case) and

input 1 MAX (2000 in this case) are the subset of therange you wish to convert to a 0-5V.

The scale MIN is how the system will internally

reference the value. For example, if you put 0 and

at 5 volts it will show 5. If you prefer dutycycle, you

can put 0 and 100 and at 5 volts it will show 100%. T

% out at min is the scale you wish the system to start

and the % out at max is the max you wish to output

0-5V output based on a SINGLE input. This can be any input, RPM, Frequency, EGT, etc.

0-5V out ut based on 2 in uts. This can be an 2 in uts.

In this example the only difference to

the above is the additional input. In

this case we used RPM and MAP

ensor that we setup to 30 PSI. In our

case 5V from the MAP sensor was 30

PSI so we user defined it from 0-30. In

the cells we chose to use a 0-100%

dutycycle, The dutycycle will be

converted to a 0-5V output and you

can send to a progressive controller

(such as vari-cool) or for your ownuse. The 0-5V output is pin #9. You

can define the entire range of both

the inputs and the 0-5V output.

Further more, you can clamp the 0-

5V output to any dutycycle based on

any input value if you wish.

Clamping the output. (If you have a need)

You may have a need to clamp the 0-5V output. For example, in this case we set it up that if virtual outpu

#3 is active then clamp the 0-5V output to 0. We could have chosen any number between 1 and 100 (or

what ever you set the max range of the output to). Why would we do this? Lets say you are using a

progressive controller to control your pump with this 0-5V signal, but you have one of the outputs

programmed to detect that you are out of fluid. You can turn the entire system off by setting the dutycyle

to zero under those conditions.


9/16

Failsafe: Detecting a blocked Jet or hardware failure. 9

This feature requires coolingmist status monitor ($52.95) or if you have your own heavy duty pressure

switch you can use it. We recommend ours since its tested with high pressure and methanol. If you

can imagine it, you can likely do it with the Smart Controller. For this feature look at the diagram a

the end of this document labeled Smart Injection with RPM/Boost (Progressive 2d). We will show you how

detect blockage or hardware problem and how to fine tune it for your vehicle. NOTE: this is just one examplYou can choose to use a flow sensor or something completely different.

In the example to the right we set up 0-

5V input #1 for the status monitor and

0-5V input #2 for the float switch. The

smart controller will know at all times if

there is pressure in the line or if you ar e

out of water. You must program the

unit to activate a failsafe under failure

condition.

Below we setup virtual output #1 To detect hardware failure. Condition #1 checks voltage on 0-5V in 1. If its less than

3 we know for sure that there is no pressure in the line. In reality if there is pressure it will show 4.8 or 4.9 or 5.0. If there is

no pressure it may say .1 or 0 or .12. It makes it easy to just say less than 3 volts. Condition 2 says AND the 0-5V output

is less than 40%. We chose 40% because in our case we would be concerned if we have no pressure in the line when

we are at 40%. You choose a number that fits your situation. We setup virtual output #3 to determine if we are low on

fluid or if we have a clog. Condition #1 checks the 0-5V output to see if its less than 15%. If condition 1 is true it looks

at condition 2 which checks to see of the 0-5V input #1 is > 3 volts. If so we know there is a clog. You should not have

pressure in the line when you are not activating. Condition #3 is an OR condition. Your low level fluid switch is

attached to 0-5V input #2. In otherwords if there is a clog virtual output #1 sets a true condition (1). If you are low on

fluid OR you have a hardware failure (hardware failure is determined because there should be pressure in the line but

there is not) virtual output #3 sets a true condition (1). We did not use virtual output #2, however we could haveintegrated more conditions. Virtual outputs do not use any Input/output so are ideal for setting flags. You could set

the same conditions on your 5 outputs. Infact, in the next section you wil l see how we reference the virtual outputs in

the actual outputs.

Condition 3 for virtual out ut 3

Note: We set a 3 second delay on

the clog feature. Your status monitor

should be as close to your nozzle as

possible. Pressure can remain in the

line for a second or 2 after the system

stops. You can set this delay to suit

your needs.


10/16

Failsafe: Activating your failsafe based on conditional situations 10

Ground Output #1. Not part of the failsafe, but we

open the water solenoid by when the 0-5V output

reaches 20%. You connect solenoid ground to your

output and tell the output to connect the ground.

Ground Output #2 Condition #1 simply checks

virtual output #1 if that is 0 (not true) it then looks

condition #2 and sees if virtual output #3 is 0 (not

true). If that is also not true it keeps the ground

connected. If either virtual output #1 or virtualoutput #3 is false it will disconnect the ground

from ground output #2. If you have your

electronic boost controller grounded to ground

output #2, it would turn it off if there was a

problem. You can also manipulate your

wastegate solenoid or any other device.

NOTE: When you reference the return value of an

output (virtual or outputs 1-5) it will be 0 or 1.

=means false (off) 1 means true (on).

Ground output #3 simply looks at ground output

#2. If the ground output #2=false it will activate

ground output #3. In otherwords, when the failsafe

is not tripped and everything is working correctlyground output #2 is on and ground output #3 is

off. If there is a problem #2 turns off and #3 turns

on. You can connect an LED to #3, use a 3 way

valve to manipulate a manual boost controller, or

whatever your setup needs.


11/16

Optional Senders:

The smart controller can use sensors from your engine, sensors bought from Coolingmist or off the

shelf sensors from various manufacturers. If your sensor has a 0-5V output, 12V output, Frequency

output or mil livolt output, you can set it up and use it through the software. Here is a list of our

current offerings. Checkwww.coolingmist.com for the latest sensors and pricing.

Status Monitor. This product reads pressure in the line and reports back to the smart controller. Youcan program the system to disable a boost controller if there is a clog, or out of fluid or if the system

is not injecting when it should do to hardware failure. Retail is about $53.00

Flow Sensor. Our new flow sensor can read from 100 cc/m to 2500 CC/M. With this unit you can

program your controller to react based on exact flow. For instance you can check your MAP and

RPM and flow and if flow is not atleast X amount at that map and RPM, turn your boost controller of

or do some other action. Using MAP and RPM was simply a suggestion, you can integrate EGT or

any other sensor for exact failsafe action. These send a pulse signal to the smart controller

indicating the flow rate. Retail is about $125.00.

Air Temp/Water Temp Senders: These are 1/8th NPT and give a 0-5V signal to the Smart Controller

indicating the temp range. The range is from 40F to 500F. These retail around $30.00. These can

be used to turn on an injection system based on air temp, or turn a fan on based on water temp or

activate an IC sprayer, etc.

Low level warning light. These install in the bottom of your tank and send a 12V signal to the smart

controller to indicate low on fluid. You can integrate this as part of your failsafe. Retail is about

$22.00

EGT Probe: The EGT probe is a standard K series probe to indicate your EGTs. If you have an EGT

gauge in your vehicle you can use that sender. You can integrate EGT into your injection map orfailsafe. Retail is about $70

EGT AMPLIFIER: If you have an EGT thermocoupler (standard on any EGT Gauge) you can purchase

our amplifier so our unit can read your EGT. Range is from 80F to 2000F.

Vacuum Switch: If you wish to integrate vacuum into the system we have a vacuum switch that is

adjustable from 5 to 0 inches of mercury. Retail is about $40

Boost switch. We have 2 boost switches. 1 is adjustable from 1-25 PSI, the other is adjustable from 4

120 PSI. The 1-25 PSI is priced at $24.95, the 4-120 is priced at $49.95.

Relay/relay harness. These are needed if you wish to turn on a device that draws more than 1 amp

They retail for $6.99 each.

On/Off Switch. Simple rocker switch. Can be setup to turn on/off or for other stages, etc. $6.95

each.

Solenoids: Solenoids are normally closed and open when the unit grounds them. These start at

$39.95.

Vari-Cool Controller: You can create a 2D Map 0-5V and send to Vari-Cool to inject progressively.

Vari-cool is priced at $239.95


12/16

Thank you for your purchase of Smart Injection. Always remember:

1) use the 1 AMP fuse on PIN #1.

2) If any device you are activating requires more than 1 AMP power, you need to

use a relay to activate.

3) We update our flash and our software atleast monthly with new features. Checkour website for updates under software. Current version is 1.07. Updates arealways free.

4) Install the CD software and it will create a program atStart>>Programs>>coolingmist>>installationbrowser.

5) The configuration software is located under the utilities menu. Click installsmart injection software.

6) The datalog software is located under the same menu. You can optionally installthat.

7) We have a nice 30 page PDF that is in the installation browser. You will see thepicture of the smart injection box in the upper left. Click that and print fordetailed project ideas and diagrams

8) If you are using EGT You will need to purchase our EGT amplifier (Or use a 3 rdparty amplifier). If you are using ours set up one of the 0-5V inputs under USERDEFINED. Set the MIN to 0 and MAX to 2000. Our amplifier will convert themillivolts to a 0-5V. 5Volts will mean 2000F.

9) If you have a Vari-Cool Controller you can create a 0-5V output from thesmart injection kit and send to the Vari-Cool. You can take any 2 inputs andput in a grid (for example RPM/MAP) and send that to Vari-cool to injectprogressively. You can take any single input (RPM for example) and convertto 0-5V as well. Due to the many ways to inject we cannot possibly give youall the configurations here. Just email or call us if you need help and we cantell you how to set this up.

10) We have various diagrams below. If you purchased one of the kits below we will

have your device pre-programmed. You can alter the program anyway you see fit. If

you purchased the controller and would l ike one of these maps just email us and we will

send you one. Otherwise you can create your own special programming to fit your

needs.

Always Remember.1


13/16

Note: Unless you specified otherwise, your system is pre-setup with a map to inject the first stage >

1000F EGT OR when a boost pressure switch sends a signal to pin #11 (you can set the boost switch to

anything you want). The 2nd stage is set to turn on when EGT > 1500 OR a boost switch sends a signal to

pin #12.

It is NOT necessary to integrate boost. If you have a boost pressure switch and want to, you may. You

can also use your factory MAP sensor if you wish.

You can change this programming to anything you want via our free software.

Diesel High Flow Smart Injection 13


14/16

Mitsubishi EVO 2D Diagram MAF and Boost...14

If you ordered the EVO 2D Kit (frequency and Boost) install as you see here. The smart controller wil l

read your frequency MAF (200-2000 HZ) and send this to the Vari-Cool. The Vari-Cool will read your

boost signal and the two will be merged into a 2d MAP. If boost or MAF increase so does you flow. If

boost or MAF decreases so does your flow. Due to the unique design you will never have too much

flow at high boost and low MAF.

Your system is pre-programmed as you see above. Using our free software you can make anychanges you want. You can integrate RPM instead of frequency (or with it).

Pin #5 is always on unless there is a problem with the system. Pin #6 is on when pin #5 is off and off

when Pin #5 is on. You can use either of these to enable or disable a device during a failure. Use

these pins as the GROUND for your device. If your device draws more than 1 amp use a relay.

Common things to use are boost controllers, MAC valves, etc.


15/16

If you ordered the EVO 2D Kit (frequency and Boost) install as you see here. The smart controller will rea

your RPM and send this to the Vari-Cool. The Vari-Cool will read your boost signal and the two will be

merged into a 2d MAP. If boost or RPM increase so does you flow. If boost or RPM decreases so does

your flow. Due to the unique design you will never have too much flow at high boost and low MAF.

Your system is pre-programmed as you see above. Using our free software you can make any change

you want.

Pin #5 is always on unless there is a problem with the system. Pin #6 is on when pin #5 is off and off whe

Pin #5 is on. You can use either of these to enable or disable a device during a failure. Use these pins the GROUND for your device. If your device draws more than 1 amp use a relay. Common things to u

are boost controllers, MAC valves, etc.

PLEASE NOTE: some late model vehicles such as the STI/WRX/IMPREZZA and EVO have an RPM signal a

the ECU. Most classic vehicles have a tach signal at the distributor. Other late model vehicles do not

have a good RPM signal. In the case of coil packs and no RPM signal at the ECU you will need to get a

TACH Adapter. These are typically about $40 and connect to the primary coil wire and convert the

signal to a clean RPM signal.

Smart Injection with RPM/Boost (Progressive 2d) ..15


16/16

Smart Injection With S-HSV and Flow Sensor ...16

This would be a diagram to show you how to integrate dual S-HSV valves and a flow sensor. Obvious

you would need to program the inputs/outputs as you see fit. In a nutshell you would program the

smart controller to read some inputs, create a 0-5V output from the 8 X 8 Grid (for example you can d

RPM/MAF or oRPM/AIR TEMP, etc. Send that 0-5V to Vari-cool. Vari-Cool can then read your boost an

create a 3d MAP to send to the Super High Speed Valves.

cooling mist smart injection controller

Documents