Download - Cooling Mist Smart Injection Controller
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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.
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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
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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.
5: Gnd Output #2. Switchable ground output. You
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.
6: Gnd Output #3. 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.
7: Gnd Output #4. 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.
8: Gnd Output # 5. 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.
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.
14: 0-5V input #3. 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 lower limits a
well.
15: 0-5V input #4. 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 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.
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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.
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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
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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.
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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.
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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.
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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.
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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
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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
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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
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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.
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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
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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.