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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 output……………………………………………6

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

Setting up your LEDS ……………………………....6

Ground outputs 1-5………………………………….7

Pulsing the outputs…………………………………..7


Please take the time to read this entire document Setting a delay on the outputs……..…………….…..7
before installing your product/kit. It is also important to
note that we are updating the documentation 0-5V Output…………………………………………8
daily/weekly with new examples and the latest
0-5V Grid…………………………………………....8
information. Software is also updated constantly with
new features. We will be putting the latest software Clamp Output Feature…………………………….…8
and flash on our website under our “installation” menu.
It is recommended that you check to see the date of Optional Senders………………………………….…9
the new software release so you can get the latest fixes.
Setting up EGT………………………………………9
We recommend that you check back to our website to
see the latest details/features. Please read on to see Setting up a failsafe.………………………………..10
why we are your best choice. Your smart controller is
not programmed; this technical guide shows you the Activating the failsafe based on conditions………...11
concept of how to use the software.
Things to know …………………………………….12
PLEASE NOTE: If you already own a Smart Injection/DMS
controller and see that you don’t have the same Diagrams for Pre-Programmed Systems:
features, please contact us for the latest flash/software.
Diesel High Flow Smart Injection ………………....13
Upgrades are free. We always update this with the
latest software functions so if you have an older unit it Evolution M Boost + MAF and Failsafe …………..14
may need flashed to use them. The current version is
1.09 released on 8/12/2008. Universal Boost + RPM and Failsafe ………….…..15
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 ground
outputs and 3 virtual outputs.. and much more. The pin out is below. All of the inputs and outputs can be
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 are
millions 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.
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
PLEASE READ ALL INSTRUCTIONS export to a file. If you are in Config mode it will say IMPORT
CAREFULLY AND TEST YOUR UNIT and you can import an existing file. Don’t forget to click
AFTER YOU PROGRAM IT. “SAVE”
Pin Layout. 3

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.

1: + 12 V Power (Switched ignition). Main System 11: 0-5V input #1. Any sensor that gives a 0-5V signal can be
Power. Always use the 1 amp fuse with this. used here. TPS, MAP, MAP are typical. We have Air Temp and
Water Temp probes as well. You can define the upper and lower
2: System Ground. Main System Ground limits as well.

3: Aux 5 Volt Power. If you have a 5V device, you 12: 0-5V input #2. Any sensor that gives a 0-5V signal can be used
can power it with this output. Use a relay if it uses here. TPS, MAP, MAP are typical. We have Air Temp and Water
more than 1 AMP. Temp probes and EGT amplifiers as well. You can define the
upper and lower limits as well.
4: Gnd Output #1. Switchable ground output. You
can turn this on/off based on a single input or a 13: 0-5V Ground (optional). If your 0-5V sensor needs a ground
combination of upto 3 inputs. Use a relay if it uses you can use this. If you are using a sensor from your vehicle, you
more than 1 AMP. will not need to use this.

5: Gnd Output #2. Switchable ground output. You 14: 0-5V input #3. Any sensor that gives a 0-5V signal can be used
can turn this on/off based on a single input or a here. TPS, MAP, MAP are typical. We have Air Temp and Water
combination of upto 3 inputs. Use a relay if it uses Temp probes as well. You can define the upper and lower limits as
more than 1 AMP. well.

6: Gnd Output #3. Switchable ground output. You 15: 0-5V input #4. Any sensor that gives a 0-5V signal can be used
can turn this on/off based on a single input or a here. TPS, MAP, MAP are typical. We have Air Temp and Water
combination of upto 3 inputs. Use a relay if it uses Temp probes as well. You can define the upper and lower limits as
more than 1 AMP. well.
.
7: Gnd Output #4. Switchable ground output. You 16: 0-5V Ground (optional). ). If your 0-5V sensor needs a ground
can turn this on/off based on a single input or a you can use this. If you are using a sensor from your vehicle, you
combination of upto 3 inputs. Use a relay if it uses will not need to use this.
more than 1 AMP.
17: Millivolt input +. This is our Millivolt + input. It’s a millivolt port.
8: Gnd Output # 5. Switchable ground output. You If you have a different sender that has a range anywhere
can turn this on/off based on a single input or a between 0 – 400 mV you can use this as well (you can user define)
combination of upto 3 inputs. Use a relay if it uses
more than 1 AMP. 18: Millivolt Input –. This is our Millivolt - input. It’s a millivolt port. If
you have a different device that has a range between 0 – 400 mV
9: 0-5V out. Programmable 0-5V output. you can use this as well (you can user define).

10: Aux Ground. If you need to ground a device 19: Counter #1 Frequency (Square Wave) counter. Range of 2 hz
you can use this. Make sure you use a relay if your to 20 Khz. RPM, MAF, etc.
device uses more than 1 AMP.
20: Counter #2 Frequency (Square Wave) counter. Range of 2 hz
to 20 Khz. RPM, MAF, etc.

VIRTUAL OUTPUTS:
These outputs do not turn any devices on and do not have a pin attached
Virtual Output #1
but they can be used to set a condition or a flag that you can reference in
Virtual Output #2 any of your outputs, leds, etc. This will be detailed later.

Virtual Output #3
Configuring the software. 4

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.

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.

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
don’t 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 be
updating the update box. (See image above)
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 don’t 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.
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. If
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 max
range (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 give
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 don’t know the
MIN/MAX, choose MAP from the dropdown box and it will reference 0-5V.

You can use any sensor with a 0-5V output, this includes air temp senders, water
temp sensors, flow sensors, etc. You can also use a 12V signal from something
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 EGT
please 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 flow
sensor that gives a millivolts output from 30 MV to 160, so
we set that range in the boxes
5V power output 6

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 fast
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 is
greater than 4.5V. LED #1 will be off when Virtual Output #1 is off and will go solid (ON) when the Virtual
Output #1 conditions are all true.
Ground Outputs 1-5. Pulsing your outputs, setting delays. 7

These will activate your device or devices. Can be as simple as a LED, shift light,
water/alcohol system, nitrous system, fan or all of the above. You can even program
this to interact with your other devices so they know exactly when to turn on/off.

In this example we set ground output #1 to


turn on when counter #2 has a frequency
>1500. For example on a GM MAF that
goes from 200 to 2000 HZ.

If you needed to add a 2nd or 3rd condition


you can. Notice condition #2? Earlier we
setup virtual output #1 to flag when 0-5V
input #1 is between 2 and 5 AND MV input
is greater than 49. If both virtual output 2
conditions are met it will have a value of 1
NOTE: If your devices (true). Otherwise, it will have a value of 0.
require more than 1
AMP of power, use a SETTING A DELAY!!!
relay or you will
damage the On any of the outputs if you want to set a
controller. delay, just check the delay box and enter
the number of seconds you want it to
delay. This is useful in some situations
where you need the output to turn on, but
only after a delay.

Pulsing your outputs If for any reason you need to PULSE the outputs you can do so,
this will turn the outputs on/off for the period of time specified.

In the example to the left we have the on time to


50 and the off time to 100. That translates to 500
MS on time and 1 second off time. Your on/off
time range is 100 MS to 25 seconds. Accuracy is
within 1 ms.

In this example we are running about 25%


dutycycle. We set the on time for 1 second and
the off time for 3 seconds.
0-5 Volt Output. 8 X 8 Grid 8

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

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


on a single input. In this case we are using frequency
as the input. The input1 MIN (250 in this case) and
input 1 MAX (2000 in this case) are the subset of the
range 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 5
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%. The
% out at min is the scale you wish the system to start at
and the % out at max is the max you wish to output.

0-5V output based on 2 inputs. This can be any 2 inputs.

In this example the only difference to


the above is the additional input. In
this case we used RPM and MAP
sensor 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 own
use. 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 output
#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.
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 at
the end of this document labeled Smart Injection with RPM/Boost (Progressive 2d). We will show you how to
detect blockage or hardware problem and how to fine tune it for your vehicle. NOTE: this is just one example.
You 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 have
integrated 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 will see how we reference the virtual outputs in
the actual outputs.

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.

Condition 3 for virtual output 3


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 virtual
output #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 correctly
ground 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.
Optional Senders: 11

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 millivolt output, you can set it up and use it through the software. Here is a list of our
current offerings. Check www.coolingmist.com for the latest sensors and pricing.

Status Monitor. This product reads pressure in the line and reports back to the smart controller. You
can 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 off
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 or
failsafe. 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
Always Remember…………………………………………………………….12

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. Check
our website for updates under software. Current version is 1.07. Updates are
always free.

4) Install the CD software and it will create a program at


Start>>Programs>>coolingmist>>installationbrowser.

5) The configuration software is located under the utilities menu. Click “install
smart injection software”.

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

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

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

9) If you have a Vari-Cool Controller you can create a 0-5V output from the
smart injection kit and send to the Vari-Cool. You can take any 2 inputs and
put in a grid (for example RPM/MAP) and send that to Vari-cool to inject
progressively. You can take any single input (RPM for example) and convert
to 0-5V as well. Due to the many ways to inject we cannot possibly give you
all the configurations here. Just email or call us if you need help and we can
tell 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 like 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.
Diesel High Flow Smart Injection ……………………………………………13

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.
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 will
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 any
changes 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.
Smart Injection with RPM/Boost (Progressive 2d) ……………………..15

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

PLEASE NOTE: some late model vehicles such as the STI/WRX/IMPREZZA and EVO have an RPM signal at
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 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. Obviously
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 do
RPM/MAF or oRPM/AIR TEMP, etc. Send that 0-5V to Vari-cool. Vari-Cool can then read your boost and
create a 3d MAP to send to the Super High Speed Valves.