Inputs in Smart Controllers 8 X 8 Grid:
RPM. He got the RPM from his ECU.
Air Temp. He used his stock Air temp sensor.
Vari-Cool inputs.
Boost: The boost signal is read from Vari-cool.
0-5V in (RPM and AIR signal from Smart Controller)
I. Coolingmist Smart Injection Unit
a. Assumptions/Estimates, i.e. these will change when we have measured values
1. MAP: 0 V = 0 psi, 5V = 26 psi and linear scale
2. Air Sensor: Air Temp 0 V = 65% and 5 V = 100% of max input temp
3. EVC Stepping Motor: 4 V = boost high enough to need 2nd fuel pump turned on
4. Fluid Flow Sensor: Calibrated in cc/min. Max output is approximately 1400
cc/min.
b. 0-5V OUT (Terminal 9)
1. 2-D mapping of RPM and Input Air Temp to 0 - 100% scale. The 2-D map is
shown in the attached table
c. Virtual Output #1 (provides conditions for real outputs)
1. Condition 1: 0-5V IN 4 (Terminal 15) is less that 2 V, i.e. the water/methanol
tank is not empty; AND
2. Condition 2: 0-5V OUT (Terminal 9) is less than 4.25 V, i.e. the RPM/AIR map
is less than 85%; AND
3. Condition 3: 0-5V IN 1 (Terminal 11) is less that 1.9 V, i.e. less than 9.9 psi of
boost measured by MAP sensor
d. Virtual Output #2 (provides conditions for real outputs)
1. Condition 1: 0-5V IN 4 (Terminal 15) is less that 2 V, i.e. the water/methanol
tank is not empty; AND
2. Condition 2: 0-5V OUT (Terminal 9) is less than 4.25 V, i.e. the RPM/AIR map
is less than 85%; AND
3. Condition 3: 0-5V IN 1 (Terminal 11) is less that 3.1 V, i.e. less than 16.1 psi of
boost measured by MAP sensor
e. Virtual Output #3 (provides conditions for real outputs)
1. Condition 1: 0-5V IN 4 (Terminal 15) is less that 2 V, i.e. the water/methanol
tank is not empty; AND
2. Condition 2: 0-5V OUT (Terminal 9) is less than 4.25 V, i.e. the RPM/AIR map
is less than 85%; AND
3. Condition 3: 0-5V IN 1 (Terminal 11) is less that 3.7 V, i.e. less than 19.2 psi of
boost measured by MAP sensor
f. Ground Output #1
1. Condition 1: Virtual Output #1 greater than 0.8, i.e. conditions are all true - less
than 9.9 psi of boost; OR
2. Condition 2: Counter 1 (Terminal 19) indicates a fluid flow greater than 240
cc/min; AND
3. Condition 3: 0-5V IN 1 (Terminal 11) is less that 2.5 V, i.e. less than 13.0 psi of
boost measured by MAP sensor
g. Ground Output #2
1. Condition 1: Virtual Output #2 greater than 0.8, i.e. conditions are all true - less
than 16.1 psi of boost; AND
2. Condition 2: Counter 1 (Terminal 19) indicates a fluid flow greater than 360
cc/min
h. Ground Output #3
1. Condition 1: Virtual Output #3 greater than 0.8, i.e. conditions are all true - less
than 19.2 psi of boost; AND
2. Condition 2: Counter 1 (Terminal 19) indicates a fluid flow greater than 600
cc/min
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i. Ground Output #4
1. Condition 1: 0-5V IN 1 (Terminal 11) is less that 4.7 V, i.e. less than 24.4 psi of
boost; AND
2. Condition 2: Counter 1 (Terminal 19) indicates a fluid flow greater than 840
cc/min
j. Ground Output #5
1. Condition 1: 0-5V IN 3 (Terminal 14) is greater that 4 V, i.e. we have very high
boost and we need the 2nd fuel pump on
II. Coolingmist Vari Cool Controller (Black Unit)
a. Min Duty Cycle = 34
b. Max Duty Cycle = 100
c. Tuning Factor = 10, i.e. the Duty Cycle to Boost curve is below linear
d. Boost as measured by the Vari Cool Controller vacuum/boost line
1. Boost Min = 8
2. Boost Max = 26
e. Average = 66%
1. this is the weight given to the 0-5V input (Blue 22 AWG) when being combined
with the boost input, i.e. the 0-5V In is given 66% weight, while the boost is given
34% weight. This effectively makes the system inject based on 3 inputs.
