Wow, I did not realize we had an installation instruction from 2003, so we updated this. We will "snaz" this up later with pictures and more details on the standard and trunk mount kits.
standard kit diagram:
http://www.coolingmist.com/instructions.aspx
Controller function/instructions
http://coolingmist.com/info.aspx?key=controllerinstall
Coolingmist Vari-Cool Controller Installation Instructions
The state of the art Vari-Cool Controller From Coolingmist comes in several formats. Most vehicles will run our standard controller which can read 1-30 PSI. Others may have our heavy duty Vari-Cool which can read from 4-120 psi.
1-30 PSI Model Features:
Minimum Setting:
This is the start boost. Set this at the PSI you want the system to start injecting. You can have the minimum setting between 1 and 30 psi.
Maximum Setting
This is the Full Flow setting. Set this to where you want the system to be at max flow. You cans et this between 1 and 30 psi.
Tune Setting:
The tune setting limits the maximum flow of the injector. This is useful to dial in the exact flow you need. If you have the tune setting on 10 you will get 100% flow at full boost. If you have it on 9 you will be to approx 92%. Each level drops the flow by roughly 7.5 %.
Turning Off the Unit:
If you set the Min higher than the Max setting the system will turn off and not inject.
The 1-30 psi controller can handle upto 60 psi of manifold pressure. The controller can only read up to 30, so the min and max can only be set between 1 and 30. After 30 psi the system will be on full flow.
The system will give you a variable flow output from your Min and Max settings.
4-120 PSI Model Features:
There is no physical difference between the 1-30 psi controller and the 4-120 PSI version. The only difference is the range. For vehicles running lower boost its better to run the 1-30 PSI version as the resolution of that controller is better.
Normally Aspirated Vari-Cool
Our Normally Aspirated Vari-Cool is identical to the other controllers except it runs off of vacuum instead of boost. Set the Min, Max and Tune the same as with the other models. Alternate modes for this model are also listed below.
Software
You can download our software from our website. Visit our controller software link at
www.coolingmist.com for the latest software. Its important to note that this controller is designed to work right out of the box. You do not need to ever use the software. If however, you want to calibrate the controller to your specs, real time datalog, change your curves, min, max and other features you can do this with our software.
Commander Option
The Vari-Cool controller has an optional hand held commander that connects to the controller. This has the ability to datalog, show boost, egt, voltage, iat, etc. Visit us at
www.coolingmist.com for this option. If you purchased the commander it will have a separate document for instructions.
Vari-Cool Controller Alternate Modes:
0-5 V input (MAF, TPS, MAP, etc)
If you prefer not to run the system using boost (or vacuum for n/a models) you can change the switch on the controller to the right position. Next to the boost/vacuum port there is a recessed switch. To run it in boost mode it must be in the LEFT position. If you prefer to run it using any device that has a 0-5 V output you must change the switch to be in the right position.
Special Control Mode
To run the system in 2 D mode you must download and install our software. You can get the software at
www.coolingmist.com. You must have a windows 2000, XP, 2003 or NT system to use the software. Alternately if you have our hand held commander you will not need a computer to do this. Software instructions for 2D Special Control mode will download with the software. Under this scenerio you can do the following:
Run the system with boost as your primary input and the 0-5V and your secondary. Or as 0-5V as primary and Boost as secondary (or vacuum). Remember the 0-5V can be your MAF, TPS or any other 0-5V device. We also have several other senders that will be listed below. For example, boost is primary and TPS is secondary you can set the system to vary the flow based on boost but only when the TPS is above a certain voltage. Likewise, you can make the system vary the flow based on voltage, but only when above a certain boost (or below a certain vacuum).
We have senders that will allow the system to use Exhaust Gas Temperature or Intake Air Temperatures as an input. If you need one of these senders, contact us at
www.coolingmist.com
We have different versions of controllers. Our latest at the time of this print is our Version 3 controller. This controllers led will function in several ways:
1) at system power up the LED will blink slow for a few seconds. Once it passes the test the LED will blink fast.
2) When the system sends power to the pump the LED will turn solid.
3) When the Max is lower than the MIN the led will blink fast for a few seconds, go solid for a few seconds and then go back to blinking again. This means the system is disabled.
4) When you are in configuration mode with our software (using your laptop or our pocket pc commander) the system will blink slow).
Mounting the Unit
It is critical to mount the unit in the cockpit of the car and not in the engine bay. The system has computer chip and is heat sensitive. The base of the unit has an area where you can use screws to bolt the controller down. As an alternative you can use Velcro. Make sure the unit does not move around and is secured.
WIRING THE UNIT:
The most important part for longevity of the Vari-Cool Controller is proper wiring.
Step 1: hook the black wire from the pump to the green wire on the controller
Step 2: hook the red wire from the pump to the red wire on the controller.
Step 3: hook the thick black wire from the controller to a GOOD CHASSIS ground. DO NOT HOOK THIS WIRE TO THE BATTERY GROUND. The most important part of the installation is to make sure you hook to a very good chassis ground.
Step 4: Hook the orange wire to your vehicles switched ignition wire.
Using Boost To Vary the flow:
Run a vacuum line to the controller port.
Using a 0-5 V input such as TPS or MAF:
Hook the blue wire to the signal wire from your MAF/TPS. This is the wire that gives you a 0-5V output. Ground the small black wire. Change the recessed switch to the right position (this is the switch next to the boost port).
Installing the Rest of the Coolingmist KIT:
Included in kit:
1) Vari-Cool Controller
2) Tank Option (2 quart, trunkmount, or 1 Gallon)
3) 1 large, 1 Medium Injector. If you have less than 500 HP use the small injector. If you have more than 500 HP use the large injector. Turn the injector upside down and look at the orifice to see size.
4) 1/8th NPT Quick Disconnect fitting for one injector.
5) Brass Checkvalve
6) 2 NPT Quick Disconnect Fittings for the checkvalve.
7) 15 feet of black nylon hose
8) 3 feet of black nylon hose
9) 1/8th NPT quick disconnect fitting for tank (except for trunk mount tank)
10) High Pressure Coolingmist Pump. EPDM Seals. Methanol compatible
12) 10 feet of red 16 gauge wiring.
Exceptions for Above:
Stainless hose/Teflon and stainless compression fittings are provided if you upgrade to our stainless hose.
The trunk mount tank option has a float switch in it.
It is impossible to give step by step instructions due to the wide variety of vehicles this kit is sold for. We can however give you tips for installation.
In most cases the pump will ship with the fittings all ready on the pump. DO NOT OVER TIGHTEN THE FITTINGS. NPT thread is tapered. If you crack the housing it will NOT be covered under warranty. You cannot make the fittings go flush. If the fittings are not in the pump already, torque the wrench ? turn until there is significant resistance and stop.
PUMP
Install the pump and tank first. The pump and tank must be near each other. Install both pump and tank in the engine bay, or both in the trunk. The pump should be below the tank to insure proper priming. If you have our Trunk Mount 1.5 Gallon Tank, you need to strap it down. Straps are not included.
Our pump is the high pressure black pump. It can run a max of 150 psi. It has EPDM seals.
The Fittings are quick disconnecting for the nylon hose. Simply slide the hose all the way in. They will not come off. If you want to take off the hose, you must press in on the clip and pull the hose out at the same time. If you have our stainless hose you must cut the hose to length and install the compression type fittings. Stainless hose is an advanced hose and if you are not familiar as to how to install the fittings we recommend you take it to a shop to install for you. Installation of that type of hose is advanced and beyond the scope of this document.
Nozzle Placement:
Next, route the hose to the location where the nozzle is going to be installed (once you connect the hose to the pump). For a roots style supercharger you will typically put prior to the supercharger. For a turbo the nozzle needs to be installed after. We recommend between the intercooler and manifold, or just before the manifold.
We have 2 types of nozzles depending on the flow requirements. Both are 1/8th NPT. The outside thread nozzles you tap with 1/8th NPT and then just screw in place. We recommend the first time you install it to remove the pipe so you can clean it out. For maintenance purposes you will not need to remove the pipe again for replacement or cleaning.
The inside thread nozzle must be installed from the inside of the pipe. Using a 3/8th or 5/16th drill bit, drill a hole in your pipe after removing it. Install from the inside of the pipe with the injector holder clamped down on the outside.
If you have dual nozzles install the 2 nozzles and our quick disconnect tee.
Direct Port:
The direct port will ship with our outside thread nozzles and our Tees or Distribution Tree. You must mount the Tree somewhere to the vehicle. Place the checkvalve just prior to the tree.
Checkvalve:
Our brass checkvalve is the industries most robust valve. It can handle 100% methanol and over 600 PSI. This valve should be placed just prior to the injector(s). We recommend placing it within 1 foot of the injector. If you have dual nozzles or direct port, put the valve in line just before the split. The ? quick disconnect fittings will connect to either side of the valve and it gets put in line. There is no electrical wiring for the valve.
Controller Install:
Wiring for the controller is listed above. The controller should be installed in the cockpit of the vehicle. Use either screws or Velcro tape to hold the controller down and keep it stable.
Status Monitor:
The status/flow detector (product code 05) will light up when your system is flowing and will also tell you if you have a clog. This can be added to your system at any time. Please visit us at
www.coolingmist.com and see the item under safety devices if you need one.
Brass Water Filter:
The brass water filter will help keep your nozzles from clogging. This is an optional component. You can find this under the water tank section on our website. Only the BRASS filter is compatible with our kits.
Vari-Safe Smart Injection:
The upcoming Vari-Safe Smart Injection Module will attach to your controller. Designed to be the ultimate in Tuning and Safety, this programmable module will be available shortly.
WARRANTY:
VARI-COOL CONTROLLER KITS
All kits have a full 1 year warranty. .
This warranty will cover the entire kit with the exception of the following:
The Commander (pocket pc) in the Vari-Cool Kit has a 90 day manufacturers warranty. The rest of the kit has a full year warranty
1) clogged nozzles
2) abuse
3) transfer of ownership
4) electrical damage from installation.
5) Damage to system from not running alcohol in the winter.
We warrant all parts to be methanol compatible 100% including the pump. We warranty all parts to be free of defects in material and workmanship.
You are responsible for shipping the item to us, we will ship back to you. We cover shipping to the US. We do not cover express shipping or international shipping.
Coolingmist will inspect the returned goods and make a decision on the warranty. Our decision is final.
For the first 90 days if your controller is proven defective, once you ship your controller back we will ship you a new controller. After 90 days, we will repair your unit and ship back once the repair is complete.
Call us with any warranty questions.
Updated Instructions
Linear Mode
