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Coolingmist Smart Injection DMS Controller

Technical Reference and Guide



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

and much more. etc. There are 2 frequency inputs which can read RPM. each of these have different functions. Due to the fact that there are millions of applications we will give the basics of how the controller works. how the controller works and what you can do with it. 2 There are 20 pins. The pin out is below. 5 on/off ground outputs and 3 virtual outputs. All of the inputs and outputs can be custom defined. Don’t forget to click AFTER YOU PROGRAM IT.DMS Layout. There are 4 0-5V inputs. pulses. Software Configuration. Just click the “SMART INJECTION” tab after installing the CD.. If you are in Config mode it will say IMPORT CAREFULLY AND TEST YOUR UNIT and you can import an existing file. We have a 30 page PDF which has many sample programs that you can get from the CD. Its important to note that this document focuses almost exclusively on the elements of the smart controller. 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. 1 mv input (EGT) a programmable 0-5V output. “SAVE” .

Make sure you use a relay if your to 20 Khz. you combination of upto 3 inputs. MAF. RPM. Switchable ground output. MAP are typical. 18: Millivolt Input –. If you fry the unit due to mis-wiring. 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. TPS. TPS. well. We have Air Temp and Water Temp probes as well. If your 0-5V sensor needs a ground combination of upto 3 inputs. Use a relay if it uses Temp probes as well. MAP. more than 1 AMP. You 14: 0-5V input #3. It’s a millivolt port. This will be detailed later. 8: Gnd Output # 5. Range of 2 hz to 20 Khz. MAP are typical. MAP. MAP. 17: Millivolt input +. Temp probes and EGT amplifiers as well. Any sensor that gives a 0-5V signal can be used can turn this on/off based on a single input or a here. 1: + 12 V Power (Switched ignition). Always use the 1 amp fuse with this. If you have a different device that has a range between 0 – 400 mV 9: 0-5V out. Care must be taken not to damage the unit due to mis-wiring. TPS. you 12: 0-5V input #2. Main System 11: 0-5V input #1. Main System Ground limits as well. You can turn this on/off based on a single input or a 13: 0-5V Ground (optional). This is our Millivolt + input. Use a relay if it uses here. You can define the upper and lower limits as more than 1 AMP. If you need to ground a device 19: Counter #1 Frequency (Square Wave) counter. ). Any sensor that gives a 0-5V signal can be used can turn this on/off based on a single input or a here. We have Air Temp and Water more than 1 AMP. 6: Gnd Output #3. 4: Gnd Output #1. Switchable ground output. Any sensor that gives a 0-5V signal can be used can power it with this output. You 15: 0-5V input #4. Switchable ground output. device uses more than 1 AMP.input. 3: Aux 5 Volt Power. We have Air Temp and Water combination of upto 3 inputs. It’s a millivolt port. You can define the upper and lower limits as more than 1 AMP. You can define the upper and lower 2: System Ground. Use a relay if it uses will not need to use this. Range of 2 hz you can use this. MAP are typical. This is our Millivolt . If you are using a sensor from your vehicle. leds. Switchable ground output. Any sensor that gives a 0-5V signal can be Power. We have Air Temp and Water combination of upto 3 inputs. 5: Gnd Output #2. MAP. 3 Smart injection has 20 pins that have various functions. 20: Counter #2 Frequency (Square Wave) counter. will not need to use this. Use a relay if it uses you can use this.Pin Layout. used here. If you are using a sensor from your vehicle. well. Switchable ground output. Use a relay if it uses Temp probes as well. You can define the upper and lower limits as well. On the controller you will see a 1-10 label and 11-20 label. etc. Programmable 0-5V output. If you have a 5V device. 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. you more than 1 AMP. Virtual Output #3 . you can use this as well (you can user define). etc. You 16: 0-5V Ground (optional). etc. Use a relay if it uses more than 1 AMP. MAP are typical. If your 0-5V sensor needs a ground can turn this on/off based on a single input or a you can use this. those will match the outputs you see below. warranty will not be honored. TPS. . MAF. 7: Gnd Output #4. 10: Aux Ground. RPM.

This box contains the available ports on your computer. if you choose the right one. Once you click the save button. but you cant change it. You will need to choose the 1 that is assigned to your serial port. (See image above) Click on the configuration button to put the system in configuration mode. If no ports show up. If you don’t know. Once you do that a new box will appear. 4 Connect the software to Vari-Safe. If you don’t click this. You must click this every time you wan to make a change. . your computer is not setup correct. you can guess.Configuring the software. you will need to purchase a USB to Serial Converter at your local electronics store or on-line. Choose the port and click Connect. For obvious reasons you must have 12V power and ground to the Smart Controller. the system updates and you must click this button again if you want to configure another input or output. our system will respond. TIP: If your computer does not have a serial port (9 pin RS232). you can View the configuration. In the file menu click “controller>>>connect”. Choose your COM Port. Make sure you have your serial cable OR USB> Serial converter and have connected to your windows based laptop or desktop. If your connected the controller version # will appear AND your computer will be updating the update box.

Once you click the mv configuration button you get options. For example. choose MAP from the dropdown box and it will reference 0-5V. 6 or 8 cylinder. you can set that up. Later we can activate an output based on the readings. etc. 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. remember you are simply reading the information into the Smart Controller. We will show you how to do this later on. You can do a user defined and set the MIN/MAX boost.Counters 1 and 2 5 Counters #1 and #2 are designed to read the HZ of an input. pressure switch or throttle switch. in this case the person setting this up has a flow sensor that gives a millivolts output from 30 MV to 160. choose 4. If you don’t know the MIN/MAX. These can be custom sensors as well. The range of our high speed counters are 2 HZ to 20 KHZ. If you decide to setup the counters. 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. If you are doing RPM. so we set that range in the boxes . You can use any sensor with a 0-5V output. this includes air temp senders. You can also use a 12V signal from something such as a boost switch. 6 or 8. water temp sensors. if you have a MAP sensor that gives a 0-5V. Once you are in config mode setup what you want. 0-5 Volt Inputs 1-4 0-5V inputs 1-4 can read any sensor that gives a 0-5V reading. If you have something other than a 4. This signal can be any hall effect signal. you can choose user defined. RPM/TACH or FREQUENCY such as MAF . To use EGT please purchase our EGT amplifier to use with your EGT probe. You can also give a 12V input as well. flow sensors.

. Setting up the LEDS In the above examples we have LED 3. You can use things such as a low level fluid switch. 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. All other times will be off. 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. This is for low power devices. LED 3 is going to blink fast when the MAP sensor (0-5V input 1)>3.5V power output 6 Pin #3 on the smart controller is a dedicated 5V power supply. The concept is simple. it only has an effect on real digital outputs that we will discuss shortly. it always has 5V. You cannot configure this. 2 and 1 setup to do different things. If your device draws more than 1 AMP use a relay. The “Pulse Output” box has no effect on virtual outputs. status monitor. You can setup as many as 3. 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. you can use these to setup a conditional flag that you can reference on any of your outputs or leds.5V. If those conditions are true the value will be 1 otherwise it will be zero. on/off switch. boost switch. water temp sender or any other low power device. Later we will reference this in ground output #1 to illustrate this simple concept. When the MAP sensor =5 it will be solid. 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. We setup 2 conditions on virtual output 1. air temp.

water/alcohol system. nitrous system. If both virtual output 2 conditions are met it will have a value of 1 NOTE: If your devices (true). Your on/off time range is 100 MS to 25 seconds. That translates to 500 MS on time and 1 second off time. this will turn the outputs on/off for the period of time specified. In this example we are running about 25% dutycycle. We set the on time for 1 second and the off time for 3 seconds. This is useful in some situations where you need the output to turn on. Ground Outputs 1-5. fan or all of the above. Pulsing your outputs If for any reason you need to PULSE the outputs you can do so. For example on a GM MAF that goes from 200 to 2000 HZ. 7 These will activate your device or devices. In this example we set ground output #1 to turn on when counter #2 has a frequency >1500. . Can be as simple as a LED. You can even program this to interact with your other devices so they know exactly when to turn on/off. shift light. require more than 1 AMP of power. it will have a value of 0. Otherwise. 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. Accuracy is within 1 ms. delay. In the example to the left we have the on time to 50 and the off time to 100. but only after a delay. just check the delay box and enter the number of seconds you want it to delay. setting delays. Pulsing your outputs. use a SETTING A DELAY!!! relay or you will damage the On any of the outputs if you want to set a controller.

but you have one of the outputs programmed to detect that you are out of fluid. 0-5V output based on 2 inputs. Further more. This can be any 2 inputs. etc. 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. EGT. Why would we do this? Lets say you are using a progressive controller to control your pump with this 0-5V signal. You can turn the entire system off by setting the dutycyle to zero under those conditions.0-5 Volt Output. in this case we set it up that if virtual output #3 is active then clamp the 0-5V output to 0. if you put 0 and 5 at 5 volts it will show 5. For example. The scale MIN is how the system will internally reference the value. 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. In the cells we chose to use a 0-100% dutycycle. In this case we used RPM and MAP sensor that we setup to 30 PSI. The example to the left sets up a 0-5V output based on a single input. For example. This can be any input. In this case we are using frequency as the input. The 0-5V output is pin #9. Frequency. (If you have a need) You may have a need to clamp the 0-5V output. . In our case 5V from the MAP sensor was 30 PSI so we user defined it from 0-30. You can define the entire range of both the inputs and the 0-5V output. If you prefer dutycycle. RPM. you can clamp the 0- 5V output to any dutycycle based on any input value if you wish. Clamping the output. 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. We could have chosen any number between 1 and 100 (or what ever you set the max range of the output to). 8 X 8 Grid 8 0-5V output based on a SINGLE input. In this example the only difference to the above is the additional input. you can put 0 and 100 and at 5 volts it will show 100%.

Your low level fluid switch is attached to 0-5V input #2. Infact.0. Note: We set a 3 second delay on the clog feature. 9 This feature requires coolingmist status monitor ($52. If there is no pressure it may say . you can likely do it with the Smart Controller. In otherwords if there is a clog virtual output #1 sets a true condition (1). Pressure can remain in the line for a second or 2 after the system stops. Below we setup virtual output #1 To detect hardware failure. 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). Condition #1 checks the 0-5V output to see if its less than 15%. Condition 2 says AND the 0-5V output is less than 40%. We setup virtual output #3 to determine if we are low on fluid or if we have a clog. You could set the same conditions on your 5 outputs. You can choose to use a flow sensor or something completely different. Condition 3 for virtual output 3 .Failsafe: Detecting a blocked Jet or hardware failure. If you can imagine it.9 or 5. You can set this delay to suit your needs. You choose a number that fits your situation. 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. NOTE: this is just one example. If so we know there is a clog. In reality if there is pressure it will show 4. We chose 40% because in our case we would be concerned if we have no pressure in the line when we are at 40%. in the next section you will see how we reference the virtual outputs in the actual outputs. For this feature look at the diagram at the end of this document labeled Smart Injection with RPM/Boost (Progressive 2d). Condition #1 checks voltage on 0-5V in 1. however we could have integrated more conditions.8 or 4. We recommend ours since its tested with high pressure and methanol. Your status monitor should be as close to your nozzle as possible. It makes it easy to just say less than 3 volts. Virtual outputs do not use any Input/output so are ideal for setting flags. We did not use virtual output #2. Condition #3 is an “OR” condition. The smart controller will know at all times if there is pressure in the line or if you ar e out of water.1 or 0 or .12. You should not have pressure in the line when you are not activating. You must program the unit to activate a failsafe under failure condition.95) or if you have your own heavy duty pressure switch you can use it. We will show you how to detect blockage or hardware problem and how to fine tune it for your vehicle. If its less than 3 we know for sure that there is no pressure in the line. If condition 1 is true it looks at condition 2 which checks to see of the 0-5V input #1 is > 3 volts.

If either virtual output #1 or virtual output #3 is false it will disconnect the ground from ground output #2. You can also manipulate your wastegate solenoid or any other device. =means false (off) 1 means true (on).Failsafe: Activating your failsafe based on conditional situations 10 Ground Output #1. You connect solenoid ground to your output and tell the output to connect the ground. Ground output #3 simply looks at ground output #2. 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). when the failsafe is not tripped and everything is working correctly ground output #2 is on and ground output #3 is off. NOTE: When you reference the return value of an output (virtual or outputs 1-5) it will be 0 or 1. You can connect an LED to #3. it would turn it off if there was a problem. Not part of the failsafe. but we open the water solenoid by when the 0-5V output reaches 20%. use a 3 way valve to manipulate a manual boost controller. If there is a problem #2 turns off and #3 turns on. . If the ground output #2=false it will activate ground output #3. or whatever your setup needs. If that is also not true it keeps the ground connected. If you have your electronic boost controller grounded to ground output #2. In otherwords.

These install in the bottom of your tank and send a 12V signal to the smart controller to indicate low on fluid. sensors bought from Coolingmist or off the shelf sensors from various manufacturers. Retail is about $22. Solenoids: Solenoids are normally closed and open when the unit grounds them. You can integrate this as part of your failsafe. These retail around $30. Relay/relay harness.99 for the latest sensors and pricing.00 EGT Probe: The EGT probe is a standard K series probe to indicate your EGTs. Low level warning light. Retail is about $40 Boost switch. This product reads pressure in the line and reports back to the smart controller.95. For instance you can check your MAP and RPM and flow and if flow is not atleast X amount at that map and RPM.95 .Optional Senders: 11 The smart controller can use sensors from your engine.00. 1 is adjustable from 1-25 PSI. Retail is about $125. 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. or turn a fan on based on water temp or activate an IC sprayer. the other is adjustable from 4- 120 PSI. Retail is about $53.00 Flow Sensor. On/Off Switch. These are needed if you wish to turn on a device that draws more than 1 amp. turn your boost controller off or do some other action. etc. They retail for $6. These start at $39. Check www. you can set it up and use it through the software. If your sensor has a 0-5V output. the 4-120 is priced at $49. 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. $6. Our new flow sensor can read from 100 cc/m to 2500 CC/M.95. Range is from 80F to 2000F. With this unit you can program your controller to react based on exact flow. Status Monitor. The 1-25 PSI is priced at $24.95 each. We have 2 boost switches.coolingmist. 12V output. Air Temp/Water Temp Senders: These are 1/8th NPT and give a 0-5V signal to the Smart Controller indicating the temp range. Frequency output or millivolt output. Here is a list of our current offerings. Vari-Cool Controller: You can create a 2D Map 0-5V and send to Vari-Cool to inject progressively. The range is from 40F to 500F. If you have an EGT gauge in your vehicle you can use that sender. or out of fluid or if the system is not injecting when it should do to hardware failure. etc. Simple rocker switch. Using MAP and RPM was simply a suggestion. Vari-cool is priced at $239. you can integrate EGT or any other sensor for exact failsafe action.00. Can be setup to turn on/off or for other stages. You can program the system to disable a boost controller if there is a clog. These send a pulse signal to the smart controller indicating the flow rate. These can be used to turn on an injection system based on air temp.

Updates are always free. . 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 alter the program anyway you see fit. You can take any single input (RPM for example) and convert to 0-5V as well. Just email or call us if you need help and we can tell you how to set this up. 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. 3) We update our flash and our software atleast monthly with new features. Check our website for updates under software. Otherwise you can create your own special programming to fit your needs. 10) We have various diagrams below. Due to the many ways to inject we cannot possibly give you all the configurations here.12 Thank you for your purchase of Smart Injection. 2) If any device you are activating requires more than 1 AMP power. 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). 7) We have a nice 30 page PDF that is in the installation browser. Always remember: 1) use the 1 AMP fuse on PIN #1. 6) The datalog software is located under the same menu.07. 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. 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. 5Volts will mean 2000F. You can optionally install that. If you purchased the controller and would like one of these maps just email us and we will send you one. you need to use a relay to activate. Current version is 1. If you purchased one of the kits below we will have your device pre-programmed. Our amplifier will convert the millivolts to a 0-5V. You will see the picture of the smart injection box in the upper left.Always Remember……………………………………………………………. Click “install smart injection software”.

you may. . You can change this programming to anything you want via our free software. You can also use your factory MAP sensor if you wish.Diesel High Flow Smart Injection ……………………………………………13 Note: Unless you specified otherwise. If you have a boost pressure switch and want to. 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). It is NOT necessary to integrate boost. The 2nd stage is set to turn on when EGT > 1500 OR a boost switch sends a signal to pin #12.

If boost or MAF decreases so does your flow. MAC valves.……………………………. etc. You can integrate RPM instead of frequency (or with it). You can use either of these to enable or disable a device during a failure.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. Your system is pre-programmed as you see above. .. The Vari-Cool will read your boost signal and the two will be merged into a 2d MAP. Using our free software you can make any changes you want. Use these pins as the GROUND for your device. Due to the unique design you will never have too much flow at high boost and low MAF. Pin #6 is on when pin #5 is off and off when Pin #5 is on. If your device draws more than 1 amp use a relay. If boost or MAF increase so does you flow. Common things to use are boost controllers. Pin #5 is always on unless there is a problem with the system.

If your device draws more than 1 amp use a relay. You can use either of these to enable or disable a device during a failure. Use these pins as the GROUND for your device. etc. The smart controller will read your RPM and send this to the Vari-Cool. Other late model vehicles do not have a good RPM signal. MAC valves. If boost or RPM increase so does you flow. Pin #5 is always on unless there is a problem with the system. The Vari-Cool will read your boost signal and the two will be merged into a 2d MAP. Most classic vehicles have a tach signal at the distributor. Pin #6 is on when pin #5 is off and off when Pin #5 is on.15 If you ordered the EVO 2D Kit (frequency and Boost) install as you see here. PLEASE NOTE: some late model vehicles such as the STI/WRX/IMPREZZA and EVO have an RPM signal at the ECU.Smart Injection with RPM/Boost (Progressive 2d) ……………………. . Due to the unique design you will never have too much flow at high boost and low MAF. Using our free software you can make any changes you want. If boost or RPM decreases so does your flow. Your system is pre-programmed as you see above.. These are typically about $40 and connect to the primary coil wire and convert the signal to a clean RPM signal. Common things to use are boost controllers. In the case of coil packs and no RPM signal at the ECU you will need to get a TACH Adapter.

……………………. Obviously you would need to program the inputs/outputs as you see fit. .16 This would be a diagram to show you how to integrate dual S-HSV valves and a flow sensor. Vari-Cool can then read your boost and create a 3d MAP to send to the Super High Speed Valves. Send that 0-5V to Vari-cool. create a 0-5V output from the 8 X 8 Grid (for example you can do RPM/MAF or oRPM/AIR TEMP.Smart Injection With S-HSV and Flow Sensor ……. etc.. In a nutshell you would program the smart controller to read some inputs.