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Intelligent Intercooler Water Spray - Part 5

Other uses for the module.

by Julian Edgar

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The AutoSpeed / Labtronics Intelligent Intercooler Water Spray control module is, as the name suggests, designed to turn the pump on and off in an intercooler water spray system. However, the relay output can be used to perform other functions, and the water spray itself need not be connected in exactly the way we outlined last week.

Here are some of the other options and uses.

Carby Turbo Cars

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If you have a carby (or mechanically injected) turbo car, you can still use the Intercooler Water Spray Controller - but it won't be quite as intelligent as when it's working on an EFI car. Instead of connecting the Duty Cycle input to an injector, connect this wire to a boost pressure switch, with the other side of the switch connected to earth. That way whenever the car comes on boost, the controller will assume that there is a high load and will trigger the Fang Mode LED - the Fang sensitivity pot will then have no affect. (Note that the Duty Cycle green LED will be dark, as there is a short circuit to ground rather than a duty cycle coming in.) The temperature and pump connections can be made as for an EFI car, with the switch-on point of the pump still able to be adjusted by turning the Temp Sensitivity pot. Set up in this way, the spray will trigger whenever the car comes on boost and the intercooler is hot.

Intercooler Fan Control

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You can also use the module to control an intercooler fan that blows air through the core. In this case, it's best to use the temperature inputs alone to control the system. To do this, permanently connect the Duty Cycle input to earth and then configure the temperature inputs just as for the intercooler water spray application (ie one sensor on the intercooler core and the other measuring ambient temp). Wire the intercooler fan through the module's output relay. When set up like this, the intercooler fan will only operate when the intercooler is hotter (by the user-adjustable amount) than the temp of the day, meaning that it will typically come on at idle (because of the low airflow) and/or after times of high load (because of the heat needing to be dissipated). The switch-on point can be adjusted with the Temp Sensitivity pot.

Water/Air Intercooler Pump Control

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The control module can also be used to operate the pump in a water/air intercooling system. The duty cycle input and ambient temp sensor are wired as normal. The 'intercooler' temp sensor is attached to the outlet of the intercooler heat exchanger, so that it measures the temp of the intake air after it has passed through the intercooler. The relay can then be wired to the pump so that the fluid only circulates when both the car is being driven hard enough to trip the Fang Mode, and the intake air is actually becoming warm. Note that this approach does not provide a variable pump speed - you would typically have the duty cycle and temp modes set to trip much earlier than you would in an intercooler water spray application.

Water Injection Control

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Instead of spraying water over the intercooler core, you can use the same module to control the operation of a water injection pump. We suggest that all inputs remain the same as for the intercooler pump system described above, but that a finer atomising nozzle is used to inject the water directly into the intake manifold. In this application, the Fang Factor sensitivity should always be set high enough that the pump cannot operate at light loads. If no intercooler is fitted, the 'intercooler' temp sensor can be located so that it measures intake air temperature. However, the supplied sensor is not designed for extreme temperatures (eg over 100 degrees C), and its location should take this into account. Note though, that it is likely that we will develop a dedicated water injection controller soon.

Water-Cooled Brakes

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Brake fade can be substantially reduced by the use of a very fine, atomised mist of water being injected into the airstream in front of the brakes. (Note that we are not suggesting that you spray a solid cannon of water straight onto the red-hot disc!) In order that this spray can be regulated intelligently, you can mount the ambient temp sensor to detect the temp of the day, and the 'intercooler' temp sensor in the airstream well behind the brakes. (ie, don't mount the 'hot' temp sensor anywhere near the brakes themselves - the sensor will melt!) Use a new relay that is activated by the brake light switch (ie its coil wired in parallel with the brake lights) to connect the injector duty cycle input to earth whenever the brake pedal is pushed. That way, the Fang Factor LED will light under brakes, rather than under acceleration. The module's relay can then be connected to the pump so that the pump switches on when the temp of the air behind the brakes shows that they're getting hot, and when the car is under braking.

Dashboard 'Relay On' Indicator

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While the Relay On LED clearly shows when the switched device is being fed power, if you house the module away in a box you won't be able to see any of the LEDs in normal day-to-day driving. So that you can still know when the output relay is on, simply wire a normal 12-volt pilot light in parallel with the load (eg the pump). It will then light whenever the relay switches on. During development testing of the intercooler spray, we had a piezo beeper in the cabin performing the same function.

Intelligent Intercooler Water Spray - Part 1
Intelligent Intercooler Water Spray - Part 2
Intelligent Intercooler Water Spray - Part 3
Intelligent Intercooler Water Spray - Part 4

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The Intelligent Intercooler Water Spray Controller is available from the AutoSpeed Shop.

Click here to order

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