gear based high performance electronic boost controller user manual
Contents
1. 2015 9 Start Duty Cycle Adjusting Start Duty Cycle will have a very similar effect to adjusting a manual boost controller A constant Start Duty Cycle setting will usually produce a boost curve that spikes to a peak value and then gradually tapers as engine speed increases Boost taper can be offset by increasing Start Duty Cycle in the appropriate engine speed ranges when utilizing the ml and mA Control Map User Levels Maximum Possible Boost Start Duty Cycle 100 0 Boost Level Wastegate Spring Pressure Start Duty Cycle 0 0 Peak Boost Level vs Start Duty Cycle Control Duty Cycle Control Duty Cycle is calculated by the Cortex EBC logic based on the Desired Boost and Gain Level settings APID Proportional Integral Derivative style control algorithm is utilized by the Cortex EBC to determine the Control Duty Cycle This type of controller uses three sub algorithms whose outputs are summed together to form the final control signal On the Cortex EBC these sub algorithms are referred to as Direct Control Cumulative Control and Rate Control for those who have experience with P D control these correspond to Proportional Integral and Derivative algorithms respectively Direct Control Cumulative Control gt Control Duty Cycle Rate Control Cortex EBC Control Duty Cycle Calculation Each control sub algorithm outputs a duty cycle which can be positive or negative The input to each control sub algorithm is Boos2. Cortex Nexus software For detailed usage instructions visit https sirhclabs com cortex ebc fa Cortex Nexus Editor The Cortex Nexus Editor is the primary component of the software application and will be active when the Cortex Nexus is first launched on your computer The primary actions that can be completed with the Cortex Nexus Editor are e A USB connection can be established with the Cortex EBC device e Control Map Vehicle Configuration and Output Configuration files can be created edited saved to or opened from your computer transferred to from the Cortex EBC device e The Cortex Nexus Logger can be accessed e The basic preferences for the program can be set e The Cortex EBC device firmware can be updated Cortex Nexus Editor 1 0 0 File Device Logger Advanced e A comez W O e BH B A E An 3 Ex Cortex Nexus Editor Window Cortex EBC User Manual SIRHC Labs LLC 2015 18 Cortex Nexus Logger The Cortex Nexus Logger can be used to collect and display vehicle and control information from the Cortex EBC in real time This information can be used to help make the best decisions possible when adjusting control and output settings on the Cortex EBC In addition the Cortex Nexus Logger includes an extremely powerful Road Dyno Power Calculator which estimates your vehicle s horsepower and torque based on vehicle sensor data While collecting data from the Cortex EBC new information is transmitted at t
3. Cycle Limit sets the duty cycle to apply to the 3 Port BCS while boost pressure is less than the Spring Pressure Limit setting Spool Duty Cycle Limit 0 0 100 0 96 NOTE A setting of 0 096 will cause the Cortex EBC to use the Start Duty Cycle table values instead of the Spool Duty Cycle Limit when boost is below the Spring Pressure Limit The Cumulative Duty Cycle Limit sets the maximum allowable duty cycle contribution for Cumulative m the Cumulative Control algorithm 0 0 100 0 96 Duty Cycle Limit NOTE Setting this limit to 0 0 will disable the Cumulative Control algorithm Control Map Profile Limit Settings Cortex EBC User Manual SIRHC Labs LLC 2015 5 Control Map User Level There are 3 Control Map User Levels to choose from when setting boost with the Cortex EBC basic tuning mB intermediate tuning ml and advanced tuning mA The resolution at which Control Map parameters can be set is determined by the Control Map User Level USER LEVEL CONTROL MAP PARAMETER RESOLUTION Le Desired Boost and Start Duty Cycle ImB o 1 Point Per Gear 1 Set Per Profile 1 Set Per Profile 16 RPM Dependent Points Per Gear 1 Set Per Gear 1 Set Per Profile mA 64 Points Per Gear 16 RPM x 4 Throttle Position 1 Set Per Gear 1 Set Per Profile Control Map Parameter Resolution vs User Level Cortex Nexus Editor 10 0 coc o File Device Logger Advanced a Cr S HE oo m amp Cortex EBC mB Control Map PROF
4. Verify engine speed is being calculated correctly by the Cortex EBC before collecting EVS Ratio values 8 Reopen Vehicle Configuration window and enter the values collected in Step 7 into the appropriate fields in the TPS Scaling and Gear Detection sections 9 Click the Write button at the bottom of the Vehicle Configuration window to store the settings to the Cortex EBC 10 Close the Vehicle Configuration window 11 Use the Cortex Nexus Logger or the display on the front of the Cortex EBC device to verify that gear and throttle position are being calculated correctly by the Cortex EBC Cortex EBC User Manual SIRHC Labs LLC 2015 37 Boost Control Verification The final step of the installation process is to verify that you are able to control boost with the Cortex EBC Guidelines 1 Establish a USB connection with your Cortex EBC device in the Cortex Nexus Editor and create a new mB User Level Control Map file Transfer the Control Map to your Cortex EBC device without making any changes to the settings Set your Cortex EBC to use Control Map Profile 1 for boost control Open the Cortex Nexus Logger and capture a Data Log at full throttle You will want to capture as much data as possible starting from around 1500 RPM and going all the way to redline You can use any gear but 3rd or 4th is usually ideal Review the Data Log and examine the Actual Boost curve while you are at full throttle You should reach a peak boost t
5. compare Actual Boost to Desired Boost in your Data Logs After setting Desired Boost your goal will be to adjust Start Duty Cycle until you have little to no Boost Error in your Data Logs Because the Gain Levels are zeroed out in the simple approach Desired Boost settings will have no actual influence on your boost curve The RPM based Start Duty Cycle mapping available in the ml and mA Control Map User Levels can be used to fine tune many aspects of your boost curve when using the simple control approach Rise time can be reduced by increasing Start Duty Cycle at lower engine speeds overshoot can be reduced by lowering the Start Duty Cycle around the RPM full boost is reached and steady state response can be improved by increasing decreasing Start Duty Cycle in the appropriate RPM ranges to offset falling or rising boost conditions Procedure 1 Set all Gain Level settings to 0 0 to disable Direct Cumulative and Rate Control algorithms 2 Adjust Start Duty Cycle until acceptable boost curve is obtained Guidelines for Control Map Settings e Boost Limit Set as desired e Spring Pressure Limit Set to be 0 5 1 0 PSI less than your wastegate spring pressure e End Duty Cycle Limit 100 0 96 e Spool Duty Cycle Limit Adjust until acceptable boost curve is achieved or leave at 0 0 e Cumulative Duty Cycle Limit 0 0 e Desired Boost Use as guideline for Start Duty Cycle adjustments or leave at 0 0 PSI e Start Duty Cycle Adjust until ac
6. delay that occurs before the output is activated when the mode is first set to On o Thereisa 4 second delay that occurs before the output is activated when device is powered e When the output is set to Device it will be activated based on the Output Configuration file settings loaded into the device The programmable outputs on the Cortex EBC are controlled using window logic This type of logic uses two thresholds to determine if the output should be activated a Turn on Threshold and a Turn off Threshold The output is only activated if the input values for all enabled windows are between their respective Turn on and Turn off thresholds with a few exceptions The parameters used to control the outputs are stored within an Output Configuration file These parameters are broken into the following categories Output 1 and 2 Window Settings e Boost Window Settings e Engine Speed Window Settings e Throttle Position Window Settings e Gear Based Settings e Output Inversion Settings Progressive Settings e PWM Frequency Settings e Output 1 Progressive Settings e Output 2 Progressive Settings Output Configuration settings can only be modified using the Cortex Nexus software application and cannot be changed with the controls on the front of the Cortex EBC device Cortex EBC User Manual SIRHC Labs LLC 2015 39 PARAMETER DESCRIPTION RANGE The boost pressure above which the output should be activated This threshold can only
7. description above for more details RPM Detection Settings PARAMETER DESCRIPTION RANGE Minimum TPS Voltage Maximum TPS Voltage Minimum TPS Voltage is used by the Cortex EBC to calculate the angle of your throttle pedal This parameter should be set to match voltage produced by your 0 0 12 0 Volts vehicle s throttle position sensor when the throttle pedal is fully closed Maximum TPS Voltage is used by the Cortex EBC to calculate the angle of your throttle pedal This parameter should be set to match the voltage produced by 0 0 12 0 Volts your vehicle s throttle position sensor when the throttle pedal is fully open TPS Scaling Settings PARAMETER DESCRIPTION RANGE Gear 1 6 EVS Ratio EVS Ratio stands for Engine to Vehicle Speed Ratio This value is calculated by the Cortex EBC whenever the vehicle is moving The Gear 1 6 EVS Ratio parameters should be set to match the EVS Ratio calculated by the Cortex EBC Cortex EBC User Manual while driving in each gear Gear Detection Settings SIRHC Labs LLC 2015 17 CORTEX NEXUS SOFTWARE OVERVIEW Adjusting Control Map Vehicle Configuration or Output Configuration settings requires the use of a laptop computer running the Cortex Nexus software application A copy of the software is not provided with the Cortex EBC but can be downloaded online at any time from https sirhclabs com cortex ebc downloads This section provides a very basic overview of the
8. ratio over your wastegate spring pressure For example with a 5 PSI wastegate spring the maximum boost pressure that can be achieved will be between 10 and 20 PSI If your Spring Pressure Limit setting is too high it may simply be impossible to achieve changing your exhaust wastegate configuration If boost pressure does not increase at all when Start Duty Cycle is set to 100 check that you have installed the 3 Port BCS correctly Also verify that you are making changes to Profile 1 in the Control Map and you have the Cortex EBC set to use Profile 1 for boost control Cortex EBC User Manual SIRHC Labs LLC 2015 38 CORTEX EBC PROGRAMMABLE OUTPUTS The Cortex EBC hardware includes two highly programmable outputs which can be used to drive a variety of devices These outputs can be activated based on boost pressure engine speed and or throttle position In addition progressive control can be added with output ramping based on boost engine speed or time There are three modes of operation available for each output Off On and Device The output mode is set using the buttons on the front of the Cortex EBC device If boost control is disabled on the Cortex EBC Control Map Profile set to OFF the outputs will ALWAYS be inactive regardless of the output operation mode e When the output is set to Off it will always be inactive e When the output is set to On it will always be active except for the following situations o There isa 2 second
9. 29 Wiring Instructions The Cortex EBC requires five connections to be made between the Cortex EBC wiring harness and your vehicle s electrical system On many cars manufactured between 1988 and 2007 the necessary signals can easily be found in a common location at the ECU Engine Control Unit On vehicles manufactured after 2007 some of these signals may no longer be available at the ECU but can usually still be found elsewhere in the electrical system gauge panel other control units sensors outputs etc Required Parts e Cortex EBC Wiring Harness e Fuse Holder and 2 Amp Fuse Guidelines 1 Disconnect the vehicle s negative battery terminal 2 Place the 10 pin connector of the Cortex EBC wiring harness near the Cortex EBC device 3 Connect the wiring harness to power and ground 4 Connect the wiring harness to appropriate throttle position engine speed and vehicle speed signals 5 Cover the ends of programmable outputs 1 and 2 and tuck them away in a safe place until installation process is complete and the Cortex EBC has been setup for your vehicle 6 Route the black sub harness connector into the engine bay to the location you plan to mount the 3 Port BCS 7 Plug the 10 pin wiring harness connector into the back of the Cortex EBC device The harness should be plugged in such that the purple red orange and black wires are towards the TOP of the Cortex EBC device Cortex EBC Wiring Harness Orientation empty p
10. CORTEX EBC GEAR BASED HIGH PERFORMANCE ELECTRONIC BOOST CONTROLLER USER MANUAL Rev 1 2 0 Table of Contents INTRODUCTION Mover ccc CT A A 4 CORTEX EBC CONTROL MAP essor xg pa d dnra nie vibus ve ew E LAUS dave qu Pe eie uoa eu Se ubev pa tens E ora EE S UqU US P PO UE skies QUE VIRO EAE V REI UEDS 5 Control Map User Level lt a 6 CONTROL THEORY t n 8 Mac stdte soie ddnde mei EN MI I MI MM uM eM M 9 SDOOLSEdte uoc etie e AA A tem uc cubi A Leute pe pt ee er eee eee 9 CONT OLST er A A A A A cub c d LO eee Tu MD ere D I LA UE QUE 9 O isla d A TEE 10 Control Duty Cicle I OO Y 10 VETO OS UO TTE 12 SETTING BOOST WITH THE CORTEX EBC i no eei vh oe SR Ve SHE S Sea du UTR Ve S Uo vC Ya e EAR AI Rb eo ag au o apo NU EY Ka EN RE 13 Simple Approach Use Start Duty Cycle Oli AA dude nem 14 PROC NR NT UN NINE NH OT RNC A E ME CORN 14 Guidelines TO Control MapSettines maraca 14 Parameters to Watch in Data LBS ae A de dip uu Rabe uic des ated coi est esu CP eU EEE A LLhf 14 In Depth Approach Use Start Duty Cycle and Gain Levels ooocccccnoccnnonnncnnnonaconnnnanonnonanonnnonarononnononnnnoncnnnonaronnonanonnos 15 Procedure TO TRO D DT m nn nei hd Saveahe leat bbs a sie tad phalantesvaselacas 15 Guidelines ror Control Map CUNA 15 Parameters to Watch lA Dato OBS i test it desti via coccion ici Rua Rs Geta idiaads 15 Keys I
11. ERS DESCRIPTION RANGE Gear 1 6 Ratio The gear ratio for each gear inside the vehicle s transmission 0 000 9 999 Final Drive Ratio The final drive ratio for the vehicle s drivetrain 0 000 9 999 Gear Ratio Settings VEHICLE PARAMETERS DESCRIPTION RANGE Mass Theweightofthevehideandallofitscontent 0 10000lbs Vehicle Settings ENVIRONMENT PARAMETERS DESCRIPTION RANGE The outside temperature when the Data Stream Log was collected 0 120 F The barometric pressure when the Data Stream Log was collected 0 00 15 00 PSI Environment Settings Cortex EBC User Manual SIRHC Labs LLC 2015 20 CORTEX EBC DEVICE OPERATION As discussed earlier Control Map Vehicle Configuration and Output Configuration settings can only be modified using the Cortex Nexus application However the two buttons located on the front of the Cortex EBC are used to control the basic behavior of the Cortex EBC device SCROLL SELECT Cortex EBC Device Front Panel Under most circumstances the Cortex EBC device display will act as a gauge and can be configured to display the value of numerous parameters The buttons on the front of the Cortex EBC can be used to 1 Change the gauge display parameter 2 Change the active Control Map profile 3 Disable boost control 4 Enable disable external outputs 5 Adjust the LED intensity of the display The flow diagrams in the following pages provide instru
12. ILE 1 GEAR 1 6 Y w Profile 1 v p Tables DESIRED BOOST PSI VS GEAR Op Limia O 10 Copy Paste A Limits gt ME Profile 2 lt a gt ME Profilo 3 m Profile 4 gt ME Profile 5 gt MD Profile 6 START DUTY CYCLE VS GEAR OG OG o 1 2 3 E 5 6 GAIN 5 PSI O 10 Copy Paste mB User Level Control Map Tables one table set per profile Qcesesuedo O A A AAA tl Ete Device Logger Advanced co amp HB 00 ms Cortex EBC mi Control Map PROFILE 1 GEAR 1 Y w Profile 1 Y Tables DESIRED BOOST PSI VS ENGINE SPEED RPM Hi Gear2 O G 10 Copy Paste HE cear 3 BB Gear 4 1000 1500 2000 2400 5000 3500 4600 4500 5000 5500 8000 eso 7000 7500 8000 500 BH Gears A vs o0 Tea wo we wo we we we HH Gear 6 iw Limits Amit I Profile 2 im Profiles imn Profile 4 im Profile 5 B Profile 6 START DUTY CYCLE VS ENGINE SPEED RPM GOOO 10 1500 2000 2500 3000 3500 4000 4500 saoo 5500 6000 6500 1000 T7500 BO00 2500 GAIN PSI So OO ww ml User Level Control Map Tables one table set per gear Cortex EBC User Manual SIRHC Labs LLC 2015 6 mmm y co cO OOOO O OO CO OO O Oo C5 amp 2 co cO OOOO O SO O O O Co O O O C O vd O wv O wu O wv O WM OW O ud O HO O AN N n U lt lt UU u5 LO wu PFP P 00 00 On 00 mA User Level Control Map Gain Table one table per profile Cort
13. Manual SIRHC Labs LLC 2015 44 The solid state relay and standard relay should be wired as shown in the following diagram A master override switch should also be included as shown in the diagram To Switched Fused 12V L MASTER OVERRIDE SWITCH To Chassis Ground To Positive Battery Terminal m c m ttm STANDARD RELAY To Cortex EBC SOLID STATE d Wiring Harness zd RELAY zi iio No Connection Cortex EBC User Manual SIRHC Labs LLC 2015 45 APPENDIX 1 CORTEX EBC DISPLAY PARAMETER LIST BOOST PARAMETERS DISPLAY RANGE DISPLAY MNEMONIC Actual Pressure APr The current turbocharger outlet pressure Actual 0 0 36 0 PSI Boost Desired Pressure dPr The Desired 0 0 36 0 PSI Boost for the control period DUTY CYCLE PARAMETERS DISPLAY RANGE DISPLAY MNEMONIC End Duty Cycle EdC The End Duty Cycle 0 0 100 for the control period Start Duty Cycle SAC The Start Duty 0 0 100 Cycle for the control period CONTROL PARAMETERS DISPLAY RANGE DISPLAY MNEMONIC Direct Duty Cycle ddC The Direct 99 100 Control Duty Cycle for the control period RA Cumulative Duty Cycle CdC The Cumulative Control Duty Cycle for the 99 100 96 control period Rate Duty Cycle rdC The Rate Control 99 100 96 Duty Cycle for the control period Cortex EBC User Manual SIRHC Labs LLC 2015 VEHICLE PARAMETERS DISPLAY RANGE DISPLAY MNEMONIC Throttle Po
14. OTTLE PLATE IN THE THROTTLE BODY To Cortex EBC Pressure Port Firewall daiRasanRAREAANAMA 1 8 ID Hose Throttle Body Turbo Intercooler Engine Cortex EBC User Manual SIRHC Labs LLC 2015 32 3 Port BCS Installation The Cortex EBC has been designed to be compatible with both internal actuator type and external wastegate configurations How the 3 Port BCS is connected to your turbocharger system depends on your wastegate type WARNING FAILURE TO FOLLOW THE DIAGRAM CORRESPONDING TO YOUR WASTEGATE TYPE WILL RESULT IN UNPREDICTABLE BOOST BEHAVIOR AND POSSIBLE DAMAGE TO YOUR ENGINE Required Parts e 3 Port BCS e Zip Ties e 3 16 Silicone Vacuum Hose e 3 16 Hose Barbs e 3 16 Hose Tee optional Guidelines 1 Thread the 3 16 Hose Barbs into the 3 Port BCS 2 Connect the 3 Port BCS to turbocharger system using the supplied 3 16 Vacuum Hose 3 Plug the 3 Port BCS into the connector on the Cortex EBC wiring harness 4 Use the supplied zip ties to secure all hose connections Cortex EBC User Manual SIRHC Labs LLC 2015 33 Internal Wastegate Actuator Configuration SIRHC LABS BCS SIRHCLABS COM Compressor Outlet Compressor Inlet a 5 BANANA TETAS peepee Turbocharger Wastegate Actuator BCS Port 1 Leave open or connect to pre turbocharger intake tract BCS Port 2 Connect to wastegate actuator pressure port BCS Port 3 Connect to compressor outlet on tur
15. RHC Labs LLC 2015 8 Vacuum State The vacuum state is active whenever boost pressure is less than 0 0 PSI In this condition the Cortex EBC will disable the 3 Port BCS by setting End Duty Cycle to 0 0 96 Spool State The spool state is active whenever boost pressure is greater than 0 0 PSI but less than the Spring Pressure Limit setting During this time the vehicle is under load and the turbocharger has started building boost However boost is still essentially uncontrollable and the Cortex EBC will utilize a simplified algorithm for boost control In the spool state End Duty Cycle will be set according to the following table SPOOL DUTY CYCLE LIMIT SETTING END DUTY CYCLE IN SPOOL STATE Spool Duty Cycle Limit 0 096 End Duty Cycle Start Duty Cycle Spool Duty Cycle Limit gt 0 0 End Duty Cycle Spool Duty Cycle Limit End Duty Cycle Calculation for Spool State If no duty cycle is applied to the 3 Port BCS in the spool state the turbocharger s wastegate will begin to crack open as its spring pressure is approached This cracking behavior can be beneficial as it reduces pressure spikes that might occur as full boost is reached but it can also extend the time required for full boost to be achieved By applying a duty cycle to the 3 Port BCS in the spool state wastegate cracking can be delayed or completely eliminated When increasing boost significantly above your wastegate spring pressure the Spring Pressure Limit setting ca
16. al Pressure o AP re sca o dPre Display Desired Pressure S L S L s o edt o EP MN S L S L B o Edie o r EUe s S L S L s o dato o SPde E S L S L s o EdEo o EUS ME S L S L M o 5dto o JEre a Cortex EBC User Manual SIRHC Labs LLC 2015 23 Cortex EBC Profile Menu After entering the profile menu the Cortex EBC will display a number corresponding to the active Control Map profile or it will display oFF if boost control is disabled To change the active Control Map profile or to disable boost control repeatedly press the SCROLL button to navigate through the available menu options Press the SELECT button to save the selection and exit the menu system Use Profile 1 Use Profile 2 Use Profile 3 Use Profile 4 Use Profile 5 Use Profile 6 Disable Boost Control Jg uy 9 SEE 9 Cortex EBC User Manual SIRHC Labs LLC 2015 24 Cortex EBC Output Menus After entering one of the output menus the Cortex EBC will display oFF if the output is currently disabled or on if the output is currently enabled The state of the output can be toggled by pressing the SCROLL button Press the SELECT button to save the selection and exit the menu system torr me maso Output Off Output On Test Device Output Control Cortex EBC User Manual SIRHC Labs LLC 2015 25 Cortex EBC LED Brightness Menu After entering the LED brightness menu the Cortex EBC will display the lett
17. arameters which are stored within a Vehicle Configuration file Vehicle Configuration settings are broken into three categories e RPM Detection e TPS Scaling e Gear Detection Vehicle Configuration se with the controls on the ttings can only be modified using the Cortex Nexus software application and cannot be changed front of the Cortex EBC device PARAMETER DESCRIPTION RANGE Engine Configuration Fuel Injector Drive Double RPM The Engine Configuration parameter tells the Cortex EBC how to correctly interpret engine speed signals from your vehicle This parameter should be set to match the number of cylinders in your vehicle s engine NOTE If you have a 2 3 or 5 cylinder engine you will need to utilize the Double RPM setting described below For 2 cylinder engines set Engine Configuration to 4 cylinder and select the 4 6 8 10 Cylinder Double RPM option For 3 cylinder engines set Engine Configuration to 6 cylinder and select the double RPM option For 5 cylinder engines set Engine Configuration to 10 cylinder and select the double RPM option The Fuel Injector Drive parameter is used to correct engine speed detection for certain engine speed signal types This option should be selected if using a fuel True or False injector drive signal as the engine speed input to the Cortex EBC This setting is used to correct RPM readings for 2 3 and 5 cylinder engines See we True or False the Engine Configuration
18. be edited if the Enable Boost Window option is Boost Turn on Threshold PESCE 0 0 36 0 PSI NOTE A setting of 0 0 will cause the boost window to be activated whenever boost is less than the Boost Turn off Threshold The boost pressure below which the output should be activated This threshold can only be edited if the Enable Boost Window option is Boost Turn off Threshold SEHE 0 0 36 0 PSI NOTE A setting of 36 0 will cause the boost window to be activated whenever boost is greater than the Boost Turn on Threshold Selecting this option will include boost pressure in activation logic for Boost Window Settings PARAMETER DESCRIPTION RANGE The engine speed above which the output should be activated This threshold can only be edited if the Enable RPM Window option is selected Engine Speed Turn on Threshold 0 8 500 RPM NOTE A setting of O RPM will cause the engine speed window to be activated whenever engine speed is less than the Engine Speed Turn off Threshold The engine speed below which the output should be activated This threshold can only be edited if the Enable PRM Window option is Engine Speed SEIS CHER Turn off Threshold 0 8 500 RPM NOTE A setting of 8 500 RPM will cause the engine speed window to be activated whenever engine speed is greater than the Engine Speed Turn on Threshold actine this optio willanel ato IOS EGER Enable RPM Window Mi AE is option will include eng
19. bocharger Cortex EBC User Manual SIRHC Labs LLC 2015 34 External Wastegate Primary Configuration SIRHC LABS BCS SIRHCLABS COM Compressor Outlet Compressor Inlet Turbocharger BCS Port 1 Leave open or connect to pre turbocharger intake tract BCS Port 2 Connect to side port on external wastegate BCS Port3 Connect to compressor outlet on turbocharger Cortex EBC User Manual SIRHC Labs LLC 2015 Wastegate 35 External Wastegate Alternate Configuration This configuration will allow the Cortex EBC to apply equal pressure to the top and bottom ports of the external wastegate Using this configuration can help increase the maximum boost pressure that can be achieved and also improve the responsiveness of the wastegate valve SIRHC LABS BCS SIRHCLABS COM CUIDADA Compressor Outlet AA Compressor Inlet Turbocharger Wastegate BCS Port 1 Connect to compressor outlet on turbocharger AND side port of external wastegate using 3 16 hose tee BCS Port 2 Connect to top port of external wastegate BCS Port 3 Cortex EBC User Manual SIRHC Labs LLC 2015 36 Vehicle Configuration Setup After installing the Cortex EBC a Vehicle Configuration file must be created for your vehicle and transferred to the Cortex EBC device This needs to be done before you attempt to make any adjustments to Control Map settings for boost control To create a Vehicle Configuration file f
20. bove The cursor line can be moved by manipulating the slider bar between the data table and graphing area with the mouse or by using the left and right arrow keys on the keyboard Q 12 285 Cortex Nexus Logger Data Table and Cursor Slider Bar Cortex EBC User Manual SIRHC Labs LLC 2015 19 Road Dyno Power Calculator The Cortex Nexus Logger includes a power calculation algorithm that can be used to display horsepower and torque estimates based on the data collected from the Cortex EBC device For the Road Dyno Power Calculator to work properly you must provide the Cortex Nexus Logger with the following information e The gear and final drive ratios utilized in your drivetrain e The size of the tires on your vehicle e The weight frontal area and coefficient of drag of your vehicle e The outside temperature and barometric pressure during the Data Stream or Log This information is used to calculate the power required to accelerate your vehicle based on its weight in addition to the power required for your vehicle to push through the air Road Dyno Configuration File The settings used by the Cortex Nexus Logger to perform power calculations are stored within a Dyno Configuration File Road Dyno Configuration settings are broken into Gear Ratio Vehicle and Environment categories NOTE Road Dyno Configuration settings are accessed from the Cortex Nexus Logger portion of the Cortex Nexus software application GEAR RATIO PARAMET
21. ce this condition reducing the Valve Off Latency setting will lengthen the maximum control pulse that can be applied to the 3 Port BCS This will increase the maximum boost pressure that can be achieved as long as boost is not being limited by exhaust manifold backpressure In other cases the 3 Port BCS may need to bleed off a significant amount of air before boost pressure begins to increase If you experience this condition increasing the Valve On Latency setting will lengthen the minimum control pulse that can be applied to the 3 Port BCS This will increase the boost pressure achieved at low duty cycles PARAMETER DEFAULT SETTING TYPICAL RANGE FOR OPTIMAL PERFORMANCE Valve On Latency 6 8 12 Valve Off Latency 20 30 The Valve On Latency and Valve Off Latency settings can only be adjusted using the Cortex Nexus Software To access the settings you must have Cortex Nexus Version 1 2 0 at minimum and Cortex EBC Firmware Version 1 2 1 at minimum The latest software firmware can be downloaded from https sirhclabs com cortex ebc downloads NOTE As of 8 12 2015 an initial valve latency adjustment is performed during production and the Solenoid Valve Latency settings should not require any changes Cortex EBC User Manual SIRHC Labs LLC 2015 48
22. ceptable boost curve is achieved e Gain Levels 0 0 Parameters to Watch in Data Logs e Desired Boost e Actual Boost e Boost Error e Start Duty Cycle e End Duty Cycle e Engine Speed e Throttle Angle e Gear Cortex EBC User Manual SIRHC Labs LLC 2015 14 In Depth Approach Use Start Duty Cycle and Gain Levels For most applications optimal control characteristics will be obtained by using Start Duty Cycle to create a baseline for boost control and then using the Direct Cumulative and Rate control algorithms to provide smaller adjustments You will essentially use the simple approach described on the previous page to obtain a rough outline for boost control and then use the Gain Levels to fine tune your boost curve Procedure 1 Set all Gain Level settings to 0 0 to disable the Direct Rate and Cumulative Control algorithms 2 Set Desired Boost to create a target for boost control 3 Adjust Start Duty Cycle until Actual Boost is within 1 0 2 0 PSI of Desired Boost Adjust Desired Boost from Step 2 as needed to get Boost Error within acceptable range It is usually best if Actual Boost does not exceed Actual Boost at this stage 4 Adjust the Cumulative Gain Level and Cumulative Duty Cycle Limit to eliminate Boost Error in steady state response 5 Adjust Direct Gain Level Rate Gain Level End Duty Cycle Limit and Spool Duty Cycle Limit to dial in rise time and overshoot 6 Fine tune all parameters as necessary Guidel
23. ctions for performing each action In general the actions are carried out in the following manner 1 Pressthe SELECT lower button to enter the main menu 2 Usethe SCROLL upper button to navigate to the desired sub menu 3 Pressthe SELECT lower button to enter the sub menu 4 Usethe SCROLL upper button to navigate to the desired sub menu option 5 Pressthe SELECT lower button to finalize the selection and exit the menu NOTE When scrolling through the available sub menu options the changes take effect as the SCROLL button is pressed They DO NOT occur when the SELECT button is pressed and the menu system is exited Cortex EBC User Manual SIRHC Labs LLC 2015 21 Cortex EBC Main Menu To enter the Main Menu press the SELECT button on the front of the Cortex EBC device To navigate through the menu options press the SCROLL button Press the SELECT button to move onto the next menu sect Profile Menu sect tm sar Display Brightness Menu Cortex EBC User Manual SIRHC Labs LLC 2015 22 Cortex EBC Display Parameter Menu After entering the display parameter menu the Cortex EBC will display the mnemonic for the active parameter To change the active parameter repeatedly press the SCROLL button to navigate through the available menu options Press the SELECT button to save the selection and exit the menu system See Appendix 1 for detailed descriptions of each display parameter Display Actu
24. d on BOTH OUTPUTS The frequency setting should be set according to the devices PWM Frequency being controlled When utilizing the progressive control features on 1 1000 Hz both outputs the devices must be able to operate at the same PWM frequency Base Duty Cycle The minimum duty cycle to produce on the output once window 0 0 100 0 96 requirements are met Final Duty Cycle The maximum duty cycle to produce on the output when while window 0 0 100 0 96 requirements are met The rate at which duty cycle should be increased from Base Duty Cycle Ramp Rate to Final Duty Cycle The exact duty cycle change will depend on the type 0 0 100 0 96 of progressive control being utilized Selecting this option will enable boost based progressive control for the Boost Based Ramp output The duty cycle wil be increased by the value of Ramp Rate for True or False every 1 0 PSI increase in boost pressure above the Boost Turn on Threshold To use this option Enable Boost Window must be set to Yes Selecting this option will enable engine speed based progressive control for the output The duty cycle will be increased by the value of Ramp Engine Speed Based Ramp Rate for every 100 RPM increase in engine speed above the Engine True or False Speed Turn on Threshold To use this option Enable RPM Window must be set to Yes Selecting this option will enable time based progressive control for the Time Based Ramp output The duty cycle will be inc
25. ect Control algorithm Direct Gain Level Kp NOTE A setting of 0 0 will disable the Direct Control algorithm f The Cumulative Gain Level sets the aggressiveness of the Cumulative Control algorithm Cumulative in Level K Gain Level Ka NOTE A setting of 0 0 will disable the Cumulative Control algorithm The Rate Gain Level sets the aggressiveness of the Rate Control algorithm Rate Gain Level Kp NOTE A setting of 0 0 will disable the Rate Control algorithm Control Map Table Settings PARAMETER DESCRIPTION RANGE The Boost Limit sets the boost level over which the Cortex EBC will disable boost control This threshold is used to protect engines from excessive boost conditions 0 0 36 0 PSI NOTE A setting of 36 0 PSI will disable the Boost Limit feature The Spring Pressure Limit should be set to the spring pressure of your turbocharger s Spring Pressure Limit wastegate When boost is below wastegate spring pressure the Cortex EBC will deactivate the Direct Cumulative and Rate control algorithms and use only Start Duty Cycle or the Spool Duty Cycle Limit for boost control The End Duty Cycle Limit sets the maximum duty cycle that can be applied to the 3 Port BCS This can be used to provide additional overboost protection and also improve End butyeyeletinik one e Re monmante 0 0 100 0 96 NOTE The End Duty Cycle Limit is only active if boost pressure is higher than the Spring Pressure Limit setting The Spool Duty
26. er b and a number corresponding to the current brightness level To change the LED intensity repeatedly press the SCROLL button to navigate through the available menu options Press the SELECT button to save the selection and exit the menu system sar Use Bright Level 1 sect Use Bright Level 2 seor Use Bright Level 3 seor Use Bright Level 4 seor Use Bright Level 5 Cortex EBC User Manual SIRHC Labs LLC 2015 26 INSTALLATION INSTRUCTIONS It is strongly recommended that the Cortex EBC be installed by an automotive professional Use an appropriate metering device to ensure engine speed vehicle speed and throttle position signals are within the specified operating range for the Cortex EBC device Improper installation may result in damage to your vehicle and or the Cortex EBC device After installing the Cortex EBC device you MUST correctly configure the Cortex EBC Vehicle Configuration settings to correctly interpret your vehicle s electrical signals using the Cortex Nexus software application The Cortex EBC installation process requires the completion of 5 steps 1 Connect the Cortex EBC wiring harness to the correct signals in your vehicle s electrical system 2 Connect the Cortex EBC device to a suitable intake manifold pressure reference 3 Connect the 3 Port BCS to the vehicle s turbocharger and wastegate 4 Create a Vehicle Configuration file for the Cortex EBC to correctly interpret electrical signa
27. ex EBC User Manual SIRHC Labs LLC 2015 CONTROL THEORY The Cortex EBC adjusts boost by utilizing a 3 Port BCS Boost Control Solenoid to control the behavior of your turbocharger s wastegate The signal applied to the 3 Port BCS by the Cortex EBC is defined by a duty cycle which is essentially the percentage of time the 3 Port BCS is activated In general increasing duty cycle will act to increase boost above the wastegate spring pressure e The Cortex EBC updates the 3 Port BCS duty cycle 16 times per second e Acomplete activation deactivation cycle of the 3 Port BCS is called a control period e The duty cycle output to the 3 Port BCS during each control period is called End Duty Cycle 62 5 ms 15 6 ms ACTIVE DUTY CYCLE 12 9 S x 400 25 0 62 5 ms INACTIVE Cortex EBC 3 Port BCS Drive Signal The method used by the Cortex EBC to determine End Duty Cycle depends on boost pressure and the parameter settings for the active Control Map profile Based on these factors the Cortex EBC will operate in the vacuum spool control or overboost state Spool 0 0 PSI lt Boost Pressure lt Spring Pressure Limit Spool Duty Cycle Limit or Start Duty Cycle 0 0 PSI Spring Pressure Limit Boost Limit Spool Duty Cycle Limit Boost Level End Duty Cycle i Start Duty Cycle Control Duty Cycle Boost Level Cortex EBC Operation States End Duty Cycle vs Boost Level Cortex EBC User Manual SI
28. g PINK Engine Speed Input Input Connect to 0 5V to 0 12V pulsed engine speed signal Pin9 BLACK Chassis Ground Ground Connect directly to clean chassis ground Electrical Signal Descriptions Compatible Engine Speed Signals ECU TACH OUTPUT CAM CRANK ANGLE SENSOR OUTPUT ECU FUEL INJECTOR DRIVE OUTPUT NEGATIVE TERMINAL ON PRIMARY LOW VOLTAGE SIDE OF IGNITION COIL SALS Cortex EBC User Manual SIRHC Labs LLC 2015 31 Cortex EBC Pressure Port Connection To monitor and control boost pressure the Cortex EBC must be connected to an intake manifold pressure reference Required Parts e 1 8 Silicone Vacuum Hose e Zip Ties e 1 8 Hose Tee optional e 1 8 Hose Barb optional e 3 16 Hose Tee optional e 3 16 to 1 8 Hose Reducer optional Guidelines 1 Connect one end of the 1 8 ID Silicone Vacuum Hose to the pressure port on the back of the Cortex EBC device 2 Route the other end of the hose into the engine bay of the vehicle and connect it to a pressure source after the throttle plate Suitable sources include vacuum ports on the throttle body intake manifold or fuel pressure regulator A variety of hose fittings are supplied to assist in making a connection in the engine bay 3 Use the supplied zip ties to secure all hose connections WARNING THE CORTEX EBC PRESSURE PORT MUST BE CONNECTED TO A VACUUM SOURCE ON THE INTAKE MANIFOLD THAT IS LOCATED AFTER THE THR
29. gh e Your Direct and or Cumulative Gain Level setting s are too high To diagnose the cause your overshoot use the Cortex Nexus Logger to determine the setting s that are providing the largest contribution to your End Duty Cycle when the spike occurs Spool Start Direct or Cumulative Duty Cycle After the cause is determined use the Cortex Nexus Editor to make the appropriate changes in your Control Map settings 3 Steady State Response Steady state response refers to the long term characteristics of your boost curve after full boost has been reached and any overshoot has disappeared An ideal steady state response will be as flat as possible with little or no variation occurring in boost level over time Start Duty Cycle and the Cumulative Gain Level will have the largest impact on steady state response Cortex EBC User Manual SIRHC Labs LLC 2015 13 Simple Approach Use Start Duty Cycle Only The easiest way to set boost with the Cortex EBC is to zero out all Direct Cumulative and Rate Gain Level settings and then use Start Duty Cycle to adjust boost Start at 0 0 and slowly increase Start Duty Cycle until you are happy with the Actual Boost curve in your Data Logs This process will involve adjusting 1 64 Start Duty Cycle values per gear depending on the Control Map User Level being utilized You may find it is helpful to use the Desired Boost settings to help guide your Start Duty Cycle adjustments This will allow you to
30. hat is around your wastegate spring pressure This might be as low as 5 or 6 PSI or as high as 20 PSI depending on your wastegate configuration Use the Cortex Nexus Editor to set the Profile 1 Spring Pressure Limit setting to the peak boost pressure you would like to achieve 15 PSI for example Set the Spool Duty Cycle limit to 10 Transfer the settings to the Cortex EBC Capture a data log with the Cortex EBC and review the peak value of Actual Boost achieved during the pull Use the Cortex Nexus Editor to increase the Profile 1 Spool Duty Cycle Limit in 10 increments capturing a Data Log after each change As you increase the Spool Duty Cycle Limit Actual Boost should increase in your Data Logs with each change When the Spool Duty Cycle Limit is increased enough for boost pressure to reach the Spring Pressure Limit set in Step 6 boost will quickly drop back to your wastegate spring pressure At this point boost control has been successfully verified If you are unable to reach the Spring Pressure Limit setting see the troubleshooting section below Troubleshooting If boost pressure only increases a small amount when the Spool Duty Cycle Limit is set to 100 see Appendix 2 for information on adjusting the Solenoid Valve Latency settings to correct the problem Exhaust manifiold backpressure will limit the amount of boost you are able to achieve Typically the maximum boost that can be produced will be limited to a 2 1 4 1 pressure
31. he start of each control period Whenever data is collected from the Cortex EBC the Control Map Vehicle Configuration and Output Configuration settings from the device are stored along with the collected data set If the data set is saved to your computer the device settings from the Cortex EBC will also be saved and can be loaded into the Cortex Nexus Editor for later review by yourself and others Data is displayed by the Cortex Nexus Logger in two different ways 1 A subset of the data collected is plotted against time in a common graphing area In the graphing area the vertical scaling is unique for each displayed parameter so 1 000 for one parameter might be drawn at the same vertical position as 25 for another parameter Parameters that only take on positive values will be scaled such that 0 0 is at the bottom of the graphing area and the maximum displayable value is drawn at the top of the graphing area Parameters that can take on positive and negative values are scaled such that 0 0 is in the middle of the graphing area with negative values drawn in the lower half of the graphing area and positive values drawn in the upper half of the graphing area Cortex Nexus Logger Graphing Area 2 The value for all visible parameters at a single point in time is displayed in a data table beneath the graphing area The point in the graphing area that the values in the data table correspond to is marked by a white vertical cursor line see image a
32. in should be on top Cortex EBC User Manual SIRHC Labs LLC 2015 30 Wiring Diagram WARNING IMPROPER ELECTRICAL CONNECTIONS CAN RESULT IN UNPREDICTABLE BEHAVIOR AND OR DAMAGE TO THE CORTEX EBC DEVICE OR THE VEHICLE S ELECTRICAL SYSTEM SOLDER ANY CONNECTIONS AND INSULATE WITH HEAT SHRINK PREFERRED OR ELECTRICAL TAPE WARNING PIN 3 OF THE CORTEX EBC WIRING HARNESS MUST BE CONNECTED TO A FUSED POWER SOURCE 5A OR SMALLER FUSE FAILURE TO USE A FUSED POWER SOURCE MAY RESULT IN DAMAGE TO THE CORTEX EBC DEVICE WARNING CONNECTING A HIGH VOLTAGE TYPE SIGNAL PEAK VOLTAGE GREATER THAN 16 0V TO THE ENGINE SPEED INPUT MAY RESULT IN DAMAGE TO THE CORTEX EBC DEVICE DO NOT CONNECT THE ENGINE SPEED INPUT TO THE SECONDARY HIGH VOLTAGE SIDE OF AN IGNITION COIL Wire Side of 10 Pin Wiring Harness Connector with Pins Labeled VEHICLE SPEED INPUT CHASSIS GROUND ENGINE SPEED INPUT PROGRAMMABLE OUTPUT 2 THROTTLE POSITION INPUT PROGRAMMABLE OUTPUT 1 SWITCHED FUSED 12V ES NN 3 PORT BCS SUB HARNESS x O E O TY Z Z O O Z Dr e Wiring Harness Diagram PIN COLOR SINAL TYPE REQUIREMENTS Pin2 BLUE 3 PortBCSDrive Switch to Ground Plugsinto3 PortBCS O Pin3 RED Switched Fused 12V Supply Connect to FUSED 12V power source fuse rating 5A or less Pin5 ORANGE Throttle Position Input_ Input Connect to 0 5V to 0 12V throttle position sensor signal EMPTY O ooo ooo Pin
33. ine speed in activation logic for the Engine Speed Window Settings PARAMETER DESCRIPTION RANGE The throttle angle above which the output should be activated This threshold can only be edited if the Enable Throttle Window option is selected Throttle Angle 0 Turn on Threshold oe ee NOTE A setting of 0 0 will cause the throttle position window to be activated whenever throttle position is less than the Throttle Angle Turn off Threshold The engine speed below which the output should be activated This threshold can only be edited if the Enable Throttle Window option is lected Throttle Angle AS 2 0 Turn off Threshold DD NOTE A setting of 100 0 96 will cause the throttle position window to be activated whenever throttle position is greater than the Throttle Angle Turn on Threshold Selecting this option will include throttle angle in activation logic for Throttle Position Window Settings Cortex EBC User Manual SIRHC Labs LLC 2015 40 PARAMETER DESCRIPTION RANGE If selected the output logic will be enabled for the corresponding gear Gear1 6 True or False At least one gear must be selected for the output logic to be enabled Gear Based Settings PARAMETER DESCRIPTION A CTS Selecting this option will invert the signal for the output Use this True or False option with caution Output Inversion Settings PARAMETER DESCRIPTION RANGE This sets the frequency for the PWM signal produce
34. ines for Control Map Settings e Boost Limit Set as desired e Spring Pressure Limit Set to be 0 5 1 0 PSI less than your wastegate spring pressure e End Duty Cycle Limit Start at 100 0 96 reduce if necessary e Spool Duty Cycle Limit Adjust until acceptable boost curve is achieved or leave at 0 0 96 e Cumulative Duty Cycle Limit Set to 5 0 to start Increase if necessary e Desired Boost Set as desired e Start Duty Cycle 0 0 e Gain Levels Adjust until acceptable boost curve is achieved Parameters to Watch in Data Logs e Desired Boost e Actual Boost e Boost Error e Start Duty Cycle e End Duty Cycle e Direct Duty Cycle e Cumulative Duty Cycle e Rate Duty Cycle e Engine Speed e Throttle Angle e Gear Cortex EBC User Manual SIRHC Labs LLC 2015 15 Keys Items to Remember When Adjusting Boost Each time changes are made to a Control Map in the Cortex Nexus Editor the settings must be transferred to the Cortex EBC device for them to take effect Only adjust one Control Map setting at a time Capture a Data Log after each change to analyze its effects on your boost curve Make sure the Cortex EBC is set to use Control Map profile that adjustments are being made to Make sure you are making changes to the correct tables for each gear Cortex EBC User Manual SIRHC Labs LLC 2015 16 CORTEX EBC VEHICLE CONFIGURATION In order to correctly interpret sensor data from your vehicle the Cortex EBC uses several user definable p
35. ithin three different configuration files Each of these file types can be created and then transferred to from the Cortex EBC device using the Cortex Nexus software application This manual contains detailed descriptions of each file type and how their parameters influence the behavior of the Cortex EBC Additional support resources including highly detailed instructions on using the Cortex Nexus software as well as in depth guides for using your Cortex EBC can be found online at https sirhclabs com cortex ebc fa Cortex EBC User Manual SIRHC Labs LLC 2015 CORTEX EBC CONTROL MAP The settings used by the Cortex EBC for controlling boost are stored within a Control Map file Each Control Map file contains six unique configurations called profiles Each profile is includes the following parameters e Desired Boost Table s e Start Duty Cycle Table s e Gain Level Table s e Profile Limits Control Map settings can only be modified using the Cortex Nexus application and cannot be changed with the controls on the front of the Cortex EBC device PARAMETER DESCRIPTION RANGE Desired Boost defines the set point target for boost control which is the pressure the Cortex EBC will attempt to produce from your turbocharger Desired Boost 0 0 36 0 PSI NOTE For Desired Boost to influence boost control the Direct Cumulative and or Rate Control algorithm s must be enabled The Direct Gain Level sets the aggressiveness of the Dir
36. itions CONDITION RATE CONTROL OUTPUT Boost Error Negative and Decreasing Boost Error Negative and Increasing Boost Error Constant Boost Error Positive and Decreasing Boost Error Postive and Increasing Positive Basic Behavior of Rate Control Algorithm Overboost State The overboost state is active whenever boost pressure exceeds the Boost Limit setting In this state the Cortex EBC will disable all boost control and set End Duty Cycle to 0 0 96 Boost control will remain disabled until the boost level drops back below the Boost Limit When the overboost State is active the display on the front of the Cortex EBC will flash rapidly and the device will output a constant alert buzzer Cumulative Duty Cycle will be reset when control is reactivated Cortex EBC User Manual SIRHC Labs LLC 2015 12 SETTING BOOST WITH THE CORTEX EBC Setting boost with the Cortex EBC is an iterative process in which the various Control Map Profile settings are adjusted until you achieve an acceptable boost curve This can be a very involved process especially when utilizing the ml and mA User Levels This section is intended to provide a high level overview of setting boost with the Cortex EBC When setting boost there are three aspects of your boost curve you will want to consider when analyzing the performance of your control settings 1 Rise Time Rise time is the amount of time it takes to go from 0 0 PSI to full boost It is usually desirable to
37. l from your vehicle 5 Verify that the Cortex EBC is able to control boost pressure Pressure Port 10 Pin Wiring Harness Connector USB Connector Rear Panel of Cortex EBC Device Cortex EBC User Manual SIRHC Labs LLC 2015 27 Included Parts CORTEX EBC DEVICE CORTEX EBC WIRING HARNESS USB MINI B CABLE 3 PORT BCS co FUSE HOLDER AND 2 AMP FUSE ii ZIP TIES QTY 12 3 16 SILICONE VACUUM HOSE 6 FEET 1 8 SILICONE VACUUM HOSE 10 FEET ye ee 3 16 HOSE BARB QTY 3 y 3 16 TO 1 8 HOSE REDUCER 3 16 HOSE TEE QTY 1 QTY 2 1 8 HOSE TEE QTY 1 Cortex EBC Part Identification Table Cortex EBC User Manual SIRHC Labs LLC 2015 1 8 HOSE BARB QTY 1 28 Choosing a Location for the Cortex EBC The Cortex EBC device should be mounted in the interior of the vehicle in a location where it will not be exposed to dirt moisture excessive heat or other environmental elements The Cortex EBC is not waterproof and exposure to moisture will damage the device When choosing a location for your Cortex EBC pick a place that makes it possible to easily plug unplug the USB cable from the back of the Cortex EBC device Alternatively the USB cable can be left plugged into the Cortex EBC device at all times and the other end of the cable can be tucked away in a safe but accessible location when unused Cortex EBC User Manual SIRHC Labs LLC 2015
38. le will vary with Boost Error If Actual Boost matches Desired Boost the Direct Control algorithm will make no changes to the End Duty Cycle at all While this behavior can greatly improve control response especially while building boost the Direct Control algorithm can never eliminate Boost Error by itself Setting the Direct Gain Level too high will result in unwanted boost spikes and oscillation The following tables will help you to understand how the Direct Control algorithm works CONDITION DIRECT CONTROL OUTPUT Boost Error 0 Boost Error 0 Basic Behavior of Direct Control Algorithm ACTUAL BOOST DESIRED BOOST BOOST ERROR DIRECT DUTY CYCLE PSI PSI 20 2 10 60 100 40 100 400 100 100 00 100 00 180 100 80 100 800 Direct Duty Cycle vs Boost Error Kp fixed at 10 0 Cumulative Control Algorithm While the Direct Control algorithm produces a completely new value during each control period the Cumulative Control algorithm saves its output and updates the value over time The output of the Cumulative Control algorithm depends on the accumulation of Boost Error from previous control periods and the Cumulative Gain Level Kc Cumulative Duty Cycle is calculated based on the following equation x Ke 1 Cumulative Duty Cycle D Boost Error x zgsecond While activated the output of the Cumulative Control algorithm
39. minimize rise time so full boost is reached as fast as possible Rise time can be reduced by holding the wastegate shut while building boost This can be done by using a very high End Duty Cycle value until full boost is achieved A few examples of how you might accomplish this are e Use the Spool Duty Cycle Limit setting to force End Duty Cycle to 100 0 96 until boost pressure exceeds the Spring Pressure Limit setting e Use Start Duty Cycle to force End Duty Cycle to 100 0 in the RPM range that boost is usually building This is only possible when utilizing the ml or mA Control Map User Level e Increase the influence of the Direct and Cumulative Control algorithms to speed up controller response This can be used as alternative to the RPM based Start Duty Cycle method when utilizing the mB Control Map User Level 2 Overshoot Overshoot occurs when boost pressure exceeds the target pressure after reaching full boost and is commonly referred to as a boost spike A small amount of overshoot will generally be unavoidable especially if minimizing rise time is a priority Incorrect Control Map settings may induce unacceptable overshoot under certain driving conditions If you are experiencing significant overshoot it is likely caused by one of the following conditions e The difference between full boost and your Spring Pressure Limit setting is too small e Your Spool Duty Cycle Limit is too high e Your Start Duty Cycle setting s are too hi
40. n be moved towards the full boost level to further reduce spool time For instance if your wastegate spring pressure is 6 0 PSI and you would like 12 0 PSI at full boost setting the Spring Pressure Limit to 10 0 PSI will reduce spool time if the Spool Duty Cycle is set to a relatively high value 80 0 100 0 96 However this may induce a spike into your boost curve and can also reduce overall driveability at lower throttle angles when utilizing the mA Control Map User Level If the Spring Pressure Limit is set to 0 0 PSI the spool state will never be entered and the Cortex EBC will go directly from the vacuum state to the control state Control State The control state is active whenever boost pressure is greater than the Spring Pressure Limit setting but less than the Boost Limit setting In the control state End Duty Cycle is calculated as follows End Duty Cycle Start Duty Cycle Control Duty Cycle Examining the equation provided above you will see that there are two primary components to End Duty Cycle in the control state The first component is Start Duty Cycle which is generally used to provide a rough outline for boost control The second component is Control Duty Cycle which is calculated by the Cortex EBC and used to optimize various aspects of your boost curve End Duty Cycle will always be capped at the End Duty Cycle Limit setting for the Control Map profile in the control state Cortex EBC User Manual SIRHC Labs LLC
41. or your car you will need to use the Cortex Nexus Logger or the display readout on the front of the Cortex EBC device to collect the following information Y THROTTLE POSITION SENSOR VOLTAGE WITH THROTTLE FULLY CLOSED v THROTTLE POSITION SENSOR VOLTAGE WITH THROTTLE FULLY OPEN v EVS RATIO FOR EACH FORWARD MOVING GEAR Next the values you record must be entered into the Vehicle Configuration window in the Cortex Nexus Editor and finally transferred to the Cortex EBC device NOTE RPM Detection parameters for Vehicle Configuration must be set and transferred to the device before the Cortex EBC can correctly calculate EVS Ratios Guidelines 1 Usethe controls on the front of the Cortex EBC to disable boost control 2 Usethe controls on the front of the Cortex EBC to disable both programmable outputs 3 Establish a USB connection with your Cortex EBC device in the Cortex Nexus Editor 4 Access the Vehicle Configuration window and set the RPM Detection parameters to match your vehicle Make sure the Fuel Injector Drive box is checked if using a fuel injector drive signal as the engine speed input to the Cortex EBC 5 Click the Write button at the bottom of the Vehicle Configuration window to transfer the settings to your Cortex EBC device 6 Close the Vehicle Configuration window 7 Collect necessary information regarding TPS voltage and EVS Ratios using the Cortex Nexus Logger or the display on the front of the Cortex EBC device
42. reased by Ramp Rate after each output activation cycle This is used to enable disable progressive control functionality for the Enable Progressive Control output All other progressive Parameters will be disabled unless this True or False option is selected Progressive Configuration Settings Cortex EBC User Manual SIRHC Labs LLC 2015 41 Output Wiring The programmable outputs found on the Cortex EBC use fast acting transistor circuits capable of controlling resistive loads that draw 200 mA or less current The outputs are not capable of driving standard electromechanical relays solenoids or pumps motors without additional electrical components to protect the Cortex EBC device Output Wiring Diagram LED Configuration When using a programmable output to drive an LED a properly sized resistor must be used in series with the LED to avoid excessive current draw To determine the proper resistance value you must know the forward voltage V of your LED The forward voltage of an LED usually depends on its color and can be found on the LED packaging or in the LED s datasheet The following formula can be used to determine the correct resistance value based on a 20 mA current draw typical for most LED s 140V V 0 0204 For instance an LED with a forward voltage of 2 0 V would require a 600 Q resistor If you are using a super bright LED replace 0 020 in the previous equation with the recommended current rating for yo
43. rror is zero Setting Cumulative Gain Level too high will result in a boost spike and possible boost oscillation This effect can be reduced by utilizing the Cumulative Duty Cycle Limit to cap the growth positive and negative of the Cumulative Duty Cycle Whenever the Cumulative Control algorithm is active its output will always satisfy the following inequality Cumulative Duty Cycle Limit Cumulative Duty Cycle Cumulative Duty Cycle Limit NOTE Cumulative Duty Cycle is reset each time the Cortex EBC enters the control state Rate Control Algorithm The purpose of the Rate Control Algorithm is somewhat different than that of the Direct and Cumulative Control Algorithms Instead of trying to reduce Boost Error the Rate Control Algorithm tries to limit the rate at which Boost Error is changing The Rate Control algorithm depends on the change in Boost Error between consecutive control periods and the Rate Gain Level Kz Rate Duty Cycle is calculated based on the following equation ABoost Error Kp Rate Duty Cycle ia ig Second 10 The Rate Control algorithm acts as a predictor of future Boost Errors and will have the most influence on transient boost conditions immediately after changing gears Turbochargers will reach full boost much more rapidly after a shift than they will when initially spooling The Rate Gain Level can be used to lower End Duty Cycle while boost is rapidly rising to reduce boost spikes under transient cond
44. sition tPS The current voltage reading from the vehicle s throttle 0 0 16 0 Volts position sensor Engine Speed rEV The current engine speed of the vehicle scaled by a factor of 0 8500 RPM 1 10 EVS Ratio EVS The current ratio of Engine Speed to Vehicle Speed Gear gEr The current vehicle gear detected by the Cortex EBC Speed SPd The current frequency reading from the vehicle s speed sensor Cortex EBC User Manual SIRHC Labs LLC 2015 APPENDIX 2 SOLENOID VALVE LATENCY SETTINGS When a control pulse is applied to the 3 Port BCS there is a minimum duration of time that must pass before the valve opens Similarly when a control pulse is removed from the Cortex EBC there is a minimum duration of time that must pass before the valve closes If the control pulses applied to the 3 Port BCS are too short the valve will never open If the pulses are too long the valve will never close between control cycles The Cortex EBC control algorithms will perform optimally if the 3 Port BCS always opens at duty cycles above 096 and always closes at duty cycles less than 90 a few percent To achieve this the Cortex EBC uses a Valve On Latency setting and a Valve Off Latency setting to limit the range of the control pulses that can be applied to the 3 Port BCS In some cases the default Valve Off Latency setting is too conservative to achieve significant increases in boost pressure If you experien
45. t Error which is the difference between the pressure you would like the turbo to create Desired Boost and the pressure the turbo is actually producing Actual Boost If Actual Boost is less than Desired Boost Boost Error will be positive If Actual Boost is greater than Desired Boost Boost Error will be negative Boost Error Desired Boost Actual Boost CONDITION BOOST ERROR Actual Boost gt Desired Boost Actual Boost Desired Boost Actual Boost lt Desired Boost The Direct Control algorithm examines the current Boost Error during each control period the Cumulative Control algorithm examines the accumulation of Boost Error from previous control periods and the Rate Control algorithm examines how Boost Error is changing between consecutive control periods Cortex EBC User Manual SIRHC Labs LLC 2015 10 Direct Control Algorithm The Direct Control algorithm is the simplest of the control sub algorithms and its output only depends on the Boost Error at the start of the control period and the Direct Gain Level Kp Direct Duty Cycle is calculated using the following equation Direct Duty Cycle Boost Error x Kp If Actual Boost is lower than Desired Boost the Direct Control algorithm will increase End Duty Cycle to help raise boost pressure If Actual Boost is higher than Desired Boost the Direct Control algorithm will decrease End Duty Cycle to help reduce boost pressure The amount of change applied to the End Duty Cyc
46. tems to Remember When Adjusting BOOST cccccccssseccccsseccccescccceesececceecceseesececaueceseenecessensecessuneceseugecessegeeeetas 16 CORTEX EBC VEHICLE CONFIGURATION casi iE eon YER S Oxo DR Ee YOR ev EV P Po o Een a UP reu S UNE TRA OD VE Ra Co e Ed eue se TO DE e lianas 17 CORTEX NEXUS SOFTWARE OVERVIEW 5565 55 5603955935 ORAS SR e e gu EA US oR ea RENE S SAN DOR NEN VOIR E EA USER ES NES ER E REA ATO IPSE V TUNES ANS 18 Solo A OS EGO docs demittit A 5Er A ee 18 Conte Nexus LOCO aiii 19 ROAd DYNO PO Wer Calculator o e en e O 20 CORTEX EBC DEVICE OPERATION i iesesenstevibis pe eus ut ee v hec Sees see aul ve peu e pa e uaa Gub uev hav nie canoas 21 Cortex EBC Mall Men enar ioo CERE EFC ARE CARERE CAS dn A RR LANE EA EON CEN T 22 Cortex EBC Display Parameter Menti d di uei E Eia dd 23 Cortex EBC Profile Melia 24 COMEX EBC OUMU gU cR e 25 Comex EBC MED BrRentaess Meno rr 26 INSTALLATION INSTRUCTIONS cin ES 27 Nace daran iii oia ic di 28 Choosing a LocatiomtortheCortex EBC ii A Raed eee derek 29 WIRE Ca koh dal CO S ea ITUR 30 REGUE MITIS CENE cla 30 Cde E eset pP c Ee EI M DEL I EC IE NEN 30 Wiring B I4 are lo Ep 31 compatible Engine Speed SIgiidls iota esae it oit sa 31 Cortex EBC Pressure Port CONNeciONar a ASA 32 Rede RO 32 Guideline Saren n E eit areata A d o Mut E ELM hee te Si E 32 SOL Deo o RT E A A 33 A A E A A LM ERE 33 EU A O O M E IM Ma M M ia 33 Cortex EBC User Manual SIRHC Labs LLC 2015 2 literal Was
47. tesate Actuator Contisurati n anna 34 External Wastegate Primary CONSUMO Mirra AA ee nutu lh boe eR dub M ue eU du 35 External Wastegate Alternate COnfIBUFatlOl ois e ui AA AA deu det ue d eU uu 36 Vehicle CORA SUS Om SOLU Draconis 37 EU e Po Terr 37 Boost CONEO V EFiTICATION anan a a A Peedu n dee c iu EUR us pius 38 GuldellliSSsuontas a E O E o A UAM MEE 38 TOUS ADO NA E NET PM TERR 38 CORTEX EBC PROGRAMMABLE OUTPUTS sis ai 39 OUTPUT II Tec 42 Output Winne Diagram LED ContiguratiOR ete tes dde e eed a Saco e Qt 42 Output Wiring Diagram Cortex EBC Solenoid Pump Driver ccccccccnnnonnccnnncnnnonnnanccnnnnanonononancnnnnnnnnnnnnnacnnnnnnnnnnnnnacinnns 43 Output Wiring Diagram State Relay Configuration nnne nnne nnne nnne nnns nne n nessun 44 APPENDIX 1 CORTEX EBC DISPLAY PARAMETER LIST e ence eene eee eene eee hne ese tu stesse stes eese se eese sesso seo suus 46 APPENDIX 2 SOLENOID VALVE LATENCY SETTINGS sscsccsccscsccsscsccscsccsccsccscnccsccccsscsscscsscsscscescnscscescsscssoscesonses 48 Cortex EBC User Manual SIRHC Labs LLC 2015 3 INTRODUCTION Before attempting to install or configure your Cortex EBC electronic boost controller SIRHC Labs LLC recommends you take the time to carefully read the entirety of this document to become familiar with the Cortex EBC device and its operation The Cortex EBC operates based on the settings contained w
48. ur LED up to 0 20 A Nes os To Switched Fused 12V To Cortex EBC Wiring Harness Cortex EBC User Manual SIRHC Labs LLC 2015 42 Output Wiring Diagram Cortex EBC Solenoid Pump Driver If you are utilizing a Cortex EBC Solenoid Pump Driver sold separately the following diagram should be followed when wiring your output device We strongly recommend using a standard automotive relay and a master override switch in conjunction with the Solenoid Pump driver which are available at any auto parts store To Switched Fused 12V MASTER OVERRIDE SWITCH 1s To Chassis Ground To Positive T5 AMP FUSE Battery Terminal RELAY RED To Relay Pin 87 YELLOW To Solenoid Pump POWER THICK BLACK To Chassis Ground BLUE To Solenoid Pump GROUND NARROW BLACK To Cortex EBC Wiring Harness oed SOLENOID PUMP DRIVER Cortex EBC User Manual SIRHC Labs LLC 2015 43 Output Wiring Diagram State Relay Configuration As an alternative to the Cortex EBC Solenoid Pump Drivers a 12V solid state relay can be used to provide a high current switch for your output device To utilize a solid state relay you will need the following components 1 A 12V solid state automotive relay We recommend the following relay which is available from Summit Racing www summitracing com Hella H41773001 Solid State Relay 2 A standard automotive relay which you can pick up at any auto parts store Cortex EBC User
49. will be adjusted a small amount during each control period with the goal of moving Actual Boost towards Desired Boost The size of each adjustment will vary with Boost Error The adjustments will be large if Boost Error is high and they will be small if Boost Error is low BOOST ERROR CONDITION CUMULATIVE CONTROL OUTPUT Increasing with each control period Boost Error 0 Constant Boost Error lt 0 Decreasing with each control period Basic Behavior of Cumulative Control Algorithm If Boost Error were to remain constant at 1 0 PSI with Kc 10 0 then Cumulative Duty Cycle would build to a value of 10 0 96 after one second and 20 0 after two seconds If Boost Error was 1 0 PSI in the previous example then Cortex EBC User Manual SIRHC Labs LLC 2015 11 Cumulative Duty Cycle would build to 10 0 96 after one second and 20 096 after two seconds Although these situations would likely never arise in the real world they can help to understand how the Cumulative Control algorithm works Because of the characteristics of a turbocharger increasing boost pressure beyond the wastegate spring pressure will always require End Duty Cycle to be greater than 0 0 96 If this condition is not met boost will eventually drop back to the wastegate spring pressure As a result the Cumulative Control will have the most influence on your boost curve compared to the other control algorithms as it is the only one capable of outputting a value when Boost E
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