MicroTHERM users manual
Contents
1. An output can even be configured to switch MicroTHERM off after a pre determined temperature is reached this is ideal for allowing water pumps etc to remain active for as long as required when the engine is shut down not just using a set time period Data can be logged to the PC at various rates Input voltages and the corresponding output settings are both recorded along with time and date Data is displayed real time on a configurable screen Dial gauges or bar graphs can be chosen with alarm settings and filtering All dial gauges have digital displays incorporated and controllable peak recording needles to hold the maximum values Compact 87L x 67W x 31H mm plus mounting tabs Rugged fully encapsulated electronics for the toughest automotive applications Wiring harness leads are not terminated you can hardwire or fit any connector of your choice Connects to the PC s serial port RS232 or use an inexpensive USB to 232 converter if required Automatic hardware detection and port setting Updates to the basic software will be available FREE to owners as we continually seek to improve our product www dtec net au 5 MicrorTHERM users manual Software Installation Step 1 DO NOT plug in your hardware DO close all windows programs Step 2 Windows Vista installations require you to read ahead to Installation notes first insert the MicroTHERM software disc and simply execute the program MicroTHE2. Displays Firmware version hardware version and copyright information microl HERM ada Yersion micro T HERH Firmware Yersion micro THERM Hardware Yersion Warning This computer program is protected by copyright taw and international treaties Unauthorized reproduction or distribution of this program or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the gt SEC maximum extent possible under law Copyright 2009 microT HERM Software Ross McLean Firmware amp Hardware Darren Todd Open MicroTHERM Manual Opens the MicroTHERM manual the manual must be in the MicroTHERM directory for this function to operate We suggest you download the latest manual version from the DTec web site www dtec net au and simply save it in the MicroTHERM directory default directory location is C Program Files Micro THERM Of course you can just download the manual from our website save it where you please and view as any other document www DTec net au Direct link to the DTec web site access to the user manual and software information www dtec net au 24 MicroTHERM users manual Setup Screen Overview Setup Inputs Outputs Displays j Fm A Currently Setti MCtIVE Having pressed aea E PPEP i FE i a particular Setup Input Channel Setup user defined points for Value Speed On iii output channels Input Channel HH HE i
3. STOP Important notice The following quick start operating example is designed to save you time in ensuring that you get the most out of Micro THERM By giving a very brief overview of some main operations we hope to provide a basic concept that will allow easy understanding of the detailed features explained later Read this manual fully before operation After the example pages this manual will take you through the functions of the two main screens Monitor amp Setup Next you will be guided in the order that they appear through the selections that are available in the various menu options www dtec net au 15 MicroTHERM users manual Quick Start Example We will outline the basics to set up the software and program MicroTHERM to do the following tasks e Output 1 to operate a cooling fan via a relay input from Bosch 026 coolant sensor connected to input 1 e Output 2 to operate a variable speed water pump input from Bosch 026 coolant sensor connected to input 1 e Output 3 to operate a Hi pressure flashing warning lamp input from a oil pressure sensor connected to input 2 microTHERM Demo file File Setup Controller Help 3 PO i Grs microTHERM o witlily Trp on p lt El Active i 40 60 2h Active verre HE aum E Eng water pump AS 20 A Deg C Oil pressure warning Gauge 4 RM MIHAI f aom amp 1500 Setup Input Cha
4. Orange blue 1 output Blue black 2 output Red 3 output Red green 4 output Red blue 5 output Red tan 6 output Red black 7 output Red green 8 output Yellow 9 output Yellow blue 10 output Yellow red 11 output Yellow green 12 output White red 13 output White blue 14 output White 15 output Grey blue 16 output Notes e Red of input harness should be ignition as this will prevent MicroTHERM from drawing power continually and eventually discharging the battery e All outputs switch to ground when active ON they can directly switch 500mA which is enough for most warning lamps and relays e Inputs are 0 5V only if higher voltages are to be measured then a resistive divider is to be used see input examples e Black wires are internally connected For best performance use the one black wire as a ground for all additional Sensors www dtec net au 9 MicroTHERM users manual To ensure reliability in the harsh automotive environment we recommend all connections are soldered and protected with heatshrink or even better glueshrink sleeving Power Wiring Red wire of the input harness should normally be to a switched ignition power as this will prevent MicroTHERM from drawing current continually and eventually discharging the battery Power supply wiring should be fused for protection we recommend a 5 Amp fuse as a Suitable rating The white wire should preferably be connected directly to the battery not swi
5. and view the hardware settings for ports com amp LPT to check what the PC has done NOTE MicroTHERM uploads data from a controller when the PC software is started therefore it is important to have the hardware powered up and connected to the PC If you have just had to setup the port then you should restart the software again for it to now upload data from the hardware Data Smoothing The selected setting determines the level of smoothing applied to the data This has the effect of displaying data that is not wildly changing due to small variations and electrical interference Too large a number and variations that may be of interest can be hidden Log Interval Sets the rate at which values are recorded to the hard drive when logging to the PC If the time interval is set too small then the amount of data saved will be unnecessarily large If just logging temperature changes then consider the rate at which the sensors can actually respond Output Channels to Log Sets the actual channels that are logged to the PC s hard drive If channels of no interest are logged then the amount of data saved will be unnecessarily large Startup Autoload File Sets a parameter file that will be loaded each time MicroTHERM is opened This is useful if you are loading the same file into multiple MicroTHERM units regularly it is a time saving feature www dtec net au 22 MicrorTHERM users manual Monitor Screen Menu Options Set
6. erasing Program MicroTHERM Warning Channel data has been altered in the setup screen but the MicroT HERM control unit has not yet been reprogrammed with this new data This programming must be done to update MicroT HERM or it cannot carry out the control as you require i MicroTHERM Hardware Lamp Lamp is green when hardware has been 3 detected and communication established red if not If this is the case firstly mi crol HE FRA check that the unit is plugged into the computer correctly and then confirm that the Setup System menu has the correct port configuration www dtec net au 20 MicroTHERM users manual Monitor Screen Menu Options File Open microTHERM Menu option allows you to select a parameter file to load A parameter file contains your previously saved channel data and gauge configuration Setup Controller Help information option also available from a tool bar button eens Re y ag IF Open Save Save Comments Menu option allows you to save the current data and gauge configurations as a parameter file for future use option also available from a tool bar button Comments Menu option allows you to store any comments about the setup or vehicle application that you wish for future reference The notes are saved along with the parameter file uT that is currently being used therefore a saved parameter file must be open or at least the current setup is to
7. on the PC then press the Save button www dtec net au 17 MicroTHERM users manual Frequently Asked Questions FAQ s The answers to some commonly asked questions that may increase your understanding of MicroTHERM Q have altered my desired settings but the ECU isn t reacting to these changes A After any changes you must program the ECU with this new information just press the button There is even a warning symbol in the menu bar to remind you changes have been made and to re program Q I can t upload from my ECU A Ensure the ECU is powered up and the PC port settings are correct first The software will upload when first started so it will be necessary to have it connected and set up before running MicroTHERM software on the PC Q I only have one input can I control multiple output functions A Yes all 16 outputs can be allocated against the 1 input if you wish Q Can join outputs together A Yes this is called an OR connection as one or the other will control the device An example of this is you might want a warning lamp to both flash or remain lit depending on the temperature One output can be set to flash it and then at a higher temperature the other output holds it on constantly Q Can measure input voltages greater than 5V A Yes but you must use some resistors to divide the voltage down to the 0 5V range These cost only a few cents from an electronic supplier and t
8. switching between on and off states at your set switching voltage E g if setting the output to operate at 2500mV you would perhaps set the differential at 100mV this would allow the output to turn on at 2500mV but it would turn off at 2400mV 2500 100 2400 Tip Clicking on the button causes the scroll buttons to increment by units of 10 not 1 for faster setting Setup User Defined Points for Value Speed 30 50 80 100 150 10 15 40 mia If the output mode selected is variable speed mode then a table will appear with 14 data points allowing entry of any input and a corresponding output speed duty cycle All 14 points do not need to be filled in but the voltage sites used do need to be consecutive values with no blank sites left in between entries Micro THERM uses linear interpolation between the voltage and speed values of the sites to give smooth control The last speed value in the table will be speed maintained as the input exceeds the last temperature site value i e in above example a temperature of 160 C would still be 85 speed The first speed value in the table will be speed maintained as the input falls below the first temperature site value i e in above example a temperature of 20 C would still be 10 speed On Value If the output mode selected is ON OFF Mode then a table will appear with only a single data point and that controls the point at which the o
9. CAL software Bosch 026 F san beticed kThemecoulec Deac oO PK Thermocouple F P Tec T501 C DTec TSO F rr microGALl Set Logging File Hew sensors can be created with the l optional microCAL add on package manual for a full explanation of how sensor calibrations can created If you do not use sensors with characteristics then it simply means their output will be displayed in Volts mV and not a unit such as C NOTE Please see the MicroCAL Sets the location and name of the text file TXT that is used to save data to when logging is active Logging is activated by a button on the tool bar www dtec net au 23 MicrorTHERM users manual Monitor Screen Menu Options Controller Outputs are Inactive Active TA micro HERM heii ne Help Olm are Inactive Setting allows all of the outputs to be deactivated in one step rather than needing to go into each channel individually deactivate and program This allows you to y Outputs are Active temporarily shut off the outputs during setup and commissioning When Inactive the display will freeze live display you can turn this back on with the Show Live Display icon and the hardware lamp will flash red and green this is to warn you that the outputs are inactive and not malfunctioning Don t forget to turn them back on again Monitor Screen Menu Options Help About
10. Kee aa S AE f ai f A Bs le lage eae E tae setup button PRESES z Deac fo 150 80 90 200 microTHERM will have opened this sensu Type a screen Bosch 026 C yi Setup Output Channel Value Speed from user defined points Output Mode From this setup screen the Variable Speed Mode behaviour of the output is A bien ad defined the input channel a it will use is selected and Min Speed MEN any alarm functions for the Sy Ga monitor screen are set suas Na Eng water pump SS mieroT HERM LS kai M Value Speed Set Gauge Maximum Yalue 2998 10 100 1000 Low Alarm High Alarm Activate Channel Alarms Setup Input Channel Setup Input Channel Input Channel The Input channel that you wish to use 1 to 8 to control this output channel is selected from the drop down menu Input Channel Sensor Type The Input sensor type is chosen for the selected input channel Voltage 0O 5000mV can be selected as the input source and used if suitable or if your sensor type is not available in the selection MicroTHERM comes with some common sensor types already loaded if you wish Input Channel 1 Sensor Type 0 5000 rei to create your own sensor calibrations then DTec s optional MicroCAL software can be used NOTE Please see the MicroCAL manual for a full explanation of how sensor calibrations can created of required www dtec net au 25 MicrorTHERM users man
11. MONITOR screen is used to view live all of the output channel states input values alarm status activate data log to PC and to select menu functions microTHERM Demo file File Setup Controller Help microTHERM o Oil pressure warning Gauge4 A S a909 750 Pressing any output channels setup button highlighted will open the setup screen for the selected channel R The SETUP screen displays each output channels settings It shows the input channel that s allocated and if a pre defined sensor is connected or just the voltage input and can display the live reading to assist setup The output channels mode switched or variable speed its control settings and display options are performed in this screen Setup Inputs Outputs Displays Currently Setting Output Channel Setup Input Channel Setup user defined points for Value Speed mus On Input Channel Input Channel 1 m RA E E E EEEE oO 150 80 90 200 jcroTH Sensor Type j20 30 50 70 100 l microTHERM Bosch 026 C v Value Speed from user defined points Setup Output Channel Output Mode Variable Speed Mode On Off Dutput Mode IN yma Hin Speed E Setup Gauge Gauge Name Eng water pump Set Gauge Maximum Value pE 10 100 1000 Low Alarm High Alarm Activate Channel Alarms www dtec net au 14 MicroTHERM users manual D e
12. MicroTHERM users manual microTHERM Programmable Thermal Management Controller Bg Setup Inputs Cutputs Displays o i Tree l Curerty Seating D l ee y active Guput Chevel M m Setup Inpui Channel Seiup user defined points for Volue Speed Cin Tinga Channel J le a F 7 A 7 lon i fir l ae i sunk p ju ww miero HERM Genio Typ Fi a 7 Porch Wai C Value Speed from user defined points setup Quipul Channel Ouwiput Mode Viable Speed Mode Li ipl Hude F xj Eph Mon Sped Beg E A ie Seiekinge Coesceges Gauge Hame jing wales WET Artene Chand Aluma mum Manual version 1 0 0 DISCLAIMER MicroTHERM is designed for off road application only It is the user s obligation to confirm that its operation complies with local legal requirements This product is provided as is without warranty of any kind either express or implied including without limitation any warranty of merchantability and fitness for a particular purpose In no event shall the creators of this product be liable for any direct special incidental or consequential damages arising out of the use or inability to use it The creators and distributors of this product shall not be liable for any loss damages or costs arising out of but not limited to lost profits or revenue loss of use of the product loss of data or equipment the costs of recovering software data or eq
13. RM Installer exe and follow the prompts MicroTHERM Install Program MicroTHERM Install Program Directory i Choose an installation folder and click Next to continue microTHERM microTHERM Welcome to the micro THERM Install program This program allows you to install microTHERM on your hard drive MicroTHERM s files will be installed in the following directory C Program Files microTHERM tis strongly recommended that before proceeding you ensure that i Disk space needed 18 Mb no other Windows programs are running Available disk space 90252 Mb If you do not wish to install microTHERM click Exit now otherwise click Next to continue Click Next to continue Read and follow the prompts You ll be asked to select a folder in which to copy the files We recommend you allow the default directory but feel free to choose any Full installation is now complete There will be a desktop icon created for you and MicroT HERM will appear in your PC s program list along with its uninstalling program that will remove the software from your PC delete the MicroTHERM folder also aD teeta sicroTHERM after running uninstall www dtec net au 6 MicrorTHERM users manual Installation Notes Most issues with the install revolve around the wide variety of PC s in the market and the any versions of Windows and its security settings Vista operating systems can be particular
14. al port can use MicroTHERM A Yes cheap serial to USB converters are readily available and work fine Q What is stored on my PC and what is stored in the MicroTHERM ECU A The ECU stores the data for it to operate the outputs based on your settings but it also stores some additional channel information not needed to actually operate in the vehicle Sensors used gauge scales alarm settings This is so that when later connected to a PC it still allows the software to display the settings effectively However it does not store text such as any name given to the channel gauge additional comments or monitor screen layout configurations these are saved in a parameter file on the PC Q Can I plug my PC into any MicroTHERM and upload read the settings A Yes but any text associated with naming the channel gauge or additional comments won t be available these are only saved in a parameter file on the PC Q Can use my own sensors A Yes there are 2 approaches here you can use our optional MicroCAL software to generate a characteristic for your sensor what voltage what temperature this will allow the sensor readings to be in degrees and not just voltage The other option is jus to leave the sensor units in voltage as an example you might set your cooling fan to operate at a certain sensor voltage that you know i e when engines to your desired temperature observe the displayed voltage and use this as y
15. be saved to create one Any entered comments are saved automatically when the form is closed there is no need to press any buttons Any saved comments are visible for any open parameter file when the menu option File Comments is selected again The right hand side has a section called Summary of Settings this has a different function to the comments It allows a method of recording all of the data and settings that have been applied The information is saved as a text file TXT in the selected directory and this can be viewed or printed for reference with any text editor such as Microsoft Word or Notepad The summary is created and saved only when the save Summary to File button is pressed 2 microTHERM Application Description User Comments Application Description N ot Provided General Comments Summary of Settings Read Only test notes DT Mode On Off Flash Set Point 65 Hysteresis 2 Alarm Inactive Gauge 2 z Save Summary to File Tip Summary settings are related only to the active channels so if you want to record the settings for only certain channels then simply enter the setup for each of the unwanted channels and de activate temporarily Exit Saves and exits MicroTHERM option also available from a tool bar button www dtec net au 21 MicroTHERM users manual Monitor Screen Menu Options Setup System microTHERM File Setup Contr
16. compatibility as they may not have the required support A minimum screen resolution of 1024 x 768 is required to fully fit Micro THERM A smaller resolution will result in part of the display being outside the viewable area Although MicroTHERM has been tested on older slower computers you will still encounter issues if you insist on using some cobbled together PC that has an incomplete modified non standard or corrupted operating system If you are experiencing particular issues then we suggest you try on another PC to confirm the operation www dtec net au 8 MicroTHERM users manual Hardware Mounting the Hardware MicroTHERM should be mounted inside the vehicle and away from the extremes of engine bay temperature As with any electronics it is best to avoid mounting to surfaces that will expose it to excessive vibration and keep the unit away from sources of interference such as ignition components and high current carrying wiring devices MicroTHERM Wiring pin out Input Harness 12 wires in total none are striped in color Red 12V ignition Black 12V ground battery Black ground connection for any input sensors used Yellow 5V for supplying input sensors or pull up for resistive sensors White 12V battery Constant power not ignition Brown 1 input Blue 2 input Grey 3 input Green 4 input Orange 5 input Pink 6 input Tan 7 input Purple 8 input Output Harness 16 wires in total
17. d High level to activate the alarm conditions in the monitor screen and enables disables the function The button between the scroll bar allows fast incrementing of the entries If an alarm event is triggered then the display will change from white to bright red The alarms can be deactivated with the lower button rR Gauges have a peak tell tale needle that can be reset by clicking on R symbol next to each one Tool Bar Button Functions Exit Saves and exits MicroTHERM Clear Table Clears all of the data tables previous entries Show live display file Enables the dial gauge to show the live channel information if not active then the i a gauge will not update its display This function is included as continually updating the display uses much clicks computer resources and may slow down functions such as the graph display and the response to mouse y ACTIVE Activate The individual output channels operation can be turned on or off with this button www dtec net au 27 MicroTHERM users manual Specifications Supply voltage Input Channels Input resolution Input voltage Input impedance Input rate Output channels Output current Output protection Output states Output table Technology Operating temperature Current draw Communications Dimensions 6V to 18V DC 8 analogue inputs common ground 4 88mV 10 bit analogue to digital conversion 0 5 Volts resistive divider eas
18. ents cont Monitor Screen Menu Options Setup System Intake Port Number lt lt 22 Data Smoothing _ s i s isssdis 22 Log Interval ss 22 Channels to Log sss 22 MONITOR Startup Autoload File 22 SCREEN Customise Gauge Layout FUNCTIONS Dial Bar 23 Cont Visible Hidden ss 23 Relocate sss 23 Restore 2 23 Sensor List 23 Set Logging File 23 Monitor Screen Menu Options Controller Outputs Active Inactive 24 Monitor Screen Menu Options Help About 24 Open manual gt 24 www DTec net au 24 Setup Screen Overview Setup Input Channel Input Channel ss 25 Sensor Type sss 25 Setup Output Channel Variable Speed ss 26 On Off 26 Differential 26 SETUP Setup User Points Value Speed ss 26 SCREEN Setup Gauge FUNCTIONS Name cceeeeeeee 27 On Off i L 21 Value 2 Speed gt 27 Maximum sss 2 Alarms of Reset L 2 Tool Bar Functions Exit 2 oo Zt Clear Table ef Show Live Display sss 2 Activate L 2 Specifications SPECS Specifications oaa 28 www dtec net au MicrorTHERM users manual Introduction MicroTHERM is a fully programmable thermal management controller for multiple electric thermo fans water pumps intercooler sprays etc MicroTHERM can perform functions from switching of relays and blinking warning lamps to sophisticated variable speed motor control MicroTHERM is the ultimate temperature controller There are 16 outputs and 8 input
19. factor of 3 Sensor ground to battery ground as voltage divider MicroTHERM Input DTec Therm Amp and TSOT temp sensors Note For Thermo Amp to ees to 1200 C the supply ill n dto be 12V not 5Y SV sensor supply yellow Input of choice to signal wire Sensor ground black Output Connections All outputs switch to ground when active ON they can directly switch 500mA which is high enough for most warning lamps and relays Do not directly switch globes greater than 5W as a guide a typical 3W globe will draw about 210mA at vehicle voltages and this is fine We strongly suggest you consider running LED s as warning lamps high brightness versions are available cheaply and in various colours these draw very little current Switch wires for load fans pump etc MicroTHERM Output Connection to Positive Operate general purpose supply Output of choice www dtec net au 12 MicrorTHERM users manual Output Connections cont Positive Output of choice supply Bee 5 LED or low wattage elay if Hi wattage and Positive supply a2 state warning hit ig and steady Output of choice Power in Power to load fans pump etc slid state relay Output of choice www dtec net au 13 MicroTHERM users manual Two Main Screens of MicroTHERM There are two main screens shown in the software the
20. ge then the optional calibration tool MicroCAL can be used All Input wiring must be carefully routed to avoid interference from ignition components or wiring devices drawing large currents such as motors Keep the wiring well clear and if in doubt shielded screened wiring should be used with the shield being earthed at one end A 5 volt output is provided from MicroT HERM yellow wire to be used for powering external sensors or as the pull up for resistive temperature sensors such as the Bosch or Delco devices The black wires are internally connected For best performance use one black wire as a ground for all additional sensors and the other as a battery ground MicroTHERM Input Connection to an additional temperature sensor recommended 1K 0 resistor added from 5 yellow MicroTHERM Input Connection to an existing temperature Input of choice to signal wire Sensor ground black to battery ground Factory wiring www dtec net au 11 MicroTHERM users manual Input connections cont MicroTHERM Input Connection to existing general sensors Input of choice to signal wire Factory wiring Sensor ground black to battery ground 0 5V max MicroTHERM Input of choice lt T Factory wiring Input Connection to 5 EKN resistors added 0 154 max existing general voltage Bn The input voltage is divided by a
21. here is an example in the hardware section of this manual The voltage scale displayed in MicroTHERM will remain at 0 5000mV range Q Can use a relay for variable speed motor control A No an electronic solid state relay driver is needed DC motor speed control is done with a technique called PWM this involves pulsing current to the motor at high speed and varying the pulse widths to control the effective current Relays are too slow to open and close at high speed DTec s PowerMAX is one suitable driver option Q Can fit super bright warning lamps A Yes but ensure they draw less than 500mA if being directly switched be MicroTHERM 3W globe will draw about 210mA We strongly suggest you consider running LED s as warning lamps high brightness versions and clusters are available in various colours these are very efficient cheap reliable more so than globes in a vibrating environment and draw very little current Q Can easily add redundancy into my system so that if there is a circuit failure my water pump and fans still operate A Yes if your application requires this extreme approach then a normally closed relay can be wired in parallel to MicroTHERM one output can be used to turn this relay off during normal operation This will allow MicroTHERM to control the device as usual but if there is a failure the parallel relay would take over and supply full current Q My PC has no seri
22. ily extends range if required Greater than 10KQ Scan of all 8 inputs in approx 79ms rate based on active channel count 16 active low outputs Switched to ground open collector 500mA continuous 6 00mA peak Internally diode clamped via white wire to ve 50V max when in off state Switched or PWM 100Hz 1 steps 14 sites linear interpolation min max values held Digital microprocessor based 48MHz 10 C to 65 C Approx 42mA with outputs in off state Serial RS232 for PC interface 115200 baud 8 bits no parity Approximately 87L x 67W x 31H mm plus mounting tabs www dtec net au 28
23. ily safety or administrative tools if Vista is set in classic view choose user accounts and turn the user account control off un tick the box G a User Accounts Turn User Account Control On or Off hi 4 Search Turn on User Account Control UAC to make your computer more secure User Account Control UAC can help prevent unauthorized changes to your computer We recommend that you leave UAC turned on to help protect your computer Use User Account Control UAC to help protect your computer www dtec net au 7 MicroTHERM users manual Installation Notes cont If all else fails An uninstall program is provided in your PC s programs list If there are any installation issues with MicroTHERM then we suggest you simply uninstall using the Uninstall Micro THERM program and try again delete the MicroTHERM folder from your PC also after running uninstall If you have any problems then please contact us for assistance System Requirements MicroTHERM is a hardware AND software system One will not fully work without the other This manual is freely available for download from the DTec website www dtec net au The interface unit and software must however must be purchased once again from DTec MicroTHERM is a WIN32 application it should therefore run on Windows 98 ME 2000 XP and Vista Earlier operating systems such as Windows 95 may encounter issues with
24. is turned off for temperature based after un of pumps or fans oh shown with diode MicroTHERM supply red Positive battery Output of choice www dtec net au 10 MicroTHERM users manual Input Connections Micro THERM operates by reading an input voltage and responding to this based on what has been programmed Inputs are 0 5V only if higher voltages are to be measured then a simple resistive divider is to be used to reduce the input voltage range see 0 15V example below Any source of voltage can be used as an input but we suggest fitting additional sensors rather than use existing ones This will help with accuracy less interference and a stable reference and will also allow the use of our recommended sensors with their pre loaded characteristics To display the screen scales directly in degrees not just as sensor voltage these sensor characteristics need to be known i e what voltage equals what degrees MicroTHERM recommended and pre loaded sensors inputs General Voltage input 0 5000mvV 0 5V scale units displayed as mV Fluid temp Bosch 0 280 130 026 Bosch units displayed as C or F Air temp Delco 25037388 GM Holden units displayed as C or F Air fluid temp TSO1 TSO1 DTec part units displayed as C or F Hi temperature Thermo Amp Therm1 Dtec part units displayed as C or F If you wish to calibrate your own sensors to display in units other than volta
25. ltage equals what degrees MicroTHERM comes pre loaded for some common sensors inputs General Voltage input 0 5000mvV 0 5V scale units displayed as mV Fluid temp Bosch 0 280 130 026 Bosch units displayed as C or F Air temp Delco 25037388 GM Holden units displayed as C or F Air fluid temp TSO1 TSO1 DTec part units displayed as C or F Hi temperature Thermo Amp Therm1 Dtec part units displayed as C or F If you wish to calibrate your own sensors to display in units other than voltage then the optional calibration tool MicroCAL can be used Else you can set input as General and work in units of sensor voltage Speed control is in 1 increments and interpolation between voltage sites is used to ensure smooth output changes regardless of how coarse the table settings are A minimum speed can be set so that variable speed devices can shut off without running ineffectively i e running a fan too slow achieves nothing Once configured MicroT HERM is designed to operate independently of any PC but the provided software performs all programming monitoring and logging functions Common user settings are recorded and files parameters can be uploaded viewed or saved for re applying later Outputs switch to ground and can directly drive relays alarms lamps up to 500mA and can directly connect to DTec s PowerMAX relay s or other suitable drivers for high current motor speed control
26. ly troublesome Possible Windows Vista errors e Installation not allowed by Vista security messages could relate to administration rights e Error in MicroTHERM Configuration File warning when opening A configuration file error appearing the first time MicroTHERM is run can occur as Windows Vista attempts to block MicroTHERM from creating and saving its information files Vista has many inbuilt security features here are some handy hints to help you live with Vista a micro HERM Properties General Shortcut Compatibility Securty Details F you have problems with this program and it worked corectly on an eanier version of Windows select the compatibility mode that matches that earier version Compatibility mode cha ke cm Right click on the MicroTHERM icon or program choose Windows 2000 O Z oO properties select compatibility tab and then set compatibility mode to run as Windows 2000 also tick privilege level to run m n ings as an administrator Run in 256 colors E Run in 640 x 480 screen resolution Disable visual themes E Disable desktop composition Disable display scaling on high DP settings Privilege Level Run this program as an administrator Show settings for all users Your User Account Control UAC can also block programs Left click the Windows icon for start select control panel select user accounts and fam
27. nnel Input Channel Input Channel 1 Sensor Type Bosch 026 C v Setup Output Channel Output Mode ON OFF Mode On Off Output Mode Normal v ea Differential as Setup Gauge Gauge Name Eng cooling fan Set Gauge Maximum Yalue 40 100 1000 High Alarm a Low Alarm Y Deactivate Channel Alarms Currently Setting Output Channel e Off On microTHERM Value Speed from user defined points Setup user defined points for Value Speed www dtec net au To setup any output channel click on its setup button This will open the Setup screen as shown below We will start with channel 1 In our example we wish to tell it to use input channel 1 as the signal source and that a Bosch 026 temperature sensor is connected to this The output will be simply on or off normal rather than flashing and the output will turn off 15 C below when it turns on this stops the fan cycling rapidly at the switching point We will label the gauge Eng cooling fan so it is meaningful when we monitor it later We will set the fan to turn on at 95 C in the table as it s only on off there is only 1 site available Press the ACTIVE button to turn on our channel now it s configured Close the screen to return to monitor 16 MicroTHERM users manual Quick Start Example cont Setup Inp
28. oTHERM Eng cooling fan kili Load a parameter file Allows you to select a parameter file to load A parameter file contains your previously saved channel data and gauge configuration information Save a parameter file Allows you to save the current data and gauge configurations as a parameter file for future use The ECU does not save text such as gauge names comments and gauge configurations which is the function of this parameter file Log data to PC Will start logging to the file specified in the menu option Setup Set Logging File Only output channels that are active will be logged The settings for the logging rate are in the menu option Setup System Files are saved as a text file TXT Show live displays Enables the monitor screen to show live channel information if not active then the i y 7 F monitor screen will not update its display This function is included as continually updating the display uses much computer resources and may slow down functions such as the graph display and the response to gt mouse clicks Program MicroTHERM Screen below will appear the current data that has been set for the output channels in the setup screen is sent to MicroTHERM to be stored and subsequently used by it at all times From within the programming screen you can erase all settings from Micro THERM s memory The progress bar will show the status of the programming or
29. oller Help System Customise Gauge Layout microTHERM Set System Data Smoothing Mone C Low C Medium High iga Sensor List i Set Logging File pE fr Output Channels to Log i Output M OutputS M Dupas fe Output 13 i Output M Output6 f Output iO i Output 14 i Output i Output i Outpt i Output 15 Interface Port Number MicroTHERM software Outputt fe Output fe Outputi2 i Output 16 needs to know which PC serial port is being used If you are using a USB to serial converter the pak e e Pine ant Pale e e allocated port must also be known Startup Autoload File Unfortunately when installing particular USB devices modern PC s allocate them to almost any port number and will even change this depending on what USB socket is being plugged into The easiest way to set the port No is to plug in the hardware and press the AutoFind Hardware button It will step through all of the port options and try to establish communication with the hardware be patient as 99 different options are catered for and this can take some time When found the port setting is automatically saved and should remain valid for the USB socket you have plugged into if you use another socket you may need to search again Tip The communication port can also be manually chosen if it is known Those with good computer skills can go into windows device manager
30. our switch point Q What is the resistor for in the temperature sensor diagram A The 1000 ohm resistor connected to the 5 volt wire is called a pull up resistor It is required for resistive style sensors such as typical temperature sensors it converts the changing sensor resistance into a voltage the ECU can read By not building it into the ECU it allows the input to also be used for other sensor types www dtec net au 18 MicroTHERM users manual Monitor Screen Overview Output Channel Display All of the 16 output channels can be E _microTHERM Demo file viewed live on this screen or the screen ka a ere can be customised to show only those 2E microTHERM L channels that you are actually using via Eng cooling fan ji On pressure warning cae Gauge 4 the menu option Setup Customise Gauge Layout A live display is only shown when the tool bar icon show live display is active A dial gauge or bar graph style of gauge can be selected via the menu option Setup Customise Gauge Layout R CE GaugeS SSS E Gaugeto SS rm All gauges have a peak tell tale eo ae needle that can be reset by clicking on R symbol next to each one The range on the scales shown can be set in the Setup screen The default scale is based on the input type selected in the Setup screen By default each gauge is numbered according to its out
31. points for Value Speed Off channel 2 as the signal source and EEF m a aan that s it s a 0 5 volt 5000mV input Sensor Type Pr microT HERM 0 5000 n The output will be on or off and set to Value Speed from user defined points Sap Oupa Channel Lamp Flash as a warning indicator i a The output will turn off 200mV below zc when it turns on this stops the lamp Lamp Flash z cycling rapidly at the switching point Differential EW i We will label the gauge Oil pressure etup Gauge ii ah Eae Wie warning so it is meaningful when we il pressure warning monitor it later We will set the warning to occur when the oil pressure sensor voltage is at 3500mV in the table as it s only on off there is only 1 site available Set Gauge Maximum Yalue tc 3 BERT o elo Press the ACTIVE button to turn on Low Alam High Alarm our channel now it s configured se a t 1400 00 2800 00 4200 00 7000 00 Activate Channel Alarms Close the screen to return to monitor This message icon in the monitor screen reminds us to now press the program button we have made changes so that our settings are loaded into MicroTHERM s memory It can now follow our settings in the vehicle and no longer requires a PC unless re setting again or monitoring logging data If you want to store your settings and gauge labels
32. put wire e g gauge1 is output channel 1 s gauge The gauge title can be renamed to a more meaningful name of your choice e g gauge1 might be renamed to coolant temp this is done in the Setup screen i aE The display in the upper right corner shows the current reading Eng water pump from the allocated input channel Either the input voltage or a e TTT temperature is shown depending on the input type selected in the Setup screen ctiv Pressing any output channels setup button will open x the setup screen for the selected channel The word Active above the icon shows that the output channel is being used it was activated 5 B T m TENN T an The display in the lower right corner shows the state of the output if in variable speed mode the current duty cycle being 3 e at output is shown if in on off mode then display will indicate either jpe on or off depending on output If an alarm event is triggered enabled in the Setup screen then the display will change from white to bright red All of the gauge configurations and actual data values entered for each channel can be saved as a file called a parameter file This is explain next as it s a tool bar button function www dtec net au 19 MicroTHERM users manual Monitor Screen Overview cont Tool Bar Button Functions Exit Saves and exits Micr
33. s available to allocate for any application and the included software ensures quick and easy mapping Each output has a 14 site table that can be programmed for absolute control regardless of your use Any of the 16 outputs can be configured as variable speed on off or flashing you choose Any output can be set to use any input and this can be from a temperature sensor that already exists or has been added The input source can also be from any general sensor voltage It can be used as a monitoring device with alarm settings and can even log the data to your PC for analysis and storage MicroTHERM s secret is its flexibility the uses for this versatile device are limited only by your imagination www dtec net au 4 MicroTHERM users manual Features 16 outputs can be configured for basic on off switching with separate on and off points to prevent any hunting between on off as variable duty cycle PWM for motor speed control or as a switching function with flashing for operating warning lamps and alarms 8 precision analogue inputs for all your sensing needs Input voltages are read and the output controlled according to your user lookup table Each output has a 14 site table map allocated to control the output setting for any given input voltage temperature To display the screen scales directly in degrees not just as sensor voltage the sensor characteristics need to be known i e what vo
34. tched This wire is used to protect MicroTHERM from damage and reduce vehicle interference when switching inductive loads such as relays There are 2 black wires they are internally connected Use one as the power ground for MicroTHERM and the other as the return for any sensors connected Power connections standard method MicroTHERWV f Supply red Vehicle Ignition Supply switched SESE EREREEEREREERE ERE Power Basic connection f Battery white Vehicle Battery Positive to vehicles electrical system y5 Ground black Vehicle Battery Ground Alternate connections for power supply red wire only for temperature controlled shut down The power supply to MicroTHERM can be controlled by one of its outputs this allows the unit to have control over its own shutdown not just when ignition is turned off This wiring concept is useful if you want devices such as water pumps or fans to continue to operate after the vehicle is turned off and until a pre set temperature is reached Positive battery MicroTHERW Power Connection to keep Ignition MicroTHERM active after the wiero THERM switched ignition is turned off for supply red Positive temperature based after Relay In of pumps or fans on shown with relays Output of choice ignition switched Low voltage drop diode 1H5817 Micro THERN Power Connection to keep MicroTHERM active after the ignition
35. ual Setup Screen Overview cont Setup Output Channel Setup Output Channel Variable Speed Mode It is used to control motor speeds solenoid positions and lamp brightness by varying the average current supplied to the devices Output Mode The output will be Pulse Width Modulated PWM also known as variable duty cycle Variable speed Mode a fixed frequency is used the ON to OFF ratio is varied On Ott Dutput Mode When selected a choice of Min Speed is available this allows you to select the minimum percentage of PWM that will be supplied This is available as often devices such as cooling fans will not flow sufficient air at low speed to be useful therefore it is aay l no value running them all the way down to zero speed Min Speed ah Setup Output Channel ON OFF Mode The output will be either on or off not variable speed Output Mode It can be also selected so that the output will be set to Lamp Flash so that if m connected to a warning lamp it will automatically blink the lamp to get the drivers UMYOFF Mode attention rather than just illuminate it constantly when triggered as Normal n Off z Output Mode y When selected a Differential setting is available this allows the output to be turned Normal off at a lower setting than it was turned on at This provides a form of hysteresis that a is important to prevent the output from wildly
36. uipment or claims by third parties damage to equipment or other similar costs For continuous product improvement and due to ongoing development we reserve the right to alter specifications without notice WARNING this hardware and software is protected by law and international treaties Unauthorized reproduction or distribution of MicroTHERM or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum extent possible under law MicroTHERM software is copyright Ross Mclean 2009 MicroTHERM hardware amp firmware is copyright Darren Todd 2009 www dtec net au 1 MicrorTHERM users manual FEATURES SETUP DETAILS BASIC OPERATING CONCEPTS MONITOR SCREEN FUNCTIONS Table of Contents Introduction Introduction Features Software Installation Installation Steps Install Notes System Requirements Hardware Mounting the Hardware Wiring pin out Power Wiring Input Connections Input Connections Two Main Screens of MicroTHERM Monitor Setup Quick Start Example Basic Functions FAQ s FAQ s Monitor Screen Overview Output Channel Display Tool Bar Functions Exit Load Parameter File Save Parameter File Log Data to PC Show Live Displays Program MicroTHERM Program Warning Hardware Lamp Monitor Screen Menu Options File Open Save Comments Exit PTO www dtec net au MicrorTHERM users manual Table of Cont
37. up cont Customise Gauge Layout Gauge 3 Gauge 44 Dial Dial Visible Visible Gauge 12 Dial Visible Gauge 16 Visible Visible Visible Visible Gauge 13 Gauge 15 fe Dial Da Dial Visible Visible The gauge layout displayed on the monitor screen can be customised to your preference Generally this is done to remove any excess displays that are not being used Dial Bar Button toggles between a bar graph display or a dial gauge format Visible Hidden Button toggles between displaying or hiding a channel Allow gauges to be relocated Allows you to drag gauges around to position them in the monitor screen when button is activated To relocate the gauges position the mouse cursor on the gauge and hold the left mouse button down after a couple of seconds you will be able to move the gauge box to any location To let go of the gauge box release the left mouse button Restore default gauge layout Returns all a channels to be displayed simultaneously and restores their positions and size Any pre loaded sensor calibrations Revision Information Date 971172009 0 5000 miy m mo P Bosch 26C Dea CP Time 5 26 36 AM can be viewed here MicroTHERM comes with some common sensor characteristics already loaded if you wish to create 50010 your own sensor calibrations then DTec s optional Micro
38. utput is activated www dtec net au 26 MicroTHERM users manual Setup Screen Overview cont Setup Gauge Setup Gauge Gauge Name Eng cooling fan The gauges on the monitor screen get their settings from here The gauge can also be viewed live on this screen to assist with monitoring input output operation and setting up the control functions to achieve your goals A live display is only shown when the tool bar icon show live display is active Gauge name By default each gauge is named its output wire e g gauge is output channel 1 s gauge name The gauge title can be renamed to a more meaningful name of your choice e g gauge1 might be renamed to Eng coolant fan this is done by clicking in the box and typing your text of choice Value The display to the lower left of the gauge shows the current reading from the allocated input channel Either the input voltage or a temperature is shown depending on the input type selected in the Setup screen Speed The display to the lower right of the gauge shows the state of the output if in variable speed mode the current duty cycle being output is shown if in on off mode then display will indicate either on or off depending on output Set Gauge Maximum Value Sets the gauges full scale range from the default The 10 100 1000 button between the scroll bar allows fast incrementing of the entries Alarms Sets a Low an
39. uts Output Deis We will now setup channel 2 In our O he Suter Chennel at example we wish to tell it to also use input channel 1 as the signal source the Bosch 026 temperature sensor tio Some Fe a Fa ee Cc SL eS bc eh nput Channe 7 50 80 90 200 microTHERM Sensor Type Speed 20 30 50 70 100 i z I e The output will be mapped to vary the Bosch 026 C v Setup Input Channel Setup user defined points for Value Speed On Value Speed from user defined points water pumps speed based on Setup Output Channel i temperature so select Variable Speed Variable Speed Mode Mode We are happy for the pump to On Off Dutput Mode run down to any min speed the lowest set here is 20 so no mater how cold it won t go slower anyway aange Nane We will label the gauge Eng water pump so it is meaningful when we monitor it later We will fill in the table sites so our pump runs at our desired speed vs C Set Gauge Maximum Value Press the ACTIVE button to turn on eE Enli our channel now it s configured ow Alarm igh Alarm aes he Activete Chanel Ate Close the screen to return to monitor E3 Setup Inputs Outputs Displays F A active ir We will now setup channel 3 In our gt sh ACTIVE Output Channel m i F example we wish to tell it to use input Setup Input Channel Setup user defined
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