INSTALLATION INSTRUCTIONS. Revision 3.1.1
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1 INSTALLATION INSTRUCTIONS Revision 3.1.1
2 Table of Contents INTRODUCTION... 4 INSTALLATION OVERVIEW... 5 Included Parts... 6 DEVICE WIRING... 7 Required Parts... 7 Guidelines... 7 Wiring Diagram... 8 Compatible Engine Speed Signals:... 8 PRESSURE PORT... 9 Required Parts... 9 Guidelines... 9 BCS Required Parts Guidelines Port BCS Internal Wastegate/Actuator Configuration Port BCS External Wastegate Primary Configuration Port BCS External Wastegate Alternate Configuration Port BCS External Wastegate Configuration VEHICLE CONFIGURATION SETUP STEP 1: PREPARATION STEP 2: CONFIGURE RPM DETECTION GUIDELINES FOR TACH SIGNAL GUIDELINES FOR FUEL INJECTOR TRIGGER SIGNAL GUIDELINES FOR COIL TRIGGER SIGNAL GUIDELINES FOR SHAFT SPEED SENSOR SIGNAL (CAM/CRANK POSITION, A/T INPUT SHAFT, ETC.) STEP 3: DETERMINE EVS RATIOS STEP 4: COLLECT TPS DATA STEP 5: CONFIGURE ANALOG INPUT AND EVS RATIOS ANALOG INPUT CONFIGURATION FOR TPS ANALOG INPUT CONFIGURATION FOR WBO GEAR DETECTION CONFIGURATION STEP 6: VERIFICATION BOOST CONTROL VERIFICATION STEP 1: PREPARATION Cortex EBC Installation Instructions SIRHC Labs LLC
3 STEP 2: VERIFY WASTEGATE SPRING PRESSURE STEP 3: VERIFY BOOST CONTROL Troubleshooting Cortex EBC Installation Instructions SIRHC Labs LLC
4 INTRODUCTION This manual provides detailed instructions for installing your Cortex EBC device. Complete documentation for the Cortex EBC (including the instructions found in this document) can be accessed from Cortex EBC Help Navigator, which is incorporated into the Cortex Nexus software. To access the Cortex EBC Help Navigator, install and launch the Cortex EBC software on your PC. The Cortex Nexus software can be downloaded from: Next, select Help Launch Cortex EBC Help Navigator from the menu at the top of the Cortex Nexus Editor window. Cortex EBC Installation Instructions SIRHC Labs LLC
5 INSTALLATION OVERVIEW 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 analog voltage 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. 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. 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 or 4-Port BCS to the vehicle s turbocharger and wastegate. 4. Create a Vehicle Configuration file for the Cortex EBC to correctly interpret electrical signal from your vehicle. 5. Verify that the Cortex EBC is able to control boost pressure. Rear Panel of Cortex EBC Device Cortex EBC Installation Instructions SIRHC Labs LLC
6 Included Parts Cortex EBC Part Identification Table Cortex EBC Installation Instructions SIRHC Labs LLC
7 DEVICE WIRING 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 Cortex EBC Wiring Harness Fuse Holder and 2 Amp Fuse Guidelines 1. Disconnect the 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 +12 V power and chassis ground. 4. Connect the wiring harness to appropriate engine speed, vehicle speed, and TPS or WBO2 signals. 5. Cover the ends of the wires for the programmable outputs 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 or 4-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 pin should be on top) Cortex EBC Installation Instructions SIRHC Labs LLC
8 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 Wiring Harness Diagram PIN COLOR SIGNAL TYPE REQUIREMENTS Pin 1 PURPLE BCS Power Supply Plugs into BCS connector. Pin 2 BLUE BCS Drive Switch to Ground Plugs into BCS connector. Pin 3 RED Switched/Fused + 12V Supply Connect to FUSED +12V power source (fuse rating 5A or less). Pin 4 TAN Output 1 Drive Switch to Ground Resistive load, 200 ma max current. Pin 5 ORANGE Analog Voltage Input Analog Input Connect to throttle position sensor (TPS) or wideband oxygen sensor (WBO2) linear analog output. Voltage Range: 0 V to +12 V Pin 6 GRAY Output 2 Drive Switch to Ground Resistive load, 200 ma max current. EMPTY Pin 8 PINK Engine Speed Digital Input Connect to pulsed engine speed signal. Voltage Range: -12 V to +12 V Pin 9 BLACK Chassis Ground Ground Connect directly to clean chassis ground. Pin 10 GREEN Vehicle Speed Digital Input Connect to pulsed or sawtooth vehicle speed sensor signal. Voltage Range: -12 V to +12 V Electrical Signal Descriptions Compatible Engine Speed Signals: ECU TACH OUTPUT CAM/CRANK ANGLE SENSOR OUTPUT ECU FUEL INJECTOR TRIGGER NEGATIVE (-) TERMINAL ON PRIMARY (LOW VOLTAGE) SIDE OF IGNITION COIL Cortex EBC Installation Instructions SIRHC Labs LLC
9 PRESSURE PORT To monitor and control boost pressure the Cortex EBC must be connected to an intake manifold pressure reference. Required Parts 1/8 Silicone Vacuum Hose Zip Ties 1/8 Hose Tee (optional) 1/8 Hose Barb (optional) 3/16 Hose Tee (optional) 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. Cortex EBC Installation Instructions SIRHC Labs LLC
10 BCS The Cortex EBC has been designed to be compatible with both internal (actuator type) and external wastegate configurations. The manner in which the 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 3-Port or 4-Port BCS Zip Ties 3/16 Silicone Vacuum Hose 3/16 Hose Barbs 3/16 Hose Tee (optional) Guidelines 1. Thread the 3/16 Hose Barbs into the BCS. 2. Connect the BCS to turbocharger system using the supplied 3/16 Vacuum Hose. 3. Plug the BCS into the connector on the Cortex EBC wiring harness. 4. Use the supplied zip ties to secure all hose connections. Cortex EBC Installation Instructions SIRHC Labs LLC
11 3-Port BCS Internal Wastegate/Actuator Configuration BCS Port 1 BCS Port 2 BCS Port 3 Leave open or connect to pre-turbocharger intake tract. Connect to wastegate actuator pressure port. Connect to compressor outlet on turbocharger. Cortex EBC Installation Instructions SIRHC Labs LLC
12 3-Port BCS External Wastegate Primary Configuration BCS Port 1 BCS Port 2 BCS Port 3 Leave open or connect to pre-turbocharger intake tract. Connect to side port on external wastegate. Connect to compressor outlet on turbocharger. Cortex EBC Installation Instructions SIRHC Labs LLC
13 3-Port BCS 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. BCS Port 1 BCS Port 2 BCS Port 3 Connect to compressor outlet on turbocharger AND side-port of external wastegate using 3/16 hose tee. Connect to top-port of external wastegate. Leave open. Cortex EBC Installation Instructions SIRHC Labs LLC
14 4-Port BCS External Wastegate Configuration BCS Port 1 BCS Port 2 BCS Port 3 BCS Port 4 Connect to compressor outlet on turbocharger. Connect to side-port of external wastegate. Leave open. Connect to top-port of external wastegate. Cortex EBC Installation Instructions SIRHC Labs LLC
15 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. NOTE: RPM Detection parameters for Vehicle Configuration must be set and transferred to the device before the Cortex EBC can correctly calculate EVS Ratios. STEP 1: PREPARATION Before setting up your Vehicle Configuration file you will want to carry out the following tasks: Turn your vehicle to the on position to power the Cortex EBC device. Verify boost control is disabled. Verify both programmable outputs are disabled. Launch the Cortex Nexus Software application on your PC. Establish a USB connection with your Cortex EBC. STEP 2: CONFIGURE RPM DETECTION Access the Vehicle Configuration window from the Cortex Nexus Editor and set the RPM Detection parameters so the Cortex EBC will correctly calculate RPM by following the guidelines for the RPM signal type connected to the device. NOTE: You must click the Write button at the bottom of the Vehicle Configuration window for any changes you make to take effect. GUIDELINES FOR TACH SIGNAL Make sure the Use Fuel Injector Trigger and Use Shaft Speed Sensor options are unselected. For 4, 6, 8, or 10 cylinder engine select the correct option from the Engine Configuration drop down menu. Leave the Double RPM option unchecked. For 2 cylinder engine choose 4 Cylinder from the Engine Configuration menu and select the Double RPM option. For 3 cylinder engine choose 6 Cylinder from the Engine Configuration menu and select the Double RPM option. For 5 cylinder engine choose 10 Cylinder from the Engine Configuration menu and select the Double RPM option. GUIDELINES FOR FUEL INJECTOR TRIGGER SIGNAL Make sure the Use Shaft Speed Sensor option is unselected. Select the Use Fuel Injector Trigger option. GUIDELINES FOR COIL TRIGGER SIGNAL If your vehicle utilizes a distributor (one coil for all cylinders) use the GUIDELINES FOR TACH SIGNAL found above configured for the number of cylinders in your engine. If your vehicle utilizes a waste spark ignition system (one coil per 2 cylinders) use the GUIDELINES FOR TACH SIGNAL found above configured for a 2 cylinder engine. If your vehicle utilizes a true coil on plug ignition system (one coil per cylinder) use the GUIDELINES FOR FUEL INJECTOR TRIGGER SIGNAL found above. GUIDELINES FOR SHAFT SPEED SENSOR SIGNAL (CAM/CRANK POSITION, A/T INPUT SHAFT, ETC.) Make sure the Use Fuel Injector Trigger option is unselected. Select the Use Shaft Speed Sensor option. Adjust the Shaft Speed Scaler value until the RPM calculated by the Cortex EBC matches your vehicle s actual engine speed. Cortex EBC Installation Instructions SIRHC Labs LLC
16 STEP 3: DETERMINE EVS RATIOS Access the Cortex Nexus Logger window from the Cortex Nexus Editor and ensure the following parameters are displayed in the Logger window: Engine Speed VSS EVS Ratio Gear Start a new Data Stream. Use your vehicle s tachometer to verify the value of the Engine Speed displayed by the Cortex Nexus Logger matches your tachometer. Also verify the VSS (Vehicle Speed Sensor) value displayed by the Cortex Nexus Logger is nonzero while your vehicle is moving and increases with speed. After verifying that the Cortex EBC is correctly detecting RPM and vehicle speed, record the EVS Ratio calculated by the Cortex EBC while driving in each forward moving gear. EVS Ratio will be the highest in 1 st gear and the lowest in 6 th gear. The Data Stream can be ended after the required information has been collected. STEP 4: COLLECT TPS DATA If you have connected the analog voltage input available on the Cortex EBC to a throttle position signal you will need to collect two data points for the Cortex EBC to correctly calculate throttle angle. Access the Cortex Nexus Logger window from the Cortex Nexus Editor and ensure the following parameters are displayed in the Logger window: Analog Volts Throttle Angle Start a new Data Stream. Record the Analog Volts detected by the Cortex EBC while the throttle pedal is fully closed. This value will usually be between V. Record the Analog Volts detected by the Cortex EBC while the throttle pedal is fully open. This value will usually be between V. The Data Stream can be ended after the required information has been collected. Cortex EBC Installation Instructions SIRHC Labs LLC
17 STEP 5: CONFIGURE ANALOG INPUT AND EVS RATIOS Return to the Cortex Nexus Editor window and access the Vehicle Configuration window. Configure the Analog Input Configuration and Gear Detection settings using the information provided below. ANALOG INPUT CONFIGURATION FOR TPS Select TPS from the Analog Input Type options. Enter the TPS value recorded with the throttle pedal fully closed into the Minimum TPS Voltage box. Enter the TPS value recorded with the throttle pedal fully open into the Maximum TPS Voltage box. ANALOG INPUT CONFIGURATION FOR WBO2 Select WBO2 from the Analog Input Type options. Consult your WBO2 manufacturer s instructions to determine two data points in the form of (Volts, AFR). Enter these points into the WBO2 X1, WBO2 Y1, WBO2 X2, and WBO2 Y2 boxes. GEAR DETECTION CONFIGURATION Enter the EVS Ratio value recorded in each gear into the corresponding Gear 1-6 EVS Ratio boxes. Write the new settings to the Cortex EBC device. At this time it is a good idea to save the Vehicle Configuration settings to your computer. When you are finished Close the Vehicle Configuration window. STEP 6: VERIFICATION Use the Cortex Nexus Logger to verify the following conditions: Throttle Angle is around 0.0 % when the throttle pedal is fully closed if TPS is connected to the Cortex EBC. Throttle Angle is around % when the throttle pedal is fully if TPS is connected to the Cortex EBC. WBO2 matches the AFR displayed by your wideband controller if it is connected to the Cortex EBC. Gear is being correctly determined while driving in each gear. If the above conditions have been met you have successfully created a Vehicle Configuration file for your car. Cortex EBC Installation Instructions SIRHC Labs LLC
18 BOOST CONTROL VERIFICATION The final step of the installation process is to verify that you are able to control boost with the Cortex EBC. STEP 1: PREPARATION If necessary, launch the Cortex Nexus software application and establish a USB connection with your Cortex EBC device. Create a new Basic 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. STEP 2: VERIFY WASTEGATE SPRING PRESSURE 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 that 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. STEP 3: VERIFY BOOST CONTROL Use the Cortex Nexus Editor to set the Profile 1 Spool Boost Limits several PSI above your wastegate spring pressure for each gear. Set Maximum Boost Limits for each gear to a safe value for your engine and the Spool Duty Cycle to 20 % for each gear. 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 for each gear in 10 % increments, capturing a Data Log after each change. As you increase the Spool Duty Cycle, Actual Boost should increase in your Data Logs with each change. When the Spool Duty Cycle is increased enough for boost pressure to reach the Spool Boost Limits set previously, 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 Spool Boost Limit setting, see the troubleshooting section below Troubleshooting Exhaust manifold backpressure will limit the amount of boost you are able to produce. Typically, the maximum peak boost that can be produced will fall within a 2:1 4:1 pressure ratio over your wastegate spring pressure when using a 3-Port BCS. 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 Spool Boost Limit setting is too high, it may simply be impossible to achieve the pressure level without changing your exhaust/wastegate configuration. If boost pressure does not increase at all, even with Spool Duty Cycle is set to 100 %, check that you have installed the 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 Installation Instructions SIRHC Labs LLC
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