For people installing ECUs on street
cars, where this is legal to do so, often people will want to
run the factory air conditioning system through the
aftermarket ECU. This has several advantages over being wired
directly. Firstly, the biggest advantage you can gain is in
the idle control. The air conditioner compressor puts a large
torque load on the engine, so the ECU can compensate for this
with idle control. Secondly, the ECU can disable the
compressor if the engine is about to stall, and lastly the ECU
can disable the compressor at wide open throttle. Let’s first discuss how to wire in an air
conditioner system to the ECU. Firstly the ECU requires a
digital input to be triggered when the air conditioner request
is active. On most cars, this is a wire that pulls to ground
when the air conditioner is required to turn on. Normally this
comes from the user switch or a thermostat, connected in
series with a triple pressure switch on the refrigerant line.
Connect this to a spare digital input pin, and select that
input in the Digital Inputs setting as being air conditioner
request. If your pin connects to power when active rather than
ground, then you will need to select that input as being
active high.
Wiring an air conditioner system
Digital input set to air conditioner request
Tick the checkbox when pin power is switched from high
supply or 12V
The ECU then must be able to drive an external
relay, which provides 12V power to the compressor magnetic
clutch. On almost every car, this output to the relay coil
must pull to ground to activate the relay (and turn on the air
conditioner). In this case you can connect the output to any
of the unused injector, ignition or auxiliary outputs on the
ECU, and configure the output to be air conditioner. In terms of settings, let’s discuss idle control
first of all. There are several parameters to get right here,
but when you do, it works really nicely. The first setting is
the new, higher idle speed when the air conditioner is on. We
used to have an additional RPM that gets added to the target,
but that meant that the target RPM became very high at low
engine temperatures, so instead we have a new “minimum idle
RPM”, so whichever is greater out of the base target idle
table and the aircon RPM value will be the actual target RPM.
So wherever you want to set this is up to you, but often this
is set to about 1000 – 1100 RPM where the engine has a bit
more torque reserve than at the low speeds and has some room
to recover if a stall is imminent.
Functions->Idle Stepper-> Base Idle-> Base duty
cycle table
Set 1000 as new target RPM
The next setting is the additional idle effort when
the air conditioner is on. The easiest way to set this is
practically; if you already have closed loop idle working,
then you can watch what the idle effort is before you turn on
the air conditioner, and then watch what it changes to, after
turning on the air conditioner and the RPM has stabilized to
the new target. Remember that this will also include the extra
effort for the thermofans which will also come on at the same
time, so their extra efforts have to already be configured
when you do this. This difference, minus the difference for the
thermofans, is what you need to put into the additional idle
effort for aircon setting. The next setting is the delay for turning on the
compressor. When the input is first enabled, the new idle
target and idle effort is applied straight away to bring up
the idle speed. After a short delay, the compressor is
enabled. This gives the engine some time to prepare for the
additional load of the compressor, which helps stabilize the
idle when cycling the aircon compressor. Here’s a graph of how
I got it to behave on a pretty much stock GTR. Notice how
smooth the RPM trace is; there’s a small amount of overshoot
but this is a well set up system. The next setting is the minimum RPM. Below this
value, the ECU won’t enable the aircon compressor at all. So
you can set this to a low value eg 600 RPM, so that if the
engine is about to stall, this will help save it. It has the
other benefit of disabling the aircon compressor during
cranking. The ECU will always disable the aircon during a wide
open throttle condition. Sample of logs from ECU are presented below.
Aircon is turned ON (red line) you might notice that the
step is going down because in this case it is switch to the
ground. The request for idle effort (white line) and idle
speed (pink line) immediately comes after getting the
request and then A/C compressor turned on after some time
approximately about 0.56s.
A/C compressor (yellow line) switched off automatically
when it reached certain RPM (green line),in this case
minimum RPM is set to 600.
When throttle (blue line) is closed, the A/C
compressor (yellow line) is running constantly and
as the throttle opens it shuts the aircon off on some
point before reaching WOT.