Programmable Boost Controller

ALTERNATIVE PERFORMANCE ENGINEERING, LLC

1 Table of Contents

Introduction ...... 4 Getting Started...... 5 Vehicle Health ...... 5 What’s Included ...... 6 Module Passkey ...... 7 Installation ...... 8 Flex Sensor Installation ...... 8 Flex Boost Solenoid Connections ...... 8 Wiring Harness ...... 10 Wiring Harness Connections ...... 11 Gauge 1 & 2 Installation ...... 12 iOS / Android App...... 13 Flex Boost Features ...... 14 Ethanol and Fuel Temperature Gauges...... 14 DC Gauges ...... 15 Landscape mode ...... 16 Data-Logging Screen ...... 17 Boost Controller Screen ...... 18 Boost Profile Editing ...... 19 RPM Based Boost Control ...... 20 Over-Boost Safety ...... 21 Fuel Calculator Screen ...... 22 Settings Screen ...... 23 DC Voltage Output ...... 24 Raw Ethanol Sensor Output ...... 24 Gauge Customization ...... 25 Warranty...... 27 Returns ...... 27 Contact Us ...... 27

3 Introduction

The Alternative Performance Engineering Flex Boost is an advanced electrnoic boost controller, ethanol gauge and generic Bluetooth gauge all in one. Flex Boost combines all of the features of our Flex Boost product with the addition of a programmable boost controller. Boost can be configured based on Ethanol content or RPM and if you add a manifold pressure sensor you can configure an Over-Boost Fail safe. The Flex Boost also has two generic 5V sensor inputs that can be used for additional sensors like a wideband or map sensor. All of this data can be monitored and data-logged wirelessly via Bluetooth Low Energy on our Android or iOS application.

The Flex Boost provides a raw ethanol sensor output with built in 10K pullup resistor to 5V that can be sent to external ECU. There is also a 0V- 5V DC Output signal that can be configured to send out either one of the two 5V generic gauge inputs or can be configured to send the E85 content out as a DC voltage.

• Simple plug and play installation • Bluetooth phone application available for iOS and Android. • Boost Controller functionality is configurable via Bluetooth • Can configure 4 separate profiles with custom frequency and duty cycle • Has Flex Boost mode that allows the boost controller setting to change automatically based on ethanol content • Has a tach input that can be used to configure boost settings by RPM • Has an Over-Boost Safety feature that allows you to use one of the 5V sensor such as a wideband or boost inputs to monitor boost and will automatically kill the boost controller if the over-boost condition is met. • Monitors Ethanol Content and Fuel Temperature • Has two generic 5V inputs that can be used to convert any linear 5V sensor such as wideband or boost to a Bluetooth gauge. • Gauge format is completely user configurable • Has built in Fuel Calculator to figure out desired E85 to gas mix ratios when filling at the pump • Has a raw ethanol sensor output with integrated pull-up resistor that can be sent to stand alone ECUs • Has a DC 5V output that can be configured to send out Ethanol Level or the value of one of the two 5V sensors. • Has data logging function

4 Getting Started

Vehicle Health

It is important that your vehicle is in proper working order and has been well maintained. The fuel pump and the emissions system are important for proper vehicle operation. The fuel pump pressure and flow should be within the standards set by the vehicle manufacturer. Make sure that all other vehicle sensors are in proper working condition. After confirming the compliance of the data above, you may proceed with the installation.

Change the oil, oil filter and fuel filter since ethanol will act as a cleaner. It is recommended to change your oil between 500 and 1000 miles after the module installation and E85 usage. Change the fuel filter around 1000 miles after E85 usage. From then on, the changes should be made at manufacturers recommended intervals.

• APE recommends that your Muliti-Gauge is fitted by an appropriately qualified technician. • Consult your local tuning specialist before configuring your boost controller settings, setting your boost beyond your engines capability can result in severe engine damage or failure • APE recommends that the engines Air/Fuel ratio is checked once the desired boost pressure is set. Any increase in boost pressure can cause the engine to run lean resulting in severe engine damage or failure • APE recommends that the Flex Boost is not used in conjunction with any type of “Draw Through” induction System. • APE recommends that boost pressure is set using a Dynamometer and not on public roads. • The Flex Boost may not be able to completely compensate for a drop in boost pressure at high RPM due to the turbocharger operating beyond its maximum efficiency range i.e. incorrect turbocharger sizing or excessive exhaust backpressure. • The Flex Boost cannot compensate for increases in boost pressure at high RPM due to inadequate waste gate flow capacity; the turbo system must maintain a steady base boost curve before you start using a boost controller. • The Flex Boost cannot be used with external waste gates that are in a poor, worn or non-serviceable condition. • For best results your turbocharger should be correctly sized for your application. • Erratic operation of electronic parts can be caused by Electro Magnetic Interference (EMI). EMI can be generated by aftermarket ignition systems such as CDI which, if wired incorrectly, generate large amounts of EMI through the vehicles electrical system. This can cause items such as ECU’s and boost controllers to be effected. Please follow ignition system installation instructions VERY carefully to avoid EMI affecting the Flex Boost. Sometimes, using resistor type spark plugs can reduce this problem. • The Flex Boost is not waterproof and must be mounted inside the cabin. The unit has an operating temperature range of -5 °C to 70 °C. 5

What’s Included

Check to make sure you have all of the necessary components in your kit:

• Flex Boost Module

• Wiring Harness

• Flex Boost Solenoid and fittings

• Flex Fuel Sensor (optional)

• Quick Connect Fuel Fittings and hose clamps

• 15” of 5/16” E85 compatible high pressure fuel line

• 4 fuel injection hose clamps

• Flex Fuel badge

6 Module Passkey

On the back of the Flex Boost Module there is a sticker that looks like this. This indicates the Serial Number (SN) and the Passkey (PK) that is used by the IOS or Android app to allow the user to alter any of the default configuration parameters of the device. It is recommended that you note the Serial Number and Passkey here in your manual for future reference in case it is not readable after the Flex Boost Module has been mounted in your car.

APEFlexFuel.com SN: APE-FB-XXXXX PK: YYY

Contains TX FCC ID: 2AB6YHM-1011V1

Flex Boost Serial Number:

Flex Boost Passkey:

7 Installation

Flex Sensor Installation

The picture below is representative of the factory configuration of your vehicle. You will have fuel lines that come from the gas tank and go through a fuel filter before reaching the fuel rail that feeds the fuel injectors. The factory ECU is connected to each individual fuel injector through the factory wiring harness. There may or may not be a return line.

1) Install Flex Fuel Sensor anywhere in the fuel lines. A good place is at the fuel filter. Make sure the Flex Fuel Sensor connector on the Flex Boost wiring harness is able to reach the sensor.

2) You can use the supplied fuel line adapters to connect the Flex Fuel sensor to the fuel filter. If the adapters are the wrong size, you can simply use the rubber fuel line and hose clamps.

3) Make sure to secure the sensor. Too much vibration will cause sensor errors.

8 Flex Boost Solenoid Connections

9 Wiring Harness Below is the definition for each of the connectors on the supplied wiring harness.

Flex Boost Module Connection

White Wire: DC Output (0-5V)

Purple Wire: E85 Raw Sensor Output (integrated Pull-Up Resistor)

Brown Wire: Tach Input

Yellow Wire: Switched 12V input power

Ground Connection

Flex Sensor Connector

Boost Solenoid

Orange Wire: Gauge 1 input (0V-5V)

Green Wire: Gauge 2 input (0V-5V)

10 Wiring Harness Connections Solder loose wires together and insulate joints with heat shrink. Unused wires must be properly insulated so that they do not touch other wires or the chassis.

White Wire: DC 0V-5V output that can be sent to an ECU to indicate Ethanol level or the value of one of the DC gauges Purple Wire: Raw ethanol sensor output that can be sent to an ECU

Brown Wire: Can input a tach signal or even a port injection fuel injection signal to let the Flex Boost calculate ROM

Yellow Wire: Connect to a Switched 12V input power source

These DC gauge inputs can be used to connect any 5V DC linear sensor, like manifold, fuel or oil pressure or even the DC output of a wideband controller.

11 Gauge 1 & 2 Installation

Orange: Gauge 1 input (0V-5V)

Green: Gauge 2 input (0V-5V)

Red - 5V Black - GND

Blue - Signal

1) The Gauge 1 and Gauge 2 plugs are prewired to work with

the APE Flex Fuel Pressure sensors. We also include a plug so you can wire in any 5V sensor.

2) Plug the Flex Boost Module into the harness and mount in your car. 3) Now it is time to start up the APE app on your phone. 4) Use the sensor manufacturers specifications to configure Gauge 1 & 2 in the settings tab.

Example:

APE Pressure Sensor 0.5V = -14.5PSI 4.5V = 30PSI

12 iOS / Android App

We have developed both an iPhone app and an Android app. In order to be notified of updates and availability of the apps, please send your name, serial number and email address to: [email protected]

You can install the APE X85 from either the Apple App Store or the Google Play Store.

Open the app and connect to your device, you should see your serial number listed as something like “APE-FB-10001”. Select your device and hit “Connect” to get to the main dashboard of the app. The app may ask for permissions to access the Bluetooth device, please allow.

13 Flex Boost Features

Ethanol and Fuel Temperature Gauges

The Main dashboard screen displays the Ethanol content and fuel temperature as read from the ethanol content sensor. It also has two mini gauges that are used to display the two 0V-5V inputs.

Current value read Current value read by Gauge 1 input. by Gauge 2 input. It is 0.0 to 5.0 by It is 0.0 to 5.0 by default, the scaling default, the scaling information needs information needs to be entered in to be entered in the settings tab. the settings tab. This mini gauge This mini gauge can be turned off if can be turned off if not used. not used.

Displays Ethanol Content read by fuel sensor

Selecting this area

Returns to the Connection screen Displays the Fuel temperature

Dashboard Tab

14 DC Gauges

Selecting either Gauge 1 or 2 in the top corners will swap that gauge into the center and put the Ethanol Content in the corner. The scaling and visual appearance of the gauges can be configured in the settings tab. If you set the warning range in the settings tab and your gauge hits that range, the gauge will turn red.

15 Landscape mode

If you are on the dashboard screen and rotate your phone counter- clockwise, then you the gauges will rotate to a landscape view.

If you are on the dashboard screen and rotate your phone clockwise, then you will be taken to the data-logging screen.

16 Data-Logging Screen

Rotating your device to the right will show the data logging screen. You can only get to the datat logging screen from the main dashboard, so if you are on the boost controller tab and want to see datalogging, you have to go back to the main dashboard tab and then rotate your phone clockwise. You can select any point on the graph, and it will show you the values at that point. You can pause, and zoom in and pan to a section, and hitting save will copy a screenshot to your photos. The data-logging has a limited buffer, so you should hit pause if you want to look at a specific event that just happened.

Note: Even though the are not dispalyed on the graph you can still get the ethanol level and fuel temp from the datalog by tapping the screen anywhere and a box showing all the values at that point will appear.

17 Boost Controller Screen

The Boost Controller screen shows you both of the DC gauge inputs and it shows you the current duty cycle being sent to the Flex Boost Solenoid.

It Tach Input is Current Flex Boost enabled, the Solenoid Duty current RPM is Cycle displayed here Profile Select Press this button buttons, if the to go into the button is Boost Profile edit highlighted then it screen, you can is the active have up to four profile profiles.

Boost Controller Tab

18 Boost Profile Editing

You can have up to four profiles, and they are completely customizable. See description of all of the settings below. The Flex Boost allows the user to set up the boost controller duty cycle for two different ethanol settings. This is helpful as most vehicles can run higher boost levels on E85 than gas. The upper limit will always be E85, and the lower limit defaults to E10(Gas) or you can change this value to anything like E30 for example. The E85 duty cycle always has to be equal or greater than the lower ethanol rating duty cycle. The Flex Boost will vary the boost controller duty cycle between these two points based on the ethanol content in your vehicle. Setting the two values equal will fix the boost controller duty cycle regardless of the ethanol rating.

You must tap the

Takes you back to save button to the Boost preserve any Controller screen. changes.

Profile Select tabs, You can name the “+” will add a your profile here. new profile. Frequency the You can set up solenoid will duty cycles for two toggle at. different Fuel Lower ethanol You can change rating duty cycle lower ethanol limit value here Upper ethanol rating duty cycle

19 RPM Based Boost Control

You can raise or lower the Boost Controller duty cycle across four separate configurable RPM bands. You must have the Tach input enabled and configured correctly for this to work. We recommend setting a RPM range below idle, and then setting it to -100% in order to keep the Flex Boost solenoid from clicking when the engine is not running.

Range 1 is setup here to turn off the solenoid when the engine is off

Changing the RPM 0% means the range in one range duty cycle is set by will affect the the basic settings others. above, you can increase or decrease each RPM range as much as you like.

20 Over-Boost Safety

The Flex Boost has the abilityh to configure one of the DC gauge inputs for Over-Boost Safety. You must first configure your Gauge settings and then you can select that gauge in the Over-Boost Safety drop down in the settings tab. You can the set your desired Over-Boost Safety level. In this example, we are setting it at 16 PSI.

If the Flex Boost detects the Over- Boost condition it will immediately turn off the Flex Boost Solenoid and display this message. In order to turn your solenoid back on, the Over-Boost condition must no longer be valid and you must tab the red message in the center of the gauge.

21 Fuel Calculator Screen

The fuel calculator can show you how to mix Ethanol with Gasoline to achieve a desired Ethanol mixture, for example E65. You can use the datalogging screen to help determine if you need to lower your Ethanol mixture. As a reference, for every 10 percent increase in Ethanol will increase the pulse width extension by 4%. So, at E50 the module is adding 16% more fuel, and at E60 the module is adding 20% more fuel.

Enter the capacity of your fuel tank here

Enter the Ethanol levels for Gas and E85 here

Enter the current Ethanol level here, app will auto fill this field, but the user can overwrite.

Enter your desired Ethanol level here.

Set your current fuel tank level here, and the app will recommend the Gas/E85 mix to achieve the desired Ethanol level

Fuel Calculator Tab

22 Settings Screen Hit the Save button after any changes are Displays Module made Firmware and App Version Changes Gauge Trim from silver to black Can Set the Glow color around the Select DC Output. Gauges on main tab This determines which value is output on the Pass Key not used for White wire. Flex Boost E85 (E0 = 0V, E100=5V), Gauge 1 or Gauge 2 Display Name is what is shown when Gauge Can turn off Gauge is in the Center. Display on dashboard Abbreviation is what is if not used used when Gauge is in the corner. How you enter the values in the boxes The Color ranges for will be how the when this gauge is numbers are selected for the displayed on the center can be defined Gauges. For example, here. of you put 7.35 and 29.4, the gauge will display 2 decimal Gauge scaling values points. If, however see below for you put 7.4 and 29.4 formatting rules. the gauge will only display one decimal A visible warning point, and if you put 7 range can be set for and 29 then the gauge each gauge here. will not display a

decimal point. You Turn on Tach input can also enter 0% and and set divider. 100% if you want it display the number as Select which DC gauge a percentage. to use for Over-Boost safety and set the level. Reset values

23 DC Voltage Output

The Flex Boost also has a 0V-5V DC Output signal that can be configured to send out either one of the two 5V generic gauge inputs or can be configured to send the E85 content out as a DC voltage: 0V = E0 content, 5V = E100 content. Note: The DC Out signal has a weak drive strength, if feeding into an ECU with a pullup resistor, the Flex Boost may not be able to drive this signal all the way to ground. In this event, calibrate your low voltage point accordingly in your ECU. For example, if DC Out is configured for ethanol content output, then gas(E10) would normally, put out 0.6V,if however your ECU is reading 1.6V when the Flex Boost is displaying E10, then you should configure your ECU input as 1.6V = E10, 5V = E100.

Raw Ethanol Sensor Output

The Flex Boost has a raw ethanol sensor output with integrated 10K ohm pull-up resistor to 5V that can be sent to stand alone ECUs.

24 Gauge Customization

You can change the end points in the color bar to change the upper and lower limits shown on the gauge. This can be useful if you have a sensor that displays a much higher range than what is needed for your application.

You can drag the colors around and rearrange them to determine how the gauge is shown.

26 Warranty

Alternative Performance Engineering, LLC offers a one-year manufacturer’s warranty from the date of purchase. The warranty applies only to the Flex Boost module, the flex fuel sensor, the included wiring harness, and their functionality. Always read the instructions in this user manual before attempting to install or use the flex fuel power module.

The warranty does not cover damages caused by improper installation by the buyer or by the buyer’s agent, or if the product has been damaged by wear that is not caused by normal use or by a manufacturing defect. Any modification done to the flex fuel power module or wiring harness without the consent of the manufacturer voids the guarantee.

If the product has a fault that can be regarded as a result of a faster than normal wear or a result of a manufacturing defect, the manufacturer will provide the buyer with a new product or repair the faulty product. The manufacturer has the right to redeem the faulty product if it is replaced by a new one. In no event shall this warranty exceed the original purchase price of the flex fuel power module nor shall Alternative Performance Engineering be responsible for special, incidental or consequential damages or cost incurred due to the failure of this product.

The manufacturer reserves the rights to any modifications, expansions, attachments, or improvements made by customer.

The use of the flex fuel power module happens at the user’s own risk. The manufacturer commits only to make up for damage caused to the flex fuel power module, the accompanied wiring harness, or accessories as covered by the guarantee.

The manufacturer does not make up for damage caused to the car by the use of ethanol containing fuel or the use of the flex fuel power module. Neither does the manufacturer make up for damage caused by the installation to the product, the installation’s target or the person carrying out the installation, if the installation is carried out by the customer or by customer’s agent.

Returns If you are experiencing an issue with your Flex Boost module, please contact us so we can help resolve it. If you wish to return the system, all components must be returned in original packaging, in resalable condition. The flex fuel power module will be inspected for damage prior to any refund being issued. All returns must be made within 30 days from the date of purchase.

Contact Us Alternative Performance Engineering, LLC Instragram/Facebook: @apeflexfuel Email: [email protected] Web: www.APEFlexFuel.com San Diego, California