HFS3v2.13w
Contents
1. Page 15 pagel Setting up the fail safe This final stage should be quick simple and effective please read it before proceeding It will save you time in the long run If fluid flow falls inside the fail safe detection win dow after triggering no action will be taken So setting up the width of the window to accommodate the full fluid flow is vital Setting up the fail safe should only be done after the car has been tuned or the Jet jets sizes are finalised Recommended steps to set up the fail safe 1 Adjust the SC to display 5 6 bars at full power 2 Make a mental note of the number of displayed bars during spool up This is made easier at higher gears 3 Set the WL to match the number of spool up bars It is recommended to allow 2 3 clicks below that point to avoid false triggering Full span of WL is 20 clicks covering from O bar to 4 bars 4 Same procedure is used to set up the WH allow ing 2 3 clicks above 6 bars Full span of WH is 20 clicks covering 4 8 bars This completes the fail safe set up Setting up the alternative Fail safe Channels BERTAM 1 The Map Switching Channel HFS 3 only The orange wire from the grey RJ48 connector orange is dedicated for the use of MAP Switching when an ECU is equipped with this input This wire is factory configured to send out a voltage of 4 7V DC under a no fault condition from idle to full boost This voltage will switch to Ov upon a fail2. Getting to know the Aquamist HFS3v2 pwm system Aquamist has been pioneering the IDC based water injection system since 2003 with great success The HFS3 pwm system is designed to complete the Aquamist s PLUM valve delivery system line up it allows precise metering of water methanol injection for the modern high performance engine The dash gauge flow sensor and Plug and Play features are standard to minimise installation time The system retrieves the fuel flow IDC and manifold pressure signals MPS from the engine management system as the prime source to control the flow of water This enables perfect balance of water to fuel flow under all engine loads The system can also be controlled by a third party ECU with its own custom water methanol flow map A Fast Acting Valve FAV controls the delivery rate based on the PLUM signal from the HFS 4 controller A constant line pressure 160 psi is provided by the Aquatec pump working in the by pass mode A PLM valve system guarantees wide dynamic range There is a non gauge flow sensor option HFS 2 for non critical application where a Failsafe is not needed A dash switch is provided instead The user can disable the system and reduce the manifold pressure to wastegate pressure if needed Contents System Check Page 4 Checking the contents of the box 5 Getting started on the installation Installation 6 Installation for lo
3. cleanly with a razor blade to retain the round ness The use of side cutters produces a semi round hose end resulting in a major leak sooner or and tighten the M16 plastic nut Stop the assem bly from rotating with a 6mm allen key into the centre of the assembly Do not over tighten to avoid splitting the rubber gasket seal Drill the same hole size for the water level sensor IF using a washer tank for supply do not locate the Aquamist float sensor near the stock washer pump The float arm should swing upwards e A tall and slim water tank is ideal for this type of application This minimises delivery surge prob lems at low water level TO CONTROLLER BLUE HARNESS gt gt TO FAV ASSEMBLY later It is also vital that the hose must be cut perpen dicular square relative to its length This is because the compression fitting has a short hosetail An accu rate cut will allow maximum grip on the walls of the hose Ensure the thin rubber gasket is placed between the FAV coil and electrical plug red harness before tightening Press the clip of the yellow harness into the centre section of the flow sensor body Orienta tion is not important Ensure the electrical plug s cable outlet is facing downwards All cables leading away from the assembly must be looped downwards to avoid condensed water trickling into the clip and plug The tank level sensor Drill oore the same hole size for the water level sensor A 23m
4. dry spot of the engine bay c The controller is accessible and can be secured down with minimum movement during motoring d The jets are securely installed in the inlet tract e Dash gauge installed 2 Priming and purging of the system a Fill up the tank with water half way b Disconnect the 6mm hose from the FAV assem bly and put the hose into a container securely c Ignition switch in pre crank position and gauge is switched on Uncover the controller and pull out the FAV jumper disabling the FAV and put it to the link marked SYS The pump should power up and water should come out of the 6mm hose within a few seconds Let it run for a 10 20 seconds so that trapped air and debris are purged d Listen to the pump during the priming period it should go very quiet after completion of purging procedure If not repeat step c e Upon successful completion of the above rein state the 6mm hose into FAV assembly 3 Testing the spray pattern of the jets a Secure an unused jet onto the windscreen and connect It to the outlet port of the FAV assembly b Activate the system by linking up FAV default and SYS on the controller You should see an instant full cone spray at the jet Do it for a few seconds only You can repeat the test with the remaining jets At the same time the gauge should register a few bars Remove the SYS test link 4 Activate the system by F IDC a Set the far l
5. factory default Fail safe output to ground upon activation FS1 Fail safe output switches from O to 5V or 8V upon activation this fail safe output option is on the pink wire of the grey harness DHB defaut linked Disable High Boost When the gauge is switched off all fail safe outputs be come activated This safe guards any engine damage If the DHB is unlinked the yellow led water level will be lit when the gauge is switched off giving user a reminder that the system is not protected DFS defaut unlinked Disable Fail Safe Link to stop the fail safe actvation during test or preliminary test run prior to finalising fail safe window Flow management and other trimmers Setting the onboard trimmers default 12 o clock am Y tits Se SESE SS The system requires no trimming from the factory If the user wants to alter the flow and other parameters just use a small screw driver to complete the task Below are the working details of each trimmer left to right 1 LED panel Three leds monitor the real time opera tion of the system Green F IDC Blinks upon successful detection of fuel injector duty cycle sig nal The blink rate and brightness in crease with engine speed and duty cycle respectively Amber THRES At 44 F IDC de fault this led will activate confirming the system is triggered and delivery commences Red 95 DC When the water methano
6. lines Wiring work checklist The HFS 3 is pre configured from the factory Plug in the following harness for testing the power supply into the controller 1 4 way Power in connector Red woe Switched 12V IGN SW 2 Black uo Chassis ground White Chassis ground Purple oo Head lamp switch optional 2 Signal to the grey RJ48 connector Red oo Ignition switched 12V Green Fuel injector pin Blue oo MAP sensor optional 3 grey flat cable to the Dash Gauge Power up procedure Please follow this procedure Strictly or per manent damage to the system may result Do 1 Ignition key on the OFF or 0 position Dash Gauge button is depressed system on No leds should be lit anywhere 2 Ignition key on the ACC or 1 position Absolutely no change same as the above conditions 3 Ignition key on the pre cranking or 2 position Do not crank Observe the gauge and controller leds Yellow led on the gauge will stay lit for 5 10s before the rest of the gauge lights up 4 Start the engine and let it idle for a minute or so The green led on the controller should flicker The flicker should speed up with engine speed If the system behaves as stated above you have successfully wired up the HFS 3 Now plug in the rest of the harnesses The S led should confirm the presence of the flow sensor The yellow led will a
7. path to HFS 3 from Aquamist Please submit your request directly Page 17 Fail safe wiring to other boost controllers Upon detection of water flow fault the HFS 3 can reduce the boost pressure of a third party EBC or MBC to wastegate setting This can be accom plished by using the internal fail safe relay and a MAC valve The HFS 3 does not include this valve You need to order one from www howertonengineering com Figure below shows two common types of MBC manual boost controller used on most turbo cars Type 1 pressure from the turbo to the wastegate Is vented to the atmosphere via a restrictor and a vent Boost increase is proportional to the amount vented Type 2 Boost increase is proportional to the spring pressure of the MBC When the solenoid valve is energised pressure from the turbo is diverted to the wastegate di rectly When MBC is by passed the boost pres sure will drop down to wastegate setting NOTE The same MAC valve can be used to reduce boost on any Electronic Boost control valve system Use the same hose configuration as the TYPE 1 with Port 2 blocked off CEL OFF page12 6 Important install the valve in a dry location with good air flow as the valve is energise continuously Only use a valve with low coil power or put a 50W inline resistor to reduce winding temperature mac valve SWITCHED 12V GROUND FROM TURBO GREY HARNESS DR OFF Supplementar
8. safe activation or the gauge is switched off Other voltages such as 0 5V or 8V can be user configured page 12 7 This is by far the most effective method to save your engine from lack of water injection A jumper link can a invert the map switch output if necessary 2 Change over relay channel HFS 2 3 The HFS 2 3 has an onboard relay to supply a set of voltage free change over contacts for the sole use of fail safe activation It can be used to perform various tasks to save your engine Contact rated up to 1 amp Gauge Off White Black 0 close circuit White brown nnsa open circuit Gauge On non injection period White Black e open circuit White brown circuit circuit What steps to take after the fail safe triggers The most common way to minimise engine damage in the absence of injection is to reduce the boost pressure 1 For engines with electronic boost control valve The grey harness contains a set of relay contacts that goes open circuit when the fail safe is triggered See page 18 2 and 19 for more details 2 For engines with MBC manual boost controller The onboard failsafe relay can be used to control a 3 port solenoid valve to by pass the MBC Essentially reducing full turbo boost to the wastegate See page 19 for more details 3 For an engine with map switching capabilities The pink wire on the grey connector has a dedicated output to perform
9. the area is well ventilated and isolated from the driver s compartment Take whatever measures to avoid any methanol fumes building up in trunk area Methanol is highly flammable The main delivery hose to the engine bay should be routed underneath the car En sure it is securely clipped and fastened Avoid kinks and close proximity of moving parts and heat producing compo nents Please treat this recommendation seriously If in doubt ask advice from a professional person familiar with this kind of application DO NOT take any undue risks It is recommended that a suitable fire extinguisher is placed within easy reach of the driver All electrical connections must be properly tightened to avoid spark production Warning Prolonged use of 100 methanol may cause premature pump failure and may not be covered under warranty DASH GAUGE P 15 12V HEAD LIGHT SWITCH and GROUND P 11 FAST ACTING VALVE in ENGINE BAY P 6 WATER FLOW SENSOR FAV CLUSTER P 6 ECU INTERFACE AND FAILSAFE P 11 18 aao WATER TANK and PUMP in TRUNK AREA P 5 FUTURE SYSTEM EXPANSION PORT SYSTEM CONFIGURATION BY USER P 12 FLOW amp SYSTEM MANAGEMENT TRIMMERS P 13 0 5A 20mm x 5mm FUSE LINK OOND Page 10 Quick Start Mechanical work checklist Only after testing with distilled water should methanol be used BEFORE hooking up line to the jet the system should be manually activated to flush any possibly dirt debris from the
10. Engine bay 2 5M To Flow Control assembly 1 red 24awg 12V PSU to Fast acting valve 1A max 12v 2 yellow 24awg 12V PSU to Fast acting valve 1A max 12v 3 blue 24awg PWM ground switch to Fast acting valve 1A max 0v 4 black 24awg PWM ground switch to Fast acting valve 1A max 0v Yellow Harness to Engine bay 2 5M To Flow Control assembly 1 red 24awg 5V Power supply to Turbine flow sensor 5mA max 5v 2 yellow 24awg Turbine fow sensor signal output 1mA max 5v 3 blue 24awg Feedback signal return ground 1mA max 0v 4 black 24awg OV ground power supply 1mA max 0v Grey Harness to EMS 2 5M IDC Boost detection and Fail Safe Map Switching interface 1 24awg Future extension I O channel e z 2 red 24awg Ignition Switching detection 30mA max 12v 3 green 24awg Fuel injection IDC detection 10mA max 12v 4 pink 24awg Map switching intenacing 0 5V 7 5V 1mA 5 white 24awg Failsafe Relay contact COM Wiper 1A 24V max 6 yellow 24awg Reserved for internal communication Signal level 7 blue 24awg Map Sensor Signal input 0 5 VDC 1mA 8 black 24awg Failsafe Relay contact N C contact or DR 1A 24V max 9 brown 24awg Failsafe Relay contact N O contact 1A 24V max 10 oo 24awg Future extension Ochannel2 9 e m Blue Harness to Trunk Area 6M 1 red 24awg 12V Power supply to 40A relay 0 5A max 12v 2 yellow 24awg Water level sensor signal signal ground 0 5A 3 blue 24awg Pump relay activation ground swit
11. SC is calibrated failsafe window width coverage 20 clicks sensor must be lit after power up and stay on to show the flow sensor is functioning correctly 6 Backlit flow legend Legend displays of full scale of 8 bars 7 B High Boost Enabled led When the flow falls inside the fail safe window after system trigger this B led will activate Useful indicator of the WL and WH setting NOTE In order to make the fail safe adjustment easier it is recommended to set the bargraph to display 5 6 bars at maximum flow This way the fail safe win dow can span from the centre outwards If the WL and WH is set at 12 O clock the fail safe window is approximately spanned between 2 7 bars This is a good starting point Minor trimming for the WL is necessary if the water injection trigger point is set to commence earlier The gauge will display the activation of the fail safe with two yellow leds 1 B led right of the bargraph will only stay activated if the flow is inside the fail safe window during injection period 2 The two yellow leds Both leds will activate when fail safe is triggered Only the lower led illumi nates during low tank level As soon as the fail safe is tripped there will be a 3 second reset period before it reset while the fail safe drops boost When gauge is switched off expect low boost and safe map unless the board is re configured page 12 7
12. Sussex BNIO8HF England
13. ch 4 black 24awg Water level sensor ground 9 Red 12awg 12V Power cable to water pump relay 38A 12V max 10 Black 12awg Ov ground for water pump 38A 12V max Green Harness user port 2M Reserved for future expansion Page 23 GUARANTEE ERL guarantees at our option to replace faulty goods sup plied or repair the same subject to the claim made in writing to us within 12 months after the sale by us or for such other period as may be indicated by us for specific products in lieu of any warranty or condition implied by law as to the quality or fitness for any particular purpose of the goods Any claim against us must be made to us in writing within the period of 12 months after the sale by us or our agents or our distributors of goods in question or such other period as may be indicated by us and any goods to which the claim relates must be returned to us within that period suitably packaged and cleaned and with any particular instructions which we may have notified to you at the time of supply Original invoice the nature of any claimed defect must ac company the goods in question prior to despatch to us If these requirements are not complied with our Guarantee shall not apply and we shall be discharged from all liability arising from the supply of defective goods LIABILITY We shall not be under any liability whether in contract or tort or otherwise and whether or not resulting from our neg ligence or that of our
14. ctivate if the tank level is low This completes the basic system test The next stage will be testing the system manually by using the jumper links on the controller board You will need a Page 11 not SKIP any steps please Quick Start System setting and manual testing Knowing the default controller functions function explained from left to right Tit tii 1 TRIG The system is set to triggered by IDC fuel injector duty cycle from factory The alternative mode is MPS Manifold Pressure Sensor Flow will remain progressive with fuel injector duty cycle 2 MODE PWM mode factory default Flow is progressive with IDC The user can set the system to inject as SSG single stage mode ie all on or all off 3 FAV Enable default or disable inline valve 4 PRK Parking for unused jumper link 5 TEST FDC Link to display FIDC on gauge testing only BAR Link to test bargraph with the SC trimmer SYS This link can be used to activate the pump only for the purpose of priming the system small 3 32 slotted screw driver Unlink the 3 FAV to disable FAV to avoid hydro lock 6 CEL Boost cut without CEL check engine light activation This is only used in conjunction with internal relay fail safe output DR1 No CEL 7 F SAFE OPTIONS CLP FSO FS1 configure the map switch output CLP factory default Output voltage is clipped from 8V to 5V FSO
15. e flow sensor to give an ideal visual indication of a given flow rate Ideally set the led to dis play 5 6 bars at full flow 2 S indicates the presence of a flow sensor The letter S Fail safe activation led on the new v11 only When the fail safe is triggered This led will illuminate In conjunction with the water tank level led below Dash Gauge Functions cont 8 Water injection enable button Due to extra power level achieved under WI user may want to reduce the power to the wheels in less than ideal driving conditions Disabling the WI will reduce boost to wastegate bleed valve setting if fitted as well as switching to a less aggressive MAP on custom engine management 9 Over range setting potentiometer WH It is just as important to monitor over range condi tions as well as under range flow conditions If a leak develops close to the water jet and starves the engine of the water the user must know this condi tion A 20 stepped potentiometer allows accurate and repeatable adjustment range 10 Under range setting potentiometer WL This setting can indicate partial blockage and trapped air inside a delivery hose Again a 20 stepped poten tiometer is employed Each click represents a fixed portion of the window width of 8 bars WL covers the lower 4 bars of the display and the WH covers the up per 4 bars Figure on the right illustrates the span of the coverage Setting is very simple once
16. eft trimmer to fully counter clockwise Crank the engine and leave it to idle you should see the blinking green led on the controller board b Blip the accelerator paddle sharply to induce an artificial load The amber led should respond A faint but noticeable spray should develop at the jet 5 Road test the system Still with jet on windscreen make a short drive and confirm the spray is progressive with load After a successful road test reconnect the hose to the inter nal spray jets This concludes the system test The system is ready for the next stage fail safe setting At anytime if there is a problem please con tact us Dash Gauge Functions v1 1 1 8 element Bargraph 0 100 Fullscale Each segment is equivalent to a percentage of the total flow of the sensor scaled by the SC potentiometer 4 Water Level led Failsafe yellow This LED has three functions a During power on delay period This LED will activate for approximately for 10 seconds during the system on delay before the main system turns on b During normal operation period This LED is on during the fail safe activation in conjunction with the yellow led above Water level low intermittent flashes c Led lit after the gauge is switched off If the water level sensor is activated for over 20 seconds fail safe disabled by DHB p21 6 5 SC Sensor Calibration 20 stepped potentiometer allow user to scale th
17. employees in respect of defects in goods supplied or for any damage or loss resulting from such defects We shall not be under any liability for damage loss of ex pense resulting from failures to give advice or information or giving the incorrect advice or information whether or not due to our negligence or that of our employees In no event shall any breach of contract on our part or tort including negligence or failure of any time on our part that of our employee give rise to liability for loss of revenue or consequential loss or damages arising from any cause what soever Note ERL reserves the right to make changes to our prod ucts without notice in order to improve design performance and reliability Page 24 Useful Aquamist technical links Aquamist owners have been pretty good in supporting each other Most experienced users will help new users with questions not necessary to email or make long distance phone calls and wait on hold to get help Here are a list of forum links where users can seek help and advice from others htto www waterinjection info general http forums nasioc com forums forumadisplay php f 145 Subaru http www iwsti com forums water meth injection nitrous intercooler cooling Subaru sti http forums evolutionm net water alcohol injection nos 173 Mitsubishi evos http www rx7club com forumdisplay php f 173 RX7 ERL Itd Iroko House Bolney Ave Peacehaven East
18. g up the amm l capacity of the fuel injectors Multiply the result by the preferred recommended above 450 0 9mm A Pick the nearest jet jets size to match the flow 400 Don t forget to subtract the boost pressure from 0 8mm x the line pressure of 160psi For example if you are 350 boosting 25psi you should select the jet flow at z gam i 135 psi Allow 10 15 drop due to system loss ra 300 Geman Once the jet jets and flow are determined insert I the nearest larger restrictor to regulate the fluid 250 flow so the delivery will be linear to the duty cycle Led JET 60 70 80 90 100 110 120 130 140 150 160 170PSI 200 0 4mm 0 3 108 116 124 132 139 146 152 158 164 170 176 181 T H 0 4 144 155 166 176 185 194 203 211 219 227 234 242 0 5 194 207 220 232 243 254 264 274 284 293 302 179 150 0 3mm t i T J l 0 6 215 233 249 264 278 292 305 317 329 340 352 362 0 7 251 271 290 308 324 340 355 370 384 397 410 423 100 0 8 287 310 332 352 371 389 406 423 439 454 469 483 Oe AO BY BO NLO De 190 ae ee TEONA 0 9 323 349 373 396 417 437 457 475 493 511 527 544 Pressure psi 1 0 359 388 414 440 463 486 508 528 548 567 586 604 NIW 99 3LVY MOT4 The HFS 2 3 is s
19. inject When the preset trigger point is reached the green lead will blink at a steady rate informing the user the system is spraying When the water tank level drops below the level sensor probe the green led will change to yellow Initially it will oscillate between the two colours until the water is well below the sensor probe it will turn solid yellow At about 20 seconds later the system will automatically stop injecting to prevent air enter ing the system One more useful function the internal fail safe relay works in unison with the status of the dash switch until the tank is empty or DBH disabling high boost mode is turned off jumper link removed This func tion is making use of the relay whereas lying idle Page 19 Generic wiring diagram of the HFS 2 DASH SWITCH FUEL INJECTOR or amp INDICATOR IGN SW pre crank FAST ACTING VALVE RESTATE Di injection contact office AND TURBINE FLOW FUEL SENSOR ASSEMBLY y INJECTOR MAP SENSOR optional I aE lt FAV amp FLOW SENSOR m E a ENGINE BAY nani 12V GND PUMP RELAY amp LEVEL SENSOR TRUNK HEAD a LAMP SWITCH d MEN namie PZ Shas a a a 40A 160 PSI BYPASS PU ae MADE IN USA BATTERY aA SRT il n Note Please ensure the correct harness is plugged into the appropriate socket to avoid causing permanent damage to the Electronic controller The potentiometers on the co
20. l duty cycle is approaching 95 The red led begins to turn on indicating that you have almost reached the maximum flow of your system More flow requires additional jets 2 Trimmers for fine tuning THRES Factory set to 44 User adjustment range is be tween 12 72 IDC GAIN 50 GAIN User can define the slope of water methanol relative to F IDC by 50 The factory slope is set to 1 1 ratio of fuel duty cycle Useful tool to compensate low F IDC when large fuel injector is used It can also be used to trim flow at high F IDC WATER FLOW x trip point FUEL FLOW FS DL Fail safe delay to undue fail safe activation due to spike and noise signal from the flow sensor The factory default setting 12 o clock is 400mS milli second User ad justable between 200mS to 600mS DIM This trimmer works in conjunction with the head lamp switch When it sees a 12V signal the trimmer becomes active This coincides with night drive conditions The high intensity led used on the dash gauge is too bright for night motoring so wiring in the purple wire from the 4 way power plug to the head lamp switch is essential Do not wire it to the car s interior dimming circuit or unexpected results may occur Page 13 Preparation for a test run of the system Page 14 1 First step system check list a Tank and pump is fully secured and leak free b The FAV assembly is securely located in a cool and
21. m burr free hole must be used to ensure a good seal The float arm should swing upwards Check that there is ample room for the sensor arm to swing before drilling A tall and slim water tank is ideal for this type of application This minimises delivery surge problems at low water levels If the stock washer tank is going to be used do not mount the float near the stock washer pump The motor magnet will affect the sensor reading properly The sensor can be installed 3 4 way down the tank preferably at the rear facing wall of the tank Never over tighten or the seal will split just tighten enough Generic wiring diagram for HFS 3 Aquamist FUEL INJECTOR or IGN SW pre crank Dl injection contact office g FLOW FAST ACTING VALVE AND TURBINE FLOW WINJECTION FUEL SENSOR ASSEMBLY 7 lt ie eae INJECTOR MAP SENSOR optional f A FAV amp FLOW SENSOR m a y ENGINE BAY 12V GND PUMP RELAY amp LEVEL SENSOR TRUNK HEAD ai T0000 chm a aim amp 40A 160 PSI BYPASS P 5A FU MADE IN USA BATTERY ARIER EIA E EEE E E E Choosing jet sizes Page 8 Pressuns ve Flow This is a general guide only l 100 water run 10 15 water fuel ratio 50 50 methanol water run 15 20 to fuel l 100 methanol run 20 25 to fuel 550 Choosing the jet by calculation eno First work out the total fuel flow by addin
22. ng term reliability 7 Generic wiring diagram for HFS 4 8 9 Choosing jet sizes System testing 10 HFS 4 function directory 11 12 Quick Start amp manual testing Gauge 153 Flow management and other trimmers 14 Preparation for test run of the system Dash gauge 15 16 Dash Gauge functions v1 1 Fail safe 17 19 Setting up the fail safe Advanced 90 21 Supplementary information on HFS 2 Appendix 99 94 Dimensions Guarantee and Warranty Checking the contents of the box carefully This is a must do immediately 1x water tank adapter 1 8 BSP 806 270 6mm after unpacking compression fitting and in tank filter 806 258 e 4x M5x40mm bolt washers and fasteners for pump e 1x M6 grounding stud with washer and nuts and Water pump 6mm eyelet for pump ground Unpack the corrugated sheet carefully The pump 2x 6mm to 1 8 BSP compression fitting for pump should be labelled with the original custom 2x 3 8BSP M to 1 8BSP F reducer for pump Aquatec Aquamist logo 1x 4mm to 1 8 BSP compression fitting for FAV 1x 6mm to 1 8 BSP compression fitting for FAV The white box e Water pump harness 6M of 12 AWG cable and 6M of 6mm OD nylon hose 806 261 6M of multi core cable with blue harness 2M of 4mm OD nylon hose 806 266 1x Fast acting valve with red harness e HFS 3 Flow Control Module 1x turbine flow sensor with yellow harness 0 8mm water jet 806 323 in plastic bag 1x water level switch wi
23. ntroller are preset to mid position from factory System triggers at 40 of IDC Fuel IDC to Water IDC ratio is 1 The system will operate correctly without any adjustments Aquamist HES 4 PLUUM Pulse Width Modulation valve water injection system fd ERL Designed and made by ERL East Sussex England 58mm razez HE LL EE E T E Tae Tae T 113mm v Tr r a 2 GIES GED GENE ws Ecu In Car Dash Gauge 2M Appendix Pin Colour Size Description Electrical parameter 1 HFS 2 24awg Dash indicator red or green led 20mA 5V max 2 red 24awg 12V power supply to gauge 250mA max 12v 3 green 24awg Flow Sensor output voltage 0 5 VDC 10mA 4 pink 24awg OV power supply to gauge 250mA max 12v 5 white 24awg Internal communication signal 6 yellow 24awg Float Sensor from water tank Ground active 7 blue 24awg Flow Sensor calibration output voltage 5 0 VDC 1mA 8 black 24awg Night driving dimming connection 12V active 9 brown 24awg Wastegate bleed valve option SW 1A 12V max 10 HFS 2 24awg Dash indicator yellow led 20mA 5V max Molex Microfit power harness 2 M Main Power supply and Dimmer control 1 red 20awg 12V Power supply switched 250mA max 12v 2 purple 20awg Gauge dimming input to head lamp switch 0 5 VDC 10mA 3 white 20awg OV Ground signal ground 250mA max 12v 4 black 20awg OV Ground Power ground 1A 12V max Red Harness to
24. ree 23mm hole Clear up all the burred edges and wash the tank thor oughly No debris or plastic shavings should re main in the delivery system 1 2 inches from the bottom of the tank is ideal Screw fit the in tank filter on the inlet side of the tank adaptor insert the assembly into the tank Installation for long term reliability This is the most important section of the HFS 2 3 chapter Please do not skip reading this part 52mm Dash Gauge HFS 3 only Location is not too critical as long as it is in view of the driver There aren t too many pitfalls on this Dash switch HFS 2 only A 16mm or 5 8 hole on a flat panel is required for the installation of this switch HFS 2 3 controller box Please locate the box in a dry location in the passen ger compartment The glove box is a good place Please allow plenty of slack to ease accessibility during tuning and diagnostic work Fast acting valve and flow sensor assembly FAV The location of this module is most critical to overall system reliability It is designed to be installed in the engine compartment This module must be installed in a cool dry and well ventilated area away from any heat source The bulkhead fire wall is not always a good location as most heat is flowing towards it during driving Avoid locations near any electromagnetic components such as the ignition coil solenoid valves and elec tronic motors It is very important that the hose is cut
25. such a task This pin can be user configured to match the signal requirement of the third party ECU to switch map See page 18 1 for more details This pin is factory configured to give a 5V for OK and Ov is flow fault Maximum current of this output is 5mA Note For Mitsubishi Evo this output can perform automatic map switching by utilising tephra patch More details is available at the EVOM forum Gauge On fail safe activation White Black wo close circuit os White brown osanaan open circuit S O z5 Example 1 most common ENN Disabling the OE boost control valve Cut and splice the boost control circuit ECU side to White BCV side to Brown Need to link the Anti CEL option on page 12 5 to avoid the onset of CEL during fail safe activation Example 2 Disabling the third party electronic boost con trol system Cut and splice the pulsed wire to the BCV Controller side to White and BCV side to Brown This option will not work with EBC Electronic 4 Boost controller utilising a stepper motor to control boost HKS EVC is such an example Use the MAC valve option on page 17 Note Although the dash button of the HFS 2 can energise the relay it has no provision to de energise the relay if the water jet is clogged It will however de enegise the relay if the water level is low and power to the system fails There is a direct up grade
26. th connector 806 281c 0 9mm water jet 806 324 in plastic bag 1x DDS3v11 Gauge with 2M x 8 way cable HFS 3 1 0mm water jet 806 325 in plastic bag only 1x4mm Tee compression fitting 806 395 in 1x Dash button with 6 way cable HFS 2 only plastic bag new for v2 11 kit 1 5 M of multi core with grey capped RJ48 for 2x M8 x 1 8 NPT jet adapter with plug 806 ECU interface fail safe and map switching 357N Molex type 4 way power in harness e Asetof three restrictors with insertion tool Green harness for Direct injection engines v3 e User manual on request only for D I engines Note Please contact your supplier immediately should you discover any missing parts Getting started on installation Before installation guidelines The pump and water tank are designed to be fitted in the trunk Install the water pump below the water tank if possible Ensure all fittings are tightened and leak proof before filling up with methanol test it with water first If a high concentration of methanol mix is used please vent the tank s breather hole exter nally Methanol is poisonous when inhaled Assembling the pump in steps Gently assemble the two 3 8 BSP adapters into the pump without crossing the threads Ensure the o ring is properly seated between the fitting and the I O port Do not over tighten Water tank components Ensure the outlet is facing the rear or the side of the tank Drill oore a burr f
27. upplied with a set of high flow water jets sized at 0 8 0 9 and 1 0mm see chart for flow rate A Y or T is supplied with the kit for twin jet applications There are two nickel plated brass jet adapters 1 8 NPT The tapping hole should be 11 32 or 8 8mm Do not over tap Clean the mating part with alco hol first trial fit before loctiting into position Three restrictors are supplied for duty cycle flow matching should good linearity be re quired RESTRICTOR For flow grater than 1100cc min you can omit it should be fitted in the hose side of 6mm fitting of the FAV assembly Undo the in compression fitting from the FAV inlet port Use the threaded insertion tool to push the restrictor in position Apply a smear of grease to avoid damaging the o ring 0 380cc min 0 680cc min O 1080cc min 0 5mm restrictor wo 0 7mm restrictor oo 0 9mm restrictor oo HFS 5 function directory Applications involving methanol mix beyond 50 Great care and attention must be taken to ensure the fluid tank is capable of handling methanol and is designed for this type of application These tanks are normally termed as a Fuel Cell and are available from most reputable racing parts suppliers Anti surge foam should be used for circuit racing Follow the maker s guidelines carefully The breather hole must be vented externally with a suitable hose All fluid delivery hoses and fittings must be free of all leaks Ensure
28. y information on HFS 2 The HFS 2 shares the same electronic controller as in the HFS 3 The only difference is the dash gauge and flow sensor is not supplied However a dash switch is supplied instead There is a simple upgrade kit to HFS 3 available direct from factory The design concept behind the HFS 2 system Not every application requires a fail safe to reduce power in the event of a clogged Jet or system failure In those circumstances water injection is only used as a tool to recover power loss due to low fuel octane and high ambient temperatures When water is injected it will suppress the onset of knock and lower the intake charge air temperature The ECU will not need to retard timing or add fuel to combat those situations The HFS 2 is particularly suitable for countries with high ambient temperatures Due to its unique abili ties to mirror the fuel duty cycle from as low as 12 to 100 this ultra wide dynamic range is perfect for day to day motoring and occasional power blast Another effect could improve the fuel consumption due to optimum ignition timing is retained as well TYPE 1 MANUAL BLEED OFF VALVE mac valve TURBO WASTEGATE d TYPE 2 MANUAL BLEED OFF VALVE The HFS 2 Dash switch Other than the on off usage of disabling the system from injecting there are three display modes indicating the status of the system A green led indicates the system is armed and on standby by to
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