DI-IDC tracking water injection system
Contents
1. Appendix Pin Colour Size Description Molex Microfit power harness 1 5 M Main Power supply and Dimmer control Electrical parameter 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 Engine bay 2 5M To Flow Control assembly 1 red 24awg 12V to Fast acting valve 1 2A max 12v 2 yellow 24awg 12V to Fast acting valve 1 2A max 12v 3 blue 24awg PWM ground switch to Fast acting valve 1 2A max 0v 4 black 24awg PWM ground switch to Fast acting valve 1 2A 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 flow sensor signal output 1mA max 5v 3 blue 24awg Feedback signal return ground 1mA max 0v 4 black 24awg OV ground power supply imA max 0v Grey Harness to EMS 2 5M IDC Boost detection and Fail Safe Map Switching interface 1 24awg Reserved for external plug in use only 2 red 24awg Ignition Switching detection 30mA max 12v 3 green 24awg Fuel injection IDC detection 10mA max 12v 4 orange 24awg Map switching interfacing 0 5V 7 5V 1mA 5 white 24awg Failsafe Relay contact COM Wiper 1A 24V max 6 yellow 24awg High pressure fuel pump signal input 0 5VDC 100uA 4 blu2. TYPE CONNECTOR P 7 11 14 DASH GAUGE INPUT RJ45 FLAT CABLE P 7 amp P15 15 5A SYSTEM FUSE QUICK BLOW DO NOT REPLACE IT WITH A HIGHER RATED FUSE P 7 Page 11 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 lines Wiring work for first three harness only The HFS 4 is pre configured from the factory Only plug in the following harness for testing the power supply into the controller 1 4 way Power in connector Red uu Switched 12V IGN SW pre crank Black o n Chassis ground White Chassis ground Purple Head lamp switch optional 2 Signal to the grey RJ48 connector Red wee Ignition switched 12V pre crank Green Fuel injector pin conventional Blue oe MAP sensor optional 3 Black flat cable to the Dash Gauge Power up procedure Please follow this procedure Strictly or per manent damage to the system may result Do NOT SKIP any steps please 1 Ignition key in the OFF or 0 position Dash Gauge button is depressed system on No LEDs should be lit anywhere 2 Ignition key in the ACC or 1 position Absolutely no change same as the above conditions 3 Ignition key in the pre cranking or 2 position Do not cra
3. and reliability THE END
4. fuel injec tor duty cycle from factory The alternative trigger mode is MPS Manifold Pressure Sensor Flow will be progressive depends on MODE setting 2 MODE PWM mode factory default Flow can be progres sive with IDC Boost or Both P I R trimmer P 13 2 SSG single stage mode all on or all off 3 ON Enabled FAV default or disable FAV 4 M TEST FDC Link to display F IDC on gauge testing only BAR Link to test bargraph with the SC trimmer SYS This link can be used to activate the system for testing For pump activation only unlink the 3 FAV to disable FAV to avoid hydro locking DR1 ai CLP V DHB 70 Q m N A 5 CEL Boost cut without CEL check engine light activation This is only used in conjunction with internal relay fail safe output DR1 No CEL 6 SET FAIL SAFE CLP factory default Output voltage is clipped from 8V to 5V FSO factory default upon activation FS1 Fail safe output switches from 0 to 5V or 8V upon activation this fail safe output option is on the orange wire of the grey harness DHB default 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 the user a reminder that the engine is not protect
5. DI IDC tracking water injection system Introducing the Aquamist HFS4 v4 In keeping with the excellent integration with the Di engines the latest HFS4 v34 is packed with even more capabilities An additional AUX input O 5V allows the system to alter flow based on air exhaust temperature or air fuel ratio IF one of signals exceeds a pre set level Failsafe will be triggered to protect your engine The standard turbine flow sensor based failsafe remains A Fast Acting Valve FAV controls the delivery rate based on a PLUM signal From the HF4 controller The FAV enables superior linearity and atomization across the entire injection range A constant line pressure 160 psi is provided by an Aquatec pump Working in the by pass mode This method is very similar to the conventional fuel injection systems allowing wide dynamic range and ighten responses to engine load The combination of quality components superior method of delivery and a preci sion Di signal decoding algorithm the HFS4 v5 remains to be the most advanced and capable water methanol injection system in the world to date Contents System Check Page 4 Checking the contents of the box 5 Getting started on the installation Installation 6 Installation for long term reliability 7 Generic wiring diagram for HFS4 v3 8 9 Choosing jet sizes Sustem testing 10 HFS4 v4 Function directory 11 12 Quick St
6. Disable High Boost jumper is unlinked p 12 7 The engine is no longer protected by low boost or safe map 1 8 element Bargraph 0 100 Fullscale Each segment is equivalent to a fixed percentage of the total flow of the sensor scaled by the SC potentiometer 2 S indicates the presence of a flow sensor The letter S sensor must be lit after power up and stay on to show the flow sensor cable is con nected and on standby 3 Fail safe activation LED normally off When the fail safe is triggered This yellow LED will illuminate with the water tank level LED below it 5 SC Sensor Calibration default table 20 stepped potentiometer allows user to scale the flow sensor to give an ideal visual indication of a given flow rate Ideally set the LED to display 5 6 bars at full flow page 22 for alternative flow tables 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 the system triggers the B LED stays on This is a useful indicator that the WL and WH are set up cor rectly It also stays lit if the DFS jumper is selected Page 17 Dash Gauge Functions cont 8 Water injection enable button NOTE Due to extra power level achieved under WI user may n order to make the fail safe adjustment easier it is want to reduce the power to the wheels in less than recommended to set the bargraph to displa
7. 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 and trial fit before loctiting into posi tion Three restrictors are supplied for duty cycle flow matching should good linearity be re quired FLOW SENSOR RESTRICTOR For flow greater than 1100cc min you can omit it It should be fitted in the hose side of 6mm fitting of the FAV assembly Undo the compression fitting from the FAV inlet port Use the threaded insertion tool to push the restrictor into position Apply a smear of grease to avoid damaging the o ring 0 380cc min O 680cc min 0 1080cc min 0 5mm restrictor 0 ee 0 7mm restrictor 0 9mm restrictor 0 ee Applications involving a 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 delivery hoses and fittings must be free of all leaks Ensure the area is well ventilated and isolated from the driver s compartment Take whatever measures nec essary to avoid any methanol fumes building up in trunk area Methanol is highly f
8. arly useful to control IAT and EGT automatically This is a powerful new option b x1 5 For systems with over sized fuel injectors designed for E85 fuel that run on 100 gasoline c x2 5 For 95 of the current DI fueling systems Page 22 HFS 4 flow sensor configuration The HFS 4 flow sensor Extensive progress has been made over the last few years to stretch the operat ing range of the new flow sensor assem bly now up to 2 500cc min coverage HFS 4 flow sensor flow range coverage In order to maximize the output resolu tion from one to multiple jets we have created three flow tables for single twin and four jet applications Changing the table requires a simple under board Cut and solder link opera tion See page 21 The image on the right m _ _ shows a factory default 0 40 80 120 160 200 240 28 321 360 400 map2 table 0 250 500 750 1000 1250 150 1750 2000 2250 2500 2 3 There is no need to mod Hz cc min ify the board if you intend to run two jets flowing within the region of map2 see chart Renee ea A up to 1000cc min However if you are run E 2 ing tres or more jets you need to modly SOLDER LINK Pae o sida condoned o a the circuit board by depositing a solder blob E ED M covering pads 2 amp 3 See diagram on the right ra ies and white wire 5V pulses to 1 amp 2 for one jet the green harness
9. art amp test run Gauge 5 Flow management and other trimmers 14 Configurating system setting for other setups Dash gauge 15 19 Failsafe setups and Gauge functions Fail safe 20 Direct and Peak amp Hold integration Advanced 91 22 Advanced system setup amp Aux failsafe Appendix 23 Guarantee and Warranty Checking the contents of the box carefully This is a must do immediately after unpacking e 1x water tank adapter 1 8 BSP 806 270 6mm compression fitting and in tank filter 806 258 Water pump 4x M5x40mm bolt washers and fasteners for pump Unpack the corrugated sheet carefully The pump 4 1x M6 grounding stud with washer and nuts and should be labelled with the original custom 6mm eyelet for pump ground Aquatec Aquamist logo 2x 6mm to 3 8 BSP M pump O fittings e 1x 4mm to 1 8 BSP compression fitting for FAV The white box e 1x 6mm to 1 8 BSP compression fitting for FAV 6M of 6mm OD nylon hose 806 261 e Water pump harness 6M of 12 AWG cable and 2M of 4mm OD nylon hose 806 266 6M of multi core cable blue harness e HFS 4 Electronic Controller 1x Fast Acting Valve cable red harness 0 8mm water jet 806 323 in plastic bag 1x Turbine flow sensor cable yellow harness 0 9mm water jet 806 324 in plastic bag e 1x Water level switch with connector 806 281c 1 0mm water jet 806 325 in plastic bag 1x Dash Gauge with 1 5M x 8 way flat cable 1x4m
10. dded two more engine load re lated signals boost pressure and fuel rail pressure Only when combining those sig nals are we able to determine the actual fuel flow in real time DI signal pre amplification The vast range of DI waveforms and pulse durations require different levels of gains to achieve full flow range The HFS 4 has three pre set amplifications x1 default x1 5 and x2 5 x2 5 will cover 95 of pulse duration systems of 0 to 5mS common DI systems see page 21 for re configuration details MAP sensor input This sensor monitors the manifold pressure Depending on the application the sensor s operating range can vary from car to car The HFS 4 is equipped with three pre configured ranges Absolute default 2 bar and 3 bar FUEL RAIL PRESSURE SENSOR DIRECT INJECTION MAP SENSOR signal pick up Please ensure the controller is set to match the operating M ECU DRIVE FRO 12V PRE CRANK pressure range 2 or 3 bars see instruction on next page ws EU Gis oS T POWER NEUT a l K1C12H K1C12H m j coit 12vDC coo G 39 OHM 7W 5 eee 2 S0VDCII25VAC sa 3OVDCN2SVAC 0 160 400 esos o FEIWARIAEI TYPICAL DI INJECTOR The user needs to pre set this see page 21 2 for more details Fuel rail pressure input As the fuel flow is governed by pulse width as well as fuel pressure the HFS 4 has an input to monitor this pressure and alter the water methanol flow pro
11. ded above Pick the nearest jet jets size to match the flow Don t forget to subtract the boost pressure from the line pres sure of 160psi For example if you are boosting 25psi you should select the jet flow at 135 psi Allow 10 15 Flow cc min on top in case flow needs to be increased in future Once the jet jets and flow are determined insert the JET 20 40 60 80 100 120 140 160 180 ps Nearest 03 23 32 36 41146 50153157160 larger re 04 54 71 85 97 108 117 126 135 143 5 Strictor to 0 5 75 99 118 1134 149 163 175 186 197 regulate the 0 6 93 123 147 168 186 203 219 233 247 2 fluid flow so 0 7 112 148 177 202 224 244 262 280 296 ai the delivery 0 8 133 188 220 250 278 303 326 347 367 Q will be linear 0 9 153 217 252 288 319 348 374 399 1422 to the duty _ 1 0 174 246 285 325 361 393 423 451 477 Z cycle 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 1 2 215 305 373 431 482 528 570 610 646 Pressure psi The HFS 4 is supplied 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
12. e 24awg Map Sensor Signal input 0 5 VDC 100uA 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 24awg Reserved for external pluigin use wsnvenennenenen Blue Harness to Trunk Area 6M 1 red 24awg 12V Power supply to 40A relay 2 yellow 24awg Water level sensor signal 3 blue 24awg Pump relay activation ground switch 4 black 24awg Water level sensor ground Green Harness For direct injection engines 2M 0 5A max 12v signal ground 0 5A red 24awg _ Di injector signal pick up green 24awg _ Di injector signal pick up blue 24awg Auxillary failsafe input new yellow 24awg Flow sensor S conditioned Voltage output white 24awg Flow sensor raw pulse output black 24awg system signal in out ground oOnaRwrn Power supply cable to pump 6M 0 5v 0 5v TO 4 5v TTL logic 1 Red 12awg 12V Power cable to water pump relay 38A 12V max 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 sal
13. e 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 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
14. e capacity injectors A test drive under load is necessary in this case 5 Road test the system Still with jet on the windscreen make a short drive and confirm the spray is progressive with load After a suc cessful road test The system is now ready for dialling in the failsafe windows WL amp WH Page 13 Flow management and other trimmers The onboard trimmers functions default 12 o clock 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 a 5 THRES The system requires no trimming from factory If the user wants to alter the flow and other parameters just use a small screwdriver to complete the task GAIN Increases decreases the rate of ramp relative to the incoming signal after trigger point No flow increase is expected when the 95 IDC red LED is activated P I R Alter the flow relative to boost or fuel 2 Trimmers for fine tuning THRES Factory set to 42 12 o clock User adjustment range is between 12 to mx 72 fully clockwise a IDC GAIN WATER FLOW X trip point FUEL FLOW For 100 boost controlled set the trimmer Below are the working details of each trimmer left to right 1 LED panel fully counter clockwise Vice versa for fuel Flow is shared equally when trimmer at mid point between pressure a
15. ed againist High Boost DFS default unlinked Disable Fail Safe Link to stop all fail safe activation during test or preliminary test run prior to finalizing fail safe window Fail safe output to ground 7 PRK Parking for unused jumper link 8 DEFAULT Factory default setting gold dots Page 15 Setting up the fail safe What do you want the system to to do upon a failsafe activation Setting up the fail safe should only be done after the jet or jets sizes are finalised and road tested or engine dyno tuned The most common way to minimize engine damage in Setting the fail safe will not affect any previous the absence of flow is to reduce the boost pressure flow delivery settings It is an independent opera tion performed by the DASH GAUGE trimmers 1 For engines with an electronic boost control valve The grey harness consists a set of relay contacts that goes open circuit when the fail safe is triggered See page 18 2 and 19 for more details Recommended steps to set up the fail safe SC WL and WH trimmers are on the dash gauge 1 Ensure the DSF jumper link is relocated to DHB 2 Re check SC is set to display 5 6 bars at full power from before This is vitally import Recal if necessary 2 For engines with MBC manual boost controller The onboard fail safe relay can be used to control a 3 port solenoid valve to by pass the MBC or a stepper motor type of boost controller Contac
16. fect 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 to prevent leakage no more The pump relay assembly is NOT designed for en gine bay installation unless the pump cable entry gland is sealed and the relay harness is insulated Warranty will not cover this type of installation Generic wiring diagram for HFS4 v5 WIRE THIS ACROSS WIRE ACROSS THE WHOLE FAILSAFE THE CONVENTIONAL OR RESISTOR PACK PLUS FAST ACTING VALVE RELAY HI IMP F INECTOR THE NON PEAK amp HOLD jam AND TURBINE FLOW w necron amp F INJECTOR LO IMP F INJECTOR SENSOR ASSEMBLY WATER LEVEL sc WL WH MAP 000 g TO PEAK amp HOLD AND meee SENSOR Di INJECTORS PAGE 20 12V 5A switched Head lamp for dimmi dashi gaida A nt l l Ww ot Be USER flex RELAY 160 PSI BYPASS PI E K1C12H NN S amn eras O ae MADE IN USA a oe AQUATEC 15 0A 12V fused eeeceeTAMUAAn a S Choosing jet sizes Pressure te Fiow This is a general guide only l compensated 100 water run 10 15 water fuel ratio 50 50 methanol water run 15 20 to fuel 100 methanol run 20 25 to fuel Choosing the jet by calculation First work out the total fuel flow by adding up the capacity of the fuel injectors Multiply the result by the preferred recommen
17. he outlet is facing the rear or the side of tighten the M16 plastic nut Stop the assembly 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 as the tank adapter for the water level sensor 23mm If using a washer tank for supply do not locate the levelf sensor near the stock washer pump The float arm should swing upwards when full A tall and slim water tank is ideal for this type of application This minimizes delivery surge prob lems at low water level TO CONTROLLER BLUE HARNESS U0 0 UD gt gt TO FAV ASSEMBLY Installation for long term reliability This is the most important section of the HFS 4 chapter Please do not skip reading this part 52mm 2 1 16 Dash Gauge Location is not too critical as long as it is in view of the driver There are not many pitfalls on this HFS 4 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 and away from any heat source The bulkhead fire wall is not al
18. 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 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 the purg ing procedure If not repeat step c e Upon successful completion of the above reinstate the FAV jumper and 6mm hose into the FAV assembly 3 Test spray pattern and SC setting a Secure the intended jet jets onto the windscreen and connect it to the outlet port of the FAV assembly b Activate the system by linking up the SYS with the spare PRK jumper p16 7 You should see an instant full cone spray at the jet Do it for a few seconds only Good time to set the SC on the gauge to display 5 6 bars Remove the SYS test link after test Leave the FAV jumper link in the slot 4 Activate the system by Gas paddle a Set the THRES trimmer to fully counter clockwise Start the engine You should see the green LED on the controller board blinking b Blip the accelerator paddle sharply to induce an artifi cial load The amber LED should respond A faint but noticeable spray should develop at the jet This may not work with very larg
19. itching tables Sloe one CDer DHBUNLINKED DFS LINKED eae i 1 IGNITION SW KEY OUT te ae we o O OM Smr aa vite oO ae 2 IGNSW ACCESSORY fwre o9 PON Areo O ERO Spreo O OMN ISh re o O BROWN Ie a aa a A IGNITION PRE CRANCRUN wire o 2 ahi tte o om te 27 ae wire 2 AOK IE ot Romeo So ett Rare Bo mt Rye em ed ee eer 7 FLOW Oursie FALSAFE WiNDow HTE O S See WHTE o OM SN iTe o SR e 0 0 ee 8 OMTESETAFTER BGECONDS PHTE O S minae THTE O O SUM ne O SA re oe Fail safe relay output truth table The above table is created to simplify the fail safe Based on the table above you can use these con relay switching status under all circumstances White Brown and Black wires are located in the grey harness The relay contacts are capable of switching 1A 30V continuous and 3A pulsed due to the 24awg wires used tacts to either connect or disconnect electro mechanical components such as a wastegate con trol valve or third party fail safe devices The con tacts are gold flashed so it can be used for low current signal switching Direct injection fuel system integration DI engine overview Due to the vast variation of switching meth ods employed on the direct injection fueling systems we have created a special input channel for the sole purpose of decoding those complex signals In addition to the IDC input we a
20. lammable 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 this warning applies to all Aquatec pumps Page 10 HFS4 v4 Function directory POWER INPUT K1C12H COIL 12VDC 3A 30VDC 125VAC FLOW SENSOR MAPS 80 160 400 CONTROLLER S SERIAL NUMBER FLOW SENSOR MAP IDENTIFICATION pp 22 SYSTEM STATUS LED INDICATORS P 13 SYSTEM CONTROL TRIMMERS P 13 _ 30 TEST POINTS FOR SYSTEM DIAGNOSTIC WORK SYSTEM CONFIGURATION JUMPER LINKS P 14 CUSTOM CONFIGURATIONS IDENTIFICATIONS ONDAN DI INPUT and FLOW SENSOR SIGNAL OUTPUT P 20 22 K1C12H COIL 12VDC 3A 30VDC 125VAC Lit E E 9 LEVEL SENSOR and PUMP CONTROL BLUE HARNESS 10 ECU INTERFACE I O PORTS GREY HARNESS P 7 18 20 11 FLOW SENSOR I O PORTS YELLOW HARNESS P 7 12 FAST ACTING VALVE FAV OUTPUT RED HARNESS P 7 13 POWER INPUT 4 WAY MOLEX
21. m Tee compression fitting 806 395 in 1x ECU interface fail safe and map switching cable plastic bag grey harness 2x M8 x 1 8 NPT jet adapter with plug 806 1x Molex type 4 way power in harness 357N e 1x Di and Aux input cable green harness Asetof three restrictors with insertion tool e User manual Note Please contact your supplier immediately should you discover any missing parts Getting started on installation Before installation guidelines The system is designed to be trunk mounted Install the water pump below the water tank if possible as the assembly is not water proof 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 embedded between the fitting and the I O port Do not over tighten Water tank components the tank Drill oore a burr free 23mm hole Clear up all the burred edges and wash the tank thoroughly No debris or plastic shavings should remain in the delivery system Locating the outlet 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 and Ensure all fittings are tightened and leak proof before filling up with methanol Test it with water Ensure t
22. nd fuel flow FS DL Fail safe delay to minimise undue fail safe activation due 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 42 F IDC de fault this LED will activate confirming the system is triggered and delivery commences Red 95 DC When the water methanol duty cycle is approaching to spikes and noise signal User can adjust between 0 2 to 0 6s The factory default setting is 0 4s DIM Activated when the purple wire of the power connected is connected to a 12V source Headlamp is an ideal location AUXFS Setting the over range of Auxillary Failsafe input Page 21 3 Additional failsafe for third party signal to active the HFS4 s onboard failsafe relay to reduce boost Useful for engine equipped with a WBO2 sensor or EGT probe Input range is 0 5V It can also be used to detect high inlet air temperature Page 14 Re configurating system setting for other setups Knowing the function of each jumper link DFLT gt J K K K e K K K K e DFS K amp sys R K o DR ery 71 m Q PRK m MPS SIFAV FDC K BAR K K IDC E 4 ODE 0 ae oo 2 The system factory set to trigger by IDC
23. nk for 2 3 minutes Observe the gauge LEDs Yellow LED on the gauge will stay lit for 5 10s before the rest of the gauge lights up The pump or FAV should not come on during this whole period 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 sys tem behaves as stated above you have successfully wired up the HFS 4 Now plug in the rest of the harnesses The S LED should confirm the presence of the flow sensor The yellow LED will activate 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 small 3 32 slotted screwdriver Preparation for a test run of the system spray test 1 First step system check amp setup list a Tank and pump are fully secured and leak free b The FAV assembly is securely located in a cool and 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 on the wind screen e Dash gauge switched on and in sight f Link DSF using the DHB jumper to disable the failsafe temporarily See p14 6 4 2 Priming and purging of the system a Fill the tank with water half way up b Disconnect the 6mm hose from the FAV as sembly and put the hose
24. portionally The cor rection factor is set internally and cannot be changed This input is on the yellow wire of the grey connector More custom configurations Page 21 9 Configuring the MAP sensor type cut thin track and solder link A or 3 a Absolute This can be used for any sensors with 0 5V output such as 1 bar MAP throttle position mass air flow sensors etc b 2 5 bar MAP sensor default This link to convert a 2 5 bar MAP sensor to atmospheric to 22psi 0 5V output c 3 5 bar MAP sensor Select this to convert a 3 5 bar MAP sensor to atmospheric to 36psi 0 5V output 1 6 Reserved for customising the system 10 Reserved for customising systems 11 Flow sensor flow maps see P 22 12 AUX input select EGT or IAT EGT WBO2 default or cut thin track to E and solder link A for Inlet Air Temp sensor 8 IDC pre amplifier gain 13 Enabling the AUX input failsafe Three options cut thin track and solder link Solder link F for failsafe trip or W a x1 0 default This one is for conventional fuel gauge for Water Level led trip Connect injection systems and some DI systems the blue wire of the green harness to the appropriate sensor such as WBO2 EGT or IAT inlet air temperature The signal from those sensors must be scaled to 0 5V except 7 AUX input options Enables flow compensation based on aux input signal This is particul
25. t Aquamist for 3 Set the WL trimmer to fully Counter clockwise further instructions and advance 10 clicks 3 For an engine with MAP switching capabilities The orange wire on the grey connector has a dedicated output to perform 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 4 Set the WH trimmer to fully Clockwise and wind back ten clicks 5 This give a reasonable window width for the moving bars before tripping the faisafe 6 Test drive and fine tune the WL and WH trim mers Allowing a few sessions under different loads before switching to a more aggressive map pagel 4 Water Level LED Failsafe normally off This LED has three functions a During power on delay period This LED will activate for approximately for 5 seconds during the system on delay before the main system turns on Check tank level if the system does not start Knowing Dash Gauge Functions Aquamist b During normal operation period This LED is turned on during the fail safe activation in conjunction with the yellow LED above Water level low intermittent flashes Solid after 20s of low level detection c LED stays lit after the gauge is switched off This LED warns the user that the DHB
26. t CEL during fail safe activation Dummy effective method to save your engine from lack of resistor replaces the BCV water injection A jumper link can invert the MAP Example 2 third party boost controllers switch output if necessary Disabling the third party electronic boost Although it is simple and convenient to use a control SYSE Cut and splice the ae l pulsed wire to the BCV White to the single wire to communicate a fail safe activation this can Controller and Brown tothe BCV side only be achieved as long as the system is powered up properly The alternative way is to use the on board relay This option will not work with EBC Elec f to convey a fail safe activation since the relay will guaran tronic Boost controller utilizing a stepper tee a make or break circuit when system s power is motor to control boost HKS EVC is such lost or a blown system fuse an example Use the MAC valve option on page 2 Change over relay iy The HFS 4 has an onboard relay to supply a set of Suggestion During the initial testing period soon voltage free change over contacts for the sole use of after the installation you can disable the fail safe fail safe activation It can be used to perform various from activation by connecting the DFS Dis tasks to save your engine Contact rated up to 1 amp able Fail Safe jumper link Page 19 Relay Fail safe output sw
27. ways 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 If possible locate it not too far away from the water jet jets It is very important that the hose is cut cleanly It is also vital that the hose is cut perpendicular square relative to its length This is because the compression fitting has a short hosetail An accurate cut will allow full grip on the walls of the hose The thin rubber gasket must be placed between the FAV coil and electrical plug red harness before tight ening Press the clip of the yellow harness into the centre section of the flow sensor body Orientation 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 con densed water trickling into the clip and plug The tank level sensor Drill oore the same hole size as for the tank adaptor for the water level sensor A 23mm 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 minimizes 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 af
28. y 5 6 ideal driving conditions Disabling the WI will reduce bars at maximum flow This way the fail safe win boost to the wastegate bleed valve setting if fitted as dow can span from the centre outwards well as switching to a less aggressive MAP on custom engine management If the WL and WH is set at 10 amp 2 o clock the fail safe window is approximately spanned between 9 Over range setting potentiometer WH 3 7 bars This is a good starting point It is just as important to monitor over range conditions as well as under range flow conditions If a leak devel If you prefer to start the spray earlier adjust WL to ops close to the water jet and starves the engine of the extend the lower section of the fail safe window water the user must know this condition A 20 stepped potentiometer allows accurate adjustment of The gauge confirms fail safe activation the upper 4 bars of the flow range with both yellow LEDs turned on 10 Under range setting potentiometer WL 1 B LED right of the bargraph will only stay This setting can indicate partial blockage and trapped activated if the flow is inside the fail safe window air inside a delivery hose Again a 20 stepped potenti during the injection period Otherwise blink once ometer is employed Each click represents a fixed portion of the window width 2 The two yellow LEDs Both LEDs will activate of 8 bars failsafe window width when the fail safe is triggered Onl
29. y the lower LED coverage 20 clicks illuminates during low tank level Recap WL covers the lower As soon as the fail safe is tripped there will be 4 bars of the display and the a 3 second reset period before it resets while the WH covers the upper 4 bars _ ot fail safe drops boost The figure on the right illus ae o trates the span of the cover r When the gauge is switched off expect low boost age Setting is very simple Owe wH and safe MAP unless the board is re configured to once SC is calibrated DHB page 12 7 Page 18 Wiring up the additional Fail safe Channels 1 The MAP Switching Channel The orange wire from the grey RJ48 connector is a voltage based MAP Switching for an ECU orange Please refer to page 19 for full switching se quence under various conditions equipped with this input This wire is factory config Example 1 OE boost control valve BCV ured to send out a voltage of 4 7V DC under a no Disabling the OE boost control valve Cut J E z fault condition from idle to full boost This voltage and splice the boost control circuit 2 O will switch to Ov upon a fail safe activation or the White to ECU side Brown to BCV gauge is switched off side You will need to link the Anti CEL Other voltages such as 0 5V or 8V can be user even pr page 12 6 19 avoid the onset of configured page 12 7 This is by far the mos
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