IDC tracking wmi system for Di engine
Contents
1. When the gauge is switched off all fail safe outputs become 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 protected 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 7 PRK Parking for unused jumper link 8 DEFAULT Factory default setting gold dots Page 15 Setting up the fail safe Setting up the fail safe should only be done after the jet or jets sizes are finalised and road tested or engine dyno tuned Setting the fail safe will not affect any previous flow delivery settings It is an independent opera tion performed by the DASH GAUGE trimmers 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 3 Set the WL trimmer to fully Counter clockwise and advance 10 clicks 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 failsafe 6 Test drive and fine tune the WL and WH trim mers Allowing a few sessions under different2. d th di t i ti f li MAP SENSOR signal pick up 12V PRE oas employed on e adirect Injec lon ue INQ Please ensure the controller systems we have created a special input Lee a channel for the sole purpose of decoding see instruction on next page those complex signals In addition to the IDC input we added two more engine load re lated signals boost pressure and fuel rail pressure Only when combining those sig eur o ae DI signal pre amplification nals are we able to determine the actual fuel The vast range of DI waveforms and pulse flow in real time durations require different levels of gains to sss es sH HE achieve full flow range The HFS 4 has eight pre set amplifications x1 default to x2 75 x2 5 will cover most DI engine see page 21 The user needs to pre set this see page 21 2 for more for re configuration details details TYPICAL DI INJECTOR 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 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 proportionally The cor rection factor is set internally and cannot be changed by user This input is on the yellow wire of the grey connecto
3. Page 22 HFS4 v3 1 flow sensor configuration The HFS4 flow sensor HFS 4 flow sensor flow range coverage Extensive progress has been made over s5 the last few years to stretch the operat ing range of the new flow sensor assem bly now up to 2 500cc min 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 2H N e gt Changing the table requires a simple _ under board Cut and solder link opera tion See page 21 af C E The image on the right 0 O shows a factory default 0 40 80 120 160 200 240 280 320 360 400 1 2 3 map2 table 0 25 500 750 1000 1250 1500 1750 2000 2250 2500 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 Note For the benefit of third party control lers failsafe and data logging purposes up to TuuUco mn However Ifyou are run SOLDER LINK raw pulses and signal conditioned voltage ning three or more large jets 1mm or bigger co A from the flow sensor are available on yel you need to modify the circuit board by depos _ low voltagel andwhitewire IBV pulses to iting a solder blob cover
4. gauge is switched off side You will need to link the Anti CEL Other voltages such as 0 5V or 8V can be user option n page 12 6 to avoid the onset of configured page 12 7 This is by far the most 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 System Cut and splice the l ae pulsed wire to the BCV White to the single wire to communicate a fail safe activation this can Controller and Brown to the 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 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 te 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 act
5. period Otherwise blink once ometer is employed Each click represents a fixed por 2 The two yellow LEDs Both LEDs will activate tion of the window width of failsafe window width when the fail safe is triggered Only the lower LED 8 bars coverage 20 clicks illuminates during low tank level As soon as the fail safe is tripped there will be a 3 second reset period before it resets while the Recap WL covers the lower Ue aes Dyk fail safe drops boost The figure on the right illus E When the gauge is switched off expect low boost trates the span of the cover OWL WH and safe MAP unless the board is re configured to age Setting is very simple DHB page 12 7 once SC is calibrated 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 G will switch to Ov upon a fail safe activation or the White to ECU side Brown to BCV Sh
6. 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 to prevent leakage no more The pump relay assembly is NOT designed for engine 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 THE CONVENTIONAL OR RESISTOR PACK PLUS HI IMP F INECTOR THE NON PEAK amp HOLD amp F INJECTOR LO IMP F INJECTOR TO PEAK amp HOLD AND gt Di INJECTORS PAGE 20 FAST ACTING VALVE AND TURBINE FLOW SENSOR ASSEMBLY W INJECTION WATER LEVEL sc WL 12V 5A switched Head lamp Head lam tor dimming i C00 0 00D RFU 30A RELAY K1C12H K1C12H COIL 12VDC coLiavoe 47 OHM 7W 5 m 2A 30VDC 125VAC 3A 30VDC 125VAC m j Battery or 15 20A 12V fused see of se EHT Choosing jet sizes Pressure oo This is a general guide only z0 compensa
7. 0 9mm water jet 806 324 in plastic bag 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 1x4mm 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 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 embedded 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 free 22mm hole Clear up all the burred edges and wash the tank thoroughly No debris or plastic shavin
8. 94 409 424 437 451 464 477 489 60 70 80 90 100 120 130 140 150 160 170 180 190 200 1 00 314 339 362 384 405 425 444462 479 496 512 528 543 558 573 z Pressure psi 1 20 370 400 427 453 478 501 523 545 565 585 604 623 641 659 676 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 adapters 1 8 NPT The tapping hole should be 11 32 or 8 8mm Do not over tap Clean the mating part with alcohol first and trial fit before loctiting into position 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 7mm restrictor 0 9mm restrictor HFS4 v5 function directory K1C12H COIL 12VDC 3A 30VDC 125VAC CONTROLLER S SERIAL NUMBER FLOW SENSOR MAP IDENTIFICATION P 22 SYSTEM CONTROL TRIMMERS P 13 30 TEST POINTS FOR SYSTEM DIAGNOSTIC WORK SYSTEM CONFIGURATION JUMPER LINKS P 14 SNOaPrans gt CUSTOM
9. CONFIGURATIONS IDENTIFICATIONS LABEL DI INPUT and FLOW SENSOR SIGNAL OUTPUT P 20 22 IDC PRE SCALER FOR DI amp OVERSIZED INJECTORS P 21 Applications involving a methanol mix beyond 50 The fluid tank should be capable of handling methanol and is designed for this type of application Ideally a baffled tank should be used to minimise any trapped air problems 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 The aquamist tank oump system is designed to be trunk mounted not suitable for engine bay installation 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 this war
10. IDC tracking wmi system for Di engine v3 1 oum User manual v4 11 s n 121 750 on Introducing the Aquamist HFS4 Vv3 In keeping with the seamless integration with the Di engines the latest HFS4 v5 1 has a few additional features to ease with setting up the IDC pre scaler without soldering Jumper links is offered Pre scaler range has now been extended ready for the next generation of Di engines The system can now be triggered by boost and IDC combined based on the setting of the onboard P I R Pressure IDC ratio trimmer Multiple failsafes remain the same protecting the engine should air or egt temperature exceed a reset value or Fluid flow is interrupted A Fast Acting Valve FAV controls flow from a progressive PLUM signal from the con troller This ensures excellent linearity and good atomization across the entire injection range Constant line pressure 160 psi is provided by the Aquatec pump This method is very similar to the conventional fuel injection systems allowing wide dynamic range and lighten responses to engine load The combination of quality components superior method of delivery and a precision Di signal decoding algorithm the HFS4 v4 1 continues to be the most advanced and capable water methanol injection system on the market to date Contents System Check Page 4 Checking the contents of the box 5 Getting started on the installation Installa
11. 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 display 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
12. age 14 Re configurating system setting for other setups Knowing the function of each jumper link 1 TRIG The system factory set to trigger by IDC 12 72 or MPS boost P l trigger boost and IDC com bined is tied to the P I R trimmer setting If trimmer is set to fully MPS biased IDC signal will have no effect 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 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 Fail safe output to ground 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
13. e controller is accessible and can be secured down with minimum movement during motoring d The intended jet jets are securely installed on the windscreen not in the charge pipe 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 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 disp
14. gs 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 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 22mm If using a washer tank for supply do not locate the level 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 minimises delivery surge prob lems at low water level TO CONTROLLER BLUE HARNESS 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
15. ing pads 2 amp 3 See 1 th A diagram on the right 1 amp 2 for one jet eer eee 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 12 V to Fast acting valve 1A max 12v 2 yellow 24awg 12V 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 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 ye
16. ivation 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 switching tables ice oa DEFAULT OHBUNLINKED DFSLINKED Okun 1 IGNITION SW KEY OUT Site oO Sipe wate oO BROWN wate oO Aen Swe a 5 2 IGN SW ACCESSORY wit oO le wae o_O BROWN wate o 2 OS Tine ee 3 sexo en Pre a Hem yom 41 mon En eoa on Paroa HH RS preoa on EE a lt are orSe e neta oo at Buros nen reo 9 tt Rye em Tot E EEE o Ceo ran Beos Bae ooon ur o0 on g AUSE OMTALE TIEGEED e oo EON Re 200 armor 20 Ro O 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 certain circumstances 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 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 Direct injection fuel system integration Page 20 DI engine overview FUEL RAIL PRESSURE SENSOR RAIL PRESSURE SENSOR Due to the vast variation of switching meth d
17. lay 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 large 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 Page 13 Flow management and other trimmers The onboard trimmers functions default 12 o clock F IDC 35 1DC Gres O 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 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 T
18. llow 24awg High pressure fuel pump signal inpput 0 5VDC 100uA 7 blue 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 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 switch 4 black 24awg Water level sensor ground gt Green Harness For direct injection engines 2M red 24awg Di injector signal pick up green 24awg Diinjector signal pick up blue 24awg Auxillary input new yellow 24awg Flow sensor S conditioned voltage output white 24awg Flow sensor raw pulse output black 24awg system signal in out ground DNAR Power supply cable to pump 6M 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 writi
19. loads before switching to a more aggressive map Knowing Dash 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 Gauge Functions What do you want the system to to do upon a failsafe activation The most common way to minimize engine damage in the absence of flow is to reduce the boost pressure 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 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 Contact Aquamist for further instructions 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 detail
20. 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 crank 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 Plugging in the Green harness is required for DI engines 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 Th
21. ng 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 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 withou
22. ning applies to all Aquatec pumps oN K1C12H COIL 12VDC 3A 30VDC 125VAC 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 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 10 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 four 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 onnan Switched 12V IGN SW pre crank Black zena Chassis ground White Chassis ground Purple Head lamp switch optional 2 Signal to the grey RJ48 connector Red oo Ignition switched 12V pre crank Green Fuel injector pin conventional Blue oo MAP sensor optional 3 Black flat cable to the Dash Gauge 4 6 way Green harness for DI engines Power up procedure Please follow this procedure Strictly or per manent damage to the system
23. r Page 21 More custom configurations 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 boost pressure up to 21psi c 3 5 bar MAP sensor default Boost pres sure up to 36psi 8 do QD G3 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 13 Enabling the AUX input failsafe Solder link F for failsafe trip or W 1 6 Reserved for customising the system 7 AUX input options Enables flow compensation based on aux input signal This is particularly useful to control IAT and EGT automatically This is a powerful new option 8 IDC pre scaler topside ce EBs line option allows ne Saam oe aal as gauge for Water Level led trip Connect match the incoming IDC signal x1 25 Jsts x22503 the blue wire of the green harness to the Can be used for oversized injec y4 59 3 x2 50 E appropriate sensor such as WBO2 EGT or tors with low duty cycle and 475l x275 IAT inlet air temperature The signal from Direct injection engines _ those sensors must be scaled to 0 5V except Select x2 5 for Di engines for the IAT sensor naturally 0 5V
24. rimmers for fine tuning THRES Factory set to 42 12 o clock User adjustment range is between 12 to mx 72 fully clockwise re 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 and 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 P
25. s This pin is factory configured to give a 5V for OK and Ov is flow fault Maximum current of this output is 5mA 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 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 Disable High Boost Jumper is unlinked p 12 7 The engine is no longer protected by low boost or safe map 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 pagel Page 17 Dash Gauge Functions cont 8
26. t notice in order to improve design performance and reliability THE END
27. ted 100 water run 10 15 water fuel ratio 50 50 methanol water run 15 20 to fuel a 100 methanol run 20 25 to fuel 600 Choosing the jet by calculation ss First work out the total fuel flow by adding up the capac ity max DC of the fuel injectors Multiply the result 500 1 2mm M7 by the preferred recommended above 450 EA Pick the nearest jet jets size to match the flow Don t 1 0mm M6 0 forget to subtract the boost pressure from the line pres aa Tes sure of 160psi For example if you are boosting 25psi E mm MS 3 you should select the jet flow at 135 psi Allow 10 15 3 2 0 8mm V45 on top in case flow needs to be increased in future reg ASAE For Di engines where actual fuel flow is not easy to ses eon M39 quantify allow 1 5cc hp M50 W50 ie 400hp 600cc m 0 6mm M3 2 JET 60 70 80 90 100 110 120 130 140 150 160170 180 190 200 PSI 200 M3 2 0 44 46 49 53 56 59 62 65 67 70 72 75 77 79 82 84 10 0 5mm M2 6 0 4B 63 69 73 78 82 86 90 93 97 100 104 107 110 113 116 2 0 4mm C 1 9 0 4C 88 95 102 108 114 119 125 130 135 139 144 1481153157 161 2 400 J gt 0 50 120 129 138 147 155 162 169 176 183 189 196 202 208 213 219 m 0 4mm B M1 5 0 60 152164175 186 196 205 214 223 231 240 247 255 262 270 277 8 50 0 4mm A MO 8 0 70 190 206 220 233 246 258 269 280 291 320 330 339 347 3 T 0 80 229247 265 281 296 310 324 337 350 362 374 386 397 408 418 8 7 nass 0 90 268 289309 328 346 3633793
28. 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 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 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 22mm 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
29. tion 6 Installation for long term reliability F Generic wiring diagram for HFS4 v3 1 8 9 Choosing jet sizes System testing 10 HFS4 v3 1 function directory 11 12 Quick Start amp test run Gauge 153 Flow management and other trimmers l 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 29 Advanced system setup amp Aux failsafe Appendix 25 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 ion fitting and in tank filter 806 258 Water pum compression LAST PUp 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 l 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 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
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