FIDC tracking water injection system
Contents
1. band supplied Assemble the rest of the 1 8 BSP elbow fittings and blanking plugs Ensure all o ring type fittings are not overly tightened Mark dye is smeared on to the bottom of the pump s rubber feet and drill four holes for the pump Water tank components Ensure the outlet is facing the rear or the side of the tank Drill oore a burr free 7 8 hole Clear up all the burred edges and wash the tank thor oughly No debris or plastic shaving should re main in the delivery system 1 2 inch from the bottom of the tank is ideal Don t over tighten 4 Same size hole for the water level sensor Do not place the sensor near the washer pump It will not operate properly The float should swing up wards The tank venting hole must be re directed externally if high alcohol concentration is used A tall and slim water tank is ideal for this type of application This minimises delivery surge prob lems at low water level Aquamist HFS Installation for long term reliability This is the most important section of the DDS3 chapter Please do not skip reading this part The 52mm Dash Gauge Location is not too critical as long as it is in view of the driver There isn t too many pitfall on this The Junction box This is the heart of the system and must be installed in a dry location preferably sited close to the glove compartment Do not install it in the engine com pa2. pump speed controller uses a positive PWM switching driver you need to re configure the DDS3 circuit board manually p15 F MPS IN pin18 0 5V input signal for triggering the system instead of PWM This type of signal is normally associated with MAP MAF and TPS sensors The trigger point of the above is set by the Trip adj potentiometer 8 13 12V input to enable led dimming A 12V signal at this input enables the uses to set the brightness of gauge p12 7 It is normally wired to the head lamp switch so the gauge will automatically dim during night driving 14 Tank level pump control output These four connections control the delivery pump and detects water tank fluid level Control signals are transmitted viaa 5M of 4 core cable to the trunk area 15 Main power input fused IGN SW 2 It is important the 12V power is only active at ignition switch position 2 Ideally it should be wired to the same 12V supply to the fuel injectors 16 Internal Anti CEL Dummy resistor If the stock ECU controlled boost valve is discon nected by the DDS3 during a fail safe activation a CEL check engine light is often illuminated To prevent this from happening A dummy resistor is used to create an artificial load of a boost control valve During this period the resistor will warm up If heat is a concern use an external resistor see pagel 1 3 DDS5 junction board pinout descriptions 17 LED red to show system ac
3. switched off M SW1 and M SW 3 contacts are closed normally until fail safe is triggered or gauge is switched off Page 12 DDS5 junction board pinout descriptions cont 7 Led brightness for night driving p 9 When pin 19 is linked to the headlamp switch this potentiometer enables user to adjust the brightness level of the gauge leds 8 System trigger point adjustment p 9 This potentiometer sets the triggering point of the injection system O 36 42 48 32 1 54 24 60 12 q 66 12 In PWM mode the figure on the left indicates the IDC trip point in 6 steps Most common onset point Is 42 12 o clock 72 PWM MOD In MPS mode the figure on the left will help to identify the trip point of a 12 to 72 Manifold Pressure Sensor To translate the signal to PSI please see the table below is 48 Nl 545 36 32 24 60 12 f 12 66 72 MPS MODE 12 18 24 30 36 42 48 54 60 66 72 11 93 7 6 5 8 41 23 06 12 29 46 56 PS 93 67 41 1 5 1 7 3 8 64 9 0 11 6 14 2 16 8 PSI MAP sensor conversion table from to PSI shaded vacuum Trip adj 2 bar 3 bar 9 LED green to monitor IDC This led will active when a PWM signal is success fully detected on pin17 It should pulse in unison with the frequency and grows brighter as the duty cyle increas
4. Aquamist HFS BLK 08 6M OF 12AWG CABLE un a DDSSvV10 pinout function directory TRIP ADJ 3 3 BBE N me a cia 00 S R 09 b3 11 12 T3 14 15 16 17 18 RJ 45 socket for dash gauge p 11 Inline flow control valve p 11 External Anti CEL dummy load resistor p 11 MAP switching signal output p 11 Boost Control valve output p 11 Voltage free relay outputs p 11 Led brightness for night driving p 12 System trigger point adjustment p 12 LED green to monitor IDC p 12 Selecting external dummy resistor p 12 4 core cable to turbine flow sensor p 13 System trigger signal input p 13 12V input to enable led dimming p 13 Tank level oump control output p 13 Main power input fused IGN SW 2 p 13 Internal Anti CEL dummy resistor p 13 LED red to show system activation p 14 User selectable system configuration p 14 DDS5 junction board pinout descriptions 1 RJ 45 socket for dash gauge The DDS3v10 uses a RJ45 connector to link up with the Dash gauge 2 Inline flow control valve This output can be used to switch an inline solenoid valve to control flow Output current is limited to 1 Amp It is activated by the signal applied to the PWM pin17 or MAP pin18 input User can set the triggering point by using the Trip adj potenti
5. FIDC tracking water injection sustem HFS 9 icc gt User manual vl Ow GETTING TO HNOUJ THE AQUAMIST HFS 5 Over the last few years the demand for great engine power output has increased The cubic inches option is no longer the norm Squeezing out 200 500he per litre is within the reach of the ordinary folks on the street The tuning industry has grown to embrace new tuning techniques as well as readily affordable components to produce powerful and reliable engines We at Aquamist have also come to terms with the inevitable meeting the demands of the market and offering new systems capable of supporting engine powers output up to 1000 BHP The HFS 5 reads the duty cycle of a fuel injector and delivers water proportional to fuel flow Water quantity is metered by a high speed inline valve and flow is monitored by a turbine flow sensor for clogged jet and severed hose detection A number of options are available for the user to limit engine power in the absence of water flow We believe the HFS 5 meets all the requirements of a high end water injection system for achiev ing fast engine transients and responds with absolute precision Tracking the fuel delivery is the most reliable method to deliver your fluid flow under the whole engine operating cycle Anything short of this means having to tailor your fuel map to compensate for the irregular fluid quantity in gested by the engine Contents System Check Page Checking the cont
6. Flow Sensor 30mA 12v 2 Blue 24awg OV power supply of Flow Sensor OV Ground 3 Yellow 24awg Flow Sensor output voltage 0 5VDC 10mA 4 Green 24awg Flow Sensor calibration input voltage 5 0VDC O 1mA DDS3 Junction Box 25 ways Pin 1 top left corner Pin 25 bottom right corner Pin Colour RJ45 1 Red 2 Brown 3 D Grey 4 D Grey 5 Orange 6 Red 7 Brown 8 Black 9 Grey 10 White 11 14 15 Green 16 Blue 17 Pink 18 Yellow 19 Green 20 Red 21 Blue 22 Red 23 Black Size Description 8 core Same as Dash Gauge Above 22awg 12V power supply to Solenoid valve 22awg Switching to ground for Solenoid Valve 22awg Extending Dummy resistor 12V side 22awg Extending Dummy resistor EMS 22awg Programmable Map switch signal 22awg Boost control valve 12V supply 22awg Boost control valve switch to ground 22awg Normally closed relay contact fail safe 22awg Wiper common relay contact 22awg Normally opened relay contact 4 core See 4 core cable description above 22awg FIDC detect or MAP sensor 22awg MAP sensor or 0 5v based sensor 22awg Night driving dimming connection 22awg To ground when tank is empty 22awg Common ground 22awg Priming pump 12V supply 0 5A FUSED 22awg Priming pump ground switch active 20awg 12V switched power supply for all 20awg OV ground supply for all Electrical parameter 12V 1A fused 1A maximum 1A maximum 1A maximum 5m signal 1A max 600mA max 1A max 1A max 1A max Wave inp
7. 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 1 MANUAL BLEED OFF MBC 12V IGN NORMALLY CLOSED VALVE RESTRICTOR VENT INJ IDC SYS O FROM TURBO WASTEGATE 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 It is important to use a solenoid valve with a low power coil winding to avoid over heating during the by pass mode A typical coil power between 3 6W is acceptable when installed in a cool place TYPE 2 MANUAL BALL SPRING MBC FROM TURBO EA EN NORMALLY CLOSED il W SW2 DIM ADJ AON 5 2 ak ms we My INJ ID SYS O OP aon m e SOR TO WASTEGATE Advance system configuration solder link Links are factory preset no need to alter the setting unless customising Says eg E 7 hae ripe n EER E au 80 8 cei i a LASSOO 0000 O l Ka Advanced sustem configuration solder link The DDS3v10 is pre configured at the factory for a specific application When in doubt please check the round label on the lid of the box or the small label on the RJ45 socket at the top right of the junction board
8. d This link is useful for testing the system without driving the car at full boost and RPM When this link is shorted it simulates a 100 IDC signal appearing at the PWM input terminal pin1 7 Warning Linking this pin will start the pump and energise the Inline valve resulting in 100 maxi mum fluid delivery to the water jet jets Do not activate this link for more than 5 10 seconds at a time for risk of burning up a solenoid valve designed for pulsing purpose use only Remove this link as soon as the manual system test is completed DDS4v10 Dash Gauge Functions 25 50 75 100 FSD N Fao w m W INJECTION I SC WL WH Made in England 1 8 element Bargraph Display 80 1800ml min Each segment is equivalent to a percentage of the total flow of the sensor scaled by the SC potentiometer A 2 S indicates the presence of sensor The letter S sensor must be lit after power up and stay on to show the sensor is functioning correctly 3 Water injection system ON led This led comes on the when the system Is switched on and in readiness to inject 4 Water Level led yellow This LED has three functions a During power on delay period This LED will activate for approximate for 10 seconds during the system on delay v10 be fore the main system turns on b During normal operation period This LED is on during the safe fail activation Water level low interm
9. e water jet Is clipped on the windscreen K Upon a successful test run spray pattern is uniform splutter free and activation is predictable As engine load increases the spray should progressively become fuller The bargraph on the gauge should change with load What next The system is now ready The correct water jet can be connected to spray internally reset the trip point to the preferred value Allow time for the system to settle down before proceeding to the next stage of the setting up the Setting up the Failsafe This final stage should 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 accommo date 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 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 0 bar to 4 bars 4 Same procedure to set up the WH allowing 2 3 clicks above 6 bars Full span of WH is 20 clicks c
10. ee S cain co ajnulw Jed 99 I Advanced delivery management The HFS 5 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 piece is supplied with the kit for twin jet applications There are two nickel plated brass jet adapters Three pre HSV in hose restrictors are supplied for duty cycle flow matching should good linearity be required restrictor HSV clipsy ome cme T Please note the HSV should not be installed in areas where there heat and vibration is pre sent At any point of priming sequence espe cially if no fluid is flowing pass it Do not allow the HSV to be energised for 30 second at a time The HSV s wetted parts are designed to work with 99 9 pure methanol or ethanol only Avoid using alcohol with unknown denaturant Always buy alcohol in seal containers or risk cross contamination during dispensing 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 the area is we
11. ents of the box Getting started on the installation Installation Installation for long term reliability Advanced delivery management Wiring Generic wiring diagram Junction board Z 5 Choosing jet size 8 9 O Junction board function index 11 14 Junction board pin out descriptions Gauge 15 16 Gauge function descriptions Fail safe 17 18 Setting up the fail safe Advanced 19 2 Customising the system Appendix 25 Wiring details Guarantee and Warranty Unpack the corrugated sheet carefully The pump should be labelled with the original custom Shurflo Checking the contents of the box carefully This is a must do immediately after unpacking Water pump Aquamist logo gt gt gt gt 9 9 9 The white box 6M of 6mm OD nylon hose 806 261 2M of 4mm OD nylon hose 806 266 15A Fused water pump harness with 40A relay 75mm stainless hose clip and support bracket HSV with 6 4 mm hose connector and clips and 2 way sealed plug and socket set 806 244 0 8 mm water jet 806 323 in plastic bag 0 9 mm water jet 806 324 in plastic bag 1 0 mm water jet 806 325 in plastic bag 1x 4mm Y piece 806 362 in plastic bag 2x M8 x 1 8 NPT jet adapter with plug 806 357 00 ooo o 1x water tank adapter 1 8 BSP 806 270 6mm qck fit elbow 806 376 100 micron inline water filter 806 257 4x M5x 40mm nuts washers and fasteners for pump 1x M6 groundi
12. es This led should not be lit before cranking After the engine has started it should pulse in time with engine speed If the DDS3 is used as a fail safe to a third party WAI system this led will only pulse when the PWM pump is activated under normal injection events 10 Selecting external dummy resistor Selecting ext int dummy resistor The on board Anti CEL resistor is rated for intermittent usage during fail safe activation In the event of prolong activation it will get very warm To avoid exces sive heat build up it is recommended to use an external dummy resistor for this purpose The external resistor is not supplied with the kit but it is widely available in electronics store The resistor should be 39 ohms 10VW 25W in metal body NOTE If anti cel is not necessary please leave it on the XDR position or remove the link completely DDS5 junction board pinout descriptions cont 11 4 core cable to turbine flow sensor Please ensure the stripped wires are twisted without any loose strands before insertion into the terminal block connector 12 System trigger signal input Choice of two system triggering signal inputs Selectable by jumper links page14 18 PWM IN pin17 It reads and translates any negative going pulses such as fuel injector or PWM based pump speed controller in to a refer ence signal to trigger the system and fail safe circuitry The system is factory set to detect negative PWM signals Some
13. factory default for Universal fail safe use If the user wishes to change the original setting this is the section to explain it all You will require a small tipped soldering iron and a small pointed tool As seen from the PCB figure on the left All the user configurable links are marked with alphabetised circles Some pads are pre linked from factory If you need to change those pick off the thin track pointed tool and solder link the alternative solder pads A WLS Water Level Sensor default linked Pick off the thin circuit track if you do not wish the tank level sensor to disable the system after 10 20 seconds of low level reading not recommended B DHB Disable High Boost default linked Pick off the thin circuit track if you want to retain high boost or Aggressive MAP after the system Is switched off at the gauge only if you are using pin 9 10 to reduce boost to wastegate setting after fail safe activation C D MSW Map Switch polarity default D linked The factory default output is preset to give a OV output upon a fail safe activation Otherwise the output will stay at 8V To invert this output to give out a 8v signal upon a fail safe activation un solder the pad D and solder link pad C to the long soldering pad E CMP Clamping MSW signal default clamped Solder linking this pin will clamp the above MSW signal down to 4 7V suitable for most digital de vices It is factory lin
14. ittent flashes c Led lit after the gauge is switched off If the water level sensor is activated for over 20 seconds Fail safe output Is in the active state 10 6 5 SC Sensor Calibration 20 stepped potentiometer allow user to scale the 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 6 Backlit flow legend Legend displays of full scale of 8 bars 7 B Boost Enabled led When the flow falls inside the fail safe window after system trigger this B led will activated Useful indicator of the WL and WH setting DDS4v10 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 20 stepped po
15. k level sensor Avoid locating the sensor tip close to a washer mo tor The motor magnet will affect the sensor to read properly The sensor can be installed 3 4 way down the tank Preferably at the rear facing wall of the tank A 23mm burr free hole must be used to ensure good seal Never over tighten or the seal will split just tight enough to prevent leakage no more Flow cc min 600 Pressure vs Flow 950 pressure pump 80 90 100 10 120 125 150 Pressure pei Choosing jet size This is a general guide only 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 recommended above Pick the nearest jet jets size to match the flow Don t forget to subtract the boost pressure from the line pressure of 125psi For example if you are boosting 25psi you should select the jet flow at 100 psi Once the jet jets and flow are determined insert the nearest HSV restrictor to regulate the fluid flow so the delivery will be linear to the duty cycle JET 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130PSI 0 3 46 48 50 52 54 55 57 58 60 61 63 64 66 67 68 0 4 0 5 0 6 0 7 0 8 399407 41 0 9 1 0 498 509 519
16. ked to give 4 7V F PWM MODE polarity default negative switched To change the PWM detection polarity to positive pick off the thin track and solder link the pad to the long pad This mode is rarely used except the DDS3 is used for monitoring WAI system using a positive PWM signal to control the water pump speed For example Snow and Devilsown system GENERIC WIRING DIAGRAM FOR HFS 5v10 with MBC Aquamist 4 100 200 300 400mI m 4 WAY 22AWG CABLE 2M W INJECTION WATER LEVEL sc WL WH GK Made in Eng ond FUEL INJECTOR MPS 0 5V 12v TO DIM 12V SWITCHED 3A FUSE 12V IGN 6M OF 12AWG CABLE Aquamist HFS 40A 30 RELAY 806 276 SET TO XDR FROM TURBO WASTEGATE MANUAL BLEED OFF VALVE 806 281 806 270 In Car Dash Gauge 8 core cable Appendix Pin Colour Size Description Electrical parameter 1 24awg 12V power supply to gauge 250mAmax 12v 2 24awg Flow Sensor output voltage 0 5 VDC 10mA 3 24awg OV power supply to gauge 250mAmaxQ 12v 4 24awg Internal communication signal 5 24awg Float Sensor from water tank Ground active 6 24awg Flow Sensor calibration output voltage 5 0 VDC 1mA 7 24awg Night driving dimming connection 12V active 8 24awg Wastegate bleed valve option SW 1A 12V max Flow Sensor 4 core cable Pin Colour Size Description Electrical parameter 1 Red 24awg 12V power supply of
17. ll 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 Ensure it is securely clipped and fastened Avoid kinks close prox imity of moving parts and heat producing components 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 recom mended that a suitable fire extinguisher is placed within easy reach of the driver All electrical connections must be properly tightened to avoid spark production Aquamist 100 200 300 400mI m 7 FLOW W INJECTION WATER LEVEL sc WL WH Made in England EXT DUMMY R OPTIONAL FAIL SAFE OKE SV OUTPUT OPTIONS FOR 12V INTERFACING TO ECU OR GND SW BOOST CONTROL VALVE FAULT DETAILS CAN BE FOUND WIPER IN THIS USER MANUAL GERE GENERIC WIRING DIAGRAM FOR HFS 5 with DDS3v10 TO HSV DDS3v10 JUNCTION BOARD 12V WFS i 0V WFS SENSOR C FLOAT SW PRELAY P RELAY 12V IN M SW 2 0V IN er PE ON on 39R 806 281 806 270 4 WAY 22AWG CABLE 2M 3A FUSE GND 37 sf 86 40A 30 RELAY 806 276 806 428 FUEL INJECTOR J Ve Np 318 09 1 07 N amp ELECTRONICS T12V SWITCHED MANAGEMENT SYSTEM
18. ng stud with washed and nuts and 6mm eyelet for pump ground 5 port brass manifold with 3 8BSP adapter 3x blanking plugs 1x 3 8 BSP M to 1 8BSP F adap tor 2x 6mm 1 8BSP M elbow 1x 22cc surge arrestor accumulator 806 409 1x Pump label DDS3v10 fluid monitoring system box Assortment of 22 AWG coloured hook up wires 1x DDS3 Dash Gauge with 1 5 M x 8 way cable 1x Version 10 Junction box 1x water level switch with connector 806 280c 1x Digital flow sensor 806 428 A set of wires for inter connection 3A fuse link with 1 25 inch quick blow fuse 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 and inline filter below the water tank Ensure all fittings are tightened and leak proof before filling up with methanol test it with water first If high concentration of methanol is used please vent the tank s breather hole externally Methanol is poisonous at high concentrations Assembling the pump in steps Gently assemble the two 3 8 BSP adapters into the pump without crossing the threads The female one goes into the inlet of the pump Flow direction is moulded onto the plastic pump head Ensure o ring is properly seated Ensure the accumulator lies horizontally after final tightening Assemble the accumulator supporting bracket with the metal
19. ometer near the bottom of the junction board 3 External Anti CEL dummy load resistor A more powerful anti CEL dummy resistor can be connected to this output when excessive heat Is produced by the on board dummy resistor This option only applies if pin 9 10 is used for cutting the PWM signal to a boost control solenoid valve in the event of failsafe or prolonged gauge off period 4 MAP switching signal output Fail safe output for map switching usage This out put is about 5V and switch to Ov upon fail safe activation The signal is short circuit proof with a current limit of 5mA If an alternative or an inverted output signal is required this output pin can be reprogrammed via a set of soldering pad on the underside of the circuit board Please go to page 15 section C D for a more de tailed description of how this can be done 5 Fail safe window output SW GND When flow signal falls inside the fail safe window pin7 will switch to ground immediately This output can be used to activate a solenoid valve to increase boost pressure This output can also be used to switch MAP GND active on an ECU 6 Voltage free relay outputs There are three terminals representing a set of voltage free change over contacts from a relay if anti CEL dummy resistor jumper link is un used 010 6 M SW1 is the wiper or common pin M SW1 and M SW 0 contacts are opened normally until fail safe is triggered or gauge is
20. overing 4 8 bars This completes the fail safe setup What steps to take after the failsafe trigger The commonest way to minimise engine damage in the absence of injector is to reducing the boost pressure 1 For engines with electronic boost control valve Pin 9 10 is a set of relay contact that goes open circuit when the fail safe is triggered See page 10 6 for more details Connect pin 9 to the ECU side 2 For engines with MBC manual boost controller Pin 8 9 is a set of relay contact that goes close circuit during fail safe activation Use this output to power up a solenoid valve to by pass the MBC Essentially allowing full turbo boost to the wastegate See page 19 for more details 3 For engine with map switching capabilities Pin 5 see page 10 4 is a dedicate output to perform such a task This pin can be user configured match the signal requirement of the third party ECU to switch map See page 20 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 Fail safe wiring for MBC Upon detection of water flow fault the HFS 1 can reduce the boost pressure of a MBC to wastegate setting with a 2 way Low Current Solenoid valve not supplied A typical supplier is MAC valve 36A AAA JDBA 1BA www macvalves com or Clippard valve ECO 3 12 L M5 www Cippard com Figure below shows two common type of MBC man ual
21. rtment It has been done Assuming all cables from various locations are routed to the junction box neatly Please label the flow sensor cable to prevent it from wrongly identi tied with the 4 core cable from the truck area Once marked the cables and wires can be cable tided The most common mistake at this point is cutting the bundled cables very short to improve tidiness Please don t Allow a minimum of 2 feet so that the junction box Is accessible when a problem occurs Longer cable length will not degrade the system performance at all The Flow sensor The location of this sensor Is most critical to overall system reliability It is normally located it in the en gine compartment But there is no reason why it can t be spliced into any where between the pump outlet and jets nozzles The sensor must be installed in a cool area well away trom the a heat source Bulkhead fire wall is not a good location as most heat is flowing towards it during motoring Avoid location near any electro magnetic components such as the ignition coil solenoid valves and electronic motors It is very important that the hose is cut cleanly with a razor blade to retain the roundness Side cutter produces a semi round hose end major leak will result sooner or later The hose exiting the fitting must be straight so that the hose is not distorted and will be badly affected in a hot environment Again in time it will develop a leak The Tan
22. stem for the first time The system can be activated manually for priming and leak checks An external water jet can be used temporarily check the spray and bargraph display It is not neces sary to set up the fail safe at this point Please follow the steps below assuming the system is in PWM mode a Put the ignition switch to position 1 ACC No activity should be observed on the gauge or junction board If not check wiring b Process to ignition switch position 2 pre cranking c The yellow led on the gauge should light up immediately d Within 10 seconds the gauge will power up No other activity should be observed e Start the engine and let it idle f Check the green led INJ IDC on the Junction board is pulsing in time when throttle is applied g Remove the spare jumper link prk on the b way program ming link to the TST link This will active the pump the HSV and the red led SYS ON If all is well unlink after a few seconds h This is a good time to check the installation for leaks Never over tighten the fittings to cure leaks I Set the gauge and junction board as follows if necessary SC sendor calibration is set to 12 o clock gauge WL window low is set to fully counter clockwise WH window high is set to fully clockwise MPS CAL amp TST on the J Board are unlinked Trip adj is set to 9 o clock 24 IDC J The system is ready for a test drive Ensure th
23. tenti ometer is employed Each click represents a fixed portion of the window width of 8 bars WL covers the lower 4 bars and the WH cov ers the upper 4 bars Figure on the right il lustrates the span of the coverage Setting is very simple once SC is calibrated failsafe window width coverage 20 clicks WL WH 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 7bars A good starting point Minor trimming for the WL is necessary if the water injection trigger point is set to commence earlier The v10 gauge will display the activation of the fail safe with two leds Further useful hints B led right of the bargraph will active if the flow is inside the fail safe window during injection period The yellow led water level will activate if the flow is outside the fail safe window during injection As soon as the fail safe is tripped there will be a 4 second reset period before it resets If the fail safe drops boost expect 4 seconds of low boost The same will apply for fail safe induced map switch When gauge is off expect low boost and safe map unless the board is re configured page21 B Powering up the system Powering up the sy
24. tivation This SYS ON red led actives when the PWM MPS input signal reaches the trip adj setting The sys tem will commence injection 18 User selectable system configuration Figure on the right shows a set of default user selecta ble jumper links for setting up the triggering mode and manual system test Read on for further details 1 MPS Manifold Pressure Sensor MODE link Selecting this link instead of the default PWM link changes the system s triggering mode Now the system will be looking at the MPS signal 0 5V at pin 18 to turn the system on see texts 12345 umea EE a L e EKAA INJ IDC amp SYS ON 2 PWM Pulse Width Modulation MODE link PWM MODE Factory set The system looks for switch to ground PVVM signal from the pin17 to turn the fail safe circuitry and V A injection on For positive edge trigger see Advance setting Page21 F Upon successful detection of PWM pulses the Green led will pulse in time with the incoming PWM signal 3 PRK Parking unused jumper link This link space is for parking an un used Jumper link socket No other usage 4 CAL Calibration Simulation Default unlinked Linking this pin turns the SC potentiometer into a flow sensor simulator Fully clockwise for minimum water flow Useful to check the fail safe window width B led will activate when the simulated flow is inside the window 5 TST Manually test Default unlinke
25. 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 THE END ERL Itd Iroko House Bolney Ave Peacehaven East Sussex BNIO 8HF England
26. ut 0 to 5V input 12V active 0 25A maximum 0 25A maximum 0 5A maximum 1A maximum 3A maximum 3A maximum 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 employees in respect of defects in goods supplied or for any damage or loss resulting from such defects We shall not be
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