HFS-5-v3w

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FIDC tracking water injection system
Instruction manual v3w1
GETTING TO KNOW THE AQUAMIST HFS-5
Over the last few years, demand for great engine power output is increasing. Cubic inches option is
no longer the norm. Squeezing out 200-300hp per litre is within the reach of the ordinary folks on the
street. The tuning industry has grown to embrace new tuning technique as well as readily affordable
components to produce powerful and reliable engines.
We, at Aquamist has also coming to terms with the inevitable, meeting the demands of the market
and offering new systems capable of supporting engine power 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. 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 requirement of a high-end water injection system for achieving
fast engine transient and responses 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 the irregular fluid quantity ingested by the
engine
.
Page 2
Contents:
System overview Page
3
Checking the contents of the box
4
Getting started on installation
Junction Box
5
Junction box pin-out description
6
Flow Sensor
HFS/DDS3
7-8
HFS-5/DDS3 Dash Gauge Functions
9
Powering the system up for the first time
10
Failsfe with a number of options
Failsafe:
11
Boost control / MAP switch
Wiring:
12
Jet sizes & Advanced delivery management
13
Final check-up and setting up the failsafe
14-16 Generic wiring for PWM and MPS mode
Appendix:
17
Electrical / Mechanical specifications
18
Wiring details Guarantee and Warranty
Page 3
Checking the contents of the box carefully
♦
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 grounding 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
This is a “must do” immediately
after unpacking ....
Water pump
Unpack the corrugated sheet carefully. The pump
should be labelled with the original custom Shurflo/
Aquamist part #8030 912 239 .
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 BSP jet adaptor with plug (806-357)
♦
FIA2 (806-441) module with HFS-5 harness -3A
FUSE
DDS3v8 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 8 Junction box
♦
1x water level switch with connector (806-280c)
♦
1x Digital flow sensor (806-428)
♦
A set of wires for inter-connection
Note: Please contact your supplier immediately should you
discover any missing parts.
 Page 4
Getting started on installation
Before installations guidelines
♦
The pump and water tank is designed to be fitted
in the trunk. Install the water pump and inline
filter below the water tank.
♦
Ensure all fittings are tighten 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.
Water tank components
♦
Ensure the outlet is facing the rear or the side of
the tank. Drill/bore 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-
mained in the delivery system. 1-2 inch from the
bottom of the tank is ideal.
♦
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. Tank venting hole must be re-directly
externally if high alcohol concentration is used.
♦
A tall and slim water tank is ideal for this type of
application. Minimise delivery surge problems at
low water level.
Assembling the pump in steps
♦
Gently assemble the two 3/8 BSP adapters into
the pump without crossing the threads. The
female one going 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 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 (dyes smeared on the bottom of the
pump’s rubber feet) and drill four holes for the
pump.
Junction box pin-out description
Page 5
Pin1-8
Legends are colour matched and
connects directly to DDS3 Gauge
via a 8-core cable.
Pin 9-10
It will activate a wastegate sole-
noid valve directly when correct
water flow is detected (system
on). Pin 9 is a fused +12Vand
Pin10 Switches to ground.
Pin 11-12
This relay output can be used to
disconnect the OE boost control
valve and switch to a “Dummy
load resistor” to prevent “engine
check lamp” activation. “Dummy
Load Resistor” is supplied can be
soldered in. It can also be used to
switch pre-defined MAP on a third party EMS, if
available. Open circuits under fault or “DDS3-OFF”.
Pin 13-16
Flow Sensor connections, colour matched.
Pin 19-22
To water level switch and priming pump
relay (up to 0.2A). Pin 22 switches to
ground on activation when pin 17 is
triggered.
Pin 23
Main +12V power supply to the DDS3.
Wired to the Fuel injector’s +ve supply.
Pin24
To 0V, Battery negative or chassis
ground with good electrical contact.
Pin25
FIA2 Fuel injector amplifier trigger in the
absence of manifold pressure switch or
FIDC (fuel injection duty cycle) trigger is
preferred. (for Aquamist use only)
TRIP ADJ
potentiometer
Setting failsafe tripping range between 25 to 75% full
scale of the signal seen at pin 17.
DIM ADJ
potentiometer
Adjust display/backlit intensity on the gauge for night
driving conditions.
MPS/PWM
jumper link.
Selecting mode of operation: the WI system can be
triggered by either Manifold pressure sensor (MPS)
or fuel injector’s Duty cycle (PWM). Adjustable be-
tween 12% to 72% via “TRIP ADJ”
Pin 17
Failsafe triggering input. PWM or MPS (mode) -
section by jumper link at the bottom of the board.
Pin 18
To car’s +ve of parking lamp circuit to enable “DIM-
ADJ” potentiometer on the DDS3 junction board
Page 6
Flow Sensor
sensor via a 4-core cable. Length can be extended up
to 20 feet without any loss of accuracy.
Diagram below show the pin-out and functions of the
DDS3 terminals. Sensor V refers to the actual flow
signal from the sensor. Sensor C is for internal
reference use only. If you need to data-log the flow
rate, take the signal form the Sensor V terminal.
Do not install the
sensor near any mag-
netic radiated de-
vices such as ignition
coil, motors or sole-
noids because it in-
terferes with the hall
effect sensor that
reads the turbine
speed. Avoid areas
with high heat and
vibrations. A cool and
dry location is ideal.
The standard sensor has a 1/8BSP (parallel
thread) female port on each end. Do not use 1/8
NPT fitting male thread as the tapped thread may
crack the ports. Use a 1/8BSP(M) to 1/8NPT(F)
adaptor to convert the fitting if the hose you are
using is not the same as the Aquamist type
(4mm and 6mm OD). The sensor is bi-directional
but do not change flow direction after long period
of usage unless the two internal disc filters are
properly cleaned. The sensor is suitable for use
with water or methanol at any concentration.
Sensor is fitted with 1/8BSP 4mm qck-fit hose
connectors from factory.
The DDS3 junction board supplied all the neces-
sary electrical power and signals to and from the
Never reverse the
polarity of the power
feed to the sensor or
permanent damage may occur.
Page 7
HFS-5/DDS3 Dash Gauge Functions
It will switch to full brightness when the DDS3
is triggered. (Pin 17)
1
6
4. Water Level Sensor led (yellow)
When the water level in the tank is below the
sensor, this led will light up and disables the
water injection as well as any other related
functions such as high boost, priming pump
and main pump.
7
2
3
8
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 full scale of
the sensor about two/three segments below
maximum so a problem is easier to identify. It
can also be used to trim the sensor to show a
absolute or relative values for a particular set up.
4
9
10
5
1. 8-element Bargraph Display (80-1200ml/min)
Each segment is equivalent to 50ml/min. of flow if the
sensor is calibrated for absolute mode.
Depends on user preference, the display can be scaled
to suit the liquid flow up to 1 litre per minute. (see 5)
6. Backlit flow legend
Fixed scale to indicate absolute flow rate.
Sensor must be calibrated for each application
for accuracy - scale will be updated .
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.
7. “B” Boost Enabled led
This led lights up to show the “extended
boost” over wastegate is triggered. Provided
the following conditions are met: “Water Injec-
tion On” button is depressed, flow-rate is in-
side the set window and water tank is above
the set level.
3. Water injection ON led
This led comes on the when the dash button is de-
pressed, showing the water injection system is enabled.
.
 Page 8
Installation
8. Water injection enable button
Due to extra power level achieved under WI, user
want 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.
The gauge will fit into any 52mm gauge pod and a
two-prong bracket is provided. Do not over-tighten
the thumb-wheel since it has an embedded o-ring to
create high friction between the surfaces thus pre-
venting loosening due to vibrations.
9. Over-range setting potentiometer
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.
An open ended 8-core cable is provided for connect-
ing the gauge to the junction box where all the other
sensors and peripheral devices are terminated. We
avoid using plug/socket termination because it is
difficult to thread them through the firewall between
the engine bay and pas-
senger compartment
10. Under-range setting potentiometer
This setting can indicate partial blockage and trapped
air inside a delivery hose. Again a 20-stepped poten-
tiometer is employed.
All the core colours are
coded and matched to
the legends in front of
the terminal block, this
helps to avoid any acci-
dental termination er-
rors. The wires should
be stripped and twisted
before inserting into the
terminal blocks. The
eight top left terminals
are reserved for the
DDS3 gauge.
NOTE:
The two range potentiometers “9”and“10”
form the basis of a SOA (Safe Operating Area) that
allow users to tune their car more safely.
Please note that methanol has only 80% mass of
water and 50% latent heat of water. If water and
alcohol mix is injected, allow a bigger jet to compen-
sate this. This is a common mistake often made.
Every 25% of methanol added should allow a 0.1mm
Increase of jet size diameter.
Powering the system up for the first time
Page 9
The HFS-5 is setup as
PWM-triggered mode
from factory, ie, when the fuel duty cycle has
reached a preset %, the water injection com-
mences. Please check the DDS3 junction box set to
“PWM” on the jumper link.
Step 3: Check the rest of the system.
Upon the triggered period, you should check the
following peripherals are receiving the correct signal
from the DDS3 Junction board.
1. The red led on the FIA2 illuminates
2. The “water injection” led on the gauge should get
brighter.
3. The HSV should click and buzz.
4. The water pump should turn on,
All above conditions should revert back after trig-
gered period is over.
5. The DDS3 bargraph should register flow.
Make a note of anyone of the item/items did not meet the
above conditions,contact Aquamist or your Supplier.
Step 1: Powering up the system
Disconnect the hose from the water jet and locate
it into a container, Ignition key on #1 & 2, the pump
should remain idle. Switch the DDS3 on via the
dash gauge button, again the system should remain
idle, Two leds should illuminate - “S” and “water
injection” Start the engine,
Step 2: FIA2
If the FIA2 is wiring and reading the fuel duty cycle
correctly, the green led should illuminate after the
engine is fired up and not before. You should see a
faint pulse following the engine RPM. The red led
should not illuminate at this stage.
Step 4: Final check-up before going for a drive
Repeat the throttle blipping until all the air is purged
out of the system. You should see a continuous
stream of water coming out of the hose every time
you blip the throttle, purging is now completed.
Adjust the “TRIP ADJ” to mid way, reconnect the
hose to the jet take the system for a test drive.
Step 2: Manually triggering the DDS3 J.Box
Locate the “TRIP ADJ” potentiometer and turn it
fully counter-clockwise. At 12% injector duty cycle
(IDC) the WI should commence.
Blip the throttle to induce more IDC, you should see
the red led below the potentiometer lights up.
Repeat it several times to confirm this.
You have successfully installed the system. The
system can also be triggered by manifold pressure
by relocating pin 17 to a map sensor and set
to“MPS”.
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