HFS-6-3w

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FIDC tracking water injection system
osa
User manual v4w
Page 2
GETTING TO KNOW THE AQUAMIST HFS-6 osa
Aquamist has been pioneering the IDC based water injection system since 2003 with
great success. The HFS-6 now offers “user re-scaling” and “manifold pressure compensa-
tion” adjustment. This new capability sets a new level to the concept of WAI system to
date.
.
The concept behind the HF5-6 osa (open source architecture) design is somewhat unusual
in many ways in the key-tapping digital age. It goes one step beyond the current cell by
cell on-screen programming via a lap top. The only tool needed is a small screw driver. User
can define the entire flow curve by manipulating five onboard trimmer potentiometers. Each
trimmer is pre-programmed with a mathematical formula to simplify the flow mapping work.
The wiring task has also been revamped to cut installation time. Three dedicated colour
coded, pre-terminated wiring harnesses are allocated for each area of the car, covering the
engine bay, ECU and water tank/pump in the trunk. Continuing the same tradition of constant
water pressure and fluid flow is controlled by newly designed inline high speed valve. This
new valve is necessary to handle the new line pressure of 160psi, risen from the previous
pressure of 125psi.
 Page 3
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
8-9
Choosing jet size
System testing
10
HFS-6 pin-out function directory
11-12
Quick Start
Gauge
13-14
Advanced delivery management
Dash gauge
15-16
Dash Gauge functions
Fail-safe
17-19
Fail-safe configurations
Advanced
20-21
Advance system configuration
Appendix
22-23
Wiring details Guarantee and Warranty
Page 4
Checking the contents of the box carefully
♦
2x M8 x 1/8 NPT jet adapter with plug (806-357N)
♦
A set of three restrictors with threaded tool
♦
1x water tank adapter 1/8 BSP (806-270) + 6mm
qck-fit elbow (806-376)
♦
100 micron inline water filter (806-257)
♦
4x M5x40mm bolt, washers and fasteners for pump
♦
1x M6 grounding stud with washed and nuts and
6mm eyelet for pump ground.
♦
5-port brass manifold. 2x blanking plugs. 1x 6mm
to 1/8 BSP compression fitting.
♦
1x 6mm to 1/8 BSP elbow for water tank outlet
♦
1x 4mm compression fitting for flow control outlet
♦
1x 6mm compression fitting for flow control outlet
♦
1x 22cc surge arrestor/accumulator (806-409)
♦
Water pump harness. 6M of #12 AWG cable and
6M of multicore cable with blue RJ45.
♦
HFS-6 controller box
♦
1x water level switch with connector (806-280c)
♦
1x DDS3 Dash Gauge with 1.5 M x 8-way cable
♦
2M of multicore with yellow capped RJ45 for
. ECU interface, fail-safe and Map switching.
♦
User manual
This is a “must do” immediately
after unpacking ....
Water pump
Unpack the corrugated sheet carefully. The pump
should be labelled with the original custom
Aquatec/Aquamist
logo.
Model
number:
58832P0D-B664AM
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
♦
HFS-6 Flow Control Module with 2.5M of red
capped RJ45 connector harness.
♦
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
 Page 5
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 ex-
ternally. Methanol is poisonous at high concen-
trations.
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 (relative to the pump length).
♦
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 fit-
tings are not overly tightened.
♦
Mark (smear dye on to 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/bore a burr-free 23mm hole. Clear up
all the burred edges and wash the tank thoroughly.
No debris or plastic shaving should remain in the
delivery system. 1-2 inch from the bottom of the
tank is ideal. Don’t over tighten.
♦
Same hole size for the water level sensor. IF using
a washer tank for supply, do not locate the Aq-
uamist float sensor near the stock washer pump..
The float should swing upwards.
♦
A tall and slim water tank is ideal for this type of
application. This minimises delivery surge prob-
lems at low water level.
40A
RELAY
DDP5800
THIS PUMP IS FACTORY SET TO 160PS. DO NOT
ATTEMPT TO INCREASE THE BY-PASS VALVE
PRESSURE OR THE LIFE EXPECTANCYWILLBE
GREATLY REDUCED. IT IS NOT RECOMMENDED
TO RUN BEYOND 50% METHANOL BECAUSE OF
FLAMMABILITY AND VAPOUR INHALATION CAN
BE HAZARDOUS TO YOUR HEALTH.
BATTERY+
160 PSI BYPASS PUMP
MADE IN USA
BY
AQUATEC
WATER TANK
IN TRUNK
PUSH-FIT ELBOW FITTING
ALL METAL COMPRESSION FITTING
Installation for long-term reliability
This is the most important section of the HFS-6
chapter. Please do not skip reading this part.
Page 6
blade to retain the “roundness”. Side cutter pro-
duces a semi-round hose end, major leak will result
sooner or later. It is also vital that the hose must be
cut be perpendicularly relative to this length. This is
because the compression has a short hosetail, an
accurate cut will allow maximum grip on the walls
of the hose.
The ground tag must make a good electrical contact
to the chassis ground. Smear some grease on the
junction to protect it from moisture.
8-feet of two-core cable from the FCM is intended
for fail-safe purposes. It activates a low-power 3-
way solenoid valve to by-pass boost pressure to the
wastegate. In the event of a fail-safe activation, it
will lower the boost down to the mechanical fail-
safe setting. This option is normally intended for
use with a manual boost controller and some step-
per-motor based electronics boost controller.
52mm Dash Gauge:
Location is not too critical as long as it is in view of
the driver. There aren’t too many pitfall on this.
HFS-6 controller box:
Please locate the box in a dry location in the pass
compartment. Near a glove box is whats been
found to be best. Please route the wiring and secure
loosely so that tuning and diagnostics can be made
without too much dis assembly in order to gain easy
access = its been found by professional installers
and advanced users that it would be nice to hold the
box in the hand while sitting in the front passenger
seat when tuning or diagnosing.
Flow Control Module (FCM):
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 and dry area,
well away from the heat source. Bulkhead/fire wall
is not a good location as most heat is flowing to-
wards it during driving. Avoid location near any elec-
tromagnetic components such as the ignition coil,
solenoid valves and electronic motors. It is very
important that the hose is cut cleanly with a razor
The Tank level sensor:
Check there is ample room of the sensor arm to
swing before drilling. If stock washer tank is going
to be used, do not mount float near stock washer
pump. 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.
 Generic wiring diagram
Page 7
Aquamist
FLOW CONTROL MODULE
100
200
300
400
ml/m
HFS-6 os
a
Flow Control Module
FLOW
IGNITION SW. (INJECTOR +)
FUEL INJECTOR (-)
MAP SENSOR (0-5V)
W. I NJE CT ION
WAT ER LEVEL
IN OUT
SC
WL
WH
OPTIONAL
WASTEGATE
BY-PASS
VALVE
WATER PUMP IN TRUNK
E
FUTURE
PRODUCT
INTERFACE
PORT
SWITCHED
1
2V
+
HEAD
LAMP
SWITCH
40A
RELAY
DDP5800
THIS PUMP IS FACTORY SET TO 160PS. DO NOT
ATTEMPT TO INCREASE THE BY-PASS VALVE
PRESSURE OR THE LIFE EXPECTANCYWILLBE
GREATLY REDUCED. IT IS NOT RECOMMENDED
TO RUN BEYOND 50% METHANOL BECAUSE OF
FLAMMABILITY AND VAPOUR INHALATION CAN
BE HAZARDOUS TO YOUR HEALTH.
POWER
INPUT
BATTERY+
DASH
GAUGE
ENGINE
BAY
TO
ECU
TRUNK
AREA
USER
PORT
160 PSI BYPASS PUMP
MADE IN USA
BY
AQUATEC
WATER TANK
IN TRUNK
K1C12H
COIL 12VDC
3A 30VDC/125VAC
K1C12H
COIL 12VDC
3A 30VDC/125VAC
5A FUSE
47OHM 7W
9716
785
PUSH-FIT ELBOW FITTING
ALL METAL COMPRESSION FITTING
Choosing jet sizes
Page 8
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 160psi. For example, if you are
boosting 25psi, you should select the jet flow at
135 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.
Pressure vs Flow
600
550
500
1.0mm
450
0.9mm
400
0.8mm
350
0.7mm
300
0.6mm
250
0.5mm
JET
60 70 80 90 100 110 120 130 140 150 160 170 PSI
200
0.3
108 116 124 132 139 146 152 158 164 170 176 181
0.4mm
0.4
144 155 166 176 185 194 203 211 219 227 234 242
0.5
194 207 220 232 243 254 264 274 284 293 302 179
150
0.3mm
0.6
215 233 249 264 278 292 305 317 329 340 352 362
0.7
251 271 290 308 324 340 355 370 384 397 410 423
100
0.8
287 310 332 352 371 389 406 423 439 454 469 483
60
70
80
90
100
110
120
130
140
150
160
170
0.9
323 349 373 396 417 437 457 475 493 511 527 544
Pressure (psi)
1.0
359 388 414 440 463 486 508 528 548 567 586 604
 Page 9
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 well ventilated and isolated
from the driver’s compartment. Take whatever measures
to avoid any methanol fumes building up in trunk area.
Methanol is highly flammable. The main delivery hose to
the engine bay should be routed underneath the car. En-
sure it is securely clipped and fastened. Avoid kinks, close
proximity 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.
Warning: Prolonged use of 100% methanol may cause
premature pump failure and may not be covered under
warranty.
The HFS-6 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 (1/8 NPT). The
tapping hole should be 11/32“ or 8.8mm. Do
not over tap. Clean the mating part with alco-
hol first, Trial fit before loctiting into position.
Three restrictors are supplied for duty cycle/
flow matching should good linearity be re-
quired. For flow greater than 1100cc/min you
can omit it. It should be fitted inside the inlet
port fitting of the Flow Control Module (FCM).
FLOW
Remove the inlet fitting first from the FCM.
Use the threaded insertion tool to push the
restrictor in position, Apply a smear of grease
to avoid damaging the o-ring.
0.5mm restrictor .................... 0 - 380cc/min
0.7mm restrictor .................... 0 - 680cc/min
0.9mm restrictor .................. 0 - 1080cc/min
HFS-6 function directory
Page 10
1
2
3
4
5
6
POWER
INPUT
DASH
GAUGE
ENGINE
BAY
TO
ECU
T
RUNK
AREA
USER
PORT
K1C12H
COIL 12VDC
3A 30VDC/125VAC
K1C12H
COIL 12VDC
3A 30VDC/125VAC
10
5
A FUSE
47OHM 7W
8
7
9716785
9
1. DASH GAUGE (P.15)
2. 12V, HEAD LIGHT SWITCH and GROUND (P.7)
3. FLOW CONTROL MODULE in ENGINE BAY (P.7)
4. ENGINE MANAGEMENT and FAIL-SAFE (P.18)
5. WATER TANK and PUMP in TRUNK AREA (P.7)
6. FUTURE PRODUCT INTERFACE (P.7)
7. DUMMY LOAD RESISTOR for ANTI-CEL (P.18)
8. SYSTEM CONFIGURATION BY USER (P.13-14)
9. FLOW and FAILSAFE POTENTIOMETERS (P13-14)
10. 5A 20mm x 5mm FUSE LINK
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