HFS3v2w1

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Page 1
F-IDC tracking water injection system
pwm
User manual -v2
Page 2
Getting to know the Aquamist HFS3v2-pwm system
Aquamist has been pioneering the IDC based water injection system since 2003 with great
success. The HFS3-pwm system is designed to complete the Aquamist’s PWM-valve
delivery system line-up, it allows precise metering of water/methanol injection for the
modern high performance engine. The dash gauge, flow sensor and “Plug and Play”
features are standard to minimise installation time.
The system retrieves the fuel flow (IDC) and manifold pressure signals (MPS) from the
engine management system as the prime source to control the flow of water. This enables
perfect balance of water to fuel flow under all engine loads. The system can also be
controlled by a third-party ECU with its own custom water/methanol flow map.
A “Fast Acting Valve” (FAV) controls the delivery rate based on the PWM signal from the
HFS-3 controller. A constant line pressure (160 psi) is provided by the Aquatec pump
working in the “by-pass” mode. A PWM valve system guarantees wide dynamic range.
There is a non-gauge/flow sensor option (HFS-2) for non-critical application where a
failsafe is not needed. A dash switch is provided instead. The user can disable the
system and reduce the manifold pressure to wastegate pressure if needed
.
 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 for HFS-3
8-9
Choosing jet sizes
System testing
10
HFS-3 function directory
11-12
Quick Start & manual testing
Gauge
13
Flow management and other trimmers
14
Preparation for test run of the system
Dash gauge
15-16
Dash Gauge functions
Fail-safe
17-19
Setting up the fail-safe
Advanced
20-21
Supplementary information on HFS-2
Appendix
22-23
Dimensions, Guarantee and Warranty
Page 4
Checking the contents of the box carefully
This is a “must do” immediately
after unpacking ....
♦
1x water tank adapter 1/8 BSP (806-270), 6mm
compression fitting and in-tank filter (806-258)
♦
4x M5x40mm bolt, washers and fasteners for pump
♦
1x M6 grounding stud with washer and nuts and
6mm eyelet for pump ground.
♦
2x 6mm to 1/8 BSP compression fitting for pump..
♦
2x 3/8BSP-M to 1/8BSP-F reducer for pump.
♦
1x 4mm to 1/8 BSP compression fitting for FAV.
♦
1x 6mm to 1/8 BSP compression fitting for FAV.
♦
Water pump harness. 6M of #12 AWG cable and
6M of multi-core cable with blue harness.
♦
1x Fast acting valve with red harness
♦
1x turbine flow sensor with yellow harness
♦
1x water level switch with connector (806-281c)
♦
1x DDS3v10 Gauge with 2M x 8-way grey cable
(HFS-3 only)
♦
1x Dash button with 6-way cable (HFS-2 only)
♦
1.5 M of multi-core with grey capped RJ48 for
. ECU interface, fail-safe and map switching.
♦
Molex type 4-way power in harness
♦
User manual
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)
♦
HFS-3 Flow Control Module
♦
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 (806-361) in plastic bag
♦
2x M8 x 1/8 NPT jet adapter with plug (806-
357N)
♦
A set of three restrictors with insertion tool
Note: Please contact your supplier immediately should you discover any missing parts.
 Getting started on installation
Page 5
Before installation guidelines
♦
The pump and water tank are designed to be
fitted in the trunk. Install the water pump below
the water tank if possible.
♦
Ensure all fittings are tightened and leak proof
before filling up with methanol,
test it with water
first
and tighten the M16 plastic nut. Stop the assem-
bly 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 for the water level sensor.
IF using a washer tank for supply, do not locate
the Aquamist float sensor near the stock washer
pump. The float arm 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.
. 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 seated between the fitting
and the I/O port. Do not over-tighten.
TO CONTROLLER
(BLUE HARNESS)
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 thor-
oughly. No debris or plastic shavings should re-
main in the delivery system. 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
DDP5800
40A
RELAY
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.
160 PSI BYPASS PUMP
MADE IN USA
BY
AQUATEC
WATER TANK
IN TRUNK
BATTERY+
Installation for long-term reliability
Page 6
This is the most important section of the HFS-2/3
chapter. Please do not skip reading this part.
52mm Dash Gauge (HFS-3 only):
Location is not too critical as long as it is in view of
the driver. There aren’t too many pitfalls on this.
Dash switch (HFS-2 only):
A 16mm or 5/8“ hole on a flat panel is required for
the installation of this switch.
HFS-2/3 controller box:
Please locate the box in a dry location in the passen-
ger compartment. The glove box is a good place.
Please allow plenty of slack to ease accessibility
during tuning and diagnostic work.
Fast acting valve and flow sensor assembly (FAV):
The location of this module is most critical to overall
system reliability. It is designed to be installed in the
engine compartment.
This module must be installed in a cool, dry and well
ventilated area 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. It is very important that the hose is
cut cleanly with a razor blade to retain the “round-
ness”. The use of side cutters produces a semi-
round hose end, resulting in a major leak sooner or
later. It is also vital that the hose must be cut perpen-
dicular/square relative to its length. This is because
the compression fitting has a short hosetail. An accu-
rate cut will allow maximum grip on the walls of the
hose.
Ensure the thin rubber gasket is placed between the
FAV coil and electrical plug (red harness) before
tightening. Press the clip of the yellow harness into
the centre section of the flow sensor body, Orienta-
tion 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 condensed water trickling into the clip and
plug.
The tank level sensor:
Drill/bore the same hole size for the water level
sensor. A 23mm burr-free hole must be used to
ensure a good seal. The float arm should swing
upwards. Check that there is ample room for the
sensor arm to swing before drilling. A tall and slim
water tank is ideal for this type of
application. This
minimises delivery surge problems at low water
level
s.
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
 Generic wiring diagram for HFS-3
Page 7
FUEL INJECTOR(+) or
IGN. SW+ (pre-crank)
Aquamist
FAST ACTING VALVE
AND TURBINE FLOW
SENSOR ASSEMBLY
100
200
300
400
ml/m
FLOW
DI-injection (contact office)
FUEL
INJECTOR(-)
W. INJECTION
MAP SENSOR (optional)
WATER LEVEL
SC
WL
WH
FAV & FLOW SENSOR
(ENGINE BAY)
FAST
ACTING
VALVE
FLOW
806-239
E
+
12V
GND
PUMP RELAY & LEVEL SENSOR (TRUNK)
HEAD
LAMP
SWITCH
POWER
DDP5800
40A
RELAY
TRUNK
GAUGE
FAV
WFS
ECU
USER
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.
160 PSI BYPASS PUMP
MADE IN USA
BY
AQUATEC
K1C1
2H
COIL 12VDC
3A 30VDC/125VAC
K1C12H
COIL 12VDC
3A 30VDC/125VAC
5A FUSE
47OHM
7
W
WATER TANK
IN TRUNK
BATTERY+
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 larger 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
Pre ssure (psi)
1.0
359 388 414 440 463 486 508 528 548 567 586 604
Page 9
The HFS-2/3 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 alco-
hol first, trial fit before loctiting into position.
Three restrictors are supplied for duty cycle/
flow matching should good linearity be re-
quired.
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 flammabl
FLOW
e. 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.
RESTRICTOR
For flow grater than 1100cc/min you can omit
it. I should be fitted in the hose side of 6mm
fitting of the FAV assembly.
Undo the in compression fitting from the FAV
inlet port. 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
Page 10
HFS-3 function directory
POWER
GAUGE
FAV
WFS
ECU
TRUNK
USER
K1C1
2H
COIL 12VDC
3A 30VDC/125VAC
K1C12H
COIL 12VDC
3A 30VDC/125VAC
5A FUSE
47OHM
7
W
1. DASH GAUGE (P.15)
2. 12V, HEAD LIGHT SWITCH and GROUND (P.11)
3. FAST ACTING VALVE in ENGINE BAY (P.6)
4. WATER FLOW SENSOR (FAV CLUSTER) (P.6)
5. ECU INTERFACE AND FAILSAFE (P.11/18)
6. WATER TANK and PUMP in TRUNK AREA (P.5)
7. FUTURE SYSTEM EXPANSION PORT
8. SYSTEM CONFIGURATION BY USER (P.12)
9. FLOW & SYSTEM MANAGEMENT TRIMMERS (P.13)
10. 5A 20mm x 5mm FUSE LINK
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