AEM Water Methanol Failsafe Device 303020M User Manual

							AEM Performance Electronics 2205 126th Street Unit A, Hawthorne, CA. 90250 Phone: (310) 484-2322 Fax: (310) 484-0152 http://www.aemelectronics.com Instruction Part Number: 10-3020 Rev 02  2011 AEM Performance Electronics 
 
 
 
 
 
Installation Instructions for P/N 30-3020M 
 
Water/Methanol Failsafe 
For Use With 4mm Injection Tubing 
(Injection Monitor) 
 
WATER/METHANOL FAILSAFE PARTS LIST 
 
 
 
 
 
 
 
 
 
This product is legal in California for racing vehicles only and should never be used on public 
highways. 
WARNING: 
! 
Completely read this instruction manual before attempting to install or use this 
product!  This installation is not for the electrically or mechanically challenged! 
Use this system with EXTREME caution! Misuse of this system can damage your 
engine!  
 
If you are uncomfortable with anything about this, please refer the installation to 
an AEM trained tuning shop or call 800-423-0046 for technical assistance. You 
should also visit the AEM Performance Electronics Forum at 
http://www.aemelectronics.com. 
 
NOTE: AEM holds no responsibility for any engine damage that results from the 
misuse of this product! 
Qty P/N Description Qty P/N Description 
1 35-3020 W/M Failsafe Gauge 2 35-4527 Fitting, ¼ NPTF to ¼ Tube 
1 35-2128 Flow Sensor with Fittings 1 35-8553W Faceplate 1000 White 
1 35-3411 8-Pin Power Harness 1 35-8529S Silver Bezel 
1 35-3418 4-Pin I/O Harness 1 35-4302 Install Kit (6 Butt Connectors) 
1 35-3415 3-Pin Sensor Harness 1 35-8441 Rubber Band  
1 35-3010 USB Cable 1 10-3020M Inj Mon Instructions 
1 35-8552W Faceplate 500 White 1   Faceplate Config Instructions 
1 35-8552B Faceplate 500 Black 1   Needle Removal Tool 
       
						

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INSTALLATION DIAGRAM 
 
OVERVIEW 
 
Water/methanol injection is used to lower air charge temps and reduce detonation which allows for aggressive tuning to 
be utilized while using a low octane base fuel.  When relying heavily on water/methanol injection a safety device is 
strongly recommended in order to prevent detonation and possible engine damage in the event of a leak or clog.  
Progressive injection systems have a dynamic flow output and monitoring both the injection flow rate and the injection 
percentage means a high level of engine protection can be achieved.  
 
The AEM W ater/Methanol Failsafe is an advanced safety device that allows the end user to closely monitor the 
performance of their water/methanol injection system.  Water/Methanol Failsafe collects flow versus injection percentage 
data points and plots them in a graph to create an injection flow curve using PC configuration software.  “Injection 
percentage” is a calculated value that is indicative of injection pump or injection valve duty cycle and is based on a scale 
of 0-100 percent. 
 
Once a baseline flow curve is established, the end user can then assign high and low flow threshold lines that can be 
contoured to closely follow the baseline flow curve.  If injection data points occur outside of the high and low flow 
threshold lines, an alarm condition will be triggered.  Injection data points that occur in the area between the high and low 
flow threshold lines are considered acceptable and an alarm condition will not be triggered.   
 
Once an alarm condition is triggered, two outputs will activate along with a visual alarm alert.  The W ater/Methanol 
Failsafe has one high side or +12 volt output and one low side or ground output.  Both outputs can be configured to turn 
on or off when an alarm condition is triggered.  These outputs can be used to turn off a boost controller, retard ignition 
timing, switch fuel and timing maps, activate a warning light or buzzer, or deactivate another external system (nitrous, 
etc.).  The gauge backlighting and needle can also be set to flash to notify the vehicle operator of an alarm condition.   
  
						

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The Water/Methanol Failsafe also has an auxiliary input that can be used to trigger an alarm condition.  Users with the 
AEM W ater/Methanol Injection System (PN 30-3000 & 30-3001) can use the “Boost Safe” ground output to trigger the 
auxiliary input if any of the internal fault conditions are detected by the AEM progressive controller.  
 
NOTE: It is HIGHLY recommended that the Water/Methanol Failsafe be used in conjunction with the AEM 
Water/Methanol Injection Filter (AEM part# 30-3003).  Using a filter will maximize the performance and longevity 
of your flow sensor as well as your entire injection system.   
 
INSTALLATION 
 
1. Disconnect the negative battery cable. 
2. Temporarily install gauge without bracket into desired mounting location.  Gauge mounts into a 2 1/16” (52MM) hole.  
The supplied rubber band can be used as a spacer around the gauge if it fits loosely in mounting hole. 
3. Splice into injection line and install flow sensor as close as practically possible to final injection point.  Flow sensor can 
be installed before or after check valves or flow control solenoids.  A filter is highly recommended and should be 
installed ahead of the sensor.  Ensure arrow on flow sensor points in the direction of flow.  Avoid exposing flow sensor 
to high heat sources (exhaust, turbo, etc.).  Route flow sensor cable to gauge mounting location. 
4. Install USB cable so the PC end of the cable is easily accessible and route the gauge end of cable to the gauge 
mounting location.  USB cable is meant to be permanently installed to gauge and left in vehicle.  Stow PC end of 
cable in location such as glove box or center console, etc. 
5. Install the 4 & 8 pin harnesses and connect wires as described below: 
 
8 Pin Power Harness 
Color Label Description 
Red PWR Constant power; connect to a fused constant +12V power source  
Black GND Ground; connect to good chassis ground or directly to battery negative (−) terminal 
Pink IGN PWR Ignition power; connect to a fused key on +12V power source  
Grey LIGHT Gauge backlighting; connect to instrument lighting dimmer wire 
White ANALOG + *OPTIONAL* 0-5V analog output for flow; connect white wire to + analog input and brown 
wire to − analog input of data logger or EMS; see note below Brown ANALOG − 
 
4 Pin Input & Output Harness 
Color Label Description 
Yellow HI SIDE +12V output; connect to an external auxiliary device (1.5A max current) 
Blue LOW SIDE Ground output; connect to an external auxiliary device (1.5A max current) 
Green AUX 
*OPTIONAL* Auxiliary alarm input; if using AEM W ater/Methanol Injection System, connect 
to the green wire of progressive controller (Boost Safe output); other injection systems may 
connect to optional ground switch (fluid level, etc.) input  
Orange INJ PER 
Injection percentage input; if using AEM Water/Methanol Injection System, tap orange wire 
of progressive controller; all others tap wire that connects from progressive controller to 
pump 
 
6. NOTE: The analog output is a differential output so the brown wire should be connected to an analog ground input for 
best results.  If the EMS, logger or similar device does not have an analog ground input, the brown wire should be 
connected to a sensor ground.  If no sensor ground is available, the brown wire should be connected to a power 
ground.  The brown wire must be connected in order to obtain correct flow readings from the analog output. 
7. Connect all cables and wiring harnesses to gauge.  Fully install gauge into hole using mounting bracket and nuts. 
 
PC SOFTWARE 
 
Download and install the Water/Methanol Failsafe configuration software from the AEM Performance Electronics forum at 
http://forum.aempower.com/forum/.  Open the configuration software and connect the USB cable to the PC.  If permanent 
power is present the W ater/Methanol Failsafe will turn on with ignition key-on power.  Alternatively, the W ater/Methanol 
Failsafe can be bench-programmed outside of the vehicle without powering it by connecting just the USB cable, however, 
the backlighting, needle and warning lights will not activate.   
  
						

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Water/Methanol Failsafe Configuration Tab 
 
This is the section where the flow monitoring and alarm output functionality of the Water/Methanol Failsafe is configured.   
 
 
 
 
Flow vs. Injection Graph 
Description 
Displays flow vs. injection percentage data points. Flow points will be populated live whenever the PC is connected to the 
Water/Methanol Failsafe and injection is occurring. The current injection percentage and flow rate values are shown live 
on the right side of the graph.  This is also where the high and low flow limit lines are established. 
Graph 
Button Description 
Auto Scale Scales the graph down to best resolution; the graph automatically scales up in the event flow 
data is collected beyond the highest shown flow value    
Auto Set Limits  Automatically sets the upper and lower flow limit lines based on an average of the collected flow 
data points   
Reset Limits Resets the upper flow limit line to max and the lower flow limit line to zero 
Clear Graph  Clears all the displayed flow data points from the graph; does not clear stored flow data from 
logger  
Logger 
Button Description 
Download Log Downloads all the collected flow data that is stored in the logger; will prompt to save log to disk; 
log files saved as .daq for direct viewing in AEMdata program    
Clear Log  Clears all stored flow data from the logger    
						

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Alarm Configuration 
Option Description 
Aux Input Status Shows the status of the auxiliary alarm input; on or off   
Alarm Delay  Period of time that measured flow can be outside the upper and low flow limit lines before an 
alarm condition is triggered; 100-1000 milliseconds 
Alarm Reset Period of time flow must be within the acceptable range before the alarm will automatically reset; 
1-10 seconds 
Disable Auto Reset Select to require power cycle to reset alarm; overrides the automatic alarm reset period.  NOTE: 
this option is only applicable to software version 1.3.0.0 
12V Output  Select to turn the 12V output on when an alarm is triggered or to turn the 12V output off when an 
alarm is triggered; 1.5 amps max 
GND Output  Select to turn the ground output on when an alarm is triggered or to turn the ground output off 
when an alarm is triggered; 1.5 amps max 
Alarm Status 
Parameter Description 
Status Indicator Color indicates status; green is system ready, red is alarm triggered 
Source Indicates the source of the alarm condition; possible alarm conditions are high flow, low flow, 
auxiliary input, and alarm test 
Alarm Flow Flow rate when alarm was triggered; cc/min 
Alarm INJ Injection percentage when alarm was triggered 
Option Description 
Alarm Test Simulates an alarm to test output configuration; test duration set by Alarm Delay value  
						

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Gauge Configuration Tab 
 
This is the section where the gauge backlighting is configured. 
 
 
 
 
 
 
 
 
Live Gauge View 
Backlighting Color 
Option Description 
Color Scale Adjustable RGB color levels; use to match gauge backlighting to OEM gauge backlighting color 
Needle Intensity Adjustable intensity level; use to select desired needle brightness 
AEM Presets Preset backlighting colors to match existing AEM analog gauges; seven color options are red, 
white, violet, teal, green, blue and orange 
Alarm Flash 
Option Description 
Flash Select visual output to occur when alarm is triggered; can flash gauge backlight only, flash 
needle only, flash both backlight and needle alternately, or do nothing 
Flash Speed Select speed of flashing while alarm is triggered; flash slow or fast 
Flow Range & Dimmer Max Brightness 
Option Description 
Flow Range Select 500 or 1000 cc/min; gauge face plate must match flow range selection - see additional 
instructions for face plate removal information 
Dimmer Max 
Brightness Select whether +12V or ground indicates maximum backlighting brightness  
						

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The Water/Methanol Failsafe PC software has a live gauge display.  Injection Percentage is shown on the left from 0-
100% and flow, in cc/min, is shown on the right.  The flow range shown in the live gauge will match the flow range 
selected in the Gauge Configuration tab.  Faceplate color can be black or white.   
 
  
						

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WATER/METHANOL FAILSAFE CONFIGURATION 
 
The following is a basic guideline strategy for configuring the Water/Methanol Failsafe for the first time.  The ideal time to 
configure the Water/Methanol Failsafe is while the vehicle is being dyno tuned for water/methanol injection.  Ensure your 
injection system is fully functional with no leaks or clogs or other issues before starting to configure the 
Water/Methanol Failsafe!    
 
1. In the W ater/Methanol Failsafe Configuration tab, click on Clear Graph and Reset Limits to zero out all settings.   
2. Complete a series of long sweeping high load 3rd and 4th gear pulls going from zero to full injection each time to 
populate the graph with flow data.  Avoid making quick hard pulls as this may skew the flow data points. Repeat this 
procedure until a baseline flow curve is established.  Alternatively, if using the AEM W ater/Methanol Injection System, 
simply press and hold the test button on the progressive controller a number of times while the injection nozzle is 
removed from the intake and pointed into a container. 
 
 
 
 
 
NOTE: You may notice that a few random flow data points are plotted well outside of the normal flow curve when the 
system goes from being commanded full on to full off very quickly.  This occurs when the signal driving the pump is shut 
off and returns to 0% injection very quickly while there is still a slight amount of measureable flow.  The electrical signal 
driving the pump can drop back to zero faster than the physical movement of the fluid flowing can be stopped.  This is 
normal behavior which should not create a false trigger and can be ignored in virtually all cases.    
 
 
 
Establishing baseline flow curve  
						

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3. With a baseline flow curve now established, click on Auto Set Limits and the software will produce its best suggested 
high and low flow limit lines based on the populated flow data shown on the graph. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
High and low flow limit lines are automatically 
generated after pressing Auto Set Limits  
						

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4. Review and adjust the high and low flow limit lines as needed to contour the lines around the baseline flow curve by 
clicking and dragging on a break point.  Once a break point is selected you can also move left and right using the 
arrow keys and then move the break point up or down.  Pressing the Tab key will toggle back and forth between the 
high and low limit lines.   
 
 
 
 
 
 
5. Test the configuration using your anticipated normal operating conditions with varying injection progression rates to 
account for starting, stopping, accelerating, high boost, low boost, tip in, fast shifts, slow shifts, etc. If false triggers 
occur either adjust the high or low flow curve up or down at the injection percentage where the alarm occurred or 
adjust the Alarm Delay setting. 
 
There are two general configuration strategies to follow when using the Water/Methanol Failsafe.  The high and low flow 
limit lines can be set very tightly to the baseline flow curve and a longer Alarm Delay can be used.  Conversely, the high 
and low flow limit lines can be set further way from the baseline flow curve and a shorter Alarm Delay can be used.  All 
injection systems are different and only thorough configuration testing will reveal which strategy is best for your 
application. 
 
Contouring the high and low flow limit lines to 
better fit the baseline flow curve