AEM Water Methanol Failsafe Device 303020M User Manual
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Page 11 DATA LOGGER The Water/Methanol Failsafe has an internal logger that can store approximately 2.5 minutes of injection data. The logger maintains two levels of data logs. First, all flow data points are stored and downloadable for viewing on the Flow vs. Injection Graph in the Water/Methanol Failsafe Configuration tab. Second, all injection events, inputs, outputs, and alarm triggers are logged in special log file format for viewing with the AEMdata software that comes as part of the Water/Methanol Failsafe download package. Once the logger memory has filled up, the logger will begin to loop log and the oldest data will be discarded as new data is collected. Logging will start when Injection Percentage is more than 5% and stop when Injection Percentage is less than 5%. Each individual injection event is indicated by a marker. The following is a basic guideline on how to use the internal data logger. 1. Connect USB cable to PC. In the W ater/Methanol Failsafe Configuration tab under Logger, click Download Log. All logged flow data points will now be displayed in the Flow vs. Injection Graph. 2. To download the log to the PC click Yes when prompted to save data to disc and then save log in desired location. 3. Click Yes when prompted to open file in AEMdata. 4. The saved data log is now shown in a special log viewing template that is pre-loaded into AEMdata. The data log will now open and be displayed in three separate plots as described on page 12.
Page 12 Plot One Parameter Description Flow Measured flow rate in cc/min Lower Flow Limit Lower flow limit value as related to Injection Percentage Upper Flow Limit Upper flow limit value as related to Injection Percentage Plot Two Parameter Description Alarm Source Indicates what triggered the alarm condition; 1-low flow condition, 2-high flow condition, 3-auxiliary input, 4-alarm test Alarm Status Indicates state of alarm; 1-alarm triggered, 0-alarm not triggered Alarm Reset Counter Counts up from zero to Alarm Reset value once flow has returned into the acceptable range Alarm Delay Counter Counts up from zero to Alarm Delay value when flow occurs outside the high or low flow limits; once full Alarm Delay value is reach the alarm will trigger; counter will reset back to zero if flow returns back into the acceptable range once count up has began Plot Three Parameter Description INJ Injection percentage value Alarm Reset Limit Alarm Reset value Alarm Delay Limit Alarm Delay value Calibration Changed Indicates that a configuration setting has changed
Page 13 OUTPUT CONFIGURATION The Water/Methanol Failsafe has two outputs that are triggered when an alarm condition exists; one +12 volt (high side) output and one ground (low side) output. These outputs can be used in a multitude of ways to reduce boost, pull timing, or otherwise protect an engine in the event there is a problem with the water/methanol injection system. The following is an index of possible auxiliary devices that can be triggered by the alarm outputs: AEM EMS Function Description Nitrous Fuel & Ignition Maps Use the ground output to trigger the nitrous fuel and ignition maps; ignition timing can be reduced and fuel can be added Boost Switch Use the ground output to trigger the boost switch; a lower boost value can be targeted Two-Step Use the ground output to trigger the two-step; a lower engine rev limit can be selected MSD Ignition Products Product Description DIS2 (62112) Brown wire: apply +12V to trigger ignition interrupt Blue wire: apply +12V to trigger two step Pink wire: apply +12V to trigger timing retard DIS4 (62152) Brown wire: apply +12V to trigger ignition interrupt Blue wire: apply +12V to trigger two step Pink wire: apply +12V to trigger timing retard 6AL-2 (6421) Blue wire: apply +12V to trigger two step Programmable 6AL-2 (6530) Dark blue wire: apply +12V to trigger launch rev limit, overrides all others Light blue wire: apply +12V to trigger burn out rev limit Pink wire: apply +12V to trigger timing retard Digital 6 Plus (6520) Blue wire: apply +12V to trigger two step Pink wire: apply +12V to trigger timing retard Start/Retard Control (8982) Violet wire: apply +12V to trigger timing retard Timing Controller (8980) Grey wire: remove ground input to trigger timing retard
Page 14 NC/NO Relay The following are examples of how a NC/NO relay (Bosch PN 0-332-019-203 or similar) can be configured for use with the Water/Methanol Failsafe. Signal Interrupt − The high side (12 volt) output from the W ater/Methanol Failsafe can be used to turn on a NC (normally closed) relay and interrupt the output signal from a boost controller to its boost control solenoid – see Figure 1. Conversely, the low side (ground) output can also be used to trigger the relay − see Figure 2. Auxiliary Device − The high side (12 volt) output from the Water/Methanol Failsafe can be used to turn on a NO (normally open) relay and activate or deactivate an auxiliary device that can be used to reduce timing or boost or control some other function when the current requirement is greater than 1.5 amps – see Figure 3. Conversely, the low side (ground) output can also be use to trigger the relay − see Figure 4. Figure 4 Figure 1 Figure 2 Figure 1 Figure 3 Figure 3
Page 15 Warning Light The Water/Methanol Failsafe can also be used to directly activate a warning light (Autometer PN 3239 or similar). Connect the warning light black wire to ground and power the light with the high side output – see Figure 5. Alternatively, the low side output can also be used to turn the light on if the white wire is connected to +12V – see Figure 6. WATER/METHANOL FAILSAFE GAUGE The Water/Methanol Failsafe gauge comes with the black bezel installed however, a silver bezel is also included. To change the bezel, orient the gauge so you are looking at the faceplate. Rotate the bezel counter-clockwise to unscrew it from the gauge cup. The bezel, lens, and rubber spacer are all removable. Reassemble the gauge as shown below in Figure 7. Note: W hen reassembling the gauge, it may be necessary to apply a light amount of pressure on the lens and spacer to keep the faceplate from rotating when reinstalling the bezel. Do not over tighten the bezel when reassembling the gauge. Figure 7. Changing Bezels BEZEL LENS RUBBER SPACER Figure 5 Figure 6
Page 16 Status Lights The Water/Methanol Failsafe gauge has two status lights (see below) that indicate when an alarm has been triggered. The left status light will turn on if there is a low flow alarm. The right status light will turn on if there is a high flow alarm. Both status lights will turn on if the auxiliary input is triggered. Analog Output The analog output from the Water/Methanol Failsafe is a linear dc voltage signal that varies with flow. The signal is used for sending information to a data logger or an engine management system like the AEM EMS or F/IC. The output range is automatically scaled when either the 500 cc/min or 1000 cc/min flow range is selected in the Gauge Configuration tab. The transfer functions for the analog output of each flow range are listed below in cc/min and gal/hr. 500 cc/min Specifications: Minimum Voltage/Flow: 0.5Vdc at 0 cc/min Maximum Voltage/Flow: 4.5Vdc at 500 cc/min Transfer Function cc/min: Flow (cc/min) = (125 * Voltage) – 62.5 Example: Output voltage of 2.5Vdc = 250 cc/min (125 * 2.5) – 62.5 = 250 cc/min Transfer Function gal/hr: Flow (gal/hr) = (1.98 * Voltage) – 0.99 Example: Output Voltage of 2.5Vdc = 3.96 gal/hr (1.98 * 2.5) – 0.99 = 3.96 gal/hr A list of output voltages and corresponding flow rates is shown on Page 17 - Table 1. 1000 cc/min Specifications: Minimum Voltage/Flow: 0.5Vdc at 0 cc/min Maximum Voltage/Flow: 4.5Vdc at 1000 cc/min Transfer Function cc/min: Flow (cc/min) = (250 * (Voltage)) – 125 Example: Output voltage of 2.5Vdc = 500 cc/min (250 * 2.5) – 125 = 500 cc/min Transfer Function gal/hr: Flow (gal/hr) = (3.96 * (Voltage)) – 1.98 Example: Output Voltage of 2.5Vdc = 7.93 gal/hr (3.96 * 2.5) – 1.98 = 7.93 gal/hr A list of output voltages and corresponding flow rates is shown on Page 17 - Table 2. Illuminated Status Lights Left Status Light Right Status Light
Page 17 Connector Pinouts The pinouts for the 3-pin sensor harness, 4 pin I/O harness, 8-pin power harness, and 5 pin USB harness are provided below. Voltage cc/min gal/hr 0.50 0 0.00 0.75 31 0.50 1.00 63 0.99 1.25 94 1.49 1.50 125 1.98 1.75 156 2.48 2.00 188 2.97 2.25 219 3.47 2.50 250 3.96 2.75 281 4.46 3.00 313 4.95 3.25 344 5.45 3.50 375 5.94 3.75 406 6.44 4.00 438 6.93 4.25 469 7.43 4.50 500 7.93 Voltage cc/min gal/hr 0.50 0 0.00 0.75 63 0.99 1.00 125 1.98 1.25 188 2.97 1.50 250 3.96 1.75 313 4.95 2.00 375 5.94 2.25 438 6.93 2.50 500 7.93 2.75 563 8.92 3.00 625 9.91 3.25 688 10.90 3.50 750 11.89 3.75 813 12.88 4.00 875 13.87 4.25 938 14.86 4.50 1000 15.85 Harness Pinouts Table 1 – Analog Voltages 500 cc/min Table 2 – Analog Voltages 1000 cc/min
Page 18 12 Month Limited Warranty Advanced Engine Management, Inc. warrants to the consumer that all AEM High Performance products will be free from defects in material and workmanship for a period of twelve (12) months from date of the original purchase. Products that fail within this 12 month warranty period will be repaired or replaced at AEM’s option, when determined by AEM that the product failed due to defects in material or workmanship. This warranty is limited to the repair or replacement of the AEM part. In no event shall this warranty exceed the original purchase price of the AEM part nor shall AEM be responsible for special, incidental or consequential damages or cost incurred due to the failure of this product. Warranty claims to AEM must be transportation prepaid and accompanied with dated proof of purchase. This warranty applies only to the original purchaser of product and is non-transferable. All implied warranties shall be limited in duration to the said 12 month warranty period. Improper use or installation, accident, abuse, unauthorized repairs or alterations voids this warranty. An AEM Warranty Claim Form Must Accompany All Warranty Claims. Products returned to AEM with no Return Goods Authorization and or No Warranty Claim Form may be rejected and returned to sender. AEM disclaims any liability for consequential damages due to breach of any written or implied warranty on all products manufactured by AEM. Warranty returns will only be accepted be AEM when accompanied by a valid Return Goods Authorization (RGA) number. Credit for defective products will be issued pending inspection. Product must be received by AEM within 30 days of the date RGA was issued. Please note that before we can issue an RGA for any product, it is first necessary for the installer or end user to contact our EMS tech line at (800) 423-0046 to discuss the problem. Most issues can be solved over the phone. Under no circumstances should a product be returned or RGA requested before the above process transpires. AN AEM WARRANTY CLAIM FORM MUST ACCOMPANY ALL ELECTRONICS WARRANTY CLAIMS. AEM ELECTRONIC Products returned to AEM with no RGA and or No Warranty Claim Form may be rejected and returned to sender. A copy of the AEM Warranty Claim Form can be e-mailed or faxed by contacting (310) 484-2322 and ask for Warranty/Claims Department. Need additional help? Contact the AEM Performance Electronics tech department at 1-800-423-0046 or [email protected], or visit the AEM Performance Electronics forum at http://forum.aempower.com/forum/