the complete Installation and tuning manual
Contents
1. 1 818 764 1901 1 818 764 0155 fax topend racetep com http www topendperformance com INSTALLATION INSTRUCTIONS WATER INJECTION SVSTEM 449 Shipping P N 30993 AN x LD GAIN as THRESHO lt 1 818 764 1901 CACI 1 818 764 0155 fax AUDE DENTS topend racetep com http www topendperformance com READ THIS FIRST Studv these instructions completelv before proceeding Engine damage mav occur if anv component within these instructions is improperly installed Turbonetics Inc or any of its distributors cannot be held responsible for damages as a result of negligent or improper installation This complete water injection system can be installed using common tools and automotive procedures but installer must have a thorough knowledge of automotive engine operation and feel comfortable working on the vehicle If in doubt contact Turbonetics technical support staff at 805 581 0333 between the hours of 8 00AM and 5 00PM PST Monday through Friday Remove the water injection system from its carton and inspect for any obvious physical damage All kit components are thoroughly inspected and carefully packaged prior to shipment from the factory If any shipping damage is evident contact your supplier and request that they process a claim with the shipper involved Be sure to review the parts list on page 3 to verify that you have all necessary system components to proceed If any components in the parts list are2. 100 The gain potentiometer can be set to arrive at any level at any boost The water injection system can be switched off via an ON OFF push button indicated by a green LED on the controller This latest Plug and Play water injection from Turbonetics sets a new standard for the growing water injection market currently shared by many new water injection manufacturers MAP SEN SOR Wy i si l Af WI JU i JM l Mi OUTPUT VOLTAGE OI D z 4 6 amp 10 12 Applications and Features OUTPLIT amp 14 16 Charge air cooling for force induction engines Minimizing the onset of detonation Suitable to run water and alcohol mixtures Plug and Play controller for ease of installation All components are properly engineered for reliable operation Intermittent diaphragm pump more reliable than the normal windshield washer pump Built in Thermal Cut in water pump Enable Meaner A Leaner air fuel ratio Increase octane rating on low grade pump fuel Dash controller allows real time user flow control with status LEDs Only three wires needed to be connected for total control Can be used with any 0 5V load sensors built in over voltage protection circuitry Inline 100 micron stainless steel filter Water tank optional 449 Shipping LEJK ER CARER TPRESSURE L 20 i id 26 28 30 ABSOLUTE PRESSURE bars
3. missing contact Turbonetics customer service staff The information contained in this publication was accurate and in effect at the time the publication was approved for printing and is subject to change without notice or liability Turbonetics reserves the right to revise the information presented herein or to discontinue the production of parts described at any time SAFETY REQUIREMENTS It is recommended to follow these precautions Always wear safety glasses amp gloves Turn the ignition switch to the OFF position amp disconnect the battery Always use properly rated jack stands when working under the vehicle Prevent unexpected vehicle movement by using wheel chocks and or parking brake Operate the vehicle only in well ventilated areas Do not smoke or use flammable items near or around the vehicle s fuel system Keep hands clothing and other objects away from moving parts when engine is running SUPPLIES It is recommended to have the following items before beginning installation Factory service manual for your model year vehicle A large table or bench and plenty of adjacent available workspace Standard selection of automotive tools primarily metric sizes An assortment of zip ties and or thin gauge steel wire The ability to securely lift the vehicle at least a few feet off the ground High temp automotive RTV sealant NPT thread sealant 60151 revA Page 2 of 6 1 818 764 1901 1 818 764 0155 fax topend rac
4. 1 bar sensor Is normally found on Naturally Aspirated Engines and the 2 3 bar type on Force Induction Engines The WIS is designed to work on all those A vertical line in the middle on the chart crosses three sensor response lines At the point of intersection it translates into three values For the 1 bar MAP sensor the WI turn on point is 4psi below the atmospheric and 2 3 bar sensors trigger at 2 and 11 psi respectively THRESHOLD 4 3 2 The GAIN DIAL EXPLAINED In an attempt to accommodate the vast operating range of input signals the WIS has a huge electronic input gain Taw adjustment stage It is basically shared between eight amplification settings A to GAIN The A line on the chart right is the least amplified It starts to increase the pump speed at 1psi ON threshold ramps the pump speed to 20 at Apsi If the dial in set to D the pump will reach 95 in the same 4psi signal Please note when the D line crosses the 85 duty cycle region the MAX led will be lit 60151 revA MANIFOLD PRESSURE RANGE PSI CO INTER TERSE WATER PUMP DUTY CYCLE j 0 1 818 764 1901 1 818 764 0155 fax topend racetep com http www topendperformance com THRESHOLD vs MAPS d bar 11 PSI START a l bar 2 PSI START a 4 PSI START xi 1 bar D 1 d 3 4 5 6 THRESHOLD SETTING NUMBER 1 8 The numbers along the bot
5. etep com http www topendperformance com EE EE Eeer if RACING INTERCOOLERSI INSTALLING THE WIS SVSTEM Select a area that is well ventilated to keep the pump cool and securelv mount the pump Connect the red wire to a switched positive power supply Connect the black wire to ground Connect the blue wire to any positive 5V signal source map sensor TPS etc Locate where you would like to install the nozzle and drill a XX hole Using the supplied 1 8 NPT coat the tap with grease and tap the hole Make sure to clean out any chips prior to re intalling the part or starting the engine 6 Connect one end of the supplied nylon water line from the water pump to the reservoir windshield washer reservoir etc Connect one end of the supplied nylon water line from the water pump to the supplied nozzle O APON f N THRESHOLD GAIN INJECT MAX POWER ON OFF 1 THRESHOLD ADJUSTMENT DIAL This dial determines the starting point of the water injection system it has eight indexed positions The actual point of injection is relative to the sensor used Most sensors such as MAP Manifold Absolute Pressure sensor MAF Mass Air Flow sensor etc has an output voltage of 0 5VDC The WIS require such a voltage input to start the Water spray More details on this later 2 GAIN ADJUSTMENT DIAL Once the injection point is determined we need to set the amount of quantity of liquid relative to the i
6. nput voltage from the sensors The GAIN dial does such that In order to make the setting relative simple the WIS provides two leds to indicate the START point and END point of the progressive spray range The GAIN dial has a wide gain range so only adjust it with very small increments 3 INJECT LED blue This LED shows the starting point of the water spray The brightness of the led will increase as the duty cycle of the water injection pump increases The WIS sends a PWM Pulse Width Modulated signal to control the speed of the water pump Higher pump speed creates more pressure so mass flow will increase relatively 4 MAX LED red When the pump speed is approaching 85 of the maximum power this led will come on and alert the user that the setting of the GAIN dial is near this ideal setting This feature makes the setting up of the WIS system very simple 4 POWER LED green This led indicates the WIS is switched on 5 ON OFF BUTTON Toggle press button switch for tuning the WIS off or on 60151 revA Page 3 of 6 The THRESHOLD DIAL EXPLAINED We have created a chart of the right to show the details of how the dial works with different types of sensors We have chosen to use a MAP sensor since it has many variations Since the WIS is designed to read any sensor with an output voltage of 0 5Volts There are basically three common variations to a MAP sensor 1 bar 2 bar and 3 bar The
7. tom of the chart is same as the numbers indexed on the THRESHOLD dial User can shift the vertical line from the left to the right to arrive at the desired water spray onset point by turning the THRESHOLD dial PUMP DUTY CYCLE vs BOOST m De H if D LT 0 5 1 0 1 5 2 0 25 3 0 45 MANIFOLD PRESSURE GAUGE 3 5 4 0 Page 4 of 6 Specifications Input voltage riens 10 15V Input current SE 50ma 100 duty CY CIE ue eegene 5A MAP sensor input range ss ennnenzannnnnzzznnzzni 0 5V Dash Controller PWM output DUD COLE niket 0 100 PWM frequency cccccceseeeeseeeeeeeeeeees 100Hz PWM Pump PWM input range ss enennnnnzznnnn 0 100 Max Pressure ss eesenenzzennnzenntinzenti 6 bar Max How 310cc min 6 bar Max How litre min 3bar Input port mm OD hose barb Output port 4mm OD hose barb Atomizing Water jet ii il imm WEN E Nickel over Brass Thread re M8 x 0 75mm Filter Disc type 100 micron Stainless 60151 revA EE EE een j ACING INT RCOOLERS 7 Micro Water Injection svstem 1 818 764 1901 1 818 764 0155 fax topend racetep com http www topendperformance com THRESHCED MAP GAIN eee0 Page 5 of 6 RACING TN TERCOOLER S 8 1 818 764 1901 1 818 764 0155 fax topend racetep com http www topendperformance com WIS Water Alcohol Injection System Full user con
8. trol over the entire operating range of a 1 2 3 bar MAP Sensor Descriptions The system is comprised of a dash mounted controller and a high pressure diaphragm pump designed to receive a Pulse Width Modulation PWM signal from the controller The pump can be used with a high concentration of alcohol 75 as well as just water alone this is particularly useful for applications where alcohol can enhance the fuel octane or just as additional fuel at high boost levels It is recommended that alcohol be added for cold operating conditions The Dash controller only measures 2 3 x 1 4 x 0 6 tall perfectly suited to fit into any small cockpit space Although small in size it contains all the necessary controls to enable the user to cover the mid to high load range of any 0 5V output MAP sensor Injection triggering point is set by the THRESHOLD potentiometer and is indicated by a blue LED on the controller It is user adjustable between 1 5 4 5V Adjustment to this potentiometer will determine the starting point of the water injection system As shown in the chart below 1 5V of a 2 bar MAP sensor represents approximately 0 4 bar below atmosphere vacuum while a 3 bar sensor represents almost atmospheric pressure The injection range is set by the GAIN potentiometer on the controller As the red LED lights up it indicates about 80 of full injection and will continue to get brighter until it approaches
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