FCM Problem ::FIXED::
 

Greetings from Russia.

Trying to install HFS-6 on turbo s2000. After finishing all the wiring and trying to start, I've noticed that there is no connection to red cable coming from FCM (under hood). Neither green or yellow lights are lit. Other connections are fine, only this red one has problem.
One thing I've noticed plugging red cable out and in - "S" light on gauge is lit only with cable inserted, also just in a moment of inserting module is making a "click" sound (similar to sound made by relay). Ground to FCM is good.

I suppose that something is working, something is not. When I tryed to run 100% inj test all indication on main board was correct, but flow didn't run, no sound from pump as well (pump fuse and relay are ok). Could be this the reason of FCM not working properly?
Basically, what is possible reason for this and how problem can be resolved? Any suggestions?

Looking through topics here I found out that red RJ connector sometimes has some problems - I will check it out tomorrow.

Thanks for your time and sorry for my english.

Re: FCM Problem
 

Firest thing to check is the RJ45 connector. It could be damaged from threding through tight opening beytwen firewall/cabin.

Is the HFS-6 new? It has been discontinued over two years ago.


http://www.aquamist.co.uk/forum/gallery/HFS6/conn1.jpg

http://www.aquamist.co.uk/forum/gallery/HFS6/conn2.jpg

Re: FCM Problem
 

Hi, Richard.
HFS-6 is new, everything is just from the box, everything was sealed. Just purchased it from ebay. Can send you details and seller contact info of the seller if necessary.

Checked the connector - it is fine. Pushed the pins additionaly - didn't help. Same thing.
https://lh3.googleusercontent.com/-5...2021.04.46.jpg

Ground (dunno what else to check with the module):
https://lh6.googleusercontent.com/-J...2019.16.21.jpg

Module itself:
https://lh3.googleusercontent.com/-p...2019.16.04.jpg
(Used black water line from previously installed AEM unit)

box with serial on it:
https://lh6.googleusercontent.com/-o...2020.12.50.jpg
Here is the video. Probably this will help to understand the situation:
http://www.youtube.com/watch?v=5jrMO677InI

Notice the "S" lamp being lit and not while plugging and unplugging the connector. Also, as I've said, there is some relay-like "click" on FCM.

I thought that maybe lamp on the socket is not working (what else to thing about? :)) - but during test run on full boost there was no flow.

I've also made a video with 100% flow simulation, but picture is similar. All the lights on controller are lit, but no flow.

Please, any suggestions, is it FCM or main unit itself? Where to dig? Now I'm feeling quite disappointed after spending almost 1k usd and two days for installation and having not working unit after all, instead of AEM which was working fine...

Re: FCM Problem
 

On the HFS6. there is a manual test jumper. Can you bridge it tell me if the system sprays.

Re: FCM Problem
 

Yes, here you are (tst jumper is bridged): http://www.youtube.com/watch?v=wtiFD43JCuA

Water line witg injector went directly to cabin, so I can tell that there was NO flow.

As for pump - wiring is 100% fine, tank and water lines are filled with water (after previously installed unit), pump relay and fuse are ok. Red wire goes directly to battery.

Re: FCM Problem
 

Can you undo the 6mm line to the FCM and manually active the system. Tell me if there are ample water coming out of the 6mm hose.

Re: FCM Problem
 

No, not coming. Pump is also keeping silent. I suppose that probably punp won't work not "seeng" FCM (just guess).
Anything else to check? :)

Re: FCM Problem
 

On the video, the S led is blinking, Is it right?

Re: FCM Problem
 

Sensor light is not blinking actually. I just tried to show that it is lit when you plug in red connector, but it disappears when you take it out. So there is some connection. Just plugged it in and out several times.

Re: FCM Problem
 

Are ypu good at soldering? It is possible to by-pass the PWM drive inside the FCM to simplify the diagnostic work.

Re: FCM Problem
 

Yes, let's try, I don't mind. Please send instructions.

Re: FCM Problem
 

open up the FCM...

1. Pick out the brown wire from the 8-core cable
2. Cut it as closely as possible from the circuit board.
3. Cut the "non-red" wire off the solenoid valve pin. Tape it up.
4. Solder the brown wire to the same pin.
5. Now the valve is driven directly from the controller.

Re: FCM Problem
 

Hi, Richard.
Sorry, had a minute to check everything only yesterday.
If I understood correctly, I had just to connect brown wire with black one which goes to solenoid. Is this correct?
https://lh3.googleusercontent.com/-U...2017.16.21.jpg

Didn't help. Same situation. Green led on red wire is not active, 100% flow simulation is not working.

I didn't notice any visible damages/burnt parts inside FCM - everything looks good. Probably solenoid itself is broken?
What else to check?

Re: FCM Problem
 

The soldering is good.

Next we will check the system operations:

1. Unplug the 6mm hose from the FCM. "TST" jumper if theer are pressurised water coming put of the hose. If yes continue to step 2.

2. Re-instate the 6mm hose. Unplug the 4mm hose from the FCM (remove restrictor if there is any). "TST" jumper and see if there are any water coming out of the FCM. If yes, let me know if the gauge shows reading.

I await your results...

Re: FCM Problem
 

Stuck on step 1. There is water in 6mm water line, but it is not coming out. Think it is left after old kit. Pump in trunk is keeping silent... :(
One more thing I've noticed: green led on red cable is lit one time in ~30-40 tries (plugging/unplugging), but even when it is lit water is not coming. When I take out the ignition key and put it again, led is not lit again.

Re: FCM Problem
 

Ok, check the relay in the trunk:

1) take a look at the thin red and blue wire underneath the relay, see if they are connected firmly into the relay base termninals. Those two wires should have 12V across it under "TST" condition.

2) If the wires are OK. check if there is 12V across the pump terminals.

Leave the red cable alone for the time being. Your problem is is thre truck area

Re: FCM Problem
 

- wiring, ground to trunk is fine (actually it is hard to do something wrong there :))
- pump is ok and working (directly put 12V on it, disconnected FCM and water was comming out from thick water line). If I connect thick line to FCM (with FCM "connected" to main module and "S" light lit) and put 12V on pump, no water is comming out from thin water line ("out" of FCM).
- Relay looks fine (to me :))
- BUT under "TST" mode NO sygnal is comming to red/blue thin cables - this means that main module doesn't give proper signal.

Re: FCM Problem
 

Can you remind me if this problem occurred recently or it is a new installation.

Re: FCM Problem
 

Can't make it work for almost 2 month now...

Re: FCM Problem
 

You took a long time between posts

Re: FCM Problem
 

1) Can you check the wiring order of the blue harness. Red is the first one (nearest to the gauge harness).

2) Can you check the voltage of the thin red wire under the pump relay. It should read 12V regardless if the TST is used.

Re: FCM Problem
 

Harness is ok - order is same as for other cables.

As for voltage - thick red, thin red and blue have positive voltage always (in tst mode and in normal) - can't tell what voltage is there exactly, will test with tester today. But, if I give 12V to red and blue cables directly - there is no response. Pump is not working, relay is keeping silent. What can this be? Relay faulty maybe?

One good thing I found out yesterday. With following pins shortened at the same time: "IDC", "PRK", "TST", "INJ" and shortening thick black and red cables on relay water is coming out from thin hose (OUT of FCM). If I shorten "IDC", "PRK", "TST" and black and red cables water is comming only through thick hose, but not through FCM (closed) - is it normal.

Re: FCM Problem
 

It is good to know both reds have 12V.

The thin blue should be grounded when test jumper is set to TST, provided you n-meet the following conditions:

1) system is powered up
2) gauge button is depressed
3) jumper link is set to IDC
4) jumper link is on TST

The TST is simulating 100% DC, not 100% MPS.

Re: FCM Problem
 

Finally, I think I figured out what the problem is. The blue wire. It should be grounded for water ingection to start. Currently I see some po wsitive sygnal on it, but if I shorten it to ground everything is working. What can be a reason for this and how to "ground it" when necessary?

Re: FCM Problem
 

The blue wire goes to ground when the system triggers. No before.

Please check the compartment of the blue wire of the RJ connector is not damaged or slightly bent.

http://www.aquamist.co.uk/forum/gallery/HFS6/conn1.jpg

http://www.aquamist.co.uk/forum/gallery/HFS6/conn2.jpg

Re: FCM Problem
 

No. already checked. Even pressed all the pins way down. Checked with the tester female pins on the controller itself - it is always +12, under normal mode and under "TST"
As for wires - red is the first one from the right, blue is the 6th - is this correct?

Re: FCM Problem
 

Yes correct.

Anyway, Make sure the jumper is on IDC. The HFS-6 can only be manually triggered on the IDC mode.

Re: FCM Problem
 

I described situation with jumpers on IDC & TST only. Optionally jumper can be on JMP for FCM to open (but this doesn't matter anyway).
So what to do with blue cable? Why ground is not coming on it when necessary?

Re: FCM Problem
 

I don't know why the blue wire is not grounding when triggered.

Question, when you do the TST test, does the ">95%" led come on at the controller?

Do you have a digital multimeter?

Re: FCM Problem
 

Yes, all 3 leds are lit as they should. I will try to replace rj45 connectors... don't know whether it will help or not...

Re: FCM Problem
 

One thing to check is if the blue wire has continuity, here is how this can be done:

System on stand-by :
1. Check there is a 12V is present at the thin blue wire on the underside of the relay socket.
2. Check the RJ socket on the controller circuit board if the soldered pin has the 12V there.
3. I believe it is pin #6 (from gauge side) Anyway, do it visually as it is in blue.

Let me know the result.

Here is a diagram will help you with voltage measuring (relative to chassis ground).

http://www.aquamist.co.uk/HFS6/pump driver.gif

Re: FCM Problem
 

Thanks for the info. Will check today.

I've tried to re-make RJ45 connectors but this didn't help - same thing. Female connectors (sockets on board) are not good (they were not good from the beginning). When I move the conectors (any) in socket I'm loosing connection ,leds are dimming. After some time of playing with this I've managed to get green led on red connector. BUT under "TST" mode I got folloving leds lit: green - red, yellow, blue; orange - red, green (user). But as I understood, orange led should be lit for yellow connector (to ecu) as well? But not for blue - it is water level indication, right?

Maybe soldering wires directly to the board will help - probably I will try this as a last chance.

Anyway, system is behaving really strangely...

One more thing - connectors for gauge are not colour matched (I mean they are not like stated out in instruction: red ... brown), but gauge itself seems working fine. Cable has simple wirng, not direct, but opposite, something like red is the 1st one on the one end and 8th on the other. Is this correct?

Also I found a thin soldered wire connecting two transistors (outside a circuit) - should it be there? I can make a photo to make it clear what I'm talkig about.

Re: FCM Problem
 

Things are going to get too complicated if you are going to do ten things all at once. I am not going to work with you this way. It will not get far and will waste both of our time.

First of all, every HFS-6 controller is tested individually before shipping. If you bought the system are buying second hand, this is no guarantee that it has not been handled by the previous owner. I only have your word on it. The HFS-6 was discontinued two years ago.

You should not have try change the RJ45 connect without letting me first, there are a few things i need to discuss with you before hand. You have now making things a lot difficult for me to diagnose as you have introduced more variable as your effort did not yield any positive results.

You know the system is way passed the 12-months warranty. I will help you if you don't do anymore DIY repairs.

Can we just concentrate on the blue harness and the pump relay ONLY?

Re: FCM Problem
 

Richard, I repeat again that this kit was bought in sealed box, means new, from ebay. When I bought it I had no idea that it is discontinued or I can purchase it directly from manufacturer.
This kit replaced my AEM kit which was working ok, but I was recommended to change it and try aquamist. I've spend over 1k$ for purchasing, handling and shipping hfs-6 and the only thing I want is to get it work. I'm not asking for repair/exchange, because I understand this is my mistake. I can't return it to seller, because already more than 2 month passed when I'm trying to make it work.

I've stated out that board has several problems, but you're reading between the lines. I'm not trying to do multiple thigs at same time, I think all of them are connected

1) there is NO ground coming to blue cable. Never. Always +12V
2) Orange led on yellow connector don't lit under TST mode (but it should according to the manual). It is only blinking accordingly to rpm, when engine is running.
3) gauge connector wire layout doesn't correspond to the one stated out in manual. Absolutely different
4) RJ45 female sockets on main board are crap. They are loosing connection all the time if you move connector a bit (same thing with oem & re-made connectors). I can't figure out which one is causing problem. Don't warry for the RJ45 connectors itself. I think I've made many more that thousands of these during my life.
5) what does this strange wire doing on PCB? should it be there? Why do such things have place on high-quality PCB?
https://lh5.googleusercontent.com/-M...2013.44.45.jpg

Richard, sorry, I really don't want to argue, but I've spend huge bunch of time with this really behaving strangely thing, and I'm really pissed off. Thank you for assisting with trying to find out what the reason is, I don't want to spend a minute more trying to bring alive the kit with bugs.

Topic now can be closed.

Re: FCM Problem
 

I am sorry that we cannot communicate effectively on solving your problem. I am happy to service your entire system at no charge if you like to return the system to me and just pay the return shipping charge

Re: FCM Problem
 

JFYI, main board is definately faulty.
https://lh4.googleusercontent.com/-W...255B1%255D.jpg
Black connector is on 4-pin ground, red is on the mark you've pointed on above picture. Chip has 12V as well on middle leg and something like 2-3V on left and right (don't remember exactly). Is this like it should behave? On the relay itself red and blue wires are having 12V constantly.
If I put ground on 6th connector pump begins to work and water is coming out.

Another thing is that when I tried to swap my controller to another which is installed on EVO IX (also here, in Moscow) everything was working smoothly, even indication on the blue connector was correct.

Are there any ways to solve this problem, fixing this board, or the only way is just to change it? I understand that this is not warranty case, and this is out of your interest, so I'm ready to purchase the board separately if it is possible. Can you please invoice a bill in paypal to my adress fplucid[at]gmail.com and I will proceed with payment.

Re: FCM Problem
 

I don't not charge minor repairs if you cover return shipping cost. Email me: richard-AT-aquamist.co.uk

We we locate aniothe rcircuit board, (v3) it will still have a link, if this is acceptable. We make links to improve the performace of the system over the interim period before moving on to the next board design. The V3 is the last version before the HFS-4 took over.

Re: FCM Problem
 

OK, lets have another go on this...

You are looking at the transistor that controls the pump relay. I have numbered the pins 1-4 on thre transistor.

Switching function of the transistor:

- Pin 1 .......... when a voltage of greater than 3V is applied, the transistor will switch on.
- Pin 2/4 .......... They will go to ground when it is switched on (pump starts) by pin1. (connected to blue wire of pump relay).
- Pin 3 .......... always grounded (connected to the black wire of molex).

Let me know if this makes sense so far

Re: FCM Problem
 

2-4 - always 12V (in normal & "TST" mode)
3 - ground, ok.
1 - normal - 0,4V, "TST" - ~1,25
So seems like there is signal coming to transistor and it is even changing, but too weak.

Re: FCM Problem
 

Thereare three small components below pin2 & 3. It is possible there is a dry joint there. If you carefully re-flow the solder on those components, it may solve the problem.

Let me know.