User Guide. Progressive Fuel Pump Controller

Transcription

1 User Guide Progressive Overview: Revision The Easy Performance Products Progressive provides a compact, high efficiency, microprocessor based, progressive fuel pump controller. It is designed to use sensory input from the engine and adjust the fuel pump speed relative to the sensor input. The microprocessor is programmed to supply the fuel pump with reduced power when the engine is not under load. This has several benefits including reduced wear on the fuel pump, lowering the heating effect of the fuel, reduced pumping noise and the reducing or eliminating the problem of fuel sump being pumped empty during deceleration. This initial fuel pump power level when not in proportional control is set by the user. As engine power demand rises, the controller proportionally increases fuel pump speed. The controller will increase pump speed until the fuel pump reaches full speed. The sensor input values that the controller begins proportional control, reaches full speed are set by the user. The controller can power the fuel pump in single fuel pump systems or can be set up to be a secondary pump drive in two pump systems. This unit delivers the following benefits: When used with powering automotive fuel pumps, the provides reduced power levels to fuel pump when engine is under light power loads. Three adjustable parameter knobs can be set by the user to provide for a simple, yet very flexible, customized fuel pump operation. Capable of powering fuel pumps up to 42 amps power draw. Improves fuel pump longevity. Lowers or eliminates fuel heating. Reduces fuel pump noise when not under full power. Fully enclosed alloy enclosure protects circuitry. Reduces or eliminates the problem of the fuel sump being pumped empty during deceleration 100% solid state design with no mechanical relays to fail or replace. Utilizes regenerative power control to provide exceedingly high efficiency as well as eliminating all switching stress on the motor s windings. Incorporates fully sealed inline connectors for reliable connections, to ease installation and allow unit to be easily removed from vehicle without needing to cut wires or connections. Trigger input allows the module to be a secondary pump drive. The control housing incorporates an integral mounting flange for simple mounting. Optional integrated manifold pressure sensor for installation into conventional engine setups without electronic engine control computers and the related sensors. Mounting: CAUTION: We recommend disconnecting the Negative Batter Cable from the vehicle s battery prior to performing any power supply wiring on the vehicle. Choose a suitable mounting location where the can be mounted securely and be free of vibration. The location must provide the with free air circulation. Do not mount the unit where it will be subjected to temperatures greater than 140 F / 60 C. Do not enclose the in an enclosed space or box. The will need some air flow around it to dissipate heat generated. Failure to heed these mounting requirements may result in thermal overload and will void warranty. Use appropriate machine screws with nuts or sheet metal screws to mount the. Wiring: (refer to Figure 1) 1. Connect continuous battery power to the fuel pump s positive lead connection. Use appropriate gauge wire for the pump s rated current draw. This power line must have an appropriate rated fuse located as close to the power source as possible. This hardware should be supplied with the aftermarket fuel pump. 2. Wire the fuel pump s negative (ground) lead connection to the Blue wire on the s fuel pump connector pigtail. Use supplied blue wire splice if needed for connection.

2 3. Locate an appropriate location to attach the s Black ground wire. Route the Black wire from the fuel pump connector to the grounding location and attach to grounding site with the supplied ring terminal. Chassis Disconnect Figure 1 Control Wiring: 1. Pink Wire 12V switched ignition power to activate internal control module circuitry. This Pink power wire may be connected to stock fuel pump relay coil control source, stock fuel pump relay output or an ignition power source. The internal circuitry draws under 50mA of current. Locate an appropriate ignition power source to tap into for this Pink power wire. Run the Pink wire from the fuel pump connector to this power source location. Use a supplied red wire splice if needed for connection. 2. Orange Wire 12V continuous/battery power to provide regenerative power back to battery. This Orange power wire MUST be connected to a power source tied continuously to the battery. The internal circuitry draws under 50mA of current. WARNING: Do NOT connect the Orange wire to an ignition switched source. Doing so will result in electrical power distribution problems in the vehicle as well as possible damage to the Control module. Locate an appropriate continuous battery power source to tap into for this Orange feedback power wire. Run the Orange wire from the fuel pump connector to this power source location. Use a supplied red wire splice if needed for connection. 3. Green Sensor Wire 0 to 5V control sensor input to provide control signal to the fuel pump controller. This Green wire is typically tapped into the Manifold Absolute Pressure (MAP) Sensor s signal wire found on the engine. Typical MAP Sensors produce a 0 to 5 volt signal that represents the absolute pressure of the intake manifold. The sensor connection harnesses typically have three wires connected to the sensor. One of these wires will be sensor power, the other sensor ground and the third will be the sensor s signal wire back to the Engine Control Module (ECM). The fuel pump controller s sensor signal wire must be tapped into the sensor s signal wire. Alternatively, any 0 to 5 volt engine control sensor can be used for the signal input to the fuel pump controller. The underlying objective is to have the input signal be representative of the engine s fuel demand. NOTE: If the fuel pump controller is equipped with an integrated pressure sensor, then the Green Sensor Wire is not to be connected to anything and should be left disconnected. Locate the desired engine sensor and its signal wire to tap into for this Green sensor signal wire. Run the Green wire from the fuel pump connector to this sensor signal wire and tap into it. Use a supplied red wire splice if needed for connection. 4. Trigger Wire 12V On trigger power to signal the fuel pump controller to apply power to the fuel pump. This yellow wire must receive 12 volts power from any source to signal when to apply power to the fuel pump. This Yellow control wire may be connected to stock fuel pump relay coil control source, stock fuel pump relay output or an ignition power source. When connected to a power source controlled by the ECM, then the fuel pump will only receive controlled power when the ECM commands the pump to be On. This type of connection provides all the safety measures the ECM employs with controlling the fuel pump. Locate the 12v trigger source desired to be use for this Yellow trigger wire. Run the Yellow wire from the fuel pump connector to this trigger source and tap into it. Use a supplied red wire splice if needed for connection. 5. Optional Integral Pressure Sensor If the control module contains an integrated pressure sensor, then the pressure sensor tube connection coming from the controller housing needs to be connected to the engine s intake manifold via the included pressure tubing. The installer will need to determine the best location on the engine to obtain a source of manifold pressure and what fittings will be necessary to connect the 1/16 inch pressure tubing. NOTE: For this type of installation, we recommend mounting the fuel pump control module as close to the engine as possible, while considering wiring and thermal aspects, to minimize the response time of the controller. As the sensing pressure tubing length increases, so will the response time of the fuel pump speed increase. In severe cases, this can result in engine lagging or stumbling during rapid throttle opening. Voltage Control Setup: Removing the four screws from the control module enclosure s top cover will allow access to the control knobs used to set the module s control parameters. The fuel pump s voltage control scheme is established by adjusting the three adjustment knobs. All of these knobs are read continuously when the engine is running. Therefore, any changes made to any of the control knobs are immediately applied to the control scheme. This allows for dynamic adjustment of the controller with the engine in operation. The function of the three control knobs are as follows:

3 1. Initial Power This control knob sets the power level, as a percent of total power, applied to the fuel pump prior to the controller increasing power. This power level is held constant until the sensor input value reaches the set point of the Initial MAP. The minimum power level set should be at least the level needed to maintain the engine s proper fuel pressure at the engine. This minimum initial level can be determined by the following procedure. a. With the controller properly installed, set the Initial Power level to 100%. b. Connect a pressure gauge or scan tool to monitor the engine s fuel pressure. c. Start the engine and allow it to come to a stable idle. d. Begin to decrease the Initial Power level slowly until the fuel pressure begins to fall off. e. Raising the Initial Power level above the fall off point determines the minimum Initial Power level. The final setting of this control knob should be some level above this minimum level. 2. Start MAP This control knob sets the sensor input value, as a percentage of sensor s full voltage range, that the controller will use to begin ramping up fuel pump speed. This set point should be set at a minimum percentage that is equal to the sensor s output at idle. Setting the value at a point lower than that at idle will just artificially raise the Initial Power level intended to be set by the Initial Power knob. Setting the Start MAP at a point too high may cause fuel pressure to drop below desired regulation pressure when engine comes off idle. This knob s minimum set point can be determined by the following procedure. a. Connect a voltage meter to monitor the voltage drop across the fuel pump. b. Set the Start MAP level to 100%. c. Start the engine and allow it to come to a stable idle. d. Begin to decrease the Start MAP level slowly until the observed voltage begins to increase. e. Raising the Start MAP level above where the voltage begins to rise determines the minimum Start MAP level. The final setting of this control knob should be some level above this minimum level. 3. FULL MAP This control knob sets the sensor input value, as a percentage of sensor s full voltage range, that the controller will achieve full fuel pump speed. This set point should be set at a minimum percentage that is equal to the sensor s output when the engine is producing maximum power. Setting the value at a point lower than when maximum power is made will have the pump running harder than it needs to but is conservative to assure the engine will not become fuel starved. Setting the Full MAP at a point too high may result in fuel starvation prior to the Full MAP sensor level is reached. One method for determining this a. Connect a voltage meter to monitor the voltage drop across the fuel pump. b. Connect a pressure/vacuum gauge or scan tool to the engine to monitor manifold absolute pressure. c. Set the Full MAP level to a setting just above the Start MAP setting. d. Start the engine and with the engine under full load, gradually throttle the engine to wide open throttle through its operating range. Monitor both the fuel pump voltage and engine s manifold pressure during the run. Note at what pressure reading the fuel pump reaches maximum voltage. e. Incrementally, increase the Full MAP level on successive runs and observed manifold pressure needed that achieves maximum voltage. f. As the Full MAP setting is increased, the manifold pressure needed to achieve maximum pump voltage should be coming closer to the maximum manifold pressure the engine is capable of producing. The final setting of this control knob should be some level below where maximum manifold pressure is achieved. For applications where an oversized fuel pump is installed and maximum flow of the pump needs to be reduced, setting the Full MAP setting above the maximum attainable manifold pressure will keep the pump from achieving full power. Through successive trial runs, the Full MAP setting can be lowered gradually from maximum pressure. pressure should be monitored to be certain the Full MAP isn t lowered too far such that the fuel pressure drops below required pressure levels throughout the engine s power range. A graphical representation of how power is applied and adjusted by the three control knobs is given in Figure 2. Progressive Power Curve Power Out to (%) Initial Power Set Level Raised and low ered w ith 'Initial Pow er' Move right or left w ith 'Start MAP' Move right or left w ith 'Full MAP' Initial Power Set Level Full Power Set Level Sensor Signal Input (% of full scale) Figure 2

4 General Wiring Diagrams: Chassis 12V Ignition Power 12V Trigger Source Wiring Diagram, electronic sensor installation: Ignition 12V F Battery 12V Turn On Trigger Sensor Input To ECM 5v Signal Gnd MAP Sensor Wiring Diagram, w/ integral pressure sensor: Chassis 12V Ignition Power 12V Trigger Source Ignition 12V F Battery 12V Turn On Trigger Manifold Pres. 1/16 Hose to Manifold Pressure Source on Engine

5 Specifications: Size: W 1.5 L 4.75 H 1.4 Weight: 6.2 oz. / 175 gm Input Voltage: Volts Output Voltage: Selectable between 0 Full System Voltage Output Power (Maximum): 420 Watts continuous Output Current (Maximum): 30 Amps Internal Control Circuit Power (Maximum): < V External Connectors: Delphi MetriPack 150 & 280 Sealed Connectors Pressure Sensor Tubing Size: 1/16 inch ID Maximum Ambient Operating Temperature: 140 F / 60 C Warranty: Easy Performance Products warranties the unit against manufacturing defects for a maximum of one year from the original date of purchase to the original purchaser. Exceeding maximum operating conditions or mounting in a manner inconsistent with the mounting instructions will void warranty. Easy Performance Products is not responsible for misuse or improper installation of this unit. Easy Performance Products is not liable for any damage done to the vehicle or any vehicle components from the proper or improper use of this product. The installer is responsible for the compatibility of the with the application. Manufactured by: Easy Performance Products, LLC 3514 Roger B. Chaffee SE Wyoming, MI Website: support@easyperformance.com If you have any question, concerns or comments on the Kit and/or the installation instructions, please visit Easy Performance Product s website at and click on the Kit link found under Products in the menu. Please browse the FAQs (Frequently Asked Questions) section for additional information that may be helpful prior to contacting us. There may be questions you have that are already answered in that section of the site. Otherwise, you can always contact us at: support@easyperformance.com