Returnless Pump Pulse Width Modulation Controller, Triple Pump Applications

Aeromotive Part Number: 66142
Legacy VaporWorx Part Number: PWTP3B-R10

The Auto-On triple fuel pump control system has everything needed to provide a stand-alone, OE-type returnless fuel system.

This system is to be used with dual or triple fuel pumps (not OEM fuel pump modules) to provide a 1:1 manifold referenced fuel pressure using the VaporWorx supplied stand-alone MAP sensor and mounting bracket. It will act just like a mechanical fuel pressure regulator would with the ECM calibrated in the same manner. The fuel injector does not know if the fuel supplied is pumped by a return or returnless system.

The standard kit is calibrated for 1:1 fuel pressure change vs. manifold pressure, the same as a traditional mechanical fuel pressure regulator.

Base fuel pressures at idle are typically 42psi, but the VaporWorx controller has much greater range if needed.

The Auto-On Pump control system monitors the MAP sensor to provide a MAP referenced fuel pressure and to turn on the second pump. The VaporWorx controller has a Pump 2 output that turns on at 4psi of boost. No Hobb's switches, relays, or other devices are needed. The supplied stand-alone MAP sensor must be used.

For pumps to operate in closed loop PWM mode, some fuel must pass through the pumps while running. This fuel volume is more than what the engine needs at idle and cruise. So, additional bypass fuel must be added. In the OEM fuel module this fuel is put to work driving the multiple transfer pumps that move fuel into the module reservoir. On some aftermarket pump hangers the single hole used to drive the transfer pump needs to be increased, or provided by some other method. 

The fuel pumps supported by this PWM Controller is Aeromotive's line of 340 LPH In-Tank Fuel Pumps.

The 3bar Auto-On Fuel Module Controller system includes these standard features:

• Everything needed electrically to drive the fuel pump module. No relays, external regulators, or return lines needed.
• Up to 2/3 reduction in power to the fuel module during idle and cruise vs traditional systems.
• 80A minimum continuous power rating in a compact controller package. Total size 4.5" L x 3.5" W x 2" H.
• Over-temperature shutdown with automatic reset that will operate indefinitely without damage.
• Short circuit protection with automatic reset that will operate indefinitely without damage.
• OEM Delphi/Aptiv connections for terminals, seals, and connector bodies where appropriate.
• All cross-linked polyethylene wiring.
• UL94 rated components used throughout.
• Integrates into the OE ECM to allow all safety systems to remain functional.
• 10-22v operating capacity. Can be used with voltage boosters. 
• Lower than 10v applied to the turn on circuit will cause controller shutdown to protect from an AFR lean condition.
• Must be used in manifold referenced fuel pressure mode.
• Second pump turn-on set to 4psi boost.
  

NOTE: Returnless systems require a safety overpressure valve. Please see here for details: 80 psi / 5.5bar Safety Overpressure Regulator