Brushless Fuel Pump Control

[Exploded_Muffin]

Hi all,

I've got a 2021 GT500 making about 1000 rwhp and running a return style fuel system I put together (Radium hat, twin Walbro 295s, Fore FC2 controller, custom harness for relay trigger and fuel level sender).
I want to switch my Walbro 295 fuel pumps to brushless ones - specifically the Fuelab 49614 as those have similar flowrates to the 295 and are compatible with the Radium hat I've got.

Question for people with a brushless fuel system - how do you control the fuel pump speed?
I currently have a PCMTec Lund tune but I'd prefer a mechanical pump speed control setup divorced from the tune (Something like 50% pump speed in vacuum and 100% in boost)

Can anyone point me in the right direction?
@Angrey @engineermike @illtal

https://fuelab.com/25314-fuelab-universal-in-tank-brushless-kit/p408

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[HKusp]

Did you see the fuel lab controller link at the bottom of the page?

 

[Exploded_Muffin]

Did you see the fuel lab controller link at the bottom of the page?

Yeap, the fuelab controller has a white wire for a PWM or 0-5v analog voltage signal.
Trying to figure out a signal source to connect to that white wire

 

[HKusp]

Understood.

 

[Timbuck]

Yeap, the fuelab controller has a white wire for a PWM or 0-5v analog voltage signal.
Trying to figure out a signal source to connect to that white wire

ive Looked into this a little for a future set up for my self. You could use throttle peddle or throttle body To get the signal.

i also got into contact with DW and the owner of this car. Check out his YT account.

he runs a radian bucket , single DW810 brushless with their controller , 50% and 100% settings and just controlling it with a hobs switch. He is 1000hp
he changed from a fore system due to issues with fuel starvation with less than 1/2 tank etc.


I like the simplicity of this set up for sure.

 

[mejohn50]

The OEM PCM has an adjustable PWM output to the FPDM that could, theoretically, control a brushless controller.

Just need someone who is willing to tune it.

 

[illtal]

Hi all,

I've got a 2021 GT500 making about 1000 rwhp and running a return style fuel system I put together (Radium hat, twin Walbro 295s, Fore FC2 controller, custom harness for relay trigger and fuel level sender).
I want to switch my Walbro 295 fuel pumps to brushless ones - specifically the Fuelab 49614 as those have similar flowrates to the 295 and are compatible with the Radium hat I've got.

Question for people with a brushless fuel system - how do you control the fuel pump speed?
I currently have a PCMTec Lund tune but I'd prefer a mechanical pump speed control setup divorced from the tune (Something like 50% pump speed in vacuum and 100% in boost)

Can anyone point me in the right direction?
@Angrey @engineermike @illtal

https://fuelab.com/25314-fuelab-universal-in-tank-brushless-kit/p408

Controller as mentioned, I have an older version of it but it is hooked up to an AEM 1 bar MAP sensor. Soon as I see boost then I get max flow rate.

Those 496s make 500LPH at 3 bar. They are stronger than the 295 pumps and draw less amps. They also lose less flow when the pressure is turned up.

 

[engineermike]

That fuellab pump is rated at 500 lph at 3 bar, or 45 psi, and appears to be available with a venturi connection and check valves. Where we run at 5 bar, the flow drops to about 450 lph.

The DW400 is rated at 410 lph at the same 45 psi and drops to 370 lph at the higher 5 bar/70 psi.

At first it looks like the fuellab pump is a nice upgrade over the DW400, but the DW400 can be boosted to 20 volts or more. We bench tested one and got 576 lph out of it at 70 psi and 22 volts and 505 lph at 18 volts, handily beating the fuellab pump.

So can you boost the voltage to the fuellab pump? Maybe; it depends on the controller. Some brushless controllers can take advantage of additional supply voltage and some can't. The DW810 for instance, does not increase output beyond 14.5 volts.

To me, the best option unless you're approaching 1000 rwhp is a simple DW400 with a bap. If you're under about 850 rwhp a typical 18v bap will work, otherwise the 22v might be needed. Basically every other aftermarket setup I've looked at had some big disadvantage such as lack of a check valve, lack of a venturi connection, lack of a bucket, lack of turn-down/PWM control, etc. I believe a stock GT500 bucket is a really good option and can most likely be run off of a single stock FPDM as long as the voltage isn't boosted. It does require a custom harness to be made and the entire fuel line to be swapped out, which involves dropping the exhaust, driveshaft, and fuel tank.

 

[illtal]

I have the older controller than can be ran at 18V. Supposedly they can handle that. There is nothing from Fuelab that says what it will do on a voltage boost.

I'm not sure if boosting voltage will shorten lifespan but having two 500 LPH capable fuel pumps puts you in a conservative range of 1700-1800 wheel on E85.

I am curious if anyone is still running the dw hat with the stock bucket. I have never heard of anyone burning pumps with that setup. But I think just running the pumps full blast all the time is what's hurting them.

 

[Exploded_Muffin]

Controller as mentioned, I have an older version of it but it is hooked up to an AEM 1 bar MAP sensor. Soon as I see boost then I get max flow rate.

Those 496s make 500LPH at 3 bar. They are stronger than the 295 pumps and draw less amps. They also lose less flow when the pressure is turned up.

I'll likely be going with a similar setup, thanks!

 

[engineermike]

https://www.mustang6g.com/forums/threads/required-upgrades-for-e-85.202422/page-2#post-4096034

 

[bankyf]

I'll likely be going with a similar setup, thanks!

I have a complete brand new set of the fuel lab stuff (pumps, controllers, regulator) that I'll make you a pretty good deal on if you go that route. They are currently mounted in a radium bucket, but I'm assuming you wouldn't need that.

 

[Exploded_Muffin]

I have a complete brand new set of the fuel lab stuff (pumps, controllers, regulator) that I'll make you a pretty good deal on if you go that route. They are currently mounted in a radium bucket, but I'm assuming you wouldn't need that.

I purchased the pumps and controller from Fuelab yesterday. Sucks for me...

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