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High-Power Brushless Fuel Pump Controller for
Automotive Racing Applications
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Available with optional Integrated Voltage
Boosting up to 24Vdc
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Unlike inferior "repurposed brushless
OEM" or "repackaged hobby RC" controller solutions where a
controller originally intended for Pump X is saddled with Pump Y, which limits
the pump's usable duty range and eventually causes premature failure of the
controller or the incompatible pump, the PM5 can be software-configured with
pump-specific profiles for most popular brushless pumps including:
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TiA (ex Walbro) E5LM (aka Unobtanium / BMW
16-11-7-212-585)
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Bosch (BMW Gen 1 / DeatschWerks DW440)
Black-Top
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Bosch (DAZA) White-Top
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Siemens VDO (BMW Gen 2 / Supra) White-Top
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PM5 interfaces directly with the factory and
aftermarket Engine Management systems and eliminates diagnostic trouble codes
(DTCs)
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Fully programmable/configurable pump duty
input/output control with our easy to use TorqBLPM PC software
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TorqBLPM software provides live-viewing,
data-logging and playback of ECU-commanded vs. Pump-actual duty helping to
diagnose ECU tuning or fuel system mechanical issues
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PM5 is the first and only LPFP driver
solution on the market that allows the ECU perform complete closed-loop control
of the requested fuel system pressure regardless of what aftermarket LPFP is
used.
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Can be reconfigured for driving most popular
brushless LPFPs including TiA E5LM, Bosch/DW Black Top, Bosch/DAZA White Top,
VDO/BMW/Supra White Top
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Supports big turbo setups by removing the
traditional LPFP fueling bottleneck and permitting the fuel system to hold any
ECU-requested pressure
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A truly scalable solution. The PM5 can be
reconfigured for different brushless pumps as the user's setup changes allowing
each pump to be safely operated over its entire duty range.
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The PM5 is available in either standard
battery voltage or optional voltage boosted variants.
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A secondary PM5 used to control a second
brushless LPF can be slaved to the primary PM5 controller and configured
completely independently of the primary pump/controller.
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Works with any LPFP set-up that draws less
than 38A at peak load and peak duty. With the PM5 you are not sacrificing
future flexibility and limiting your options by using a fueling solution that
only lets you use one particular LPFP make/model
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Works with any ECU tuning package, or even
without any ECU tuning at all. With the PM5 you are not limiting your options
by using a fueling solution that forces you to use only one vendor's ECU tuning
suite.
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Integrates seamlessly with the vehicle's
factory electrical systems
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Available with universal unterminated wiring
or with vehicle-specific Plug-n-Play Harness Adapters that transfer maximum
power to the LPFP sender through thicker 12AWG (4.0mm^2) or 10AWG (5.0mm^2)
wires - a feature not available with inferior solutions that reuse the factory
PWM control module with its thin factory LPFP wiring
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Reliable, easy to install and operate.
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Overdesigned using the highest-quality
automotive and industrial grade electronic components that far exceed the
operating ratings and endurance of the vehicle's OEM electronic modules
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Built and tested in Canada
Torqbyte PM5 is an advanced brushless low-pressure fuel pump
(LPFP) driver module designed to be used as either a generic brushless pump
controller or a complete Plug-n-Play replacement for the factory VAG/Audi
brushless fuel pump PWM control module in order to overcome the challenge of
increased fueling in VAG returnless direct injection fuel systems where the ECU
and the factory fuel pump pulse width modulator (PWM) control module perform
closed loop control of the fuel system line pressure.
Unlike brushed fuel pump controllers, brushless pump
controllers are uniquely tuned for the specific pump they are supplied with. It
is generally impossible to attach a mismatched brushless fuel pump to a
particular brushless controller and expect the combination of two to provide
long-term, trouble-free and reliable operation. Generally, a mismatch between
the pump controller and the attached pump will result in reduction of usable
pump duty range (limiting the pump's performance and requiring tuning
"bandaids" to compensate) as well as overheating and eventual failure
of either the controller or the pump.
Don't Be That Guy
PM5 can be software configured (or reconfigured as many
times as possible) for any popular pump on the market ensuring the attached
pump is driven reliably over its entire duty range. This ensures the
manufacturer-designed pump lifetime is maintained.
PM5 installs between the ECU and the upgraded fuel sender.
PM5 is capable of continuously supplying the aftermarket fuel pump with up to
38A of current.
While the PM5 does all the heavy lifting in terms of
supplying the required current to the aftermarket LPFP, its electronics
interface directly with the ECU ensuring no diagnostics trouble codes are
generated. Torqbyte's innovative technical solution implemented in the PM5
allows the ECU to maintain full control of the aftermarket LPFP operation and
maintain the closed-loop fuel pressure control mechanism that the vehicle was
originally designed with. This crucial feature is something that _none_ of the
other LPFP "upgrades" currently on the market are able to offer.
Since the ECU, in a vehicle equipped with a Torqbyte PM5,
maintains complete control of the vehicle's fuel system operation, all the
familiar pump operating characteristics are retained, such as system priming
when a door is opened. As long as the selected aftermarket LPFP is able to meet
the flow and pressure requirements of the user's desired fueling set-up, any
fuel line pressure target requested by the ECU tune will be easily achieved.
Because it interfaces directly with the ECU, PM5 is able to
live-stream the ECU command duty as well as pump actual duty, over USB, to a
laptop running the Torqbyte TorqBLPM application. These logs can be invaluable
in identifying tuning issues or diagnosing mechanical fuel system faults.
Power, Ground and Pump Connections
All Plug-n-Play kits are supplied pre-configured in terms of
PM5 to fuel-sender top hat connections.
All PM5 kits (both Plug-n-Play or generic) require custom
Power and Ground wiring connections.
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Standard PM5
The standard PM5 requires a single fused 40A connection to
the battery +ve terminal and a solid connection to the nearest vehicle chassis
ground.
Pump wires should be kept as short as possible keeping in
mind that the PM5 is not sealed and MUST be mounted inside the vehicle.
Standard PM5 Power, Ground and Pump Connections
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PM5 with Optional Integrated Voltage Boosting
The voltage-boosted PM5 requires a dual fused 40A connection
to the battery +ve terminal and a dual solid connection to the nearest vehicle
chassis ground.
Voltage-Boosted PM5 Power and Ground Connections
As with the standard PM5, the pump wires should be kept as
short as possible keeping in mind that the PM5 is not sealed and MUST be
mounted inside the vehicle.
Voltage-Boosted PM5 Pump Connections
TiA E5LM Pump Phasing is shown below. All other brushless
fuel pumps follow this same phasing convention
TiA E5LM Phasing Pinout
PM5 Pump Duty Control Options
All Plug-n-Play kits are supplied pre-configured both in
terms of required hardware and loaded software functionality.
The generic PM5 kits are available with wiring options that
allow one of the following three pump duty control strategies.
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0-5V Analog Voltage Control (aka dumb
control)
In this case, PM5's duty command is derived from a
user-supplied 0-5V variable voltage. Through the TorqBLPM software, the user
can configure the actual pump duty that is output at different duty command
(i.e. 0-5V signal voltage) levels.
Torqbyte PM5 Analog Pump Duty Control
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PWM Control
In this case. PM5 duty command is derived from an active-low
(aka Pull-to-Ground), fixed frequency, variable duty signal. Through the
TorqBLPM software, the user can configure the actual pump duty that is output
at different duty command levels.
Torqbyte PM5 PWM Pump Duty Control
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CANBus Control
In this case. PM5 duty command is derived from an active
CANBus. Through the TorqBLPM software, the user can configure the actual pump
duty that is output at different duty command levels. Depending on PM5's
physical location on the CANBus it may or may not be necessary to provide bus
termination at the PM5. If termination is required/desired, a short jumper wire
needs to be installed between connector positions 10 and 20. If no termination
is required/desired these positions should remain unpopulated.
Torqbyte PM5 CANBus Duty Control
The torqbyte_ Advantage
PM5 housings, wiring adapters and electronic boards are 100%
manufactured in Canada and the United States. We use authentic components
sourced from manufacturer-authorized distributors and our only offshore import
are wire adapters and connectors from OEM suppliers in Germany. We assemble
everything using only manufacturer-recommended tooling, procedures and
automotive-grade materials.
PM5 is housed in a rugged, thermally-conductive, CNC
machined aluminum enclosure that is hard anodized for maximum durability.
PM5 Machined Housing
Inside, PM5's electronics highlight our two principal design
goals: Quality and Reliability. PM5's design relies entirely on
industrial-grade electronic components sourced from leading semiconductor
manufacturer's including Texas Instruments, Infineon Technologies,
STMicroelectronics, ON Semiconductor and Vishay Intertechnology.
Torqbyte PM5 wiring assemblies only use US-Spec SAE J1127
SXL and TXL or European-Spec FLRY automotive wire with annealed stranded copper
conductors and premium-grade abrasion, chemical and moisture resistant, high
temperature Crosslinked Polyethylene insulation.
All pump power adapters are supplied with the thickest
possible wire gauge for the given connector family ensuring minimum line loses
and maximum power transfer to the LPFP.
Ignition/Boot-Up Time
With no IGN signal applied, the PM5 controller is asleep. As
soon +12V is applied to the IGN input, the controller wakes up and runs through
its boot-up and internal self-test sequence. This takes 5s during which time
the unit ignores its inputs and does not operate the pump. In setups where this
5s delay may not be desirable (such as all VW/Audi cars where the factory ECU
needs to be able to operate the pump any time including when the vehicle is off
in order to prime the fuel system) the IGN input may be permanently tied to a
fused, hot-at-all times, +12Vdc signal source. This will ensure the PM5 can
operate the pump immediately when the ECU control signal is received. However,
this state of constant readiness comes at the expense of increased at-rest
static current draw, which may present a concern for vehicles that are not
driven on a regular basis.
Torqbyte PM5 IGN Signal
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Static (At Rest) Current Draw
When +12V is not applied to the IGN input, the unit is
asleep and it only draws 4mA (i.e. 0.004A) of current from the car's battery.
When +12V is applied to the IGN input and command pump duty
is zero, the Standard PM5 draws 125mA (i.e. 0.125A) of current from the
battery.
When +12V is applied to the IGN input and commanded pump
duty is zero, the Voltage-Boosted PM5 draws 425mA (i.e. 0.425A) of current from
the battery.
Assuming a typical vehicle battery in good working
condition, a voltage-boosted PM5 with its IGN input permanently held at +12V
and nothing else connected to the battery (which is not a realistic assumption)
would drain the battery in about 24hrs, while a regular PM5 would drain it in a
few days.
Therefore, it's important to weigh the effects of start up
delay against the increased static current draw.
Unit Mounting and Thermal Considerations
The unit is not sealed. It must be installed on the interior
of the vehicle and not be exposed to any condensing moisture or debris.
The unit may get warm. I should not be mounted in enclosed
spaces with material (such as carpeting or seat cushion foam) coming into
direct contact with it.
Ideally, the Voltage-Boosted PM5 should mounted directly to
a large metal panel/surface in order to aid its heat dissipation.
Optional Integrated Voltage Boosting
The optional voltage booster is used to temporarily increase
the pump's power output during periods of peak demand. Its operation should be
made transient in order to avoid reducing the pump's lifespan by operating it
at high bus voltages at all times. The voltage booster maintains the pump
voltage between 15.5V and 24.0V regardless of the vehicle battery voltage. The
voltage booster output can be controlled by a secondary 0-5V analog input on
the PM5. A typical use case for this analog input is to supply it with a 0-5V
signal from a Manifold Absolute Pressure (MAP) sensor and use that signal as a
reference that progressively rises and lowers the pump voltage in accordance
with boost,
The pump voltage booster can be operated in four
different ways:
Static Voltage Mode - set by the user it never changes as
long as the unit is active
Switched Voltage Mode - pump voltage is kept at one level by
default (usually a lower voltage level) and is switched to a different level
(usually higher voltage) when the secondary 0-5V rises above a user-set
threshold. In this mode, the voltage booster acts as a Hobbs switch, raising
the pump voltage as a step when a certain 0-5V reference voltage threshold is exceeded.
Variable/Progressive Voltage Mode - pump voltage is
automatically raised and lowered in accordance with a user-entered table. The
unit monitors the secondary 0-5V reference voltage and adjusts the pump voltage
accordingly between 15.5V and 24.0Vdc.
Custom CANBus Parameter - pump voltage is automatically
raised and lowered in accordance with a varying CANbus parameter that is
broadcast on the data bus the PM5 is connected to.
The PM5 can interface with a dedicated 50PSI or 100PSI
Honeywell MAP sensor available as an optional add-on
Torqbyte PM5 Standalone MAP
Or it can be "teed" into the existing factory MAP
sensor wiring if this is the preferred approach
Torqbyte PM5 with Factory MAP
Dual Pump Control
If additional fueling is required, a second PM5 (either
standard or with integrated Voltage Boosting) can be configured as a slave and
controlled from the primary master controller. The operational setup for both
pumps is entered into the master controller. Operation of the two pumps can be
set up completely independently of one another, but since the ECU must stay in
full control of both pumps at all times, only the master controller receives
the control signals from the ECU and relays commands to the leave controller in
accordance with the slave table loaded into the master controller's
configuration. If the slave controller has an integrated voltage booster, the
master controller will ensure the secondary pump's boosted voltage rises and
falls in accordance with its own.
A special harness is required to connect the two controllers
together,
PM5 Master Slave Controller Configuration
Possible VAG Use Cases
A4,A5,A6,A7,S4,S5,S6,S7,RS5,RS7,Q5,SQ5
There are four upgrade scenarios for these vehicles listed
below in order of increasing fueling capacity.
Standard PM5 configured to drive the factory LPFP harder
than the factory fuel pump controller
Standard PM5 configured to drive an aftermarket TiA E5LM in
a modified basket
Voltage-Boosted PM5 driving a factory LPFP
Voltage-Boosted PM5 driving an aftermarket TiA E5LM in a
modified basket
Shown below is a graph comparing Scenario No. 1 (Standard
PM5 driving the factory LPFP vs. Factory Controller driving the factory LPFP)
OEM S6 vs PM5 No Load Pump Output Power
RS3 (DAZA)
There are three upgrade scenarios for these vehicles listed
below in order of increasing fueling capacity.
Standard PM5 configured to drive an aftermarket TiA E5LM in
a modified basket
Voltage-Boosted PM5 driving a factory LPFP
Voltage-Boosted PM5 driving and aftermarket TiA E5LM in a
modified basket
Plug-n-Play Vehicle Compatibility
PM5 is available in 3 Plug-n-Play kit options that cover
most popular VAG brushless applications. Please check your factory FPCM and
Fuel Pump Connector Part No.s to ensure you are ordering the correct kit.
RS3/TTRS (DAZA) - US Spec
FPCM: 4M0 906 093
Fuel Sender Top Hat (Blue): 8V0 919 087
Fuel Pump Connector: 4M0 973 724
PM5 DAZA PnP
RS3/TTRS (DAZA) - European Spec
FPCM: 4M0 906 093
Fuel Sender Top Hat (Blue): 8V0 919 087
Note: Requires 8V0 971 727 A Wire Adapter (European Models
Only)
Fuel Pump Connector: 4M0 973 724
PM5 DAZA PnP
A4,A5,A6,A7,S4,S5,S6,S7,RS5,RS7,Q5,SQ5
FPCM: 4G0 906 093
Fuel Sender Top Hat (White): 8K0 919 051
Fuel Pump Connector: 8K0 973 724
PM5 - Brushless Fuel Pump Controller
- Product Code: PM5
- Availability: Pre-Order
-
£791.67
- Ex Tax: £791.67