The Injector Dynamics BPC100 is a fuel pump controller designed for use with high-flow fuel injectors. Documentation indicates compatibility with various engine management systems, including Motec M1 ECUs, and provides instructions for wiring, configuration, and operation in different modes – Constant Speed, MAP-based, and Constant Flow. The controller requires specific wiring configurations for power, ground, and signal connections, and utilizes adjustment dials for fine-tuning pump output.
Wiring Specifications
The BPC100 requires several wiring connections for proper operation. The documentation details connections for main power, main ground, ON/OFF functionality, pump control, MAP sensor integration, and flowrate monitoring.
Main power connections require high-quality, pure copper 4 AWG wire with a temperature rating of at least 90°C (194°F). Copper-clad aluminum wire is not recommended due to lower conductivity. Tin-plated copper wire is acceptable. Secure termination of the included power and ground terminal lugs is essential, requiring a heavy-duty lug crimping tool and the supplied fasteners.
The ON/OFF function utilizes two wires: ON/OFF (Red) and ON/OFF Ground (Black). The controller activates when the ON/OFF wire receives at least 7 volts and the ON/OFF Ground wire is grounded. Utilizing an ignition-switched power or ground ensures the BPC deactivates when the vehicle is not in use. Both high-side and low-side switching options are illustrated in the documentation.
Pump wiring also requires high-quality, pure copper 12 AWG wire (tin-plated copper is acceptable).
Specific signal wire details are as follows:
- PWM + (Red/White): Ignition switched, battery + hot during cranking, 5 vdc (min). This wire initiates pump operation.
- PWM – (Black/White): Local chassis ground.
- MAP Ground (Green): Ground output to MAP sensor.
- MAP Power (Orange): +5 vdc output to MAP sensor, 20mA max.
- MAP Signal (Purple): MAP sensor signal input, 0.5 to 4.5 vdc.
- Flowrate Ground (Brown): Ground for Flowrate circuit, chassis ground.
- Flowrate Signal (Pink): Digital signal output to logger for flowrate datalogging.
Operational Modes
The BPC100 supports three operational modes: Constant Speed, MAP-based, and Constant Flow. Each mode requires specific wiring configurations and adjustments.
Constant Flow Mode
In Constant Flow mode, the pump operates at a fixed flowrate. This mode is useful for initial fuel system priming, leak checking, or troubleshooting. To activate Constant Flow mode, the PWM + and PWM – wires can be connected to the ON/OFF and ON/OFF Ground wires, respectively. This configuration activates the controller when the ignition is turned on. Alternatively, the PWM+ and PWM- wires may be wired using a fuel pump enable wire that switches to ground.
MAP Mode
MAP mode adjusts pump flowrate based on manifold absolute pressure (MAP). The controller utilizes three adjustment dials: MAX, MAP, and SPEED. The documentation notes that these dials rotate 210°, from a minimum indicator (~8 o’clock) to a maximum indicator (~4 o’clock), and should not be forced beyond these positions. A jeweler’s screwdriver is recommended for adjustments to prevent damage.
- MAX Dial: Sets the maximum pump flowrate. A counterclockwise setting corresponds to approximately 500 lph, while a clockwise setting yields 1100 lph.
- MAP Dial: Sets the MAP pressure at which maximum flowrate is reached. A counterclockwise setting corresponds to 2 bar, while a clockwise setting corresponds to 7 bar.
- SPEED Dial: While not used in MAP mode, the SPEED dial should be set to maximum (full clockwise) as a safety precaution. If the MAP sensor fails or is disconnected, the controller will revert to Constant Flow mode.
The pump’s minimum flowrate is fixed at 300 lph from 0 kPa through 50 kPa. Above 50 kPa, the flowrate increases linearly based on the MAX and MAP dial settings. Wiring for MAP mode requires the PWM + and PWM – wires to be connected to the ON/OFF and ON/OFF Ground wires, respectively, when both the PWM + and ON/OFF wires are at +12V, the PWM – and ON/OFF Ground wires are grounded, and the MAP Signal wire has at least +0.25 volts.
Constant Speed Mode
Constant Speed mode allows adjustment of the flowrate using the SPEED dial. The dial is adjusted clockwise for maximum flowrate and counterclockwise for minimum flowrate. Wiring for this mode mirrors that of Constant Flow mode, connecting the PWM + and PWM – wires to the ON/OFF and ON/OFF Ground wires, respectively.
Flowrate Monitoring
The BPC100 allows for pump flowrate monitoring via the Flowrate Signal and Flowrate Ground wires. When CAN logging is unavailable, the flowrate can be determined by grounding the Flowrate Ground wire and connecting the Flowrate Signal wire to an ECU digital input with an internal pull-up resistor. The frequency of the signal is directly proportional to the pump flowrate (e.g., 300Hz = 300 lph).
Adjustment Dial Considerations
The documentation emphasizes careful operation of the adjustment dials. The MAX, MAP, and SPEED dials have a limited range of motion (210°), and forcing them beyond these limits can cause damage. The use of the provided jeweler’s screwdriver is recommended for precise adjustments.
Application Specific Instructions
The documentation lists several application-specific instructions, including wiring and configuration details for:
- T1 ID BPC100 Wiring and Configuration for R35 Motec M1 ECU
- Resistor Box Removal with any ID Injector
- 04-06 Subaru STi Side Feed to Top Feed Conversion Line Kit
- Ford Coyote 5.0 Information
Conclusion
The Injector Dynamics BPC100 is a versatile fuel pump controller offering multiple operational modes and adjustable parameters. Proper installation requires careful attention to wiring specifications and understanding of the different modes of operation. The documentation provides detailed instructions for wiring, configuration, and troubleshooting, enabling users to optimize fuel delivery for various applications. The controller’s ability to monitor flowrate and its compatibility with different engine management systems make it a valuable tool for performance enthusiasts and professionals.