| Walbro 255L/Hr hi-pressure pumps will pull only about 12A a piece at full load (73psi rated) Combined puts you around 24A total in a full load condition. A 16 gauge wire can handle between 20-24A of current, which is what is used in the OEM harness. In this case the OEM wiring is more than capable of handling the loads. However, the Aeromotive 340L/hr pumps will pull a good bit more - around 16A each, total of around 36A in similar load condition as the walbros above. This is really getting into the territory of 14-gauge wire, perhaps 12ga to beef it up. In my controllers I preconfigure them to 40% duty for low speed, 65% duty for mid speed, and of course, full speed is 100% (battery voltage).
Total average current:
Walbro
low speed 40% = 9.6A
Mid Speed 65% = 15.6A Aeromotive:
low speed 40% = 14.4A
Mid Speed 65% = 23.4A Different pumps and configuration of pumps will have different current draw so that would need to be taken into account, but this should paint the picture pretty well. But even with the Aeromotive pumps peaking into the 36A range for only brief periods this wouldn't lead to a condition that causes any wiring failures - unless you were running on the salt flats for maximum speed. However, on vehicles that are making a load of horsepower, running loads of boost which require loads of fuel pressure and electrical power, at a certain point the wiring will become a bottleneck and prevent the pump from maintaining its output as compared to if it were wired with beefier wiring. Then my concern isn't with the wiring which can be easily changed out, it then becomes the bulkhead terminals themselves. Looks like we need to machine out a new aluminum bulkhead that has better pump mounting, AN fittings, and beefier electrical terminals. :) Another thing I have done in some cases where the aeromotive pumps are used is we took advantage of one of the terminals at the controller's connector to provide an additional ground line for the pumps. I just bridged the two end terminals on our controller's circuit board. The harness connector has a socket for a terminal and we have added that in and run an additional line parallel to the OEM line to beef things up since the terminal in the OEM harness connector and FPC connector become the power handling bottleneck - just double them up. :)
Enthusiasts soon understand each other. --W. Irving.
Are you an enthusiast? If you are out to describe the truth, leave elegance to the
tailor.
Albert Einstein
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