eSG Electronic StraightGate Instructions
Product Name: | eSG Electronic StraightGate |
Product Description: | eSG Electronic StraightGate External Wastegate |
Product Number: |
Important Notes on Your New Electronic StraightGate
Important Notes on Your New Electronic StraightGate
- Turbosmart
accepts no responsibility whatsoever for incorrect installation of this product
which is potentially hazardous and can cause serious engine damage or personal
injury.
- The
Straight external eWastegate is designed for use with a turbocharger that does
not have an internal wastegate.
- Consult your local specialist before
setting your desired boost pressure, setting boost beyond your engines
capability may result in engine damage.
- Use
only high-quality fittings ensuring maximum sealing reliability.
- Incorrectly wiring sensor to
Chassis ground will cause calibration issues, Sensor Ground must be connected
to the ECU Sensor ground. Do NOT connect ECU Grounds and Chassis Grounds
together they must remain separate.
- Correctly setting up a sensible boost control strategy to ensure engine safety is highly recommended.
Recommendations
Recommendations
- Always disconnect motor wires before removing the end cap
off the actuator
- Allow for adequate cool airflow around electronic actuator
paired with water cooling.
- DO NOT Mount the electronic wastegate so that the electronic
actuator is less than 100mm from a heat source.
- DO NOT wrap the body of the wastegate with exhaust wrap.
- Fitting your Electronic
Straight Wastegate may require fabrication or modification to your exhaust
manifold. Turbosmart recommends that your wastegate is fitted by an
appropriately qualified technician.
- Turbosmart recommends that the engines Air/Fuel ratio is
checked while setting the desired boost pressure, as any increase in boost
pressure can cause the engine to run “LEAN”, resulting in possible engine
damage.
- Turbosmart recommends that boost
pressure is set using a dynamometer and not on public roads.
- Turbosmart recommends that a boost gauge be permanently fitted to the vehicle.
Kit Contents
Kit Contents
Part | Description | Use | QTY |
1 | Turbosmart Electronic Waste Gate | Main unit | 1 |
2 | Inlet V-Band clamp | Inlet V-band clamp | 1 |
3 | Inlet Weld flange | Inlet V-band weld flange (O-Ring included) | 1 |
4 | Outlet V-Band clamp | Outlet V-band clamp | 1 |
5 | Outlet weld flange | Outlet V-band weld flange (O-ring included) | 1 |
6 | Turbosmart Sticker | Turbosmart sticker | 1 |
Tools Required
Tools Required
- ¼” drive socket 5mm
- ¼” drive extension
- ¼” drive ratchet
- 3/8” square drive deep socket
- 14mm square drive deep socket
- Square drive ratchet wrench
- Torque wrench (3/8” drive)
- Metric Allen Key set - 2.5mm,3mm, 4mm Allen key
- Non-marking spanners to tighten fittings
Suggested lubricants and Sealants
Suggested lubricants and Sealants
- Loctite 243 Thread locker
- Loctite 567 Thread Sealant
- Resbond 907TS Red
- Penetrating oil
- Inox MX8 spray grease (Or Equvilant)
Quick Start Guide
CAUTION! It is important
during the setup of the eGate, that some precautions are taken to ensure that
the unit does not malfunction. Firstly, the output from the ECU should be
limited to 15%. As well as an inline fuse (5A-10A) or breaker to protect the
eGate. Once correct operation has been completed, initial safety setups can be
lifted to operational limits.
The Turbosmart Straight Gate is a brand-new way
to control boost pressure, it involves using an electric motor to drive the
position of the butterfly valve, this allows far greater control over
conventional pneumatic boost control during its actuation on the car. This
paired with an aftermarket ECU controlling the straight gate, allows for plenty
of new and safer ways to control boost on your car.
The Body will need to be fitted to the vehicle. This involves the two V
Bands clamps, the Inlet (fitted on the exhaust manifold), and the outlet which
is where the regulated exhaust gases are bypassed. It is important to have the butterfly
valve manually set to about the middle of its stroke. This will allow for an
easier installation. The Straight Gate can be used in both directions.
Please see below for a more detailed and
helpful way of installing the Turbosmart Electronic
Straight Wastegate.
Turbosmart Electronic Straight Gate will require periodic reapplication of spray grease such as Inox MX8 spray (Any high temperature high pressure grease will suffice) grease. It is important that the manual override is used to move the butterfly valve through its range of motion, allowing the grease to be applied throughout the entire butterfly valve gearbox. Turbosmart recommends that this is done regularly at least half yearly or more in demanding temperature environments.
Inspecting motor operation is important to do when using a third party controller incase of issues with the motor. This isn't an issue with the Black Box Controller. Inspection should be done for motor operation after heavy use sessions such as racing weekends
It is also important to check V Band tightness after the wastegate has run through a couple of heat cycles. To ensure that the Straight Gate is seated and sealing correctly.
The Turbosmart Electronic Straight Wastegate
has a maximum thermal stress of 1250degC (2282degF) for 24hr if thermally cooled with the
water-cooling ports. It is important that the actuator internal housing doesn’t go above a temperature of 150degC (302degF)
as this may cause damage to the internal electronics. Turbosmart recommends
that the eWastegate is water cooled and paired with good airflow over the body
to help regulate temperature. Turbosmart also recommends data logging the
temperature sensor that is seen inside the actuator.
It is recommended that water cooling is in line
with the turbo this will increase the longevity of the Electronic Straight Gate
and allow it to operate seamlessly. This does depend on the certain application
and the rate and period at which the Electronic Straight Gate is exposed to the
high temperatures.
It is important that the basic tuning
parameters are discussed with a trained professional, please consult your ECU
manufacture. There are a few basic parameters that are worth noting.
Motor polarity is important, Due to the nature of
PID controllers (Proportional-integral-derivative controller) the Electronic
Straight Gate will be targeting a set position, this will move further away if
the motor polarity is wrong as it is trying to reach its setpoint.
Current limitations, it is important that
the Current that is driven through the motor is limited to no more than 20amps
for more than 1 second and 5 amps for more than 5 seconds. It is important that
the current values such as the dead band are correctly set in the ECU to allow
for the motor to only be active if needed.
Sensor Diagnostic limits should be monitored for
values that are lower than 0.1V and higher and 2.15V with respect to the
Temperature sensor and 0.1V-4.9V with the position sensor. It is also
recommended that safety tuning strategies are in place to lower temperatures if
the eWastegate internally reaches a temperature of 150degC (302degF).
Butterfly Position limits should be set to target
0% for butterfly closed and 90% for completely open, Since the design of the
end stops is biased to operate better with the butterfly in the closed position
it is recommended to avoid opening the butterfly at full opening.
Boost cut should be set to
ensure the safety of your engine a sensible boost cut should be set with in the
ECU to control any possible over boost issues that could be detrimentally to
your engine.
The new Turbosmart Electronic Straight Gate is
Turbosmart’s addition to its electronic wastegate line-up. A new level of
control is now available with the butterfly valve and offers the option for
customers who require another packaging or new level of control.
Control
With the introduction of the electronic
motor to drive the Electronic Straight Gate, a new level of control is now available to
boost control, there is a wide range of tuning strategies that can be
implemented to better control boost as well as engine protection. This
allows the Engine to maintain much better control over the turbocharger.
Adjustability
The straight gate now offers 3 options
for the motor and body to be mounted in, this is coupled with infinite
possibilities of the body and exhaust piping with the weld flanges. So, if you
need the Electronic Straight Gate mounted in the opposite orientation to stop
fouling with parts within the engine bay, there is an orientation that is
suitable for the Electronic Straight Gate to operate in. This mixed without the need of having to remove and
reassemble due to changes in base wastegate spring pressure the Electronic
Straight Gate has next level control
adjustability of the position of the wastegate butterfly valve.
Upgrades and Servicing
Due to the modular construction, the new range is also upgradeable
and completely serviceable, as all components can be removed or upgraded.
Components have been tested for over one million cycles, so reliability is
rock-solid.
Flow and Thermal Performance
The new straight wastegate is a world first in its class It
features excellent flow properties thanks to our world-leading engineering and
simulation abilities. Thermal performance is a critical key performance factor
within the design of all our products. Thermal stability and longevity are
further extended with the liquid cooling ports for further thermal performance
if required.
The weld flanges should be
welded to your exhaust system. The weld flanges are compatible with Stainless
Steel and Mild steel welding rod material.
The Straight Gate utilises
WG60 Outlet Flanges, this allows for a straight swap over for engines running
WG60 Valves. A new exhaust side will need to fabricated for cars running the
poppet valve.
For best results, an attempt
should be made, if space allows, to mount the Straight Gate at an angle to the
exhaust flow to allow for better flow than a 90-degree mounting. See the
schematic diagrams below for examples of mounting positions.
NOTE! The Straight Gate can
be used in both directions. Both directions will regulate the same. It is
advisable however to place the Butterfly Valve pins exhaust side up.
Water
cooling is highly recommended for sustained heat exposure.
(Best Flow) Symmetric mounting allows an excellent flow of
exhaust to the Straight Gate
(Good Flow) Angle mounting allows a good flow of exhaust
flow to the Straight Gate.
(Poor Flow) 90 Degree mounting gives poor exhaust flow to
the Straight Gate and in some circumstances may contribute to over boosting.
Not Recommended - Less than 90 Degree Mounting. An angle mounting as shown in not recommended
and gives extremely
poor exhaust flow to the Straight Gate which can contribute
to poor boost control and over boosting.
CAUTION! Do not place the Straight Gate
near a significant heat source as this could shorten the life of the internal
electronics.Fitting the StraightGate
Even though possible
to mount the Straight gate in both directions, it is suggested that the
Butterfly valve pins are facing towards the exhaust exit.
Prior to mounting the Straight Gate, place
v-band (Figure 10) over weld on flange by unscrewing the nut on the v-band as
far out as possible and then squeezing the bolt in a syringe motion to expand
the v-band (squeeze the dots together below). Once the v-band is in its fully
expanded position, slide the v-band over the flange to allow for the wastegate
to be installed.
Using the 3/8” deep socket and a torque wrench Tighten
the V-Band to 7N.m (5 ft/lbs). Ensure the wastegate is home correctly while
torquing the nut to not have a false torque as this will likely contribute to
exhaust leaks.
It is important that the butterfly valve sits
slightly open for installation. This allows for no interference during the
installation process. This can be adjusted via the manual override.
Connecting your Turbosmart Electronic Wastegate
The Turbosmart Electronic wastegate comes unterminated with 7 wires.
Wiring Pinout
Revision B (current) – Wiring
| Colour | Description |
1 single core wire each | Large Gauge Red | Motor A tending towards 0% |
Large Gauge Black | Motor B tending towards 100% | |
Multi Core Wire
| Red** | 5V |
Black*** | Sensor ground 0V | |
White | Position Signal 0-5V | |
Blue (Rev B Only) | *Unfiltered Signal Output (Position Output) | |
Yellow (Orange Rev A) | Temperature Signal 0-5V |
*Note: The Blue (unfiltered position signal) is not required for use & is for development purposes only.
**Note: The 5V red wire has no reverse polarity protection, use only 5V wired in correctly.
**Note: The sensor ground must be grounded at the ECU Sensor ground and NOT the chassis
Sensor Voltage Limits
| Deg C (Deg F) | Temperature Sensor Output (mV) |
| 0 (32) | 2630 |
| 150 (302) | 538 |
| Position Sensor | Target Voltage (V) | Duty Cycle |
| 100% (Open) | 0.2-0.6V | ~16% |
| 0% (Closed) | 4.2-4.6V | -84% |
CAUTION! Turbosmart recommends calibrating the position sensor before connecting the motor wires to your motor drive.
The two large wires are directly connected to the motor of the wastegate and need to be connected to high power drives in a Full bridge configuration like that of an electronic throttle drive circuit, see your ECU supplier documents for suitable connections. Turbosmart recommends the eWastegate should be driven by an External dual H-Bridge, which is at least 20A for seamless operation.
Connect the small Red Wire to a 5V power source from your ECU as well as the Black wire to Sensor ground. Connect the white wire to a 0-5V analogue input on your ecu as well as the orange temperature sensor signal. The blue wire (Revision B only) is an unfiltered position output signal for development purposes - This can be left unterminated.
CAUTION!
- Whilst the temperature sensor is not required for operation it is recommended for activating failsafe protocols.
- Ensure all connections are high quality and away from any heat source.
It is important during the setup of the eGate, that some precautions are taken to ensure that the unit does not malfunction. Firstly, the output from the ECU should be limited to 15%. As well as an inline fuse (5A-10A) or breaker to protect the eGate. Once correct operation has been verified the fuse and limits can be removed.
Calibration
CAUTION! Disconnect the motor wires to prevent
accidental spin up.
To calibrate the electronic straight gate
firstly the manual override cap must be removed to allow access to the manual
override. A non marking 14mm is required to remove the cap from the body.
Using a ¼” drive extension with a 5mm socket, turn the manual override in a clockwise direction with your fingers until the mechanism stops rotating. In this position the butterfly valve should be home against the valve seat and will be your 0% position.
CAUTION! Do not apply
excessive force to the manual override, doing so will damage the product and
effect the performance.
Using
your ECU manager software, read the voltage from the sensor and set this as
your closed position.
Wind
the manual adjustment in an anticlockwise direction until it stops. From this
position rotate the adjustment 2 full turns in a clockwise direction. Allowing the gate to sit in the roughly 50% Valve position, as to ensure that the valve isn't sitting on it's hard stops.
Monitor
sensor signal voltage to ensure no wrap around occurs throughout the stroke of
the butterfly valve that could affect operation.
CAUTION! It
is critical not to set the 100% position at the end of the travel as this may
lead to seizing of the wastegate and overloading the system.
NOTE! Turbosmart
recommends allowing additional clearance from the end stops until the wastegate
control is tuned to minimise risk of overshoot into end stops at high speeds.Tuning
The eWastegate will come calibrated from
Turbosmart, the targeted values have been set with regards to the position
sensor are approx. 0.5V (completely open) and approx. 4.5V as (completely
closed), It is important to note that as the wastegate butterfly valve moves
through its range of motion that the butterfly valves are monitored to move
from 4.5V decreasing to 0.5V, 0% open to 100% open. This should be done manually with the ECU
package monitoring Voltage Values. The electronic motor should be disconnected
at this point.
Voltage wraps around will cause errors with the
eWastegate, this is when the Voltage increases from 4.8V up to 5V and jumps
through to 0V.
| Position Sensor | Target Voltage (V) | Duty Cycle |
| 100% (Open) | 0.2-0.6V | ~16% |
| 0% (Closed) | 4.2-4.6V | -84% |
It
is important to set up the correct limits manually with eWastegate. Turbosmart
recommends that the butterfly valve is only ever driven electronically to the
maximum butterfly position of 90 %.
Driving
the butterfly valve to 100% will cause increased wear on components such as the
electronic motor as it tries to force the butterfly valve to completely open.
Adjust the calibration to allow plenty of
overshoot to the end stops of the butterfly valve, recalibrate as above once
you have good control of butterfly position.
PLEASE
NOTE: That temperatures over 180 degC (356degF) will create an error in the
temperature sensor readings. Therefore, the internal temperature is rated to a
temperature of 150degC (302degF) it is recommended to log and place sufficient
alarms to monitor this.
PLEASE NOTE: When driving the electronic actuator, the
current should be limit to no more than 20 amps at a period of 1 second
and 5 amps for more than 5 seconds.
Follow your ECU manufacturers guidelines for
tuning wastegate servo control. Ensure dead band is set to a reasonable level
to not have the output active when not needed.
Sensor Linearisation
Due to the nature of the
butterfly valve design, the flow characteristics are nonlinear. In some cases,
it may be advantages to correlate the linear sensor output to match the flow of
the valve. The following plot compares butterfly valve position with valve
flow. A 3rd order polynomial is provided to relate sensor position
to flow. Note due to the design of the electronic straight wastegate, the
butterfly valve is on a preloaded mechanism to minimise binding at the end
stops, this results in the sensor reading past the home positions and for this
reason the calibration sequence with low
force is essential.
y = -2.1519x3 + 3.0586x2 +
0.0582x + 0.0326 R2 = 0.999
Butterfly Position | Flow Percentage |
0% | 3.3% |
3% | 3.7% |
6% | 4.7% |
10% | 6.7% |
20% | 14.9% |
30% | 26.7% |
40% | 40.8% |
50% | 55.7% |
60% | 70.4% |
70% | 83.4% |
80% | 93.5% |
90% | 99.4% |
100% | 100.0% |
ADVANCED FEATURES ON THE STRAIGHT WASTEGATE
Water Cooling
- Turbosmart’s StraightGate is equipped with water cooling ports to keep the wastegate cool in the most extreme conditions and keep consistent actuator temperature.
- Identify the water cooling ports on the bottom
of the actuator adjacent to the water-cooling symbol engraved in the actuator.
Fit water-cooling port fittings Prior to mounting the wastegate, install 1/8” NPT fittings into the water ports, apply thread lubricant and screw in clockwise until finger tight, then tighten further 1-2 turns for seal. Choose feed and drain source for the water and connect to the wastegate. Turbosmart recommends -4SAE fittings and hose compatible with coolant. It is not important which way the water flows through housing.
CAUTION! Check for leak, ensure the water-cooling
circuit is free from leaks.
How to Conduct Maintenance on Your Electronic StraightGate
Basic Maintenance
The Straight gate will require periodic maintenance depending on application. In high demand, unusually environments, it is advisable to increase the service interval.
Turbosmart recommends that the internal gearbox is regreased with a spray type grease such as Inox MX8 spray grease this should be conducted half yearly or more depending on environment. With the top plate removed grease can be sprayed into the small inspection hole located near the magnet covered by a M4 bolt as well as located near the motor.
Motor Replacement
In the event of the motor failing, it can be
easily replaced. The Motor Housing must be disassembled, the cap must
be removed with the Turbosmart rear housing tool, this opens the rear of the
motor housing, once open the motor wires will need to be moved out of the way.
The black wire is matched to the red dot on the back of the motor cover. With
the wiring clear the 4mm Allen keys will need to be removed. The rear housing
will separate. Pulling it off the back. The replacement motor part number
A 2.5mm Allen key will be required to remove
the motor screws. With both undone. The motor can be lightly pushed out. When reinstalling, use a small application of
Loctite 243.
Sensor Replacement
In the event that the sensor fails, it is located under the top cap, it is held on with two 2.5mm Allen keys for the cap and two 2.5mm for the encoder. The replacement sensor part number (TS-0550-3123). The encoder is located under neath the top cap of the Electronic straight gate. The grommet will remain attached to the top cap and be removed as one piece.
Actuator Replacement
The actuator can be removed and rotated through 3 different orientations; these are parallel to the body, 30 deg to the body and the current configuration 90 deg to the body.
The
actuator locking pins are 3mm Allen keys that lock the body to the actuator. It
is important that the butterfly remains in the same position, the recommended position
is to be just off the valve seat. It is also advisable to not to move the
manual override during this process.
CAUTION! Moving body and actuator while separated will
cause issues with calibration. If moving to one of three mounting options
observe positions before moving readjusting.With the Allen key pins removed the body can be separated from the actuator and one of the three options can be picked.
The
actuator locking pins are to be Torqued to 6N/mm as well as a new application
of Loctite 243 is also required.
Troubleshooting
Troubleshooting
- Wastegate not actuating - Confirm continuity of wiring, manually adjust butterfly position and feel for binding.
- Poor wastegate actuation – Ensure wiring is correct, check for dirt and smooth operation by manual over-ride, ECU that is driving the butterfly may not be set up correctly.
- Wraparound of signal on position sensor – Turbosmart Pre “time” every sensor, contact Turbosmart if this occurs.
- Wastegate fluctuates and fails to find targeted position, motor wires may be the incorrect way. Swap and test to see. Ensure to use sensible current limits to prevent over currenting.
- Wastegate seized – Remove cap and manually move butterfly feeling for resistance.
- Wastegate moves but sensor not reading – Check connections.
- Boost creeping at high rpm - Wastegate flow path is poor, wastegate is too small for the application.
- Failing the above, submit a Technical Support Query Form with information about your engine, oil type and photos of the installation and one our expert technicians will respond as soon as possible.
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