GenV Electronic Wastegate Instructions

Product Name:

Gen V eWastegate (Electronic Config)

Gen V eWastegate

Product Description:

Product Number:

2

TS-055X-15XX

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V1.00 Rev A

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Document Version:

IMPORTANT NOTES ON YOUR EXTERNAL EWASTEGATE

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Turbosmart accepts no responsibility whatsoever for incorrect installation of this product which is potentially hazardous and can cause serious

engine damage or personal injury.

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The Gen V 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.

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Use only high-quality fittings ensuring maximum sealing reliability. Optional Turbosmart fitting kit available.

RECOMMENDATIONS

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Always disconnect motor wires before removing the top cap of the actuator

Allow for adequate cool airflow around electronic actuator.

DO NOT Mount the 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 Gen V wastegate may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your

wastegate is fitted by an appropriately qualified technician.

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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.

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KIT CONTENTS

Please check that the following items have been provided in your Gen V eWastegate kit.

Part

1

Description

Turbosmart Gen V eWastegate

Valve Seat

Use

Main unit

2

Valve seat

3

Inlet V-Band clamp

Inlet Weld flange

Inlet V-band clamp

Inlet V-band weld flange

Outlet V-band clamp

Outlet V-band weld flange

Adjusting actuator location

Turbosmart sticker

4

5

Outlet V-Band clamp

Outlet weld flange

Collar tool

6

7

8

Turbosmart Sticker

1

3

4

5

6

7

2

Figure 1 - Kit Contents

1

CONTENTS

KIT CONTENTS..........................................................................................................................................................1

TOOLS REQUIRED....................................................................................................................................................3

SUGGESTED LUBRICANTS AND SEALANTS..........................................................................................................3

PART NUMBERS .......................................................................................................................................................3

QUICK START GUIDE................................................................................................................................................3

HOW TO USE.............................................................................................................................................................3

MAINTENANCE..........................................................................................................................................................3

TEMPERATURE.........................................................................................................................................................3

BASIC TUNING PARAMETERS.................................................................................................................................4

WHAT’S NEW ............................................................................................................................................................4

GEN V EWASTEGATE OVERVIEW ...........................................................................................................................5

FITTING YOUR GEN V WASTEGATE........................................................................................................................6

Mounting your New Turbosmart Gen V eWastegate ....................................................................................................6

Fitting the Gen V eWastegate...........................................................................................................................................6

Connecting Your Wastegate.............................................................................................................................................7

Calibration............................................................................................................................................................................8

Tuning...................................................................................................................................................................................8

Sensor Linearisation..........................................................................................................................................................9

ADVANCED FEATURES ON THE GEN V WASTEGATE...........................................................................................9

Re-Orientation of the Actuator .........................................................................................................................................9

Water Cooling....................................................................................................................................................................10

TROUBLESHOOTING..............................................................................................................................................11

2

TOOLS REQUIRED

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¼” drive socket 5mm

¼” drive extension

¼” drive ratchet

3/8” square drive deep socket

Square drive ratchet wrench

Torque wrench (3/8” drive)

Non-marking spanners to tighten fittings

Supplied collar tool

SUGGESTED LUBRICANTS AND SEALANTS

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Loctite 243 Thread locker

Loctite 567 Thread Sealant

Resbond 907TS Red

Penetrating oil

Inox MX8 spray grease

PART NUMBERS

TS-0553-1502 – Gen-V WG45 Hyper-Gate45 Electronic Black

TS-0555-1502 – Gen-V WG60 Powergate 60 Electronic Black

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QUICK START GUIDE

HOW TO USE

The Turbosmart eWastegate is a brand-new way to drive aftermarket wastegate valves, it involves using an electric motor

to drive the position of the valve, this allows far greater control over the valve during its actuation on the car, this paired

with an aftermarket ECU controlling it, allows for plenty of new and safer ways to control boost on your car.

The Body will need to be fitted to the vehicle. Please see the exploded drawing (figure 10). 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. A Valve seat is fitted inside the inlet V Band allowing the valve to seal upon closing. It is important to have the

valve manually set to about the middle of its stroke as well as the valve seat installed. This will allow for an easier

installation.

Please see below for a more detailed and helpful way of installing the Turbosmart Gen V eWastegate.

MAINTENANCE

Turbosmart’s Gen V eWastegate will require periodic reapplication of spray grease such as Inox MX8 spray grease, this is

important that the manual override is used to move the valve up and down allowing the grease to be applied throughout

the entire valve gearbox. Turbosmart recommends that this is done regularly at least half yearly or in demanding

temperature environments.

It is also important to check V Band tightness after the wastegate has run through a couple of heat cycles. To ensure that

the wastegate is seated and sealing correctly.

TEMPERATURE

The Turbosmart Gen V eWastegate has a maximum thermal stress of 1250^oC for 24hr if thermally cooled through the

o

water-cooling ports, it is important that the actuator internal housing doesn’t go above a temperature of 150 C 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 that

is seen inside the actuator using the temperature sensor included onboard.

It is recommended that water cooling is in line with the turbo this will increase the longevity of the eWastegate and allow it

to operate seamlessly. This does depend on the certain application and the rate and period at which the eWastegate is

exposed to the high temperatures.

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BASIC TUNING PARAMETERS

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

eWastegate will be targeting a set position, this will move further away if the motor polarity is wrong as it’s trying to reach

it’s 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).

Valve Position limits should be set to target 0% for valve closed and 90% for completely open, Since the design of the

end stops is biased to operate better with the valve in the closed position it is recommended to avoid opening the valve to

full lift.

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WHAT’S NEW

Our new eWastegates are a direct fit upgrade to all 4th-generation Turbosmart wastegates and feature our unique collar-locking

system, variable motor cap and base, strap-type V-band clamps, liquid-cooling, 1/8″ NPT ports.

Control

With the introduction of the electronic motor to drive the eWastegate, 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 with the turbo boost strategies.

Adjustability

The 5th generation eWastegate range has been designed with maximum user-adjustability, without comprising performance. We

designed this unit with almost infinite possibilities of directions in which the motor assembly can be mounted with the engine bay. So,

if you need the eWastegate mounted in the opposite orientation to stop fouling with parts within the engine bay, there is an orientation

that is suitable for the eWastegate to operate in. This mixed without the need of having to remove and reassemble due to changes in

base wastegate spring pressure the eWastegate has next level control adjustability of the position of the wastegate 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 will be rock-solid.

Flow and Thermal Performance

Our new range of wastegates out-flow all competitors thanks to our world-leading engineering and simulation abilities. Thermal

performance has been improved drastically compared to our nearest rival, and all wastegates feature liquid cooling ports for further

thermal performance if required.

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GEN V EWASTEGATE OVERVIEW

Wiring Loom

“Water Cooling” port

1/8” NPT

Inlet V-Band

Outlet Weld flange

Outlet V-Band

Inlet Weld Flange

Figure 1 -Gen V eWastegate Overview

Locking tabs

Water cooling

symbol

Slave Collar

Figure 2 – Gen V eWastegate Water Cooling

Figure 3 – Gen V eWastegate Locking

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FITTING YOUR GEN V WASTEGATE

Mounting your New Turbosmart Gen V eWastegate

1

Water cooling is highly recommended for sustained heat

exposure.

The Gen V series of Wastegate including Electronic is a direct fit

replacement for the 4 gen wastegate range and no modification

is necessary provided packaging space is sufficient within the

engine bay.

th

Exhaust flow

to eWastegate

Turbine

The weld flanges should be welded to your exhaust system. The

weld flanges are compatible with Stainless Steel and Mild steel

welding rod material.

Exhaust flow

from engine

For best results, an attempt should be made, if space allows, to

mount the Gen V eWastegate 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.

Figure 6 - 90 Degree mounting

90 Degree mounting gives poor exhaust flow to the wastegate

and in some circumstances may contribute to over boosting.

CAUTION!

eWastegate

Do not place the eWastegate near a significant heat source

as this could shorten the life of the internal electronics.

eWastegate

Exhaust flow

to eWastegate

Turbine

Exhaust flow

to eWastegate

Turbine

Exhaust flow

from engine

Exhaust flow

from engine

Figure 7 - Not Recommended - Less than 90 Degree Mounting

An angle mounting as shown in not recommended and gives

extremely poor exhaust flow to the eWastegate which can

contribute to poor boost control and over boosting.

Figure 4 - Best flow - Symmetric mounting

Symmetric mounting allows an excellent flow of exhaust to the

wastegate.

Wastegate

Fitting the Gen V eWastegate

Exhaust flow

to wastegate

2

Prior to mounting the Gen V eWastegate, place v-band (figure 9)

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.

Do not forget to put the valve seat into the body before mounting

the unit on the exhaust manifold. 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 torqueing the nut to not

have a false torque as this will likely contribute to exhaust leaks.

Turbine

Exhaust flow

from engine

It is important that the valve sits slightly open for installation. This

allows for no interference during the installation process. This

can be adjusted via the manual override. (Figure 8)

Figure 5 - Good Flow - Angle mounting

Angle mounting allows a good flow of exhaust flow to the

wastegate.

eWastegate

6

Connecting Your Wastegate

3

Manual

override

The Turbosmart Electronic wastegate come unterminated with 7

wires. A revision has been made to include the ability for a PWM

signal. This is the Revision B (current). It can be identified by the

colour of the wires and number of wires in the core (5 smaller

gauge wires).

Revision B (current) – Wiring

Colour

Description

Large Gauge Red Motor A tending towards

0%

1

single core

wire each

Large Gauge

Black

Motor B tending towards

100%

Red

5V

Black

White

Blue

Sensor ground 0V

Position Signal 0-5V

Pulse Width Modulation

Signal

Figure 8 – Manual Override

Multi Core

Wire

(

Rev B Only)

Yellow (Orange

Temperature Signal 0-5V

Rev A)

Sensor Voltage Limits

Deg C (Deg F) Temperature Sensor Temperature Sensor

Output (mV) Rev A

Output (mV) Rev B

0

1

(32)

50 (302)

500

2000

2630

538

Position Sensor

Target Voltage (V) Duty Cycle (Rev B

only)

1

0

00%

%

0.20-0.60V

4.40-4.80V

~16%

~84%

CAUTION!

Turbosmart recommends calibrating the position sensor

before connecting the motor wires to your motor drive.

Figure 9 – V Band Clamp

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, that 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.

CAUTION!

Whilst the temperature sensor is not required for operation

it is recommended for activating failsafe protocols.

CAUTION!

Ensure all connections are high quality and away from any

heat source.

Figure 10 – Exploded drawing of assembly of eWastegate.

7

CAUTION!

Do not apply excessive force to the manual override, doing

so will damage the product and effect the performance.

Calibration

4

CvAUTION!

Disconnect the motor wires to prevent accidental spin up.

Valve Down

To calibrate the electronic wastegate the cap must be removed

to allow access to the manual override screw. Please note that

the valve seat must be in place before calibration.

Valve UP

Cap retaining

bolts

Figure 13 – ¼ Drive extension with 5mm socket manually

adjusting.

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. Read the sensor value and set this as 100%

valve travel.

Using an Allen key remove the 2 top bolts allowing the cap to be

removed, and a spacer or shift the cap off to one side and reinsert

at least one of the bolts. This prevents the preload in the

mechanism separating the housing potentially effecting the

calibration accuracy.

Monitor sensor signal voltage to ensure no wrap around occurs

throughout the stroke of the valve that could affect operation.

CAUTION!

Figure 11 – Top Cap removed for calibration

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.

Carefully move the motor wired allowing access to the manual

override below (Figure 12)

NOTE!

Manual

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.

Override

Tuning

5

The eWastegate will come calibrated from Turbosmart,

the targeted values have been set with regards to the position

sensor are 0.5V (completely open) and 4.5V as (completely

closed), It’s important to note that as the wastegate valve moves

through its range of motion that the 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 (Rev B

only)

Figure 12 – Manual Override

1

0

00%

%

0.20-0.60V

4.40-4.80V

~16%

~84%

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 valve should be

home against the valve seat and will be your 0% position.

Remember to have the valve seat inserted.

It is important to set up the correct limits manually with

eWastegate. Turbosmart recommends that the valve is only

8

ever driven electronically to the maximum valve position of

0%.

9

Sensor Linearisation

6

Driving the valve to 100% will cause increased wear on

components such as the electronic motor as it tries to

force the valve to completely open.

Due to the nature of the poppet 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 valve position with

rd

Adjust the calibration to allow plenty of overshoot to the end stops

of the valve, recalibrate as above once you have good control of

valve position.

valve flow. A 3 order polynomial is provided to relate sensor

position to flow. Note due to the design of the wastegate, the

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.

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

1

sufficient alarms to monitor this.

50degC (302degF) it is recommended to log and place

Sensor Linearisation

1

20%

00%

80%

120%

100%

80%

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.

1

60%

40%

20%

60%

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.

40%

20%

0%

_-20% ⁰^%

50% 100%

Valve lift

¹⁵⁰^%-20%

y = 0.5596x³ – 1.8306x²+ 2.2847x – 0.0189

2

R = 0.9989

ADVANCED FEATURES ON THE GEN V WASTEGATE

screwdriver, pry this tab out of the groove allowing the collar to

be loosened.

Re-Orientation of the Actuator

1

Using the small end of the supplied collar tool undo the slave

collar 1 complete revolution (anti-clockwise as viewed from the

bottom). One tab on the heatshield at the back of the wastegate

is folded up to locate on the actuator, rotate the actuator to

desired location ensuring the folded tab aligns with a groove in

the bottom of the actuator. It is possible to fold down this tab and

use another if the actuator cannot be positioned correctly on the

original tab.

CAUTION!

Turbosmart does NOT recommend altering to position of the

actuator once the wastegate has been used.

It is recommended that the electronic actuator be clocked

without a valve seat installed to prevent damage to the valve.

3

drive

/8” square

Turbosmart provide the Gen V eWastegate in a set orientation,

in some applications it may be advantages to clock the actuator

to allow clearance for fittings and wiring.

Locate the slave collar between the electronic actuator and the

body underneath the heatshield, A tab on the heatshield will be

folded down into a groove on this collar. Using a flat blade

9

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.

Locking

groove

Locking

collar

Locking

tabs

Pre-folded

tab

Tighten the collar using a torque wrench on the 3/8” square drive

provided in the collar tool perpendicular to the length of the tool

to 30N.m (22ft/lbs). Fold down a tab onto the slave collar to

prevent the collar from coming loose during use.

Water

feed/return

CAUTION!

Check for leak, ensure the water-cooling circuit is free from

leaks.

Water Cooling

2

Turbosmart’s Gen V eWastegate 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.

Water cooling

Port (2 holes)

Water

cooling

symbol

1

0

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TROUBLESHOOTING

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Wastegate not actuating - Confirm continuity of wiring, manually adjust valve 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 valve may not be set up correctly.

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Wraparound of signal on position sensor – Turbosmart Pre “time” every sensor, contact Turbosmart if this occurs.

Wastegate seized – Remove cap and manually move valve 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 request to tech@turbosmart.com.au with information of your engine configuration and

photos of installation.

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