9
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. Read the sensor value and set this as 100%
butterfly valve travel.
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)
0.20-0.60V
~16%
0% (Closed)
4.40-4.80V
~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 3
rd
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 = -2.1519x
3
+ 3.0586x
2
+ 0.0582x + 0.0326
R
2
= 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%
0%
20%
40%
60%
80%
100%
120%
0%
50%
100%
Fl
o
w
P
er
centa
ge
Butterfly Position
5
6
