Haltech HT-038009 User manual

DCMD
DC MOTOR DRIVER
QUICK START GUIDE
HT-038009

3
Features:
• Compatible with all Elite and NEXUS ECUs
• Two independent channels
• Switching Speeds up to 2.2kHz
• Limited automatic overcurrent protection
To ensure that your Elite ECU or NEXUS ECU is
compatible, please download the latest software
and rmware available from our website.
www.haltech.com/downloads
For more guides and instructions, visit our
Knowledge Base. https://support.haltech.com
PRODUCT OVERVIEW
22
Congratulations on purchasing a Haltech DC
Motor Driver (DCMD).
This driver has been designed to drive a DC
motor like the Turbosmart Electric Wastegate or
Varex systems. It can also be used to drive high
power, external electric throttle bodies.
Compatible with all Elite and NEXUS series
devices, this 8A full bridge DC Motor Driver
will work in applications where the current
requirements are higher than the Haltech Elite
ECU’s stepper (1A) or DBW (3A) outputs can
provide.
This driver can also be used with NEXUS devices
where no HBO (8A) or HCO (25A) pins are
available.
DCMD
Size (without connector) 86mm x 28mm x 55.5mm
Operating Voltage 8V to 18V DC
Recommended Switching Speed 2.2kHz Maximum
Operating Current 8A Continuous Per Channel,
Maximum Transient Current 30A
Ambient Operating Temperature -40C to +85C (-40F to 185F)
Supported Haltech ECUs All Elite and NEXUS Devices
Recommended Wire Size 16AWG - Power, Ground, Motor A/B
20AWG - Control A/B
Recommended Fuse 20A for Switched Power
Configuration via Haltech NSP Software
Control Source Any spare DPO, Ignition, Injection, Stepper
or DBW output(s).
The DCMD is rated for 8A continuous per
channel, with a maximum current of 30A.
Both channels can be controlled independently,
ie “Control A” switches “Motor/Output A”.
With a maximum recommended switching
speed of 2.2kHz, this driver box is perfect for
connecting devices like the Turbosmart EWG to
your Elite or NEXUS device.
NOTE: Native Turbosmart Electric Wastegate
control is limited to Elite and NEXUS series
devices and is not supported on Platinum series
ECUs.
What’s in the box?
• Haltech DC Motor Driver (DCMD)
• 1 x DT02-2S - includes wedges and pins
• 1 x DT06-4S - includes wedges and pins
• 1 x DTM06-4S-E004 - inc. wedges & pins
• 1 x DTM04-49-E004 - inc. wedges & pins
• 1 x Quick Start Guide

4 5
To begin conguring your DCMD for use with
the NEXUS Software Programmer (NSP), please
make sure you have the most up-to-date version.
With your new DCMD installed and connected,
boot your Elite or NEXUS device with NSP.
The Electric Wastegate function within NSP was
developed specically for Turbosmart EWGs,
greatly simplifying the whole setup process.
Calibration
The calibration node is used to calibrate your
electronic wastegate. Make sure your engine is
turned off through this process.
Begin by clicking “Reset”, the status bar will
read “Uncalibrated” for each wastegate.
WARNING!
Turn your engine off before calibrating your
Electric Wastegate. The calibration process
cannot be completed with the engine running.
NSP will alert you when the process has been
sucessfully completed. Your status bar should
change to a highlighted green “Calibrated”
message.
Wiring Configuration
The wiring node is used to change your boost
control method from standard solenoid to a
single or dual EWG option.
Through the navigation tree, enter the Wiring
conguration tab for Boost Control. Select your
wastegate output type in the pull down menu.
If you get prompted to reset your ECU for these
settings to take effect, please do so now.
If you have not congured your Wastegate
Temperature Sensor(s), there will be a warning
(!) in red with a hyperlink to those settings.
NSP SOFTWARE SETUP
Using NSP’s simple drop down menu, up to two
EWGs can be selected, congured and calibrated.
Wastegate Temperature is required for EWG
control, the circuitry used for EWG position
should not exceed 150ºC.
If a temperature higher than 150ºC is measured,
the EWG will hold in an open position until
temperatures have reduced to 140ºC or lower.
Click “Calibrate” and NSP will perform the
necessary adjustments automatically.
Don’t be alarmed if two messages pop up during
this process: “Step 1 - Limit Calibration” and
“Step 2 - Dynamics Calibration”.
If you are using a second EWG, repeat the same
process for the second status window.
Your wastegate(s) is now ready for use!

6 7
TURBOSMART EWG WIRING DIAGRAM
(Motor B Control)
(Motor A Control)

8 9
A B
To +12V
Battery Ground
Any Spare DPO from ECU (Motor A Control)
Any Spare DPO from ECU (Motor B Control)
To Battery Ground
To ECU
To ECU
To Sensor +5V
To Sensor Ground
To any spare AVI
To any spare AVI
ECU Sensor +5V
ECU Sensor Ground
Any spare AVI from ECU
Any spare AVI from ECU
TURBOSMART EWG WIRING GUIDE
Deutsch DT/DTM Connector Assembly
The DCMD includes spare connectors and pins,
giving you the ability to create your own
sub-harness for an E-Gate installation.
Male Plug (Utilises Female Pins)
1. Crimp pin to wire. 2. Insert pin/wire into harness side of plug.
3. Insert wedge to lock pins in connector.
Female Receptacle (Utilises Male Pins)
1. Crimp pin to wire. 2. Insert pin/wire into harness side of plug.
3. Insert wedge to lock pins in connector.
Male Plug Female Plug
DT Connector Diagram (Wire Side)
4
3
1
2
1
2
4
3
Motor A to E-Gate
Motor B to E-Gate
ECU Sensor +5V
ECU Sensor Ground
Valve Position Sensor to ECU
Temperature Sensor to ECU
Along with the visuals provided
below, please visit our YouTube
channel for a thorough walkthrough
of building DTM connectors:
www.youtube.com/c/haltech
Connector A - DCMD Side
E-Gate Connections - ECU Side
Connector B - DCMD Side
E-Gate Connections - Gate Side
20A Switched +12V IGN
To Motor A (E-Gate)
To Motor B (E-Gate)
To Sensor +5V
To Sensor Ground
To any spare AVI
To any spare AVI

10 11
20A Switched +12V
The 20A Switched +12 volt connection directly
powers the DCMD device. This should come from
a 20A rated fused source such as your vehicle’s
power distribution module.
This connection is pre-terminated within a 4-Pin
DT Connector.
Battery Negative (-)
The Battery Negative is your main ground
connection for the DCMD. This should go directly
to the battery negative terminal or another
suitable ground source.
This connection is pre-terminated within a 4-Pin
DT Connector.
ECU DPOs (Motor Control A/B)
The Digitally Pulsed Outputs from any Elite or
Nexus series ECU can control the DCMD.
Control is Active State: Low
0V on Control A = 0V on Motor A
Pull Up Resistor not required.
Can be controlled from a DPO, Ignition, Injection,
Stepper or DBW ECU output.
Please note that additional programming in NSP
may be required if using devices not directly
supported in the software.
This connection is pre-terminated within a 4-pin
DT Connector.
Motor A
The Motor A connection is supplied by the
2-pin DT connector located on the DCMD. This
connection will drive the rst “channel” or
“motor”. It can supply 8A of power continuously
at a maximum speed of 2.2 kHz.
Motor B
The Motor B connection is supplied by the
2-pin DT connector located on the DCMD. This
connection will drive the second “channel” or
“motor”. It can supply 8A of power continuously
at a maximum speed of 2.2 kHz.
DCMD CONNECTIONS
EWG TUNING TIPS
Haltech has designed the Electronic
Wastegate Control strategy to simplify and
speed up the end user’s tuning process.
Existing boost control strategies may be
used with minor adjustments, and the tuning
process should be similar to existing closed
loop boost control systems.
When using an EWG, the “Boost Control
Function” retains its existing Duty Cycle range
of 0% to 100%. Where 100% will request
maximum ow through the turbo and 0%
will request minimum ow through the turbo
(mimicing solenoid based boost control
systems).
However, when using an EWG as your Boost
Control output type, the Boost Control
Function automatically converts boost output
duty cycle into a target wastegate position.
NSP takes into account the different ow
characteristics of the EWG across multiple
valve positions. This means the relationship
between Boost Control output duty cycle and
the Wastegate Flow will be linear.
Tuners should take into consideration the
increased response time of an EWG when
compared to a pneumatic based system. This
may require different approaches to tuning the
Boost Control Function.
Haltech has provided extended tuning tables
for some Boost Control settings, eg Control
Offset, in order to further simplify the tuning
process for different Boost Control scenarios.
At Haltech we make every eort to design and
manufacture fault-free products that perform up to
or above the market expectations. All our products
are covered by a Limited 12 Month Warranty.
Haltech Limited Warranty
Unless specied otherwise, Haltech warrants its products
to be free from defects in material or workmanship for a
period of 12 months from the date of purchase.
If the Haltech product is found to be defective as men-
tioned above, it will be replaced or repaired if returned
prepaid along with proof of purchase. Proof of purchase
in the form of a copy of the original purchase invoice,
receipt or bill of sale which indicates that the product is
within the warranty period, must be presented to obtain
warranty service.
Replacement or repair of a defective product shall con-
stitute the sole liability of Haltech. To the extent permitted
by law, the foregoing is exclusive and in lieu of all other
warranties or representations, either expressed or im-
plied, including any implied warranty of merchantability
or tness. In no event shall Haltech, be liable for special
or consequential damages.
Product Returns
Please include a copy of the original purchase invoice,
receipt or bill of sale along with the unused, undamaged
product and its original packaging. Any product returned
with missing accessory items or packaging will incur ex-
tra charges to return the item to a re-saleable condition.
All product returns must be sent via a freight method
with adequate tracking, insurance and proof of delivery
services. Haltech will not be held responsible for product
returns lost during transit.
Returns of Products Supplied in Sealed
Packaging
The sale of any sensor or accessory supplied in sealed
packaging is strictly non-refundable if the sealed pack-
aging has been opened or tampered with. This will be
clearly noted on the product packaging. If you do not ac-
cept these terms please return the sensor in its original
unopened packaging within 30 days for a full refund.
A sensor or accessory product may be returned after 30
days of purchase (with its sealed packaging in tact) for
credit only (no refunds given) and will be subject to a 10%
restocking fee.
Installation of Haltech Products
No responsibility whatsoever is accepted by Haltech for
the tment of Haltech Products. The onus is clearly on
the installer to ensure that both their knowledge and the
parts selected are correct for that particular application.
Any damage to parts or consequential damage or costs
resulting from the incorrect installation of Haltech prod-
ucts are totally the responsibility of the installer.
Always disconnect the battery when doing electrical
work on your vehicle. Avoid sparks, open ames or use
of electrical devices near ammable substances. Do not
run the engine with a battery charger connected as this
could damage the ECU and other electrical equipment.
Do not overcharge the battery or reverse the polarity of
the battery or any charging unit. Disconnect the Haltech
ECU from the electrical system whenever doing any
welding on the vehicle by unplugging the wiring harness
connector from the ECU.
After completing the ECU installation, make sure there is
no wiring left un-insulated. Uninsulated wiring can cause
sparks, short circuits and in some cases re. Before at-
tempting to run the engine ensure there are no leaks in
the fuel system.
All fuel system components and wiring should be mount-
ed away from heat sources, shielded if necessary and
well ventilated. Always ensure that you follow work-
shop safety procedures. If you’re working underneath a
jacked-up car, always use safety stands!
_____________________________________________
Haltech O󰀨-Road Usage Policy
In many states it is unlawful to tamper with your vehicle’s
emissions equipment. Haltech products are designed
and sold for sanctioned o󰀨-road/competition non-emis-
sions controlled vehicles only and may never be used on
a public road or highway.
Using Haltech products for street/road use on public
roads or highways is prohibited by law unless a specif-
ic regulatory exemption exists (more information can be
found on the SEMA Action Network website www.sema-
san.com/emissions for state by state details in the USA).
It is the responsibility of the installer and/or user of this
product to ensure compliance with all applicable local
and federal laws and regulations. Please check with your
local vehicle authority before purchasing, using or install-
ing any Haltech product.
WARRANTY CERTIFICATE

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