Turbosmart TS-0565-1002 User manual

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IMPORTANT NOTES ON YOUR EXTERNAL EWASTEGATE
- 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.
- 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 restored to a more suitable limit.
- 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
- 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.
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KIT CONTENTS
Please check that the following items have been provided in your Electronic Straight Wastegate kit.
Part
Description
Use
QTY
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Turbosmart Electronic Straight
Wastegate
Main unit
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2
Inlet V-Band clamp
Inlet V-band clamp
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3
Inlet Weld flange
Inlet V-band weld flange
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Outlet V-Band clamp
Outlet V-band clamp
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5
Outlet weld flange
Outlet V-band weld flange
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6
Turbosmart Sticker
Turbosmart sticker
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Figure 1 - Kit Contents
Product Name: Electronic Straight Wastegate
Product Description: eSG50 Electronic Straight Gate
Product Number: TS-0565-1002
Document Version: V1.00 Rev B
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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
STRAIGHT ELECTRONIC WASTEGATE OVERVIEW...............................................................................................5
FITTING YOUR GEN V WASTEGATE........................................................................................................................6
Mounting your new Turbosmart Electronic Straight Wastegate.........................................................................6
Fitting the Straight Gate........................................................................................................................................7
Connecting Your Wastegate................................................................................................................................8
Tuning ...................................................................................................................................................................9
ADVANCED FEATURES ON THE STRAIGHT WASTEGATE..................................................................................10
TROUBLESHOOTING..............................................................................................................................................12

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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
- Loctite 243 Thread locker
- Loctite 567 Thread Sealant
- Resbond 907TS Red
- Penetrating oil
- Inox MX8 spray grease
PART NUMBERS
TS-0565-1002 –eSWG54 Electronic Straight Gate
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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.
HOW TO USE
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. Please see the exploded drawing (figure 3). 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.
MAINTENANCE
Turbosmart Electronic Straight Wastegate 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 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.
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 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 exposedto 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 Electronic
Straight Gate will be targeting a set position, this will move further away if the motor polarity is wrong as it is tryingto 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 biasedto 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.
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WHAT’S NEW
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 thatis suitable for the Electronic Straight Gate to operate in. This mixed
withoutthe 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 performanceis acriticalkey performancefactor withinthe designof all our products. Thermal stability
and longevity are further extended with the liquid cooling ports for further thermal performance if required.

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STRAIGHT ELECTRONIC WASTEGATE OVERVIEW
Figure 1 - Electronic Straight Gate Overview
Outlet Weld flange
Outlet V-Band
Inlet V-Band
“Water Cooling” port
1/8” NPT
Wiring Loom
Inlet Weld Flange
Water cooling
symbol
Figure 2 –Electronic Straight Gate Water Cooling
Figure 3 –Electronic Straight Gate Exploded
Manual Override
cap
3 x Housing locating
screws

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FITTING YOUR GEN V WASTEGATE
Mounting your new Turbosmart Electronic Straight
Wastegate
Water cooling is highly recommended for sustained heat
exposure.
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.
Figure 4 - Best flow - Symmetric mounting
Symmetric mounting allows an excellent flow of exhaust to the
Straight Gate.
Figure 5 - Good Flow - Angle mounting
Angle mountingallows a good flowof exhaust flowto the Straight
Gate.
Figure 6 - 90 Degree mounting
90 Degree mounting gives poor exhaust flow to the Straight Gate
and in some circumstances may contribute to over boosting.
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 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.
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Turbine
eStraight Gate
Exhaust flow
to eWastegate
Exhaust flow
from engine
Turbine
eStraight Gate
Exhaust flow
to wastegate
Turbine
Exhaust flow
to eWastegate
Exhaust flow
from engine
eStraight Gate
Turbine
Exhaust flow
from engine
Exhaust flow
to eWastegate
Exhaust flow
from engine

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Fitting the Straight Gate
Even though possible to mount the Straight gate in both
directions, it is suggested that the Butterfly valve pins (Figure 8)
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.
Figure 8 –Butterfly Valve Pins
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. (Figure
9)
Figure 9 –Manual Override
Figure 10 –V Band Clamp
Figure 11 –Exploded drawing of assembly of Electronic Straight
Gate.
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Manual
override
Valve Pins

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Connecting Your 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)
4.2-4.60V
~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.
Connectthe small Red Wireto a 5V power source fromyour 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.
Tocalibratethe electronicstraight gatefirstlythemanualoverride
cap must be removed to allow access to the manual override. A
non marking 14mm is required to remove the cap from the body.
Figure 12 –Manual Override
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.
Figure 13 –¼ Drive extension with 5mm socket manually
adjusting.
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3
4
3
Valve OPEN
Valve CLOSED
14mm Manual Override Cap

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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 valueshave been set with regards to theposition sensor
are approx. 0.5V (completely open) and approx. 4.5V as
(completely closed), It is important to note that as the wastegate
butterflyvalvemovesthrough itsrangeofmotionthatthebutterfly
valves are monitored to move from 4.5V decreasing to 0.5V, 0%
open to 100%open. Thisshouldbe done manually withthe ECU
packagemonitoring Voltage Values. The electronic motorshould
be disconnected at this point.
Voltage wraps around will cause errors withthe 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 calibrationto allow plenty of overshoot totheend 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 correlatethe linear sensor output tomatch the flow
of the valve. The following plot compares butterfly valve position
with valve flow. A 3rd order polynomial is provided torelatesensor
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%
0%
20%
40%
60%
80%
100%
120%
0% 50% 100%
Flow Percentage
Butterfly Position
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ADVANCED FEATURES ON THE STRAIGHT WASTEGATE
Water Cooling
Turbosmart’s Straight Gate 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.
Figure 13 –Water Cooling Ports
Fit water-cooling port fittings Prior to mounting the wastegate,
install 1/8” NPT fittingsintothe water ports, applythreadlubricant
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.
Figure 14 –Water Lines
HOW TO CONDUCT MAINTENANCE ON YOUR ELECTRONIC STRAIGHT GATE
Basic Maintenance
The Straight gate will require periodicmaintenance 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 onenvironment.Withthetopplateremovedgrease
can be sprayed into the small inspection holes located near
the magnet.
Motor Replacement
In the event of the motor failing, it can be easily replaced. The
Motor Housing (figure 15) must be dissembled, 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 red 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 (TS-0550-3123)
Figure 15 –Motor End Cap
Note! The red wireis matched to the red dot on the electric
motor.
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
Water cooling
Port (2 holes)
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3
Water
cooling
symbol
Water
feed/return
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2

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Figure 16 –Water Lines
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.(Figure 18 ) the
grommet will remain attached to the top cap and be removed
as one piece
Figure 17 –Removal of top cap
Figure 18 –Encoder location
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
issueswith calibration. If moving toone 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.
Figure 19 –Actuator Locking Pins
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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 request to [e-mail] with information of your engine configuration and
photos of installation.
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