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Turbosmart
eSG Electronic StraightGate Instructions
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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.
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.
https://support.turbosmart.com/portal/en/kb/articles/straight-gate
eSG Electronic StraightGate
eSG Electronic StraightGate External
Wastegate
TS-0563-1002, TS-0565-1002 ,TS-0567-
1002
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Summary of Contents for Turbosmart TS-0563-1002
- Page 1 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.
- Page 2 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.
- Page 3 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 (Or Equvilant) Quick Start Guide https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
- Page 4 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.
- Page 5 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.
- Page 6 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. StraightGate Electronic Wastegate Overview https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
- Page 7 Fitting Your Electronic Wastegate Mounting your new Turbosmart Electronic Straight Wastegate 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.
- Page 8 (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. https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
- Page 9 (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. https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
- Page 10 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. https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
- Page 11 Connecting your Turbosmart Electronic Wastegate The Turbosmart Electronic wastegate comes unterminated with 7 wires. Wiring Pinout Revision B (current) – Wiring Colour Description Large Gauge Red Motor A tending towards 0% 1 single core wire each Large Gauge Black...
- Page 12 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.
- Page 13 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. https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
- Page 14 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. ...
- Page 15 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.
- Page 16 Butterfly Position Flow Percentage 3.3% 3.7% 4.7% 6.7% 14.9% 26.7% 40.8% 55.7% 70.4% 83.4% 93.5% 99 4% https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
- Page 17 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.
- Page 18 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.
- Page 19 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 https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
- Page 20 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.
- Page 21 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. https://support.turbosmart.com/portal/en/kb/articles/straight-gate...
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