Product Name:  
Electronic Straight Wastegate  
eSG50 Electronic Straight Gate  
TS-0565-1002  
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V1.00 Rev A  
Product Description:  
Product Number:  
Document Version:  
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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 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.  
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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.  
RECOMMENDATIONS  
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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.  
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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 Electronic Straight Wastegate kit.  
Part  
Description  
Use  
QTY  
1
Turbosmart Electronic Straight  
Wastegate  
Main unit  
1
2
3
4
5
6
Inlet V-Band clamp  
Inlet V-band clamp  
1
1
1
1
1
Inlet Weld flange  
Inlet V-band weld flange  
Outlet V-band clamp  
Outlet V-band weld flange  
Turbosmart sticker  
Outlet V-Band clamp  
Outlet weld flange  
Turbosmart Sticker  
1
2
3
4
5
1
Figure 1 - Kit Contents  
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  
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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  
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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 1250oC for 24hr if thermally cooled with  
o
the 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  
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 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 Electronic  
Straight Gate will be targeting a set position, this will move further away if the motor polarity is wrong as it is trying to 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 biased to operate better with the butterfly in the closed position it is recommended to avoid opening the  
butterfly at full opening.  
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WHAT’S NEW  
The new Turbosmart Electronic Straight Gate is Turbosmarts 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 that is suitable for the Electronic Straight Gate to operate in. This mixed  
without the 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 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.  
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STRAIGHT ELECTRONIC WASTEGATE OVERVIEW  
Wiring Loom  
Manual Override  
cap  
“Water Cooling” port  
1/8” NPT  
3
x Housing locating  
screws  
Outlet Weld flange  
Outlet V-Band  
Inlet V-Band  
Inlet Weld Flange  
Figure 1 - Electronic Straight Gate Overview  
Water cooling  
symbol  
Figure 2 Electronic Straight Gate Water Cooling  
Figure 3 Electronic Straight Gate Exploded  
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FITTING YOUR GEN V WASTEGATE  
Angle mounting allows a good flow of exhaust flow to the Straight  
Gate.  
Mounting your new Turbosmart Electronic Straight  
Wastegate  
1
Water cooling is highly recommended for sustained heat  
exposure.  
Exhaust flow  
to eWastegate  
The weld flanges should be welded to your exhaust system. The  
weld flanges are compatible with Stainless Steel and Mild steel  
welding rod material.  
Turbine  
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.  
Exhaust flow  
from engine  
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 6 - 90 Degree mounting  
90 Degree mounting gives poor exhaust flow to the Straight Gate  
and in some circumstances may contribute to over boosting.  
eStraight Gate  
Exhaust flow  
to eWastegate  
eStraight Gate  
Exhaust flow  
to eWastegate  
Turbine  
Turbine  
Exhaust flow  
from engine  
Exhaust flow  
from engine  
Figure 4 - Best flow - Symmetric mounting  
Symmetric mounting allows an excellent flow of exhaust to the  
Straight
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.  
eStraight Gate  
CAUTION!  
Do not place the Straight Gate near a significant heat source  
as this could shorten the life of the internal electronics.  
Exhaust flow  
to wastegate  
Turbine  
Exhaust flow  
from engine  
Figure 5 - Good Flow - Angle mounting  
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Fitting the Straight Gate  
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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 10 V Band Clamp  
Valve Pins  
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 11 Exploded drawing of assembly of Electronic Straight  
Gate.  
Manual  
override  
Figure 9 Manual Override  
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Connecting Your Wastegate  
to protect the eGate. Once correct operation has been  
verified the fuse and limits can be removed.  
Calibration  
3
The Turbosmart Electronic wastegate comes unterminated with  
wires.  
Wiring Pinout  
4
7
CAUTION!  
Disconnect the motor wires to prevent accidental spin up.  
Colour  
Description  
Large Gauge Red  
Motor A tending towards  
1
core wire  
each  
single  
0%  
To calibrate the electronic straight gate firstly the manual override  
cap must be removed to allow access to the manual override. A  
non marking 14mm is required to remove the cap from the body.  
Large Gauge Black  
Motor B tending towards  
100%  
Red  
*5V  
Black  
White  
Blue  
Sensor ground 0V  
Position Signal 0-5V  
14mm Manual Override Cap  
Multi Core  
Wire  
**Unfiltered PWM  
Signal (Position Output)  
Yellow  
Temperature Signal 0-5V  
*
Note: The 5V red wire has no reverse polarity protection,  
use only 5V wired in correctly.  
*
*Note: The Blue (unfiltered position signal) is not required  
for use & is for development purposes only.  
Sensor Voltage Limits  
Deg C (Deg F)  
Temperature Sensor  
Output (mV)  
0
1
(32)  
50 (302)  
2630  
538  
Target Voltage (V) Duty Cycle  
Figure 12 Manual Override  
Position Sensor  
0
4
.2-0.6V  
~16%  
~84%  
1
0
00% (Open)  
% (Closed)  
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.  
.2-4.60V  
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.  
Valve CLOSED  
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. The blue wire (Revision B only) is an  
unfiltered position output signal for development purposes - This  
can be left unterminated.  
Valve OPEN  
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 13 ¼ Drive extension with 5mm socket manually  
CAUTION!  
adjusting.  
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  
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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.  
CAUTION!  
Do not apply excessive force to the manual override, doing  
so will damage the product and effect the performance.  
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.  
Using your ECU manager software, read the voltage from the  
sensor and set this as your closed position.  
Sensor Linearisation  
6
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.  
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  
Monitor sensor signal voltage to ensure no wrap around occurs  
throughout the stroke of the butterfly valve that could affect  
operation.  
rd  
with valve flow. A 3 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.  
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.  
y = -2.1519x3 + 3.0586x2 + 0.0582x + 0.0326  
R = 0.999  
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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.  
1
1
20%  
00%  
Tuning  
5
8
0%  
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  
60%  
40%  
20%  
0%  
(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.  
0%  
50%  
100%  
Butterfly Position  
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.  
Butterfly Position  
Flow Percentage  
3.3%  
0
3
6
%
%
%
Position Sensor  
Target Voltage (V) Duty Cycle  
3.7%  
4.7%  
6.7%  
0
.20-0.60V  
~16%  
1
0
00% (Open)  
% (Closed)  
4
.40-4.80V  
~84%  
1
2
3
4
5
6
7
8
0%  
0%  
0%  
0%  
0%  
0%  
0%  
0%  
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%.  
14.9%  
26.7%  
40.8%  
55.7%  
70.4%  
83.4%  
93.5%  
99.4%  
100.0%  
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.  
90%  
00%  
1
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.  
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ADVANCED FEATURES ON THE STRAIGHT WASTEGATE  
Fit water-cooling port fittings Prior to mounting the wastegate,  
Water Cooling  
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.  
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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.  
CAUTION!  
Check for leak, ensure the water-cooling circuit is free from  
leaks.  
Identify the water cooling ports on the bottom of the actuator  
adjacent to the water-cooling symbol engraved in the actuator.  
Water  
feed/return  
Water  
Water cooling  
Port (2 holes)  
cooling  
symbol  
Figure 13 Water Cooling Ports  
Figure 14 Water Lines  
HOW TO CONDUCT MAINTENANCE ON YOUR ELECTRONIC STRAIGHT GATE  
Basic Maintenance  
1
The Straight gate will require periodic maintenance 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 on environment. With the top plate removed grease  
can be sprayed into the small inspection holes located near  
the magnet.  
Motor Replacement  
2
Figure 15 Motor End Cap  
Note! The red wire is matched to the red dot on the electric  
motor.  
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)  
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  
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0
4
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  
issues with calibration. If moving to one of three mounting  
options observe positions before moving readjusting.  
Figure 16 Water Lines  
With the Allen key pins removed the body can be separated  
from the actuator and one of the three options can be picked.  
Sensor Replacement  
3
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  
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  
Figure 18 Encoder location  
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TROUBLESHOOTING  
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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.  
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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.  
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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 tech@turbosmart.com.au with information of your engine configuration and  
photos of installation.  
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