This article describes how to
configure boost control in open loop mode on the Modular ECUs.
In open loop mode, it means that the duty cycle is fixed in
your ECU settings, and whatever boost that generates is what
you get. This is the way many tuners configure boost
controllers because it’s relatively easy to do it this way. It
has its limitations though so let’s talk about basic boost
control hardware first of all. First, I’m going to look at the mechanical side of
boost control; the reason being that often people think that
what they need is to learn about the ECU settings, when they
don’t really understand the mechanical system they’re
controlling. If you do know this well then skip ahead! We know that exhaust gas comes out of the engine and
spins the turbine, which in turn spins the compressor which
generates the boost. To regulate the boost, we control how
much exhaust is allowed to bypass the turbine through one or
more wastegates. The wastegate is a flap or some other kind of valve
which is opened by an actuator. Although it’s possible to
design a wastegate like a butterfly so that exhaust pressure
does not try to push it open, the two most common types of
wastegates I’ve seen have been the flap style as on internally
gated turbochargers, where high exhaust back pressures before
the turbine will force the door open, and the common
aftermarket external gate style where again the exhaust
pressure pushes on the disc which forces it to open. This is
important to remember.
Turbo System
Apart from the exhaust pressure opening the gate,
which is an undesired effect, the position of the gate is
controlled by an actuator. The actuator has a diaphragm with
pressure on either side, and the pressure difference across
the diaphragm causes a force, which moves the gate actuator
rod and can open the gate. Holding the gate shut is a spring
which is normally a compression spring with significant
preload. The actuator can either have two pressure ports on
it, one for each side of the diaphragm, or just a single port
with the other port open to atmosphere.
Single port actuator
Two-port actuator
There are other features of some wastegates such as
water cooling, and some like some of the Turbosmart have
position sensors as well or they can be added as an option.
Wastegate with water cooling feature
Turbosmart wastegate with position sensor feature
Let’s first consider the most basic type of
wastegate system, where you have a single port actuator. The
actuator’s pressure port is fed from boosted air from the
compressor. At atmospheric pressure, ie zero boost, there’s
zero pressure differential across the diaphragm, and the
spring holds the gate shut. No exhaust bypasses the turbine,
so the turbocharger starts to build boost. If the turbocharger builds enough boost to increase
the airflow through the engine to the point where it can
increase the boost further, ie it’s in a position to spool
(the RPM is high enough to come on boost and the throttle is
open far enough), then the boost will eventually become high
enough that the air pressure in the diaphragm is high enough
to overcome the spring preload and the actuator rod will start
to move. The pressure at which the air pressure force equals
the preload in the spring, and from then on it starts to move,
is sometimes called the “cracking” pressure because it’s where
the wastegate cracks open. Usually the spring will be
described by this pressure, for example a 10 PSI spring or a 1
bar spring. As the boost increases more, the spring is
compressed further and the wastegate opens further, until a
point where so much exhaust is bypassing the turbine that it
can’t build any more boost, and boost is now stable at this
point. Note that this will be higher than the cracking
pressure because the gate has had to move further to reach an
equilibrium point. There are multiple ways to control the boost on such
a system, but we’ll only talk about the 3-port method. In this
system you have a 3-port valve under ECU control. We use the
Mac valves. The “common” port on the Mac valve connects to the
actuator, the “normally connected” port connects to the boost
source and the “normally closed” port is allowed to vent to
atmosphere.
3 way solenoid Mac valve
Mac valve port functions
In that way, when the valve is switched off, it just
connects the boost source straight to the actuator, and the
amount of boost you get is determined by the spring. When the
valve is turned on, the boost source is blocked off and the
actuator vents to atmosphere, so you get an unlimited amount
of boost. By pulse width modulating the valve, you can control
it to anywhere in between. For example if you have a 10 PSI spring, you can
achieve 20 PSI of boost by pulse width modulating the valve at
50% duty cycle. At 50% duty cycle it means that half of the
time, the actuator sees the 20 PSI from the compressor exist,
and the other half of the time it sees atmospheric pressure
which is zero boost – so the average works out to be 10 PSI
which is what the actuator is trying to regulate to. If you
set the duty cycle to 25%, then one quarter of the time it
would see atmospheric pressure and three quarters would see
boost, so that means you’d end up with 13 PSI boost . Normally
you’d PWM the solenoid at about 30 Hz. Now, let’s look at some undesired effects of this
system, limitations and so on, so that you can spot them when
they occur. The first I mentioned before; the exhaust back
pressure pushes the door open. The force exerted by a pressure
is the pressure times the area. So unless the diaphragm is
very large compared to the wastegate, then exhaust back
pressure is going to have an effect on boost. In many cases it
will limit the amount of boost you can run, because even with
the solenoid at 100% or leaving the hose off the actuator all
together, once the boost reaches a certain level, the turbo
will need a certain amount of exhaust pressure to create the
boost and that pressure will force the door open, so it will
be self limiting. So this limits the amount of boost you can
practically run in an internally gated, factory style
turbocharger. It also means that if you run a constant duty
cycle, the boost will normally drop off to some extent as RPM
increases, due to the backpressure increase at higher speeds
(the compressor has to spin faster to make the same boost at
higher RPM because the engine is hungrier, so the turbine has
to spin faster also). Turbosmart have come out with a replacement for the
factory actuator though, called the IWG. It’s similar in
construction to a proper actuator from an external gate, but
it’s packaged so it can be used as an upgrade for factory
style, internally gated turbochargers. The big advantage of
this over the standard actuators is that they can have larger
diaphragm area than the factory actuator, which makes the
behaviour less dependent on exhaust back pressure. This makes
the boost pressure more stable and predictable, and also
increases the maximum amount of boost you can run. A common mistake, in my opinion, that people make is
to get the pressure source for the boost control from the
inlet manifold, rather than from the compressor exit. We know
that whichever pressure the actuator sees is the pressure it
will attempt to regulate to because that’s all the information
it has. Consider a part throttle condition where the driver
does not want the full torque available. If the system is set
to produce 10 PSI of boost, and the actuator gets its pressure
reference from the compressor exit, then we will have 10 PSI
before the throttle body, and less after the throttle body,
for example zero boost. This is what the driver says that he
or she wants, by only applying part throttle.
Connecting the boost pressure source on the intake manifold
If the actuator reference is taken from the manifold
instead of the compressor exit (or some other point before the
throttle), then it means that the turbo will need to work
extra hard because the actuator will keep the gate shut until
it sees 10 PSI in the manifold. So the turbo might be making
say 20 PSI of boost, but because of the partial throttle
condition we only see 10 PSI in the manifold. This has two
problems:
It makes it harder for the driver to control
the torque, since whatever he’s doing with the pedal will
be undone to some extent by the action of the actuator and
wastegate
It could result in an overspeeding condition
where if you put your foot down afterwards, you would get
a boost spike because the turbo is spinning too fast.
Turbosmart also now have a dual port version of the
IWG, so rather than having one side of the diaphragm open to
the atmosphere, both sides of the diaphragm have ports on
them. With a dual port actuator, the connection method is
usually different. The standard way is to connect the boost
pressure to the “normal” of the actuator, ie the one which you
increase the pressure to open the gate. Then the second port
of the actuator, which holds the gate shut, goes to the
“common” of a 3-port valve. The “normally connected” port on
the 3-port valve vents to atmosphere, so in the normal
condition the actuator connection is the same as a single port
actuator. When the solenoid is activated though, the “normally
closed” port is connected to the pressure source and then the
actuator sees boost pressure on both sides. The mathematics is the same as the single port
actuator, but it means that there’s more pressure available to
force against the back pressure forcing the flap open, and
therefore the boost regulation at higher back pressure
conditions is better. This theory can also be applied to an external
wastegate. External gates normally have much bigger
diaphragms, but they also usually have larger gates. In this
case the “bottom” port is the one which gets the pressure to
open the gate, and the “top” or the dome gets the pressure to
close the gate. There is a third connection type, which uses a
4-port Mac valve. Conceptually it’s the same as a 3-port
valve, and if you have 2 x 3-port valves you can achieve the
same thing so I’ll just describe it as 2 x 3-port valves here.
Four-port Mac valve
In this configuration, the top and the bottom of the
actuator each connect to the common ports of their own 3-port
valves. The bottom one’s normally connected port connects to
the boost source, and the normally closed port vents to
atmosphere, just as with a single port actuator. The top
port’s connection is opposite – the normally connected port
connects vents to atmosphere and the normally closed port
connects to the pressure source. When the solenoid is turned off, the bottom of the
actuator sees boost, and the top sees atmospheric pressure so
you end up with the boost set by the spring pressure. However
when it’s turned on, the bottom sees atmospheric pressure and
the top sees boost which holds the gate shut. Because you
don’t have the boost on the other side of the diaphragm, this
can hold shut against substantial exhaust back pressure even
with a spring that isn’t that strong. A typical single 3-port valve system can usually
only hold up to about double the spring pressure level of
boost with any degree of control, but a 4-port system as
described here can hold much higher. The limiting factor is
when the exhaust back pressure ends up being more than or
close to the spring pressure plus your boost pressure; in that
case the only way to do it is with an external pressure source
like a CO2 bottle. Now that we’ve talked about the mechanical system,
we can talk about how the ECU works out the duty cycle in the
basic duty cycle mode. The first thing to understand is that there are many
variables that the ECU can use to control the boost level. The
ECU can determine boost by the main boost map, but can also
have corrections for external switch inputs, the current
transmission gear ethanol content and “push to pass” or
“scramble boost”. All the settings are found in the Tuning – Air,
boost control section in the software. Firstly, the mode you should select if you want to
do it based on the duty cycle only, is the “Open loop boost
mode, DC” Secondly, you can choose whether to enable “dual
boost maps” or not. Dual boost maps allow you to have two
separate boost maps, which is the duty cycle vs throttle
position and RPM. If you don’t enable this, then you can still
have a switch to select different boost levels and I’ll
explain that in a bit. If you do enable dual boost maps, then you will have
two duty cycle maps in the settings. To enable the second map,
you must select a digital input as boost setting 1, and then
when that input is triggered then the ECU will switch over to
the second boost map. Secondly, the ECU will only activate the wastegate
control output once the conditions of minimum TPS and MAP are
met, so set this to values like slightly on boost or slightly
on vaccum, and TPS of say 30% so it’s not always driving the
valve during cruise conditions. Of course you could just tune
this in the map anyway. Duty cycle limit is a percentage you can manually
enter to be able to limit the duty cycle of the output. This
is really put in there for convenience of testing and safety;
there’s no logical reason to use it in a final system. You’ll need to set up an output to drive the 3 or 4-
port valve. This should be an auxiliary output, or on the
Modular ECUs you can use an unused injector output instead.
Just as with driving other PWM solenoid valves, the other side
of the solenoid should connect to an ignition switched, 12V
supply. The corresponding output in the ECU should be
configured as Wastegate 1 duty, PWM at 30 Hz for most valves.
You can run two or four valves off a single output, but the
reason you would use the Wastegate 2 duty is if you’re doing
dual closed loop boost control, for example on a 300ZX or a
V12 with two separate turbos and two separate inlet manifolds. Once you’ve set up those initial settings, you can
adjust the duty cycle map. In the single map mode, you’ll just
have the duty cycle map 1, where the axes are throttle
position and RPM. Just like the other maps in the Modular ECUs
you can insert and remove columns and rows as you like. There’s another map, which hopefully you won’t need
to adjust, but it’s there in case you do, and it’s a
correction for air temperature. In theory this map should be
at zero everywhere but if you find that there’s an air
temperature sensitivity which you want to tune out, which
usually means generating more boost for the same duty cycle at
lower air temperatures, you can put in a slope with negative
values at lower air temperatures. I
know that some people use a basically open loop boost control
strategy, but with a map where they can adjust a correction
based on manifold pressure. You can also do that using this
table if you like. This is similar to using a
proportional-only controller, and just as with a PID closed
loop system, you can get it to hunt if you’re not careful and
make it too aggressive. The next item to consider is boost limits. These are
limits to the duty cycle based on circumstances in which you
want to run less than full boost. Each of these limit types
can be enabled separately. Ethanol content is the first one, and this is a
simple 2D table with ethanol content as a percentage from 0 to
100% as the input variable, and the value that you enter is
the duty cycle to which the output will be limited. For
example if you put 30 in this table at the current ethanol
percentage, then even if you have 50% in your main map, you
will only have a 30% duty cycle output (except in the case of
push to pass which I’ll describe soon). The second one is the gear based duty cycle limit –
in this case the input variable is the gear number, eg 1, 2,
3, 4, 5, 6 and the value in the table is the maximum duty
cycle for each gear. If you have a limit in this table and the
ethanol table then both limits will apply, which means that
you’ll get the lower of the two. The final limit is based on digital inputs for boost
selection. The digital input value is from 0 – 3. This allows
for 4 different boost settings via 2 digital inputs, and it’s
easy to set up using a 4-position, 2-pole rotary switch. To set this up, you will need 2 digital inputs. One
must be set as Boost Setting 1, and the second must be set as
Boost Setting 2. The following input configurations give the
following boost switch numbers:
Both inputs off (inactive, usually means open
circuit) – 0
Boost setting 1 active (usually that means
connected to ground) – 1
Boost setting 2 active – 2
Both boost setting inputs active – 3
The ECU will then use the duty cycles in this table
as the limit for the duty cycle. If you want one switch to
give the full boost as defined in the map, then set the value
to 100%. Note that on some systems, having a fixed duty cycle
might give a problem where the boost is not constant with RPM,
despite that being your intention, and in that case you would
be better off using a target boost mode which will be covered
in a different article. The final setting you have available is the “push to
pass” setting, sometimes called “scramble boost”. It’s a bit
like the proton pill that Roger Ramjet used to take which
gives him the strength of 20 atom bombs for a period of 20
seconds, but in this case you can define the duration, and you
can also specify the duty cycle that’s active for this push to
pass time. Note that the push to pass function overrides all
of the limits except for the duty cycle limit. Thank you very much!