Xs manual boost controller

Boost controllers often use pulse width modulation PWM techniques to bleed off boost pressure on its way to the reference port on the wastegate actuator diaphragm in order to on occasion under report boost pressure in such a way that the wastegate permits a turbocharger to build more boost pressure in the intake than it normally could.

The boost control solenoid contains a needle valve that can open and close very quickly. By varying the pulse width to the solenoid, the solenoid valve can be commanded to be open a certain percentage of the time.

This effectively alters the flow rate of air pressure through the valve, changing the rate at which air bleeds out of the T in the manifold pressure reference line to the wastegate. This effectively changes the air pressure as seen by the wastegate actuator diaphragm. The wastegate control solenoid can be commanded to run in a variety of frequencies in various gears, engine speeds, or according to various other factors in a deterministic open-loop mode.

Or, by monitoring manifold pressure in a feedback loop, the engine management system can monitor the efficacy of PWM changes in the boost control solenoid bleed rate at altering boost pressure in the intake manifold, increasing or decreasing the bleed rate to target a particular maximum boost. The basic algorithm sometimes involves the EMS engine management system 'learning' how quickly the turbocharger can spool and how quickly the boost pressure increases. Armed with this knowledge, as long as boost pressure is below a predetermined allowable ceiling, the EMS will open the boost control solenoid to allow the turbocharger to create overboost beyond what the wastegate would normally allow.

As overboost reaches the programmable maximum, the EMS begins to decrease the bleed rate through the control solenoid to raise boost pressure as seen at the wastegate actuator diaphragm so the wastegate opens enough to limit boost to the maximum configured level of over-boost. Stepper motors allow fine control of airflow based on position and speed of the motor, but may have low total airflow capability. Some systems use a solenoid in conjunction with a stepper motor, with the stepper motor allowing fine control and the solenoid coarse control.

Many configurations are possible with 2-, 3-, and 4-port solenoids and stepper motors in series or parallel. Two-port solenoid bleed systems with a PID controller tend to be common on factory turbocharged cars. Since less positive pressure can be present at the wastegate actuator as desired boost is approached the wastegate remains closer to a completely closed state.

This keeps exhaust gas routed through the turbine and increases energy transferred to the wheels of the turbocharger.

Once desired boost is reached, closed loop based systems react by allowing more air pressure to reach the wastegate actuator to stop the further increase in air pressure so desired boost levels are maintained.

This reduces turbocharger lag and lowers boost threshold. Boost pressure builds faster when the throttle is depressed quickly and allows boost pressure to build at lower engine RPM than without such a system. This also allows the use of a much softer spring in the actuator. For instance, a 7 psi 0. The electronic control unit can be programmed to control 7 psi 0. This partial throttle control greatly increases driver control over the engine and vehicle.

Even with an electronic controller, actuator springs that are too soft can cause the wastegate to open before desired. Exhaust gas backpressure is still pushing against the wastegate valve itself. This backpressure can overcome the spring pressure without the aid of the actuator at all. Electronic control may still enable control of boost to over double gauge pressure of the spring's rated pressure.

The solenoid and stepper motors also need to be installed in such a way to maximize the advantages of failure modes. For instance, if a solenoid is installed to control boost electronically, it should be installed such that if the solenoid fails in the most common failure mode probably non-energized position the boost control falls back to simple wastegate actuator boost levels. It is possible a solenoid or stepper motor could get stuck in a position that lets no boost pressure reach the wastegate, causing boost to quickly rise out of control.

The electronic systems, extra hoses, solenoids and soforth add complexity to the turbocharger system. This runs counter to the 'keep it simple' principle as there are more things that can go wrong.

It is worth noting that virtually all modern factory turbocharged cars, the same cars with long warranty periods, implement electronic boost control. Manufacturers such as Subaru, Mitsubishi and Saab integrate electronic boost control in all turbo model cars. Installing a boost controller in a vehicle that is already well tuned, such as a factory turbocharged car, may allow higher boost pressure than tolerable by the engine or turbocharger, reducing life and reliability.

Care should be taken to avoid exceeding the limits of any engine system components such as the engine block, fuel injectors, or engine management system. Usually, from the factory, it is a much lower level than what the engine and turbo can handle.

To increase the amount of boost is where a boost controller comes into play. The electronic boost controller overrides the stock turbo boost signal allowing the turbo to produce higher boost levels creating more horsepower.

Is it safe to increase boost levels? Some cars from the factory come with lots of playroom to increase boost where others have little. Check forums related to your vehicle such as the NicoClub for Nissan and Infiniti performance and ls1tech for ls enthusiasts to see what boost levels other owners are running with their cars and to get recommendations. Will increasing boost level void warranty? In most cases, yes. This also depends on the warranty provided by the manufacturer.

Automakers commonly overbuild their cars and then tone them down for production. They do this to decrease the likelihood of things breaking so they can get through the warranty period error-free. How can I increase boost without blowing up my motor?

One of the most common ways to increase boost safely is with an intercooler. When the exhaust gases are sucked into the turbo, the air is very hot. An intercooler takes the air and runs it through a series of cooling fins dropping the temperature of the air before it enters the turbo. When air gets colder, the density increase allowing more air to be safely pushed into the motor, significantly reducing the risk of detonation.

Another way to increase boost is with a Methanol injection system. Methanol injection, also known as meth injection, uses a mix of water and methanol that is kept in a reservoir in your car.

Then depending on how you have the system adjust a pump with shoot the mixture into the intake manifold drastically cooling the air temperature of the air.

For the mixture, you can either use winter windshield washer fluid or specifically designed fluid. Unfortunately, windshield washer fluid contains a lower concentration of methanol not allowing for the ideal 50 water to 50 meth mixture but is much more commonly found and a lot cheaper.

Electronic boost controllers vs manual boost controllers: When searching for a boost controller, manual boost controller can be a very enticing offer.

Manual controllers are priced significantly lower when compared to an electronic one. The major downsides to a manual controller are convenience and accuracy.

An electric boost controller allows you to quickly change boost levels from inside the car with precision accuracy. Where with a manual controller, you will have to pop the hood to adjust boost levels.

You will also have to keep an eye on it to ensure the adjustment is still correct as some manual controllers adjustments can slip over time. Depending on the shipping provider you choose, shipping date estimates may appear on the shipping quotes page. Please also note that the shipping rates for many items we sell are weight-based. The weight of any such item can be found on its detail page. To reflect the policies of the shipping companies we use, all weights will be rounded up to the next full pound.

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