Product Name:  
BlackBox Electronic Wastegate Controller  
BlackBox Electronic Wastegate Controller  
TS-0305-1001  
Product Description:  
Product Number:  
Document Version:  
V1.10 Rev A  
-
-----------------------------------------------------------------------------------------------------------------------  
IMPORTANT NOTES ON YOUR BLACK BOX WASTEGATE CONTROLLER  
-
If using PWM as the control strategy and the ECU is requiring 0% the gate will be closed.  
-
-
The BlackBox Instructions are not a substitute for basic tuning knowledge.  
Turbosmart accepts no responsibility whatsoever for incorrect installation of this product which is potentially hazardous and can  
cause serious engine damage or personal injury.  
-
-
-
-
-
-
-
Turbosmart recommends that your Black Box is fitted by an appropriately qualified technician.  
Consult your local tuning specialist before setting your boost pressure, setting boost beyond your engines capability can result in  
severe engine damage or failure!  
Turbosmart recommends that the engines Air/Fuel ratio is checked once the desired boost pressure is set, any increase in boost  
pressure can cause the engine to run lean resulting in severe engine damage or failure.  
Turbosmart recommends that boost pressure is set using a Dynamometer and not on public roads.  
The Black Box may not be able to completely compensate for a drop in boost pressure at high RPM due to the  
turbocharger operating beyond its maximum efficiency range i.e., incorrect turbocharger sizing or excessive exhaust  
backpressure.  
-
-
The Black Box cannot compensate for increases in boost pressure at high RPM due to inadequate waste gate flow  
capacity; the turbo system must maintain a steady base boost curve.  
For best results, your turbocharger should be correctly sized for your application.  
-
-----------------------------------------------------------------------------------------------------------------------  
KIT CONTENTS  
Please check that the following items have been provided in your Black Box packaging  
Part  
Description  
Turbosmart Black Box  
Black Box Connector  
Black Box Pins  
Use  
Main unit  
1
2
3
4
Black Box Connector 34 Pin Allocation  
34 x Black Box Pins  
Turbosmart Sticker  
Sticker  
TOOLS/PARTS REQUIRED  
-
-
-
Super seal Connector Crimping Tool  
Micro USB to USB 2.0 A  
2.5mm Allen Key  
1
ABOUT YOUR BLACK BOX  
BlackBox by Turbosmart is a dedicated Electronic Wastegate Controller. The BlackBox protects from the current demands and  
translation of basic and more advanced boost control strategies into a gate position and can be used on single or twin electronic  
wastegate systems for the ultimate boost control. They are used in cooperation with a range of Factory, Aftermarket and Motorsport  
ECU.  
The BlackBox is a Dual Channel, High current Capable H-Bridge Driver for use with the Turbosmart range of Electronic External  
Wastegates, including the StraightGate50 and our Electronic poppet style gates including CompGate40, HyperGate45, ProGate50  
and PowerGate60 electronic Wastegates.  
.
BlackBox Capability  
The BlackBox is capable of multiple strategies and will accept PWM (Pulse Width Modulation) inputs as traditional boost control  
solenoids, 0-5v position target CAN position target and CAN bus override for more advanced ECU’s where control strategy can be  
developed natively. The Blackbox auto-calibration of Electronic External Wastegates via a full sweep and includes over-temp safety  
features using the temperature sensor inputs.  
The BlackBox is pre-configured with the flow vs. lift calibration data of all Electronic Actuated Wastegates from Turbosmart for  
simple setup and accurate boost control. Settings can be adjusted via a simple USB connection and PC-based application.  
Unlimited control strategies can be implemented with the CAN-based override system, limiting your strategy only by your ECU’s  
capability.  
2
BLACK BOX CONNECTOR PINOUT  
Pin  
1
2
3
4
5
6
7
8
Channel Name  
12V Supply  
12V Supply  
Output 1+ve  
Output 1+ve  
Output 1-ve  
Output 1-ve  
Output 2 +ve  
Output 2+ve  
Output 2-ve  
12V Supply  
12V Supply  
NC  
5.0V Supply  
OV AN Ref**  
CAN 1 HI  
CAN 1 LO  
Output 2-ve  
Power Ground  
AV1  
AV2  
NC  
NC  
FREQ IN 1  
NC  
Power Ground  
Power Ground  
AV5  
AV6  
AV7  
Description  
Wiring from eGates  
Positive Battery Power Supply 1/4*  
Positive Battery Power Supply 2/4*  
eGate 1 Positive Power Supply 1/2*  
eGate 1 Positive Power Supply 2/2*  
eGate 1 Negative Power Supply 1/2*  
eGate 1 Negative Power Supply 2/2*  
eGate 2 Positive Power Supply 1/2*  
eGate 2 Positive Power Supply 2/2*  
eGate 2 Negative Power Supply 1/2*  
Positive Battery Power Supply 3/4*  
Positive Battery Power Supply 4/4*  
No Connection  
eGate 1 Red Larger Gauge Motor Wire  
eGate 1 Red Larger Gauge Motor Wire  
eGate 1 Black Larger Gauge Motor Wire  
eGate 1 Black Larger Gauge Motor Wire  
eGate 2 Red Larger Gauge Motor Wire  
eGate 2 Red Larger Gauge Motor Wire  
eGate 2 Black Larger Gauge Motor Wire  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
5V Sensor Supply  
0V Sensor (Do NOT connect with Chassis GND)  
CAN 1 High  
eGate/s Red Wire  
eGate/s Black Wire  
CAN 1 Low  
eGate 2 Negative Power Supply 2/2*  
Negative Battery Power Supply  
Analog Voltage 1  
Analog Voltage 2  
No Connection  
No Connection  
ECU eGate 1 PWM Input  
No Connection  
Negative Battery Power Supply  
Negative Battery Power Supply  
eGate 1 Enable Switch Voltage  
eGate 2 Enable Switch Voltage  
Analog Voltage 7  
Analog Voltage 8  
No Connection  
ECU eGate 2 PWM Input  
0V Frequency (Do NOT connect with Chassis GND)  
Negative Battery Power Supply  
eGate 2 Black Larger Gauge Motor Wire  
eGate 1 White Position Sensor  
eGate 2 White Position Sensor  
eGate 1 Yellow Temperature Sensor  
eGate 2 Yellow Temperature Sensor  
AV8  
NC  
FREQ IN 4  
0V FREQ REF**  
Power Ground  
NOTE:  
*Each eGate requires 4 power wires. Two Positive and two negative to allow the correct amount of current to flow to the  
eGate for correct operation. Please see Pinout Current Sharing  
**The Sensor 0V Reference pin(s) are specialised ground outputs for all analog sensors and frequency inputs. Power  
Ground should not be connected with 0V Reference Pins. They should remain separate. Grounding these sensor grounds  
to the battery ground will cause issues with calibration and sensor readings due to noise.  
.
3
NOTE! 0V Supplies from the ECU are internally connected and should not be connected to battery ground.  
4
Backside of Connector  
s
Looking into Black Box Pins  
5
FITTING YOUR TURBOSMART BLACK BOX  
Using the Black Box Connector.  
1
Pinout Designation  
2
The Black Box connector needs to be populated as defined by  
the pinout information for each eGate. To remove the  
connector, The clip needs to be pushed down, removal of the  
conn
Depending on the number of eGates that are running will  
dictate what wiring is needed.  
Focusing on 1 eGate we must use all that are designated eGate  
1. If a second eGate is used it must be wired to the  
corresponding eGate 2 Positions.  
Outputs must be wired to two pins with high current wire as pins  
are limited to 6 Amps. A suitable gauge wire should be used  
that is
To populate the connector with pins we need to disengage the  
lock tab. To unlock we need to push the tab at the bottom up.  
Pinout Current Sharing  
3
Due to the high current nature of Black Box, the connector pins  
are current limited. To allow for high current to flow a correctly  
matched power supply wire must be used. This is then Paralleled  
to allow for the correct current to flow to each eGate. The Power  
and Ground are to be wired up to each 4 pins to manage the  
correct current for the Black Box to distribute.  
To lock we
Pin Limit  
Each Pin is rated for 15A per pin (This is wire gauge dependant)  
Recommended Wire Limit  
Motor Wire  
+
+
Note: Ensure that connections are of  
good quality and insulated correctly.  
6
USB Port  
4
For example, we have selected a random boost pressure in this  
case of 20psi. bOn(Boost On) must be set to 20psi. Over boost  
should be set to the maximum possible value to ensure it does  
not interfere.  
The USB port is accessed at the opposite end of the black box.  
It is held on via a 2.5mm Allen key bolt once removed a USB  
micro female connector is visible this is required to be accessed  
to setup and configure the Black box.  
CAN Bus Input  
7
Can Bus information must be transmitted from an ECU to the  
Black Box. This information is addressed in the datasheet for  
specific address for Transmitted and Received data.  
The CAN information required for the eGate to function correctly  
at a minimum requires the Boost Control Duty Cycle to be  
transmitted to the Black Box. As An example, here is the CAN  
Address required for eGate 1 to Function  
Connections Required  
A15 - Can High  
A16 - Can Low  
Base Address 0x110 (272)  
Byte 0,1 Area Target Egate 1 0-100.0% (0-1000)  
NOTE!  
The USB port must be fitted after tuning is done.  
This address allows for the area position to be transmitted to the  
Black box for the Black Box to target the correct position to  
effectively use the CAN BUS, as much information as possible  
should be used.  
Control Options  
Pulse Width Modulation (PWM) Input  
5
CAN Bus Wiring  
8
PWM is the standard for Boost Control solenoids, the Black Box  
can use this frequency input as position input for the e-Gates.  
The PWM inputs must be wired in correctly.  
The CAN Bus is a network within a vehicle that allows for vast  
amounts of information to be shared within each part of the  
vehicle.  
The Black Box accepts both high and low side inputs. The Rising  
edge threshold is 1.65V and the falling edge threshold is 1.0V.  
As long as the PWM signal alternatives across these values the  
signal can be used.  
•
CAN BUS Trunks should be no more than 500mm long  
from the main trunk  
•
•
The twisted wire should have one twist per 50mm  
A terminating resistor must be placed on either end of  
the Main harness trunk if more than 2m. Less than 2m  
will only require one. (100Ω 0.25W Resistor)  
Max Length is 16m long.  
Note In some cases PWM input will be turned off if Over  
boost is exceeded. This will result in the valve closing as the  
PWM input is turned off (0%). Ensure that Boost Control is  
set in such a way that the value is never set to OFF.  
•
Frequency Recommended  
100Hz  
Frequency Possible Range 25-100Hz  
Connections Required  
A23 - eGate 1 PWM input  
A32 - eGate 2 PWM input  
eBoost PWM Wire  
Grey Wire  
eBoost Auxiliary Wire  
White Wire  
0
% Duty Cycle  
Gate Closed  
Gate Open  
100% Duty Cycle  
eBoost PWM Hook-up  
6
It is required to setup the eBoost to use the Auxiliary output to  
disable the Black Box in the event of a boost level reaching over  
the required level.  
The OBS (Over boost) Feature must be set, but it must be set  
greater than the Auxiliary output bOn. Failure to do so will see  
the eBoost default to off and close the valve, resulting in higher  
boost pressure. The bOn (Boost On Feature) White Wire will be  
wired to the Enable switch voltage and disable the Valve in the  
event of an over boosting.  
The Auxiliary Output is located on the white wire from the eBoost  
this must then terminate to the corresponding gate which is to be  
disabled.  
7
USING YOUR TURBOSMART BLACK BOX CONFIG TOOL SOFTWARE  
Installing Software  
1
The Turbosmart Black Box Config Tool is available to download from the Turbosmart Website at  
Turbosmart Black Box Config Tool  
Connecting to Black Box  
2
The first step after physically connecting the USB to the Black Box. We see the feedback from the software on the state  
of the connection in the top right corner.  
Note  
NOTE!  
The Black Box requires the wiring to be completed as power is sourced from the car.  
User Interface.  
2
A breakdown of the software layout and the features that are available with the Black Box.  
•
•
•
Open File  
o
Saved Files configurations can be opened from here.  
Save to File  
o
Open files can be saved in here  
Live Editing – Write to Device  
o
The Black box will give you two options depending on what state Black Box is in.  
▪
▪
Write to Device sends a configuration  
Live Editing allows the Black Box to make live edits to the configurations while being  
connected to Black Box.  
•
Translation Type  
o
Poppet Default  
▪
A default option to that operates all Poppet style eGates. This is optimised to match flow  
capacity to valve height but not optimised to the specific Wastegate size.  
▪
Example 50% Position is requested may not output 50% Valve Position due to flow matching.  
o
Poppet 1:1 Ratio  
▪
An option that matches valve height percentage and position percentage. This could be  
common if using the eGate as an exhaust cut out.  
▪
Example 50% Position is requested will output 50% Valve Position due to 1:1.  
This could be used for an Electric antilag valve.  
▪
WG40  
▪
o
o
A default option to that operates the Wastegate 40 Poppet style eGates. This is optimised to  
match flow capacity to valve height  
▪
Example 50% Position is requested may not output 50% Valve Position due to flow matching.  
Recommended for most applications running this Wastegate.  
▪
WG45  
▪
A default option to that operates the Wastegate 45 Poppet style eGates. This is optimised to  
match flow capacity to valve height  
▪
Example 50% Position is requested may not output 50% Valve Position due to flow matching.  
8
▪
WG50  
▪
Recommended for most applications running this Wastegate.  
o
o
A default option to that operates the Wastegate 50 Poppet style eGates. This is optimised to  
match flow capacity to valve height  
Example 50% Position is requested may not output 50% Valve Position due to flow matching.  
Recommended for most applications running this Wastegate.  
▪
▪
WG60  
▪
A default option to that operates the Wastegate 60 Poppet style eGates. This is optimised to  
match flow capacity to valve height  
▪
▪
Example 50% Position is requested may not output 50% Valve Position due to flow matching.  
Recommended for most applications running this Wastegate.  
o
o
Straight 1:1 Ratio  
▪
An option that matches valve height percentage and position percentage. This could be  
common if using the eGate as an exhaust cut out.  
▪
Straight  
▪
Example 50% Position is requested will output 50% Valve Position due to 1:1.  
A default option to that operates the Straight Gate style eGates. This is optimised to match  
flow capacity to valve height  
▪
▪
Example 50% Position is requested may not output 50% Valve Position due to flow matching.  
Recommended for most applications running this Wastegate.  
o
Reserved  
▪ Selected if Gate is not being used.  
•
Target Source  
o
CAN Target  
▪
▪
CAN Target selects the CAN Bus network as the source for Wastegate Information. A large  
amount of information can be transmitted and received over this network.  
Recommended to allow the full potential of the Black Box.  
o
PWM Target  
▪
Pulse width modulation is defined as a percentage of a set period. For example, to achieve a  
25% Duty cycle we need to have the PWM ON for 25% of the time period and OFF for 75%.  
▪
▪
▪
This is the most common boost control method used with three port boost controllers.  
Can be used with most Factory ECU’s  
Easier option but does not allow for the full potential of the Black box.  
•
•
Overtemp  
o
o
o
A user defined value that the eGates will shut down if the internal temperature is reached.  
The gates are internally calibrated to a maximum value of 150degC (302degF).  
Value is typically 140degC(284 degF) But must be less than 150degC (302degF).  
Egate AutoStop Feature  
o
Autostop  
▪
The Autostop feature allows for current to be preserved if the gate sees no change in position  
demand for 5 seconds. This allows the gate to remain at its current position preserving  
current until a change is registered.  
▪
Typically selected  
•
Park Feature  
o
Park Enable  
▪
The Park Enable feature, the Park Enable allows the Gate to get to a user defined Park  
Threshold percentage and stop supplying current to the motor. When selected and the target  
is less than Park Target Threshold for 2 seconds the motor will switch off.  
Typically selected  
▪
o
Park Threshold  
▪
Used when Park Enable is selected. This is the Position Percentage that the gate will be  
considered closed. This value typically should be 2%.  
When selected and the target is less than Park Target Threshold for 2 seconds the motor will  
switch off.  
▪
8
▪
•
Preload  
o
Preload Enable  
▪
Enables the Preload enable feature, this feature allows the gate to be driven harder into the  
seat once the gate measures deviation from its aim path.  
Applied to both eGates  
▪
o
o
Preload DC  
Preload Duty cycle is the amount of duty cycle the gate will preload the valve with. This Value  
is typical -20% it should be a negative valve.  
Preload MAX time  
Max time is the amount of allowable time that position demand can be ramped to ensure  
preload on the valve.  
▪
▪
•
CAN Address  
o
The CAN BUS network allows for a large amount of information to be transmitted and received over a  
simple two wire twisted pair network. This allows vast amounts of information to be shared and  
adapted to many advanced tuning strategies.  
o
o
CAN Address may need to move as other data may conflict with these base address.  
This address must correspond to the relevant address on the ECU Can bus.  
o
TX - Transmit  
▪
▪
Typically  
Decimal = 256  
•
Converted  
o
Hexadecimal (0x100)  
o
RX - Receive  
▪
▪
Typically  
Decimal = 272  
Converted  
•
o
Hexadecimal (0x110)  
•
•
Calibration  
o
o
o
Automatic Calibration is set by selecting which e-Gate and the state that the calibration is required. It is  
highly advisable to select both open and closed calibration.  
A Set value is predefined by Turbosmart, these Offsets are stored as calibration offset Voltages at  
either state.  
NOTE: It is also advisable to move the gate with Manual Override when calibrating to the 25%  
mark and 75% mark depending on which calibration is required.  
Manual Override  
o
The option to manually select the position for the valve to move to that overwrites any position data  
feed from the ECU.  
o
This should be used for diagnostic purposes.  
9
Connected User Interface.  
3
Once connected and a file has been loaded e-Gate Positions are populated. As well as Calibration options  
are now accessible.  
User Interface Data Read Out  
4
While connected to the Black Box the selection of Data that is collected via the Black Box is presented to for  
troubleshooting, verification, and tuning.  
•
Diagnostics  
o
E-Gate Position status  
▪
The Position status can be Ok, Fail Low and Fail High readout on the status of the  
calibrations that the eGate is reporting to the Black Box.  
▪
▪
Failing Low indicates a Position lower than the calibration is expecting  
Failing High indicates a Position higher than the calibration is expecting  
o
o
E-Gate Temperature Status  
▪
The Temperature status can be Ok, Fail Low and Fail High readout on the status of the  
calibrations that the eGate is reporting to the Black Box.  
▪
▪
Failing Low indicates a Temperature lower than the calibration is expecting  
Failing High indicates a Temperature higher than the calibration is expecting  
5V Supply Status  
▪
The Temperature status can be Ok, Fail Low and Fail High readout on the status of the  
calibrations that the eGate is reporting to the Black Box.  
▪
▪
▪
Failing Low indicates a Voltage lower than the calibration is expecting  
Failing High indicates a Voltage higher than the calibration is expecting  
o
EEPROM Status  
1
1
▪
Indicates the Black Box is working correctly with the required software.  
e
•
eGate 1/2 Readout  
o
Area Target  
▪
Area Target uses the position target and converts it using the flow characteristics so 50% flow  
is 50% Position, but not 50% valve position.  
0-100%  
▪
o
o
o
o
o
o
o
o
o
Position Target  
▪
Position Targeted from the ECU.  
▪
0-100%  
Position  
▪
▪
Position of eGate in a percentage for Valve Position  
0-100%  
Motor Duty  
▪
▪
Motor Duty cycle required to move the eGate to the requested target.  
+/- 0-100%  
Target Error  
▪
Percentage error from requested target.  
▪
+/- 0-100%  
Current  
▪
▪
Current flowing to the eGate to as requested to allow for movement.  
Amps  
Position Voltage  
▪
▪
Raw Voltage from eGate encoder.  
0.5-4.5V  
Control Duty Input  
▪
▪
PWM Duty cycle required while PWM option is selected.  
0-100%  
Control Frequency Input  
▪
▪
Frequency of which the signal is sent to the Black Box  
Recommended 100Hz  
Temperature  
▪
▪
▪
▪
Temperature from the eGate encoder.  
Displayed in DegC Only  
0-150degC  
32-302degF  
o
o
Enable Switch Voltage  
▪
If this Voltage is grounded, the corresponding eGate will be disabled.  
Translation  
▪
▪
Readout of the current selected eGate for the Position selected  
Turbosmarts Wastegate Selection  
o
Target Source  
▪
▪
Shows the current target source selection.  
CAN or PWM  
o
o
System Status  
▪
Current Status of logic being performed on the eGate  
PID Status  
1
2
▪
Current Status of movement logic being applied to the eGate  
o
o
o
o
Proportional Output  
▪
Percentage of Proportional Control being applied to the Motor Driver  
Integral Output  
▪
Percentage of Integral Control being applied to the Motor Driver  
Derivative Output  
▪
Percentage of Derivative Control being applied to the Motor Driver  
Feedforward  
▪
Predetermined Table applied to aid in targeting correct position  
•
General  
o
14V Motor Supply Readout  
▪
Battery Voltage being supplied to Black Box  
o
o
o
5V Supply  
▪
5V Supply Voltage being supplied to Black Box Sensors  
Device Temperature  
▪
Internal Temperature of the Black Box  
Calibration Offsets  
▪
▪
Open  
•
•
Voltage Deviation from pre-set calibration values.  
Values over indicate +/-0.2V indicate possible issue with manual calibration  
Closed  
•
•
Voltage Deviation from pre-set calibration values.  
Values over indicate +/-0.2V indicate possible issue with manual calibration  
1
3
TROUBLE SHOOTING  
-
-----------------------------------------------------------------------------------------------------------------------  
-
It is important that any issues are resolved before heavy driving.  
-
Black Box will not turn on  
-
-
-
Ensure Good quality wire is being used that is rated correctly  
Check for Wires Shorting to Ground.  
Good Quality Ground point has been selected  
-
-
No Communication with Black Box  
-
-
Ensure decent quality USB and connector is correctly seated  
Verify Voltage and Ground at Black Box Connector  
Failing the above, submit a technical request to tech@turbosmart.com.au with information of your Black Box  
configuration and photos of installation. As well as any information regarding wiring.  
-
-----------------------------------------------------------------------------------------------------------------------  
1
4