Basic Closed Loop Setup Procedure

See Boost Control on how to get some basic parameters in place to allow the closed loop boost controller to operate.
It is assumed that all the target boost levels are above the wastegate spring pressure. The electronic boost controller cannot control boost below the wastegate spring pressure.

1. Choose Closed Loop for the Control Type.

2. Set the frequency of the Turbo Waste Gate solenoid in the 'Frequency' setting. The Haltech waste gate solenoid runs at a frequency of 20 – 30 Hz.

3. Disable the controller by setting Proportional – 0%, Integral – 0% and Derivative – 0%.

4. Set the 'Control Point Before Target' to the default value of 20 kPa (3 PSI).

5. Set the 'Delay till Boost Control' to the default value of 0.5 sec.

6. Set the 'Target Boost' table at the boost level that you want to run across the whole RPM range.

7. Set the 'Start Duty' to a duty cycle that should get you close to your boost target. Start at a small duty, then slowly increase to avoid overboosting.

8. Put the engine under sufficient load (i.e. on a dyno) to get it to reach the target boost level. Watch to make sure it does not over boost. View the duty cycle of the wastegate, by displaying the Duty channel of the output that the boost controller is setup on. E.g. If boost control is setup on DPO1, then view Digital Pulse Output 1 Duty. If the boost level exceeds the target boost level reduce the 'Start Duty', if the boost is far away from the target boost level, then increase 'Start Duty'. The final value should allow boost to come close to, but just below the target boost level. If Start Duty is set too high, the controller will spike when coming on boost. If it is set too low, then it will start low and slowly rise to the target.

9. Once you are satisfied with your Start Duty setting, turn on the controller by restoring the Proportional, Integral and Derivative to the following settings:

• Proportional - 50%

• Integral - 0%

• Derivative - 0%

1. Adjust Proportional until your boost starts to oscillate. Once you find this value, set the Proportional to about half this value. While tuning this value, your boost may still not hit the target boost exactly. This is normal at this stage.

2. Once you are satisfied with your Proportional setting, start increasing the Integral value until the target boost is close enough to the target level that you wish to run.

3. Once Proportional and Integral are set, check to see if you have any overshoot when hitting the target. If you have some overshoot, then increase Derivative until that overshoot is minimised. Use caution when increasing Derivative as this setting is very sensitive and should be increased very slowly otherwise, unstable boost control may result.

Setup of the Start Duty Map

If the Target Boost is varying over RPM, or by either a boost trim or gear boost correction then it is a good idea to setup the 'Start Duty' table. The Start Duty is closely related to the target boost, so a different Start Duty for each Target Boost will allow better control over boost levels.
It is assumed that all the target boost levels are above the wastegate spring pressure. The electronic boost controller cannot control boost below the wastegate spring pressure.

• Firstly leave the 'Use Start Duty Table' un-ticked. Set the entire 'Target Boost' table to the lowest desired boost level that you wish to run.

• Use the above procedure for setting up Basic Closed Loop Setup Procedure and stop at step 8. Record the 'Start Duty Cycle' and the corresponding Target Boost. Increment the 'Target Boost' by about 20 kPa (3 PSI) and repeat steps 6 to 8 and record the 'Start Duty Cycle' and the corresponding Target Boost again. Repeat this procedure until you reach the max boost that the engine is going to run. You should have a table of Start Duty values against Target Boost levels every 20kPa or 3psi.

• Fill out the 'Start Duty' table with the data recorded. For the Target Boost Level columns above the highest target that you wish to run, use the highest value Start Duty that you have recorded. For the Target Boost Levels below the lowest target that you wish to run, taper off the Start Duty values below this column until you reach zero duty when at the wastegate spring pressure column.

In the example above, the maximum boost was 140kPa, with the Start Duty values leveled off above this Target Boost. 100kPa is the minimum Target Boost, and the Start Duty values below this are tapered off down to around 50kPa.

• Tick the 'Use Start Duty Table' in the closed loop boost control setup.

• (Optional) To fine-tune the 'Start Duty' table, setup a closed boost control trim under the analog input function page and load up the engine at different boost levels to make sure that the boost control runs smoothly.