[kettlekev]

The solenoid from DIY0-EFI looks like...

boost2.JPG (12.12 KiB) Viewed 1771 times

Looking at the ports I assume the intake return port goes to the turbo intake hose. The compressor outlet comes from the turbo and the WG actuator goes to the top of the wastegate so the plumbing should look like...?????

boost.JPG (17.72 KiB) Viewed 1771 times

[PSIG]

Probably. There are several ways to connect boost valves, for different wastegate types and different valves (how they function). In any case, the setup should allow the minimum boost possible if there is any failure of the solenoid, wiring or control. Default minimum boost for safety.

The Pierburg style valve (like below), is most commonly used to increase boost above the waste gate's normal maximum boost, as configured by the internal spring. The most common connections are as you posted.

Pierburg Boost Valve.jpg (18.66 KiB) Viewed 1730 times

As there are multiple versions of this valve type, including ones that work "backwards", be sure to test that the waste gate receives full boost on the bottom, and no boost on the top, when the valve is 'off'. For best control, the valve operation at different control frequencies (Hz) should be tested (especially clones), but similar Pierburg-style valves usually work with values like these:

Freq (Hz) Duty Cycle Control Range
10 Hz       7-84
15 Hz      10-77
20 Hz      15-70
25 Hz      18-60
32 Hz      20-50

[kettlekev]

Thanks. Knew it couldnt be that simple!!

I have a Pierburg pa6 gf30 (well thats whats written on the side) which I am trying to find a data sheet for.

I bought it from DIY-EFI.

[kettlekev]

Playing with the valve in the diagrams and the photo you sent below and looking at your comments...

Pierburg Boost Valve.jpg (29.1 KiB) Viewed 1637 times

My valve works as the labels I have put on the image so my assembly diagram should be...

boost.JPG (32.43 KiB) Viewed 1637 times

So with the valve OFF the WG bottom will receive max boost pressure.

[PSIG]

I don't see your vent/zero pressure port. Note the MAC valve example routes to the fresh air intake (no pressure). The external waste gate bottom port is separately fed boost pressure, always. The solenoid only vents the waste gate top port to atmosphere (off), or directs boost to the top port (on).

Your vendor should supply the information, or direct you to it. This is the first assumption for any purchased products - the one that sold it should be tasked first to support it, and part of what you're paying for. I'd start there when possible.

[kettlekev]

Sorry you are right my bad, missed that and I will confirm with DIY EFI but I think now...

The compressor outlet (on the valve image) joins both WG bottom and the boost pressure source, so WG bottom always sees boost. WG actuator on the valve image (which is normally open/off on this valve so sees full boost while off) goes to intake return.
Then the intake return (which is normally closed on this valve) goes to WG top to control boost when open/activated by the ECU.

Basically this valve labeling is back to front compared to how the valve is actually working.......

boost2.JPG (12.12 KiB) Viewed 1568 times

boost.JPG (27.69 KiB) Viewed 1568 times

Appreciate the help

[PSIG]

There ya go. The requirement to force minimum boost when "off" means to identify which ports do what in that condition. A similar valve I have has the two small ports connected and compressor port blocked when off, so the WG top is always vented with no pressure until on, when it blocks the vent port and connects the boost and WG ports.

I would re-test the ports both off and on to find the combination that ensures venting of the WG top when off, and pressure when on. Then you're golden to match the example diagram. I just blow in each port to see where the air goes, then jump 12V to it and test again. Draw what it does at each port and verify your plan.

[kettlekev]

Ok, just for everyone's benefit.... To summarise.....

The valve I have is from DIY-EFI and is a Pierberg PA6-GF30

Using the label below (which is from DIY-EFI's site) the function diagram is below.

boost2-1.jpg (28.88 KiB) Viewed 1034 times

Therefore with no power applied from the ECU the gas routes from the (in this valve labeling) compressor outlet to wastegate actuator and boost pressure gets routed to the intake (in the image at the bottom of this post) and the bottom of the wastegate.

When power is applied the gas routes from (in this valve labeling) wastegate actuator to intake return and controlled by ECU boost is applied to the top of the wastegate (bearing in mind its a pulsed signal).

So using the labeling from the DIY-EFI valve image and my connection diagram the valve ports get labeled as....

boost2-2.jpg (36.08 KiB) Viewed 1034 times

So basically the DFIY-EFI valve labeling is confusing.

[PSIG]

Now you've got the info to connect it. Below is an operational diagram of your Pierburg valve (and many others, e.g MAC has this on their label), a 2-position 3-way valve, as commonly seen in pneumatic and hydraulic schematics. The first block is at rest (off), while the second block is actuated (on):



From this, and knowing we must connect it to provide waste gate (WG) venting when off, and provide WG boost when on, it looks like this:



The common port is the WG port, switching between vent (less boost) and the compressor (more boost). Hook yours up so it gives you that. Now you know, whatever they were called before, which port should be connected to what. Rock on!

[kettlekev]

Thanks PSIG.
I've been travelling for a week and was thinking about my last post again and I was wrong on the labeling.

OK, start again. Back to basics and to clear it up for everyone (hopefully ).

The WG is fitted with a spring. In the diagram below, the boost pressure will build with revs and is fed to the base of the WG. This occurs until it matches the spring, then the spring will lift allowing the WG to open and the boost to limit.

boost.JPG (27.69 KiB) Viewed 660 times

Using a boost solenoid valve allows us to route a boost feed to the top of the WG and this controls the amount of boost pressure the top of the WG sees and effectively adds more boost over the spring pressure of the WG, keeping it closed.
Obviously at some point this extra pressure becomes a bad thing and must be released, ideally back to the turbo inlet.

The Pierburg valve works as below;

boost2-1.jpg (28.88 KiB) Viewed 660 times

With no power supplied ('off' control signal from the ECU), the valve stays in the normally closed position, the valve routes boost pressure to the top of the WG. With a 'on' control signal from the ECU, the valve switches from the normally closed position to the open position and vents WG top pressure back to the intake return.

To manage boost, a voltage signal between 'off' and 'on' is needed to allow the valve to rapidly open and close and 'manage' the boost pressure seen on the to of the WG to allow for the desired boost level.

This voltage signal is generated via the boost table in the ECU and a signal with a varying duty cycle, known as a pulse width modulated (PWM) signal (an on/off square wave) is provided to the boost solenoid to make the valves WG actuator port switch back and forth between compressor outlet port and the intake return port. Zero duty cycle is an 'off' control , keeping the valve closed and routing all boost pressure to the WG top and 100% duty is an 'on' control signal, switching the valve over to the intake return port and routing WG actuator top pressure to the intake. Signals in between allow varying levels of pressure to enter and leave the WG top, controlling the boost pressure.

The Pierburg solenoid is in effect a single pole 2 way valve. In the diagram below the WG actuator (top of the WG) is the pole and that port can either be routed to the boost source or the intake return.

boost2-2.jpg (35.78 KiB) Viewed 660 times

At the low ends of the boost map in Speeduino, the PWM, signal supplies low duty cycle (off), allowing boost to build and higher duty cycle (on) at the top end, allowing the solenoid valve to vent the WG top back to the inlet vent and manage boost. Therefore, the correct balling of the valve is below and not as in my previous post;

Pierburg Boost Valve.jpg (26.64 KiB) Viewed 660 times