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M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
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FEATURES
• Twoprogrammableboostcurvesforontheflyboostcurvechanges.• Twoelectronicallycontrolledairsolenoidsforprecisewastegatepressurecontrol.• DirectplugintoMSD’sCAN-Bushubforeaseofinstallation.• UtilizesthePowerGriddataacquisitiontohelpfinetuneboostcurves.• Built-inboosttimingretardoption.• Two75psigsensorstomeasuremanifoldandwastegatepressureforhighpressureapplications.• Overboostshutdown.• Spoolboostrev-limitercontrol.
OVERVIEW
TheBoostControlModuleallowsfinetuningcontroloftheengine’smanifoldpressure(boost)inforcedinductionenginesbymanagingthepressureontopofthewastegatethroughasetofelectronicallycontrolledair valve solenoids. TheModule integrateswith thePowerGridController seamlesslythroughthe4portCAN-Busconnectorwhichminimizeswiring.
AllPowerGridModulesworkthroughMSD’sCAN-Bussystem.ThePowerGridModulesareplugandplayinstallationsbutmayrequireextensionharnessesforremotewiring.
Note:DoNOTcutthewirestotheCAN-BusHarness.IntheeventanextensionharnessisneededtomounttheunitinthedesiredlocationMSDoffersthefollowingextensionharnesses-
2’CAN-BusextensionPN77824’CAN-BusextensionPN77846’CAN-BusextensionPN7786
ThemodulehasseveralprogrammablefeaturessuchasOverBoostShutdown,Spool/LaunchRPMactivationoncethespoolpressure isachieved,DataAcquisitionthroughthePowerGridControl,andallowsfortwoseparateBoostControlCurvesfor“onthefly”switching.TheModuleutilizesthebuiltindataacquisitionfunctionofthePowerGridforfinetuningoftheBoostControlCurvesandtheBoostRetardCurve.Themoduleusestwo75psigsensorstomonitoranddatalogboostpressure.
MSD Boost Control ModulePN 77631
Parts Required But Not Supplied:PowerGridControlPN77304PortCAN-BusHubPN7740CO2BottleandPressureRegulator
Parts Included:1-Controller,PN776312-12vAirSolenoids2-75PSIGRacepakSensorPN810-PT-75GVTPartsBag
2 INSTALLATION INSTRUCTIONS
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
INSTALLATION
Figure 1 Single Wastegate Plumbing
LED
INSTALLATION INSTRUCTIONS 3
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
Note:Useofapressureregulatorisrequired.AdjusttheCO2bottlepressuretonomorethan20psiabovethemaximumwastegatetargetpressure.MSDrecommendsCamozzifittingsthroughouttheairpressuresystem.
WIRING
Figure 2 Dual Wastegate Plumbing
1.MounttheBoostControlModulewiththesuppliedhardware.2. PlugthesixpinMSDCANconnectorfromtheBoostControlModuleintoafreeportontheMSDCAN-BusHubPN7740.
3. Theorangewireswitchestogroundwhenactive.Usearelaytoactivatedevicesthatconsumemorethan2amps(Figure3).
4. Routeallwiresawayfromheatsources.5. Assembletheconnectors.NOTE:Thesolenoidsarenotpolaritysensitive.6. ConnecttheredandwhitewirestothePressureINsolenoid.7. ConnectredandyellowwirestothePressureOUT(VENT)solenoid.
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4 INSTALLATION INSTRUCTIONS
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
Figure 3 General wiring
MSD 77631 WIRINGWire Grouping Wire Color Function Description6PINCONN RED MSDCANHI
BROWN SHIELD
RED POWER
BLACK MSDCANLO
BLACK MSDCANGND
SingleWire ORANGE SWITCHEDGND
SolenoidConnector RED 12V ControlwiresforthePressureINSolenoid.
WHITE SWITCHEDGND
SolenoidConnector RED 12V ControlWiresfortheVentOUTSolenoid.
YELLOW SWITCHEDGND
MAPSensor ORANGE 5V PluginforWastegateMAPSensor.
Connector BROWN GROUND
BLUE SIGNAL
MAPSensor ORANGE 5V PluginforManifoldMAPSensor.
Connector BROWN GROUND
GREEN SIGNAL
Supplies12vswitchedpowertoaddonmodulesonCAN-Hub.Allows communicationwith thePowerGridSystemControl.Thisconnector isusedonlywithModulesaddedtotheCAN-HubSystem.(Figure1)
Normallyopenandwillswitchtogroundonceactivated(2Amax).Useofarelayisrequiredforhighercurrentapplications(Figure3)
(ToCAN-Hub)
YELLOW
ORANGE
RED
LED
INSTALLATION INSTRUCTIONS 5
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
PROGRAMMING THE BOOST CONTROL MODULEMSD VIEWTheMSDViewsoftwareprogramsthe functionalityof theBoostControlModule.Whileusing theprogram,positionthemousepointeroverafunctiontodisplayitsdescription.
SAVES AND TRANSFERSWiththeignitionONandconnectedtotheBoostControlModulechangesaremadeinrealtime.YoucancreateandsavenumerousfilesonyourPCandtransferthemasneeded.
The MSDViewcandisplaypressure ineitherKPaorPSI.Tochange thedisplayunits,clickon“View”=>”Units”andselect“Metric(KPa)”or“English(PSI)”(Figure4)
Figure 4 Selecting Display Units
PROGRAMMABLE FEATURES AND SETTINGS
SETTINGS (FIGURE 5)
Over-Boost Shutdown:Allowstheusertosetanover-boostlimitthatwilldisabletheignitionastheprogrammedManifoldboostpressuresettingisexceeded.Thedefaultsettingis75psiandcanbeadjustedfrom2.9psito75psi.Boostpressuremustdropatleast1psibelowthatsettingfortheignitionfiringtoresume.
Note:SettingtheOver-BoostShutdownto75PSIdisablestheOver-BoostShutdown.
Note:Allreferencestopressureinthe77631BoostControlModulerefertoGaugePressure.
Boost Pressure Switch:TheOrangewireswitchestogroundwhilethesetboostpressureisexceeded.TheOrangewirecansinkupto2ampsofcurrent(continuous)toground(Figure3).Thedefaultsettingis75PSIandcanbeadjustedfrom0psito75PSI.
Note:Usearelayforhighercurrentapplications.
RED LEDTheLEDindicatesthatthemoduleiscommunicatingwithMSDView.WithoutaconnectiontoaPCorLaptoptheLEDwillbe"Off".
6 INSTALLATION INSTRUCTIONS
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
BOOST RETARD (FIGURE 6)ThiswindowallowsforprogrammingaBoostRetardCurve.ThiscurveretardstimingasafunctionofBoostPressure.Theverticallineindicatesamountofretardfrom0°(top)-20°(bottom).TheHorizontallineindicatesboostpressurefrom0psi(left)to75psi(right).Plottingacurveispossiblethroughtwodifferentmethods.PlotpointscanbeenterednumericallyintheMAPPRESSURE/IGNITIONTIMINGcolumnstotheleftoftheBoostRetardCurve.TheMSDViewsoftwarewillautomaticallyaddthedotstothecurvewiththismethod.Anothermethodwouldbemovingthemousepointeroverthedesiredplotpoint,right click => leftclick “AddDot.”TheMSD View softwarewil l automatical lypopulate the MAPP R E S S U R E /IGNITION TIMINGcolumns with thisme thod . Mak ingchanges to existingdots or plot pointsin the columns ispossible by clickingon t he do t anddragging it to thedesired position, orby simply edit ingtheplotpointsinthecolumns.Theyellowsquare in the righthand corner of theBoost RetardCurvedisplaysthepressureand retard timingasit follows themousepointer(Figure6).
Figure 6 Boost Retard
Figure 5 Settings
INSTALLATION INSTRUCTIONS 7
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
BOOST CONTROL: SETTINGS & BOOST CURVE
Thereare threesub tabsunder theprimary tabBOOSTCONTROL.Thesesettings in these tabscontroltheengineboostpressure..
Note:TheBoostControlModuleismanipulatingManifoldBoostPressure,bycontrollingthepressureontopofthewastegate.ChangesintheBoostPressurecurvemaynotdirectlycorrespondtowastegatepressureBoostCurvesettings.Forexample:Ifthewastegateisequippedwitha7psispring,and20psiofpressureisaddedtothetopofthewastegatethroughtheBoostCurve,theturbomaynotcreate27psiofboost,thisdueinparttophysicallimitationsoftheturbochargerand/orengine.Duringtheinitialtuning,startapplyingsmallamountsofpressuretothetopofthewastegatetodeterminehowmuchboosttheturbowillproducewithoutriskingengineorturbodamage.3psito5psiontopofthewastegateisagoodstartingpointformostsetups.UseoftheOver-BoostShutdownduringtheinitialtestingisrecommended.
Figure 7 Boost Control: Settings
BOOST CONTROL: SETTINGS
SECONDARY BOOST CURVE:DetermineswhichwirefromthePowerGridControllerPN7730willenablethesecondaryBoostCurve.Thedefaultsettingis“NONE,”buttheselectionscanbeeither“STEP3”(TAN)or“STEP4”(LT/GRN),andrefersdirectlytotheretardactivationwiresfromthePowerGridControllerPN7730.(Figure7)
BOOST CONTROL OFF RPM:ThesolenoidswillNOTactivateunlessengineRPMisabovethissetting.Thedefaultsettingis2000RPMandcanbeadjustedfrom0RPMto10000RPM.(Figure7)
Note: ThisfeatureminimizesCO2consumptionwhiletheengineisOFF.
Note: SettheBoostControlOFFRPMto0totesttheBoostControlwhiletheengineisoffwhichishelpfulindeterminingifthesystemisfunctioningcorrectly,andcheckforleaksintheairlines.
8 INSTALLATION INSTRUCTIONS
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
BOOST CONTROL: BOOST CURVE (FIGURE 8)ThiswindowallowsforprogrammingtheBoostCurve.Thiscurvewilldeterminethedesiredpressurethatwillapplytothetopofthewastegateasthetimeincreasesafterthelaunch.
Note: TheBoostControlModuleiscontrollingpressureontopofthewastegatewhilealsomonitoringManifoldBoostpressure.TheBoostControlModule,doesNOTcontrolManifoldBoostpressuredirectly.
The vertical line indicates thewastegate targetpressure from0PSI (bottom) to 75PSI (top). TheHorizontallineindicatestimeinsecondsafterthelaunchfrom0s(left)to10s(right).Plottingacurveispossiblethroughtwodifferentmethods.PlotpointsnumericallyintheLAUNCHTIME/WASTEGATETARGETcolumnstotheleftoftheBoostCurve.TheMSDViewsoftwarewillautomaticallyaddthedotstothecurvewiththismethod.Anothermethodwouldbemovingthemousepointeroverthedesiredplot point, right click=> left click “AddDot.” TheMSDViewsoftwarewill automaticallypopulatetheLAUNCHTIME/WASTEGATETARGETcolumnswiththismethod.Makingchangestoexistingdotsorplotpointsinthecolumnsispossiblebyclickingonthedotanddraggingittothedesiredposition,orbysimplyeditingtheplotpointsinthecolumns.TheyellowsquareintherighthandcorneroftheBoostCurvedisplaysthewastegatepressureandtimeinsecondsasitfollowsthemousepointer(Figure8).
Figure 8 Boost Control: Boost Curve
Forinitialtestingwithnoprevioususeoftheturbomotor,MSDrecommendssettingtheBoostCurvelow.Agoodstartingpointwouldbetoplotonedotat2-3psi@0seconds.Ifthereisa6-7psispringinthewastegate,thisshouldtheoreticallymake8-10psi.Thisnumberwillskewasboostpressureincreases.Inotherwords,20psionthetopofthewastegatecoupledwitha7psispringinthewastegate
INSTALLATION INSTRUCTIONS 9
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
willnotmake27psiofboostpressure.Itwouldn’tbeuncommontosee18-20psiofboostpressureinthatscenario.Thewaytodeterminehowmuchboosttheturbowillmakeinrelationtopressureincreasesonthewastegate is throughtesting.Therearephysical limitations intheturbochargersystem,wastegatesizeandplacement,pressuredrop,andengine limitationsthatwillaffecthowmuchboostpressuretheturbowillactuallymake.
BOOST CONTROL: SPOOL (FIGURE 9)
Figure 9 Boost Control: Boost Curve
Thenextsettingsfunctionasaspoolrev-limiterorretardwithoutwiringupthe5thstepretardwireasaspoollimiter.
Spool Boost Target:Usedtosetthetargetspoolpressure.Therangeofadjustmentis2.9psito75psi.
Launch RPM above Target: SetsthelaunchRPMoncetheSpoolBoostTargetisreached.Thesettingcanbeadjustedfrom0RPMto12000RPM.
Note: ThissettingwillfunctiononlyifsetbelowthelaunchrevlimiterwithinthePN7730.
Spool Boost Retard: Aretardusedtohelpspooltheturboduringstaging.Adjustablefrom0-30*
TheBoostControlModulehastwodifferentmethodswhichaidinspoolingtheturbo.Thesemethodsworkseamlesslywithouttheneedforadditionalwiringofthestepretardwirestoactivethespoolrev-limiterinthePowerGrid.
Note:Onlyonemethodforspoolboostrev-limiting/retardingwillworkatanygiventime.Thetwomethodscannotbeusedtogetheratthesametime.
Method 1: LowerthelaunchRPM.StartbysettingtheSpoolBoostRetardto0.SettheSpoolBoostTargettothedesiredMAPpressureatlaunch.SettheSpool/LaunchRPMtothedesiredlaunchRPM.Thiswillworkasthelaunchlimiteroncetheboostpressureisatthedesiredlevel.SettheLaunchRevLimiterinthePowerGrid7730Rev-limitertoahigherlimittoactastheSpoolRev-Limiter.Forexample,ifthedesiredmanifoldpressurewas12psi,andthecartypicallylaunchedat4400RPM;TheLaunchRevLimitercouldbesetto4800RPMtoaidinturbospool.TheSpool/LaunchRPMcouldbesetat4400RPM.Oncetheturbospooledandbuiltmorethan12psiofboost,theBoostControlModulewouldautomaticallyswitchfromthe4800RPMrev-limittothe4400RPMrev-limit.
Method 2: SettheSpoolBoostRetardtothedesiredretardamount.SettheSpoolBoostTargettothedesiredMAPpressureatlaunch.SettheSpool/LaunchRPMtotheminimumRPMthattheretardwillactivateat.
Note:OncetheSpoolBoostTargetisachieved,theSpool/LaunchRPM(Method1)orSpoolBoostRetard(Method2)willclampdownlaunchvalue,evenifthepressuredropsbelowtheSpoolBoostTarget.Thisistopreventthelimiter/timingfrom“hunting.”
10 INSTALLATION INSTRUCTIONS
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
DATA ACQUISITION
Figure 10 Data Acquisition Tab
TheDataAcquisitiontaballowsforthechannelsfromtheBoostControlModuletoeitherbeenabledordisabledinthePowerGriddataacquisition.Thedefaultsettingisenabled.
Note: Thesechannelsare recorded through thePowerGridDataAcquisitiononlyandareNOTrecordedthroughtheRacepakVNETconnection.
INTERPRETING THE POWER GRID DATA ACQUISITION
Figure 11 Power Grid Data Acquisition
INSTALLATION INSTRUCTIONS 11
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 5 - 7 1 2 3 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4
DATA ACQUISITION
Wastegate Pressure: Thistracedisplaysthewastegatepressureduringtherun.
Wastegate Target: Thistracedisplaystheactiveprogrammedboostcurveduringtherun.
Manifold Pressure:Thistracedisplaystheactualboostpressureinthemanifoldduringtherun.
Direction:Thistracedisplayswhetherthesolenoidsarebuildingpressureorrelievingpressureonthewastegateinordertoachievethetargetwastegatepressureduringtherun.Upswingsinthistracerepresentthesolenoidsbuildingpressure,Downswingsrepresentthesolenoidsrelievingpressure.
Pressure Switch:Thistracedisplaysthepressureswitchstatusduringtherun.0representstheswitchisintheOFFposition.1representstheswitchisintheONposition.
Figure 12 Power Grid Data Acquisition File
DATA ACQUISITION TRACES
Pressure Switch:TheexampleinFigure12demonstratesthePressureswitchintheOFFpositionasitisaflatlinealongthebottom.Inthisexamplethepressureswitchisnotprogrammedtoactivate.
Wastegate Target:Thisistheprogrammedboostcurvethatwasactiveduringtherun.IdeallytheWastegatePressurewillcloselyfollowthiscurve.
Wastegate Pressure: Thisistheactualpressureonthetopportofthewastegate.Note: InFigure12thewastegatepressureovershot theWastegatetargetcurvethatwas
activeduringtherun.TheDirectiontraceshowsthesolenoidsrelievingpressuretobringthewastegatepressuredown.EvenwithapressuredifferenceonthegateofseveralPSI,themanifoldpressureislargelyunaffectedasthesepressurevariancesrarelyrelatetohugepressureswingsonthemanifold.
Direction: Thereare twoarrows thatdescribehow thesolenoidsareeitherbuildingpressureorrelievingpressureinFigure12.
PlotReading INSolenoid OUTSolenoid 1 ON OFF 0 OFF OFF -1 OFF ON
Manifold Pressure:Themanifoldpressuretracerepresentstheactualboostpressureinthemanifoldduringtherun.
Note: FromFigure 12 adding 43psi to the top of thewastegatewith a 7PSI spring producesapproximately35-36psiofboostonthiscombination.
Limited Warranty MSDwarrantsthisproducttobefreefromdefectsinmaterialandworkmanshipunderitsintendednormaluse*,whenproperlyinstalledandpurchasedfromanauthorizedMSDdealer,foraperiodofoneyearfromthedateoftheoriginalpurchase.Thiswarrantyisvoidforanyproductspurchasedthroughauctionwebsites.Iffoundtobedefectiveasmentionedabove,itwillberepairedorreplacedattheoptionofMSD.AnyitemthatiscoveredunderthiswarrantywillbereturnedfreeofchargeusingGroundshippingmethods. ThisshallconstitutethesoleremedyofthepurchaserandthesoleliabilityofMSD.Totheextentpermittedbylaw,theforegoingisexclusiveandinlieuofallotherwarrantiesorrepresentationwhetherexpressedorimplied,includinganyimpliedwarrantyofmerchantabilityorfitness.InnoeventshallMSDoritssuppliersbeliableforspecialorconsequentialdamages. *IntendednormalusemeansthatthisitemisbeingusedaswasoriginallyintendedandfortheoriginalapplicationassoldbyMSD.AnymodificationstothisitemorifitisusedonanapplicationotherthanwhatMSDmarketstheproduct,thewarrantywillbevoid.Itisthesoleresponsibilityofthecustomertodeterminethatthisitemwillworkfortheapplicationtheyareintending.MSDwillacceptnoliabilityforcustomapplications.
Service Incaseofmalfunction,thisMSDcomponentwillberepairedfreeofchargeaccordingtothetermsofthewarranty.WhenreturningMSDcomponentsforwarrantyservice,Proof of Purchasemustbesuppliedforverification.Afterthewarrantyperiodhasexpired,repairserviceisbasedonaminimumandmaximumfee. All returns must have a Return Material Authorization (RMA) number issued to thembeforebeingreturned.ToobtainanRMAnumberpleasecontactMSDCustomerServiceat1 (888)MSD-7859orvisitourwebsiteatwww.msdperformance.com/rma toautomaticallyobtainanumberandshipping information. Whenreturningtheunitforrepair,leaveallwiresatthelengthinwhichyouhavetheminstalled.Besuretoincludeadetailedaccountofanyproblemsexperienced,andwhatcomponentsandaccessoriesareinstalledonthevehicle.TherepairedunitwillbereturnedassoonaspossibleusingGroundshippingmethods(groundshippingiscoveredbywarranty).Formoreinformation,callMSDat(915)855-7123.MSDtechniciansareavailablefrom7:00a.m.to5:00p.m.Monday-Friday(mountaintime).
M S D • W W W . M S D P E R F O R M A N C E . C O M • ( 9 1 5 ) 8 5 7 - 5 2 0 0 • F A X ( 9 1 5 ) 8 5 7 - 3 3 4 4© 2014 MSD LLC
FRM31732 Revised 06/14 Printed in U.S.A.