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Bosch MS 6 Manual

Engine control unit
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Engine Control Unit MS 6
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Version 1.0 06/05/2019

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  • Page 1 Engine Control Unit MS 6 Manual Version 1.0 06/05/2019...

  • Page 2: Table Of Contents

    CAN Input..........................................CAN Output ..........................................8 Online Measurement and Calibration .......................... Setting up an Online Measurement ................................Using the Measurement Sheets..................................9 Error Memory .................................. Error Memory representing in RaceCon..............................Writing an Error........................................Error Memory Properties ....................................ii / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...

  • Page 3: Getting Started

    CAUTION Risk of injury if using the MS 6 inappropriately. Use the MS 6 only as intended in this manual. Any maintenance or repair must be per- formed by authorized and qualified personnel approved by Bosch Motorsport. CAUTION...

  • Page 4: Technical Data

    2 | Technical Data 2 Technical Data The MS 6 engine control unit features a powerful digital processing dual-core with float- ing point arithmetic and a high-end field programmable gate array FPGA for ultimate per- formance and flexibility. The software development process is based on MATLAB® & Simulink®. It significantly speeds algorithm development by using automatic code and documentation generation.
  • Page 5 To accommodate the wide range of different engine requirements and race track operat- ing conditions, the MS 6 Motronic system is classified into the main groups high- and low pressure injection support, subdivided into fully equipped- and functional reduced ver- sions.
  • Page 6 Engine function package II To activate traction and F 02U V02 002-01 launch control For MS 6.1 and MS 6.3 Measurement package To increase from 21 to 42 F 02U V02 000-01 analog channel inputs For MS 6.3...

  • Page 7: Mechanical Data

    Vibration suppression via multipoint fixed circuit boards Size without connectors 226 x 181 x 44 mm Weight 1,086 g Protection Classification IP54 Temperature range -20 to 80°C Inspection services recommended after 220 h or 2 years, no components to replace Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 7 / 76...
  • Page 8 2 | Technical Data 8 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...

  • Page 9: Electrical Data

    Dual Core 667 MHz; FPGA 2.3.1 Communication 3 x CAN The MS 6 has 3 CAN buses configurable as input and output. Dif- ferent baud rates are selectable. Please note that the MS 6 contain integrated switchable 120 Ohm CAN termination resistors.
  • Page 10 Please respect: for camshaft- or wheel speed signals Hall-effect or DF11 sensors have to be used and for wide range Lambda measurement and control the Lambda sensor Bosch LSU 4.9 has to be used. 42 analog inputs in a mix of different hardware designs...
  • Page 11 2 x outputs for high pressure pump controls (MSV) 2 x 8.5 amp H-bridge for electronic throttle control 2 x 4 amp pwm lowside switch for Lambda heater 3 output signals 1 x flywheel 1 x trigger wheel 1 x engine rpm Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 11 / 76...
  • Page 12 – Ensure controller supply is activated before the power stages. – The MS 6 is able to control a main relay or even the power box itself via a low side output. – As long as the controller is activated, data logging, telemetry and communication is also ongoing.
  • Page 13 Bosch Motorsport tests check the defined connections of the pin layout. Using a MS 6.1 or MS 6.3 version ensure not using analogue inputs of the measurement package without enabled license. For MS 6.1 and MS 6.3 these hardware-options are only available if MS 6 measurement package is in use.
  • Page 14 K076 K079 Measure pack- not available Thermo- k-type sensor 24shield exhaust gas temperature bank 2 fixed function to pin coordina- utexh2 couple input thermo tion K078 Measure pack- not available 14 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 15 Lambda_IA LSU4.9 probe only Lambda fixed function to pin lambda coordination K086 Lambda_IP K087 Lambda_UN K088 Lambda_VM K068 not avl. Lambda_IA LSU4.9 probe only Lambda bank2 fixed function to pin lambda2 coordination K069 not avl. Lambda_IP Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 15 / 76...
  • Page 16 A105 not avl. 24twist Injection cyl.8 tinj_n_008 A018 not avl. 24twist Injection cyl.9 tinj_n_009 A020 not avl. 24twist Injection cyl.10 tinj_n_010 A063 not avl. 24twist Injection cyl.11 tinj_n_011 A084 not avl. 24twist Injection cyl.12 tinj_n_012 16 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 17 24twist gearshift actuator downshift PIN_OUT_K055 shiftdn_pwm K074 lowside switch 2,2 amps pwm 24twist PIN_OUT_K074 K089 lowside switch 1 amps pwm 24twist fuel pump relay PIN_OUT_K089 fpump_pwm K073 not avl. lowside switch 1 amps pwm 24twist PIN_OUT_K073 Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 17 / 76...
  • Page 18 A086 MSV1 controller FCVL1 neg. A087 not avl. MSV2 controller FCVH2 24twist high press. pump MSV valve 2 fixed pin to output control co- msv_dlvy_ang pos. ordination A088 not avl. MSV2 controller FCVL2 neg. 18 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 19 K083 not in use K084 not in use K051 LIN-Bus CWLINMODE LIN communication K030 TN digital output TNSIG_PULSENUM rpm-signal PIN_OUT_K030 TNSIG_PWM K013 TN digital output flywheel-signal PIN_OUT_K013 K037 TN digital output triggerwheel-signal PIN_OUT_K037 Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 19 / 76...
  • Page 20 A062 shield ground sensor shields K021 shield ground sensor shields K026 shield ground Ethernet and LIN shields K049 not used K009 shield ground USB shield A083 not in use 20 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 21 Technical Data | 2 2.3.7 Harness / Wiring The wiring diagram is available at Bosch Motorsport website on the MS 6 product page. NOTICE The wiring diagram shows a principle of wiring and connection op- tions. ECU pin relation may change to customer data application and program layout. Sensor-, actuator- and power supplies may also change to the request of the project.
  • Page 22 2 | Technical Data Harness connectors Bosch automotive connectors are not available as complete set of components, so Bosch Motorsport itself offers such a package. For more technical details please check Bosch- connector homepage, 196 pins http://www.bosch-connectors.com/bogscoca/category/142 MS 6 harness connector type A (105 con-...
  • Page 23 Technical Data | 2 CAN-networks need a 120 Ohm termination at 2 ends of the wiring. The MS 6 is able to switch on an internal 120 Ohm termination, set CWCANx_TERM true to enable the termination. For wiring layout, respect the common rules of failure reduction like separated sensor power supply between important system sensors (e.g.
  • Page 24 Adjust the position of the cam trigger in reference to its Hall effect speed sensor: the sensor must be at the begin of the tooth. Turn the engine by 345 crankshaft degrees to reach the position of 78° before TDC exhaust for cylinder #1. 24 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...

  • Page 25: Disposal

    Hardware, accessories and packaging should be sorted for recycling in an environment- friendly manner. Do not dispose of this electronic device in your household waste. Waste electronic equipment must be disposed of properly according to Electrical and Electronics Act (ElektroG) and the European WEE directive. Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 25 / 76...

  • Page 26: Starting Up

    3 | Starting up 3 Starting up 3.1 Installation of Software Tools PC tools and ECU programs for the MS 6 system are available at Bosch Motorsport homepage for free download. RaceCon V2.5.1.400 or higher Mainly used for system configuration Modas Sport V1.08.012 or higher...

  • Page 27: Configuration Of The System

    Starting up | 3 3.2 Configuration of the system Bosch MS 6 devices are delivered in a not engine executable mode. The customer has to include the correct programs, data applications and licenses. The MS 6 offers two mainly different configuration areas, related to the two core areas of the controller.
  • Page 28 3 | Starting up Now the ECU program archive PST files must be selected. These archives are delivered by Bosch or are available at Bosch Motorsport homepage. Specify the MS 6 program archive: MS6A_XXX_xxx.pst. Access to all configurable data is now available.
  • Page 29 3.2.2 Programs Installation Going Online for program and license configuration In the project tree both parts of the MS 6 core are shown as >red<, means MS 6 device and RaceCon project differ in the used program version. Synchronize MS 6 and RaceCon program version / update the firmware of the device: Project-tree / right mouse button to one of the red MS 6 core / synchronize / update firmware >select customer software of the MS 6 (file with extension: -.pst)
  • Page 30 NOTICE Do not interrupt flash process. In the project tree, the MS 6 logger core is shown as >yellow<, means the firmware of MS 6 device and project are identical, but the data differs. The offline preconfigured data have to be sent to the MS 6. Option one, select: Project...
  • Page 31 Generally all MS 6 licenses are related to one specific device and the delivered code is only to activate for this ECU. Both cores, MS 6 ECU and MS 6 logger, content own license structures. Double-click to the core symbol at the project and choice features info.
  • Page 32 The licenses for gearbox and engine controls are to activate at the MS 6 ECU core. The li- censes for USB or logger packages are handled in the MS 6 logger core. MS 6 ECU is now ready for customer data and use.

  • Page 33: Prepare Data Base

    Wrong engine setup data may lead to serious engine damages. 4.1.1 Basic Engine Data The MS 6 system can be used for engines up to 12 cylinders. Please ensure that the cor- rect software variant is loaded in your ECU. Define the engine parameters like number of cylinders, firing order, injection system and cam- and crankshaft designs in relation to TDC.
  • Page 34 4.1.4 Basic Path of Injection Calculation The ECU MS 6 is a so called physically based system. This means in particular that correc- tions are made according to their origin influence (e.g. air temperature, fuel pressure etc.).
  • Page 35 If unsure, set FRLPTINT to 1.0 for first startup. FRLPTHR Factor to throttle dependence. If unsure, set to 1.0 for star- tup. MP_RLP1 … P4 Relative load depending on throttle position 1-4 Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 35 / 76...
  • Page 36 Decay of the start enrichment factor over the number of engine revolutions FINJSTART_TMOT Basic start enrichment factor depending on the engine temperature FINJSTART_NMOT Basic start enrichment factor depending on the engine speed Notice: For details please refer to the Function Description INJPRECTRL 36 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 37 – Soft limitation by ignition retardation or cylinder individual cutoff of injection and/or ignition – Hard limitation by injection cut off and/or ignition cutoff of all cylinders To achieve a good dynamic behavior by advanced intervention, the engine speed is pre- dicted by means of the speed gradient. Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 37 / 76...
  • Page 38 4 15 (=1111b) 15 (=1111b) 15 (=1111b) 15 (=1111b) The cylinders are assigned bitwise, the lowest bit represents cylinder 1. Numbering refers to mechanical cylinders, e.g. pattern = 9: Mechanical cylinders 1 and 4 are fade out. 38 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...

  • Page 39: Peripherals

    Sensor configuration The MS 6 has the option to link a lot of functionalities to a possible hardware input. The chapters “ECUPINS, SWITCHMATRIX and Input Signal Processing” of the functional de- scription explains the details. All functions of Base MS 6 programs are linked like de- scribed in the MS 6 documents (e.g.
  • Page 40 The system offers a lot of different temperature channels, please see function description input signal processing for details. Example: Intake Air Temperature UTINT_MIN, UTINT_MAX Minimum and maximum accepted sensor voltage. When violated, an error is set (E_tint = 1). TINT_CONV Sensor characteristic. Consult the sensor manufacturer. 40 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...

  • Page 41: Throttle Control

    Predefined values should be suitable for NiCrNi or k-type elements. For further details and project specific variants please refer to the function description. Digital sensor inputs MS 6 digital sensor inputs used for frequency measurements are possible to configure to different of sensor types. CWINTF_CRANK...
  • Page 42 Further information you will find in docu- ment “SICHERHEITSHINWEISE-Systemanforderungen zum Betrieb eines Bosch Engineer- ing GmbH EGas-Systems” or can be enquired at Bosch Motorsport. The customer is responsible for the activation of all ETC‐relevant diagnosis and for their correct parameterization.
  • Page 43 (_b). The system expect a rising up uthrottle2 voltage for the main signals and a falling signal uthrottle2_b for the redundant one. UDTHRCM_MAX max. allowed difference between sensor output and redundant signal abs (uthrottle(x)+uthrottle(x)_b)-5V < UD- THRCM_MAX Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 43 / 76...

  • Page 44: Vehicle Test

    Before starting with your vehicle test, some initial data should be set: Speed & distance measurements The signals for speed calculation may be available from different sources, like MS 6 own measurement, GPS data or via CAN re- ceived information from ABS calculation. For...
  • Page 45 Laptrigger_xxxx_yy Results and measure channels of lap-func- tionalities Consumption-calculation Is designed in the same way as lap-inform- ation, drag and drop the subfolder to the project and follow the wizard Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 45 / 76...
  • Page 46 4 | Prepare Data Base Set time & date MS 6 device is equipped with a real time clock which is supplied for max. 14 days, if the ECU is disconnected from power sup- ply. Please connect the ECU to the PC and click on “SET DATE &...

  • Page 47: Ecu Plus Data Logger

    ECU plus Data Logger | 5 5 ECU plus Data Logger The MS 6 combines ECU and data logger in one common housing for a cost efficient and weight optimized all-in-one solution. 5.1 Software Tools RaceCon Create and configure a project Configuration &...
  • Page 48 >edit recording channel< right mouse button to one or a selection of recorded channels opens the option to modify the sampling rate and/or the selection for online telemetry >Project Window / MS 6 Logger / right mouse button / download configuration >download configuration< Send your configuration to the device, the recording will start within the defined limits (without defined condition, the recording will start immediately).

  • Page 49: Usb Data Recording

    ECU plus Data Logger | 5 5.3 USB Data Recording The MS 6 data recording contents the feature to send a copy of the recorded data to an USB stick. Required is just an activated USB-license and wire installation. Technical aspects of commercial USB sticks may lead to connection- and data storage problems.

  • Page 50: Project Configuration

    Describes the function selected above. c) Enter the formula. d) Select the logical operator. e) Choose a measurement channel. Click ‘Finish’ when done. The math channel is displayed in the MS 6 math channel window. 50 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...

  • Page 51: Conditional Function

    Enter the Then-condition. Click on the pencil symbol to open an editor to enter expressions. d) Enter the Otherwise-condition.Click on the pencil symbol to open an editor to enter expressions. e) Enter the reset value (must be a number). Click ‘Finish’ when done. Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 51 / 76...
  • Page 52 An example of a condition to set up the maximum front brake pressure is given on the next page. The conditional function is displayed in the MS 6 math channel window. Example: Setting up a condition for maximum front brake pressure Brake pressure front p_br_front Brake pressure ‘front p_br_front’...

  • Page 53: Condition Channels

    6.4 CPU Load Generating math and conditional channels, also the configuration of CAN network use ca- pacity of the MS 6`s processor. Please ensure to keep the processor load below 85 % (av- eraged). “cpu_load_001” measure channel actual measurement rate Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual...

  • Page 54: Can Configuration

    7 CAN Configuration MS 6 has 3 fully configurable CAN buses – Baudrate (125 kbit … 1 Mbit) – Input configuration: read messages from CAN bus and convert to MS 6 measurement variables – CAN bus supports row counter configuration –...

  • Page 55: Can Input

    7.2.2 Create a new CAN channel Double-click on any CAN bus item, to open the "CAN messages overview". Select ‘Add CAN-IN’ and choose the desired CAN bus for the new input channel. A CAN channel configuration window opens. Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 55 / 76...
  • Page 56 7 | CAN Configuration Insert the name and description of the channel. Click ‘OK’ when done. The channel is listed in the Data window. 56 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 57 CAN Configuration | 7 7.2.3 CAN channel configuration Extraction of data from CAN bus Mini CAN analyzer functionality Conversion to physical values Automatic assignment to measurement view Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 57 / 76...
  • Page 58 Enter data position, length and format. e) The bargraph shows assignment of the bytes. - Red colored fields show the assignment of the data bytes. - Orange colored fields show the assignment of the multiplexer bytes. 58 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 59 Select unit of physical value. e) Enter minimum physical limit of the channel. (for manual setup) f) Enter maximum physical limit of the channel. (for manual setup) g) Check the box to automatically adjust the limits of the channel. Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 59 / 76...
  • Page 60 Drag the desired Measurement element (e.g. Numeric Indicator) and drop it on the Measurement Sheet. Drag + Drop Click on folder ‘CAN Input’ of desired CAN bus to display available channels. Drag desired Measurement channel and drop it on the Measurement element. 60 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 61 A channel import window opens. Select the desired channels on the left and use the ‘Add’ button to add them to the import list. Click ‘OK’ when done. The channels are inserted in the Data window. Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 61 / 76...
  • Page 62 Click with the right mouse button on any item in the project tree. Select ‘Import…’ from menu. A file browser opens. Select the input file and click ‘Open’. An ‘Import Selection’ window opens. Select channels to import. 62 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 63 Drag and drop the channel to ‘CAN Input’ of desired CAN bus on right hand side. Click ‘Finish’. If a measurement channel belongs to more than one source (e.g. MS 6 and MS 5.1), the ‘Solve Label Ambiguity’ window opens.

  • Page 64: Can Output

    Display CAN bus properties (Baudrate) 7.3.2 Create new CAN output message channel Double-click on any CAN bus item, to open the "CAN messages overview". Select ‘Add CAN-OUT’ and choose the desired CAN bus for the new output channel. 64 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 65 Click on ‘Add channel’ or ‘Add constant’, this opens the ‘Add new CAN out channel’ window. Select the desired measurement channel and specify the message settings. Click here The measurement channel is now assigned to the CAN message. Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 65 / 76...
  • Page 66 Click with the right mouse button on any item in the project tree. Select ‘Import…’ from menu. A file browser opens. Select the input file and click ‘Open’. An ‘Import Selection’ window opens. Select channels to import. 66 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 67 Drag and drop the channel to ‘CAN Input’ of desired CAN bus on right hand side. Click ‘Finish’. If a measurement channel belongs to more than one source (e.g. MS 6 and MS 5.1), the ‘Solve Label Ambiguity’ window opens.

  • Page 68: Online Measurement And Calibration

    – Data application in online mode. – PC and device are connected. – Local PC data match to MS 6 configuration (devices are indicated as green). – From the context menu of the project, new measurement pages can be created.

  • Page 69: Using The Measurement Sheets

    – To assist the discovery of relevant labels, data list may be graduated. – Description and label symbol explain the task of the data label. – Structure of Bosch Motorsport Labels shall communicate recognition values. CWxxx Code-Word starts an action for the function...

  • Page 70: Error Memory

    = TRUE. 9.2 Writing an Error For the functional part of the MS 6 system (MS 6-ECU) the error bits are related to the function and have to be distinguished if the function is activated. If an error is detected, the information may be shown as part of the error monitor in RaceCon, as display inform- ation and as measure channel.

  • Page 71: Error Memory Properties

    At least one inactive error present in memory, no active er- rors At least one active error present in memory If displayed in a measurement sheet, this property value (0, 1 or 2) is translated into a verbal description. Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 71 / 76...
  • Page 72 9 | Error Memory It is also represented by a color scheme within RaceCon (provided RaceCon is online with the system): 0 (no error present in memory) 1 (at least one inactive error present in memory, no active errors) 72 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 73 Error Memory | 9 2 (at least one active error present in memory) Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 73 / 76...
  • Page 74 74 / 76 Engine_Control_Unit_MS_6.x_Manual Bosch Motorsport...
  • Page 75 Bosch Motorsport Engine_Control_Unit_MS_6.x_Manual 75 / 76...
  • Page 76 Bosch Engineering GmbH Motorsport Robert-Bosch-Allee 1 74232 Abstatt Germany www.bosch-motorsport.com...

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