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Engine Control Unit MS 6
Manual
1.1 8/29/2016

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   Summary of Contents for Bosch MS 6

  • Page 1

    Engine Control Unit MS 6 Manual 1.1 8/29/2016...

  • Page 2: Table Of Contents

    2.1 System Layout ....................................4 2.2 Mechanical Data ....................................7 2.3 Electrical Data ....................................9 3 Starting up the MS 6 system ..........................23 3.1 Installation of Software Tools ..............................23 3.2 Configuration of the MS 6 system ............................23 4 Prepare Data Base .............................

  • Page 3: Getting Started

    Contact data can be found on the backside of this document. Risk of injury if using the MS 6 inappropriately Caution Use the MS 6 only as intended in this manual. Any maintenance or repair must be performed by authorized and qualified personnel approved by Bosch Motor‐ sport.

  • Page 4: Technical Data

    Custom functions can be generated quickly and easily. The flexible hardware de‐ sign allows the MS 6 to support complex or unusual engine or chassis configura‐ tions. Integrated logger control areas present a cost efficient and weight opti‐...

  • Page 5

    ▪ Option to copy all data to removable USB stick Layout restrictions Ethernet Network MS 6, as Time master, permits the extension of two addi‐ tional devices. Using MS 6.1 F02UV01961‐03, MS 6.2 F02UV01867‐06, MS 6.3 F02UV01963‐03 or MS 6.4 F02UV02019‐06 permits the extension of 4 additional de‐...

  • Page 6

    Numbers To accommodate the wide range of different engine requirements and race track operating 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 versions.

  • Page 7: Mechanical Data

    Technical Data | 2 For all MS 6 Versions Gear control package II Strategy for pneumatic F 02U V02 108‐01 forced gear change con‐ trol Gear control package III Support for external GCU F 02U V02 109‐01 like Cosworth or Megaline...

  • Page 8

    2 | Technical Data 8 / 78 ECU MS 6 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. Different 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 6 x reserved for electronic throttle controls 10 x no integrated pull‐up...

  • Page 11

    The connection should be free from dirt, grease, paint, anodizing, etc. ▪ MS 6 power consumption at appr. 13 V ▪ ~ 20 – 25 amps (4 cyl. FDI at 8500 1/min/200bar, 1 MSV, 1 electronic throttle, standard chassis equipment) ▪...

  • Page 12

    ▪ Be ensure controller supply is activated in front of 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 communi‐...

  • Page 13

    Technical Data | 2 Bosch Motorsport ECU MS 6 13 / 78...

  • Page 14

    2 | Technical Data 14 / 78 ECU MS 6 Bosch Motorsport...

  • Page 15

    Technical Data | 2 Bosch Motorsport ECU MS 6 15 / 78...

  • Page 16

    2 | Technical Data 16 / 78 ECU MS 6 Bosch Motorsport...

  • Page 17

    Technical Data | 2 2.3.7 Harness / Wiring The wiring diagram is also placed at Bosch Motorsport Homepage. The wiring diagram shows a principle of wiring and connection Notice options. ECU pin‐relation may change to customer data application and program layout.

  • Page 18

    2 | Technical Data Signal Signal Signal Signal 18 / 78 ECU MS 6 Bosch Motorsport...

  • Page 19

    Technical Data | 2 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 F 02U B00 712‐01...

  • Page 20

    HP‐injector wirings and also in distance to any telemetry transmitter. CAN‐networks need an 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.

  • Page 21

    4. Rotate the engine further 15 crankshaft degrees backwards. 5. 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. Bosch Motorsport ECU MS 6 21 / 78...

  • Page 22

    The Hall effect signal may be the inversion of its cam trigger: the tooth effects a “low” signal at the sensor and vice versa for other trigger wheel configurations the indicated values may vary. 22 / 78 ECU MS 6 Bosch Motorsport...

  • Page 23: Starting Up The Ms 6 System

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

  • Page 24

    Then they are part of the project and can be configured. Select an ECU model MS 6 from the Toolbox / Devices / ECUs. Drag the ECU icon with pressed left mouse click on the vehicle view, then a dia‐...

  • Page 25

    Starting up the MS 6 system | 3 Now the ECU program archive PST files must be selected. These archives are de‐ livered 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 26

    Programs Installation of MS 6 device 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 are divers in the used program version.

  • Page 27

    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 tree / right mouse button to the yellow MS 6 core / synchronize / or fol‐ low the RaceCon menu: Both MS 6 cores are shown as green, means firmware and data of device and project are now identical.

  • Page 28

    Select the license feature and activate the functionality using the related license code. The licenses for gearbox and engine controls are to activate at the MS 6 ECU core. The licenses for USB or logger packages are handled in the MS 6 logger core.

  • Page 29: Prepare Data Base

    4.1.1 Basic Engine Data The MS 6 system can be used for engines up to 12 cylinders. Please ensure that the correct 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 30

    4.1.4 Basic Path of Injection Calculation The ECU MS 6 is a so called physically based system. This means in particular that corrections are made according to their origin influence (e.g. air temperature, fuel pressure etc.). For it, the initial engine load signal (throttle angle ath) or the engine charge signal rl (relative load) is defined as 100 %, if the cylinder is filled with air of 20°C and 1013 mbar ("standard condition").

  • Page 31

    Desired Lambda value, valid for map position 1. According to your expecta‐ tions, e.g. 0.9. For alternative positions of your map switch the maps MP_LAM_MP2 (3) or (_PACE) apply, therefore ensure correct switch position Bosch Motorsport ECU MS 6 31 / 78...

  • Page 32

    4.1.7 Main Data Labels for Injection Main Data Labels for injection CWHPI Choice LP‐ or HP battery voltage cor‐ rection CWINJANGMODE Choice of angle of injection relation MP_AOINJ Map begin/end of injection 32 / 78 ECU MS 6 Bosch Motorsport...

  • Page 33

    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 Bosch Motorsport ECU MS 6 33 / 78...

  • Page 34

    DIGN_IDLECTRL to 0.0. 4.1.9 Main Data Labels for Engine Speed Limitation The rev limiter works in two steps: ▪ Soft limitation by ignition retardation or cylinder individual cutoff of injection and/or ignition 34 / 78 ECU MS 6 Bosch Motorsport...

  • Page 35

    Predefined. Vary according to your en‐ gine´s dynamic behavior. TC_GEARNMAXPR Prediction time for rev limiter, depends on the inertial torque of the engine. If oscillations occur, reduce value or turn off by setting = 0.0. Bosch Motorsport ECU MS 6 35 / 78...

  • Page 36

    Cutoff pattern for test purposes. Bit representation as described at MP_COPATTERN CWCUTOFF_APP Codeword for type of intervention dur‐ ing test cutoff: Set: 1 = injection cutoff 2 = ignition cutoff 3 = injection and ignition cutoff. 36 / 78 ECU MS 6 Bosch Motorsport...

  • Page 37: Peripherals

    (E_...) and reliable measure values before starting the engine. Sensor configuration The MS 6 has the option to link a lot of functionalities to a possible hardware in‐ put. The chapters “ECUPINS, SWITCHMATRIX and Input Signal Processing” of the functional description explains the details.

  • Page 38

    The system offers a lot of different temperature channels, please see function de‐ scription input signal processing for details. Example: Intake Air Temperature UTINT_MIN, UTINT_MAX Minimum and maximum accepted sen‐ sor voltage. When violated, an error is set (E_tint = 1). 38 / 78 ECU MS 6 Bosch Motorsport...

  • Page 39: Throttle Control

    Throttle Control The system supports mechanic and electronic throttle controls. Using an MS 6.1 device, respect the necessary license for electronic throttle is ac‐ tivated. Electronic Throttle Control is a safety‐critical function. The Bosch Motor‐ sport Electronic Throttle Control System (ETC) is designed and developed exclu‐...

  • Page 40

    Each driver must be briefed regarding the system description. Further informa‐ tion you will find in document “SICHERHEITSHINWEISE‐Systemanforderungen zum Betrieb eines Bosch Engineering GmbH EGas‐Systems” or can be enquired at Bosch Motorsport. The customer is responsible to have all ETC‐relevant diagnosis activated and for their correct parameterization.

  • Page 41

    Throttle position main data labels: CWTHR Codeword for type of throttle controls 0 = mechanical throttle 1 = mechanical throttle with backup potentiometer 2 = electric throttle single bank 3 = electric throttle dual bank Bosch Motorsport ECU MS 6 41 / 78...

  • Page 42: Vehicle Test

    ▪ Adjust the throttle to idle point. ▪ Do not forget to set CWTHRADJ back to 0. Check calibration by moving throttle Vehicle Test Before starting with your vehicle test, some initial data should be set: 42 / 78 ECU MS 6 Bosch Motorsport...

  • Page 43

    Speed & distance measurements The signals for speed calculation may be available from different sources, like MS 6 own measurement, GPS data or via CAN received information from ABS calculation. For MS 6 own calculation, mechanical influenced data like number...

  • Page 44

    ECU is disconnected from power supply. Please connect the ECU to the PC and click on “SET DATE & TIME” in the context menu of the MS 6. time_xx The measure channels of the real time clock.

  • Page 45

    Prepare Data Base | 4 Bosch Motorsport ECU MS 6 45 / 78...

  • Page 46: Ecu Plus Data Logger

    5 | ECU plus Data Logger ECU plus Data Logger The MS 6 combines ECU and data logger in one common housing for a cost effi‐ cient and weight optimized all‐in‐one solution. Software Tools RaceCon Create and configure a project Configuration &...

  • Page 47

    >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 Bosch Motorsport ECU MS 6 47 / 78...

  • Page 48: Usb Data Recording

    USB Data Recording The MS 6 data recording contents the feature to send a copy of the recorded da‐ ta 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 49

    ECU plus Data Logger | 5 Measure channels to verify USB data recording usb_mediastate not found stick detected stick installed stick unplugged (access) error corrupted meas_cnt_furked counter of recorded data blocks Bosch Motorsport ECU MS 6 49 / 78...

  • 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 chan‐ nel window. 50 / 78 ECU MS 6...

  • 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 ECU MS 6 51 / 78...

  • 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

    ▪ Result can be used as input source for further calculations in the whole project Follow the steps shown in the screenshot. 1st: Double-click on 'Conditional Channels' in Project Tree 2nd: Click on 'Add condition' Bosch Motorsport ECU MS 6 53 / 78...

  • Page 54

    - Pulse: Result is a short one-time pulse if the condition is fulfilled. - Toggling output: Result is a pulse that lasts until the next condition is fulfilled. Click ‘Ok’ when done. The conditional channel is displayed in the MS 6 condition channel window.

  • Page 55

    ▪ Pulse: Result is a short one‐time pulse if the condition is fulfilled. ▪ Toggling output: Result is a pulse that lasts until the next condition is fulfil‐ led. Click ‘Finish’ when done. The conditional combination is displayed in the MS 6 condition channel window. Bosch Motorsport...

  • Page 56: Cpu Load

    6 | Project Configuration CPU Load Generating math and conditional channels, also the configuration of CAN net‐ work use capacity of the MS 6`s processor. Please ensure to keep the processor load below 85 % (averaged). “cpu_load_001” measure channel actual measurement rate...

  • Page 57: Can Configuration

    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 ▪ Output configuration: write MS 6 measure variables to CAN messages ▪...

  • Page 58: Can Input

    2. Select ‘New CAN Channel’ from menu. 3. Insert name and description of channel. 4. Click ‘OK’ when done. The channel is listed in the Data window and a CAN channel configuration win‐ dow opens. 58 / 78 ECU MS 6 Bosch Motorsport...

  • Page 59

    CAN Configuration | 7 7.2.3 CAN channel configuration Extraction of data Mini CAN from CAN bus analyzer functionality Automatic assignment to measurement view Conversion to physical values Bosch Motorsport ECU MS 6 59 / 78...

  • Page 60

    Enter data position, length and format. f) 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. 60 / 78 ECU MS 6 Bosch Motorsport...

  • Page 61

    The matrix table shows the assignment of the bits. - Red colored fields show the assignment of the data bits. - Orange colored fields show the assignment of the multiplexer bits. Bosch Motorsport ECU MS 6 61 / 78...

  • Page 62

    Measurement Sheet. Drag + Drop 4. Click on folder ‘CAN Input’ of desired CAN bus to display available channels. 5. Drag desired Measurement channel and drop it on the Measurement ele‐ ment. 62 / 78 ECU MS 6 Bosch Motorsport...

  • Page 63

    4. Select desired channels on the left and use the ‘Add’ button to add them to import list. 5. Click ‘OK’ when complete. The channels are inserted in the Data window. Bosch Motorsport ECU MS 6 63 / 78...

  • Page 64

    1. Right‐click on CAN Input of desired bus (CAN1, CAN2 or CAN3). 2. Select ‘Import…’ from menu. A file browser opens. 3. Select the input file and click ‘OK’. An ‘Import Selection’ window opens. 4. Select channels to import. 64 / 78 ECU MS 6 Bosch Motorsport...

  • Page 65

    5. Drag and drop the channel to ‘CAN Input’ of desired CAN bus on right hand side. 6. 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. 7. Assign the ambiguous channels to the desired source. 8. Click ‘Finish’.

  • Page 66: Can Output

    1. Right‐click on CAN Output of desired bus (CAN1, CAN2 or CAN3). 2. Select ‘New CAN Message’ from menu. The ‘Create new CAN Out message’ window opens. 3. Enter name of message, CAN‐Id and Grid (output interval). 4. Optionally, specify a multiplexer. 66 / 78 ECU MS 6 Bosch Motorsport...

  • Page 67

    Definition of CAN message Content of message 6. Click on ‘MS 6’ in the MS 6 Project Tree to display all labels. 7. Select the desired measurement channel and drop it on message’s bytes. Click here Drag + Drop The measurement channel is assigned to the CAN message.

  • Page 68

    1. Right‐click on ‘CAN Outputs’ of desired bus (CAN1, CAN2 or CAN3). 2. Select ‘Import…’ from menu. A file browser opens. 3. Select the input file and click ‘OK’. An ‘Import Selection’ window opens. 4. Select channels to import. 68 / 78 ECU MS 6 Bosch Motorsport...

  • Page 69

    5. Drag and drop the channel to ‘CAN Outputs’ of desired CAN bus on right hand side. 6. 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. 7. Assign the ambiguous channels to the desired source. 8. Click ‘Finish’.

  • Page 70: 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 cre‐...

  • Page 71: 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...

  • Page 72: Error Memory

    MON< = TRUE. 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 er‐ ror is detected, the information may be shown as part of the error monitor in RaceCon, as display information and as measure channel.

  • Page 73: Error Memory Properties

    At least one inactive error present in memory, no active errors 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 ECU MS 6 73 / 78...

  • Page 74

    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) 74 / 78 ECU MS 6 Bosch Motorsport...

  • Page 75

    Error Memory | 9 2 (at least one active error present in memory) Bosch Motorsport ECU MS 6 75 / 78...

  • Page 78

    Bosch Engineering GmbH Motorsport Robert-Bosch-Allee 1 74232 Abstatt Germany www.bosch-motorsport.com...

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