ECU MS 4 Sport: Bosch Motorsport Manual
ECU MS 4 Sport: Bosch Motorsport Manual
ECU MS 4 Sport
Manual
F 02U 002 562-02
Content
Content
1 Getting started ....................................................................................................... 4
2 Sport Systems Overview .................................................................................... 5
3 ECU MS 4 Sport ..................................................................................................... 6
3.1
3.2
3.3
3.4
3.5
3.6
PRESSURES ................................................................................................................. 20
TEMPERATURES .......................................................................................................... 20
LAMDET ....................................................................................................................... 20
GEARDET ..................................................................................................................... 20
ATHDET ....................................................................................................................... 21
5 Extensibility ......................................................................................................... 21
6 Activation of Softwareoptions ............................................................................ 22
Getting started
1 Getting started
Important Notes:
Use the ECU MS 4 Sport only as intended in this manual. Any maintenance or repair must be performed by authorized and qualified personnel approved by Bosch Motorsport.
Operation of the ECU MS 4 Sport is only certified with the combinations and accessories that are
specified in this manual. The use of variant combinations, accessories, and other devices outside
the scope of this manual are only permitted when they have been determined to be compliant from
a performance and safety standpoint by a representative from Bosch Motorsport.
For systems with drive-by-wire additional safety provisions apply. For details please refer to the
document Safety Instructions for Drive-by-Wire Systems in Motorsport Applications.
Disclaimer:
Due to continuous enhancements we reserve the rights to change any illustrations, photos and
technical data within this manual.
Please retain this manual for your records.
Edition: February 12
Before starting:
Before starting your engine for the first time, install the complete software from the installation CD.
Bosch Motorsport software is developed for Windows 2000/XP. Connect the PC Link Adapter (MSA
Box) or the Ethernet line (depending on calibration equipment) to your computer and install the
driver. Read the manual carefully and follow the application hints step by step. Dont hesitate to
contact us, contact data can be found on the backside of this document.
ECU MS 4 Sport
3 ECU MS 4 Sport
The MS 4 Sport is an engine management
system for high performance engines up to 8
cylinders. The system contains 8 ignition drivers for external power stages and 8 independent injection power stages. Two independent
wide range lambda circuits allow lambda
closed loop engine control. There is also a
version for Turbo engines, Turbo GDI engines
as well as for motorcycle engines available.
Various engine parameters can be measured
with different input channels and transferred
via CAN interface to an optional data logger.
Application
Electrical Data
Control strategy
alpha/n
Lambda control
dual
Speed limiter
Gear cut for sequential gear box
Map switch (3 positions - each corresponds to
different target lambda and spark maps)
Fuel cut off
Asymmetric injection timing
Asymmetric ignition timing
Max. vibration
Vibration Profile 2
(see Appendix or www.bosch-motorsport.com)
2 sensor supply
5 V/100 mA
Communication interfaces
Software
Modas Sport Calibration Software
Connectors
Mating connector I
Mating connector II
1 H-bridge (5 A)
Sheet-metal housing
Temperature range
Inputs
Mechanical Data
Weight
30 W at 14 V
Size
inclusive
on request
ECU MS 4 Sport
Optional Accessories
Part Numbers
MSA-Box II
MS 4 Sport
MS 4 Sport Turbo
Optional Functionality
MS 4 Sport Motorcycle
GDI
Turbo
Turbo GDI
Motorcycle
8/2
8/2
8/2
6/2
4/2
GDI support
ABS M4-interface
optional
optional
optional
Knock control
optional
optional
optional
optional
optional
optional
optional
optional
optional
optional
optional
optional
Traction control
optional
optional
optional
optional
optional
optional
optional
optional
3.1
Input Channels:
There are several inputs for temperature measurements e.g. engine temperature tmot or intake air
temperature tair. Temperature inputs have an internal pull up resistor for use with a NTC sensor
(negative temperature coefficient). Depending on the used sensor (e.g. 15 KOhm or 2.5 KOhm NTC)
the corresponding linearization curve has to fit.
For measuring of throttle position ath or pressures f.e. pfuel, poil, which deliver a voltage (active
sensors), pull up resistors are not allowed. These sensors must be calibrated with the sensors
offset and sensitivity values (printed on the sensor, if using Bosch parts).
The ECU MS 4 Sport needs an inductive speed sensor on the ignition trigger wheel. For the camshaft sensor a Hall Effect sensor is necessary. Also for wheel speed measurement Hall Effect sensors are recommended. 4 Hall Effect wheel speeds can be connected directly to the ECU.
For the wide range lambda measurement & control, the lambda sensor Bosch LSU 4.9 is needed.
ECU MS 4 Sport
3.2
Output Channels:
The ECU MS 4 Sport has 8 independent injector power stages. These output drivers can deliver a
maximum current of 2.2 Ampere. Therefore the injection valves must have at least 6 Ohm internal
resistance. A few Bosch injection valves have an internal resistance of just 1.2 Ampere. These types
can not be used here.
The 8 ignition drivers supply the signal to drive external ignition power stages. (Most of the modern
coils have integrated power stages)
The wiring for coils with integrated power stages is shown in the following picture on the left side,
the wiring for coils with external power stages is shown on the right side.
ECU MS 4 Sport
3.3
Power supply
The ECU MS 4 Sport requires an external main relay to be wired to the harness. This relay is controlled by the ECU MS 4 Sport to realize that important information can be stored after switching
off the ignition.
Please ensure that you have a good ground installation. That means:
A ground that has a solid, low resistance connection to the battery minus terminal.
ECU MS 4 Sport
3.4
The camshaft trigger sensor is a Hall-effect type with a single tooth trigger wheel.
The software assumes a 60-2 teeth or a 36-2 teeth trigger wheel for proper operation. The type can
be choosen in the software. The crankwheel trigger sensor must be an inductive type for default
configuration. For the camshaft sensor a hall sensor must be used. The picture below shows the
correct installation position.
10
ECU MS 4 Sport
3.5
Procedure to find the right postion for the crank and cam triggers:
1. Rotate the engine to the precise position of TDC compression for cylinder #1.
2. Rotate the engine (*) crankshaft degrees backwards.
3. Adjust the position of the crank trigger wheel in reference to its inductive speed sensor: the
longitudinal axis of the sensor must point exactly towards the reference mark (2nd falling
edge after the gap).
4. Adjust the position of the cam trigger in reference to its hall effect speed sensor: the sensor
must be about at the center of the tooth.
5. Turn the engine by 360 crankshaft degrees to reach the position of (*) before TDC exhaust
for cyl. #1.
6. Verify that the crank trigger reference mark is in alignment with the longitudinal axis of the
sensor (same as Step 3) and that the cam trigger tooth is at the opposite side of its speed
sensor.
Please note:
The width of the cam trigger tooth is not important, however it must be wide enough to ensure a safe overlap of the crank trigger reference mark at any time.
The hall effect signal is the inversion of the shape of its cam trigger: the tooth effects a 'low'
signal at the sensor and vice versa.
With 4 and 6 cylinder engines, the value of 66 degrees must be replaced by 78 degrees.
11
ECU MS 4 Sport
3.6
The sensors shown on this page are partly based on production type parts and proofed hundreds of
times in races all over the world. They offer good value for money.
12
NTC M12-L
NTC M12-H
TCP-K
PSA-C
PSS-10
LSU 4.9
IA-C
HA-P
RP 86
RP 100 twin
KS-P
RP 308
GSS-2
AM 600-3
YRS 3
ECU MS 4 Sport
Model
Range of application
Connector Loom
NTC_M12-L
Part No.
NTC-M12-H
TCP-K
ASL 0-06-05SD-HE
PSA-C
PSA-C
Crankcase pressure
PSS-10
PSA-C
LSU 4.9
Lambda value
IA-C
Crankshaft revolutions
HA-P
Camshaft revolutions
HA-P
Wheel speed
RP 86
Throttle angle
RP 100 twin
AS 0-07-35SN
KS-P
Knock
RP 308
Gear detection
ASL 0-06-05SA-HE
GSS-2
Gear shift
ASL 0-06-05SC-HE
AM 600-3
Acceleration
ASL 0-06-05SA-HE
YRS 3
Yaw rate
RP 308
Steering angle
ASL 0-06-05SA-HE
The volume of applied sensors may differ depending on individual software extents.
13
The following chapter deals only with the main parameters which should be checked before a first
engine startup. Several functions are recommended to be switched off, many software labels will
not be explained in detail. To work on these functions and labels after the first startup, please refer
the full-scope function description.
The Offline data application guide shall help to get the engine started the first time without problems.
Important hint
14
15
TIBAT_OFF
TI_FAK
TI_DEF
The injection time depends mainly on throttle position, engine speed, fuel pressure and injection
valve type. To get a first estimation, the following characteristics must be known:
injection valve flow rate Qstat [g/min] at reference fuel pressure pfRef [bar]
mf =
pi VC 1 1
R Ti 14.5
[kg]
ti =
mf
Qstat
p f Re f
pf
10 6 60 [ms]
TITAIR_FAK
TITMOT_FAK
TIPFUEL_FAK
TIREVPCORR_FAK
PCORR_CW
16
Note: Engines with one lambda sensor (e.g. 4-in-a-row) run as 1-Bank-Systems. Set CYLBANK_CW
to 0.
TIREVATH_FAK_x
Cylinder individual corrections. Set to 1.0 for first startup. Numbering refers
to firing order!
INJOFFPATTERN
Torque reduction by injection fade out. Different, repeating fade out patterns
can be defined for several full power strokes of the engine (720 crank or 2
full rotations). This prevents single cylinders from cooling down too much
and makes it possible to find optimal patterns.
The cylinders are assigned bitwise, the lowest bit represents cylinder 1 in firing order (FO1), e.g.
injoff = 1:
First power stroke 0-720: Cylinder 1 (FO1) is faded out
Second power stroke 720-1440: Cylinder 2 (FO2) is faded out
Third Power stroke 1440-2160: Cylinder 3 (FO3) is faded out
Fourth Power stroke 2160-2880: Cylinder 4 (FO4) is faded out
Fifth Power stroke 2880-3600: Cylinder 1 (FO1) is faded out
Base injection time for engine start. Can be set to a value near full load
from the maps TI_MIN/DEF/MAX in atmospheric engines. Scale down
proportional to boost pressure for turbo engines.
Further corrections: Predefined. If unsure, set to 1.0 for first startup.
17
End of injection pulse, refers to combustion TDC. Make sure, the injection
is ended before the inlet valve closes. Try 200 - 300 for first startup.
INJANGSTREV
Deactivate by setting = 0.
LAM_MIN
LAM-DEF
LAM-MAX
4.1.3.2 INJCUT
INJCUTGEAR
4.1.3.3 INJENRICH
INJENRICHREV_MIN
IGNSTARTTMOT_OFF
TDWELLBATTREV
Coil dwell time. Consult the coil manufacturer for details. Most coils need
dwell times about 1.5 to 2.5 milliseconds at 12 14 V.
TDWELLMAX_OFF
Dwell time limitation. Stay with predefined value for first startup.
IGNREV_OFF_x
18
4.1.4.1 IGNITION_MAPS
IGN_MIN
IGN_DEF
dant. Use modest values at the first time. Atmospheric engines may run
IGN_MAX
4.1.5.2 REVLIMIT:
The Rev-Limiter works in three steps:
Soft limitation by ignition retardation
Hard limitation by Injection cut off
Absolute limitation by full injection and ignition cut off
REVLIMITSOFTGEAR
Soft limiter, gear dependant: Apply the revs at which the limiter shall
become active (same value to all gear break points on dyno).
IGNREVLIMITSOFT
REVLIMITHARDGEAR
REVLIMITIGNOFF_OFF
4.1.5.3 SPEEDLIMIT:
SPEEDLIMITREV_MIN
4.1.5.4 TRACTIONCTRL:
TC_CW
Deactivate by setting = 0.
19
4.2
Sensors and peripherals can be checked when the system is powered up electrically. Do not start
the engine before all steps in this chapter are carried out. Make sure the battery is connected properly, all sensors are connected, ground wiring is fixed before powering up the system. Check all
sensors for errors (bits _e) before starting the engine.
4.2.1 PRESSURES
All pressures are calculated in the same way. The system offers oil pressure (poil), ambient pressure (pamb), crank pressure (pcrank) and fuel pressure (pfuel).
Example: Ambient pressure
PAMB_OFF,
Sensor offset and gradient. Consult the sensor manufacturer for details.
PAMB_GRD
PAMB_UMX,
PAMB_UMN
PAMB_DEF
Default value. If a sensor error is set, the output is switched to the default.
PAMB_FIL
All other variables are named by the same rule, replace pamb by e.g.
poil to apply data for the oil pressure sensor.
4.2.2 TEMPERATURES
All temperatures are calculated in the same way. The system offers oil temperature (toil), intake air
temperature (tair), engine temperature (tmot), fuel temperature (tfuel),
Example: Intake air temperature
TAIR_UMX,
TAIR_UMN
TAIR_LIN
4.2.3 LAMDET
LAMTYPE_CW
4.2.4 GEARDET
Refer the function description if needed. For engine application not necessary.
20
4.2.5 ATHDET
ATH_UMN,
ATH_UMX
Check if the sensor output value ath_u is changing when throttle is moved.
4.2.5.1 CALIBRATION:
ATHPOS1
ATHPOS2
ATHIDLECAL
ATH_CW
5 Extensibility
We developed a lot of extras for the ecus. That is e.g.:
Displays
Data loggers
Telemetry units
Traction control
Drive by wire
Knock control
21
Activation of Softwareoptions
6 Activation of Softwareoptions
If you buy optional software, you will get a codenumber with eight ciphers from us. We enable this
codenumber exclusively for one defined ECU-serialnumber. It will work with this ECU only.
Start the application tool Modas Sport. You will find a predefined worksheet called Licence there,
see picture below.
3
1
2
22
Contact
Europe:
Bosch Engineering GmbH
Motorsport
Robert-Bosch-Allee 1
74232 Abstatt
Germany
Phone: +49 7062 911 79101
Fax: +49 7062 911 79104
North and South America:
Bosch Engineering North America
Motorsports
38000 Hills Tech Drive
Farmington Hills, MI 48331-3417
United States of America
Phone: +1 248 876 2977
Fax: +1 248 876 7373
Asia Pacific:
Bosch Engineering K.K.
Motorsport
3-33-8 Tsuruya-cho, Kanagawa-ku, Yokohama-shi
221-0835
Japan
Phone: +81 45 410 1650
Fax: +81 45 410 1651
E-Mail: motorsport@bosch.com
www.bosch-motorsport.com
Status: 08 February 2012
All rights reserved by Bosch Engineering GmbH,
also for the case of patent reports.
All rights such as copying and forwarding through us.
Modifications reserved.