Bosch ECU MS 25 Sport Manual Download Page 8

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Engine Control Unit MS 25 Sport

Bosch Motorsport

Vehicle connector (X1 - Vehicle) 1928405312

PIN

Name

Main function

PIN Name

Signal

Battery plus 4

Battery plus %

Battery minus 1

Battery minus %

G_G_BAT-1

Battery minus 4

Battery minus %

G_G_BAT-4

airbox press. signal

airbox pressure sensor signal

I_A_AN23

pairbox

fuel return temp

temperature sensor signal for return fuel

I_A_AN22

tleak

Sensor gnd 1

Sensor Ground 1

G_R_AN10

pit speed sw

pit speed limiter digital switch

I_S_DIG03

Launch sw

Launch control switch

I_S_DIG07

egt1 signal

Exhaust gas temperature sensor signal 1

I_A_AN13

texh

egt2 signal

Exhaust gas temperature sensor signal 2

I_A_AN19

texh2

egt1/egt2 gnd

EGT1 / EGT2 Ground

G_R_AN13

glowplug relay HS

Glowplug Relay HS

O_T_RH06

Battery plus 3

Battery plus %

Battery plus 5

Battery plus %

12V Sw/FMU3 (HS) Supply

Supply for switches and FMU3 (HS)

O_V_RH31

Battery minus 2

Battery minus %

G_G_BAT-2

Map Switch

Map position switch

I_A_AN24

mapsw

Sensor gnd 4

Sensor Ground 4

G_R_AN11

Engine Speed Output

Engine Speed Output Signal (tach)

O_F_DA01

Laptrg

Laptrigger input

I_S_DIG08

Pace sw

Pace switch

I_S_DIG04

Sensor gnd 2

Sensor Ground 2

G_R_AN12

gearbox temp. signal

Gearbox Temperature Sensor Signal

I_A_AN14

tgear

Ambient temp. signal

Ambient Temperature Sensor Signal

I_A_AN26

tamb

Sensor gnd 3

Sensor Ground 3

G_R_AN14

CAN1 +

CAN Interface

B_D_CANH0

CAN1 -

CAN Interface

B_D_CANL0

Battery plus 2

Battery plus %

12V Supply Relay (HS)

Relay Supply (HS)

O_V_RH11

Battery minus 5

Battery minus %

G_G_BAT-5

VSS

Vehicle speed sensor signal (Hall)

I_F_VSS

speed

VSS GND

Vehicle Speed Sensor Ground

G_R_VSS

aps2 gnd

Accelerator pedal position sensor 2 ground

G_R_APP2

fuel reset sw

Fuel Reset Switch

I_S_DIG02

MILSpec

MILSpec Warning Lamp (LS)

O_S_RL20

fwheel_fr

Wheelspeed frequency input, front right (Hall)

I_F_DF01

vwheel_fr

Wheel sens. Gnd. Front

Wheel Sensor Ground Front

G_R_DF01

aps1 5V

Accelerator pedal supply 1

V_V_5VSS2D

5V sens. Supply 4

Sensor Supply 4

V_V_5VSS2A

5V sens. Supply 2

Sensor Supply 2

V_V_5VSS1D

Summary of Contents for ECU MS 25 Sport

Page 1: ...Engine Control Uni MS 25 Sport Manual Version 1 0 12 03 2019 ...

Page 2: ...Channels 9 1 5 Output Channels 9 1 6 Power Supply 9 1 7 Trigger Wheel 10 2 Starting up the ECU 13 2 1 Installation of software tools 13 2 2 Communication PC to device 13 2 3 MS 25 Sport programming 13 2 4 Initial Data Application 22 3 Peripherals 33 4 Getting Started 36 5 Engine Performance Calibration 37 6 Bosch Motorsport support 38 7 Wiring Harness 39 ...

Page 3: ... Two engine hydraulic bank measurement control and monitoring strategy for rail pressure with one FMU or two actuator FMU PCV operation Two engine bank related separated lines for physical air mass boost pressure and turbo speed determination and control One lambda LSU 4 9 measurement supported directly by MS 25 Sport 2 bank meas urement and control as option via external CAN measurement Integrate...

Page 4: ...1 Technical data 4 40 Engine Control Unit MS 25 Sport Bosch Motorsport 1 2 Application Installation Notes Communication Ordering Information Engine Control Unit MS 25 Sport F 02U V0U 800 02 ...

Page 5: ...t Engine Control Unit MS 25 Sport 5 40 Mechanical Drawing 1 3 Pin Layout The pin layout is also placed at Bosch Motorsport Homepage Some pins and functions are optional and not included in the base version of the MS 25 Sport software ...

Page 6: ...GT2 Waste Gate 2 Variable Turbine Geometry 2 O_T_RL3 22 GPU5 LS General purpose output 5 LS O_T_RL07 23 GPU3 LS General purpose output 3 LS O_T_RL09 24 Battery plus output 32 Battery Plus Output 32 O_V_RH32 25 InjectorPwrStg 2 InjectorPwrStg 2 bank2 O_P_SVH21 26 InjectorPwrStg 5 InjectorPwrStg 5 bank2 O_P_SVH22 27 InjectorPwrStg 8 InjectorPwrStg 8 bank2 O_P_SVH23 30 Wheelspeed ground Wheel sensor ...

Page 7: ...t Sensor Signal Inductive I_F_CASPOS 69 Sensor gnd 6 Sensor ground 6 G_R_AN07 72 LSU heat lambda sensor heater low side PWM output O_T_LSH 73 InjectorPwrStg 1 InjectorPwrStg 1 bank1 O_P_SVL11 74 InjectorPwrStg 4 InjectorPwrStg 4 bank1 O_P_SVL12 75 InjectorPwrStg 7 InjectorPwrStg 7 bank1 O_P_SVL13 76 InjectorPwrStg 3 InjectorPwrStg 3 bank3 O_P_SVL32 77 InjectorPwrStg 6 InjectorPwrStg 6 bank3 O_P_SV...

Page 8: ...2 32 Map Switch Map position switch I_A_AN24 mapsw 33 Sensor gnd 4 Sensor Ground 4 G_R_AN11 34 Engine Speed Output Engine Speed Output Signal tach O_F_DA01 36 Laptrg Laptrigger input I_S_DIG08 37 Pace sw Pace switch I_S_DIG04 39 Sensor gnd 2 Sensor Ground 2 G_R_AN12 40 gearbox temp signal Gearbox Temperature Sensor Signal I_A_AN14 tgear 41 Ambient temp signal Ambient Temperature Sensor Signal I_A_...

Page 9: ... supply 5V Accelerator pedal supply 2 V_V_5VSS1B 93 Auxiliary Relay LS Auxiliary Relay LS O_S_RL27 94 glowplug relay LS Glowplug Relay LS O_S_RL26 95 CAN 2 Diag CAN Interface Diag MSA Box2 ecu interface B_D_CANL1 1 4 Input Channels Only active 0 to 5 V exhaust gas temperature sensors are supported See chapter Initial Data Application 22 for further information and calibration ex amples for differe...

Page 10: ...0A V01 V25 V26 V49 V73 V03 V05 V28 V52 V75 Engine On Switch V69 V93 Auxiliary Relay PCV FMU E83 E58 E81 E82 LSU Heat E72 E96 MS 25 Sport V50 1 7 Trigger Wheel The software assumes a toothed trigger wheel for proper operation The number of the teeth is hard coded by Bosch Motorsport and can t be changed by the customer Custom gap teeth numbers are optional We recommend 60 2 teeth as shown in the fo...

Page 11: ...3 5 mm h2 h1 2 LSKW 0 8 mm 0 3 mm t min 5 mm LSNW 1 mm 0 5 mm The procedure for correct adjustment of the trigger wheel is described in the drawing on the next page Procedure to find the right position for the crank and cam trigger 1 Rotate the engine to the precise position of TDC compression for cylinder 1 ...

Page 12: ... begin of the tooth 6 Turn the engine by 345 crankshaft degrees to reach the position of 78 before TDC exhaust for cylinder 1 7 Verify that the crank trigger reference 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 NOTICE All angles are shown and indicated in crankshaft degrees The width of the cam ...

Page 13: ...g executable files Select your personal installation folder 2 2 Communication PC to device For assistance Bosch Motorsport homepage explains the necessary PC installations for MSA BOX 2 diagnostics cable Bosch Motorsport com Downloads Software MSA BOX Successful connection between PC and MS 25 Sport is shown as green marked connection in the top left corner of RaceCon 2 3 MS 25 Sport programming S...

Page 14: ...e vehicle Then they are part of the project and can be configured Select an ECU model MS 25 Sport from the Toolbox Devices ECUs Drag the ECU icon with pressed left mouse click on the vehicle view then a dialog opens 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 25 Sport program archive MS25_...

Page 15: ...n may now be saved as customer project for further data application 2 3 2 Connecting to the ECU for calibration and programming If in the project tree and main display area MS 25 Sport icon is shown as red it means that the software in the device differs from what is in the RaceCon project ...

Page 16: ...evice Project tree right mouse button to the red MS 25 Sport synchronize update firmware select customer software of the MS 25 Sport file with extension pst NOTICE Do not interrupt flash process In the project tree if the MS 25 Sport is shown as yellow means the firmware of the MS 25 Sport device and project are identical but the data is different ...

Page 17: ... 40 Either the offline configured data has to be sent to ECU download local data to the device or current ECU data can be read to RaceCon project upload data from the device MS 25 Sport is shown as green means firmware and data of the device and the project are now identical ...

Page 18: ...management option when MS 25 Sport WP memory limit may be reached RaceCon lets the user to pro gram the changes to the ECU to keep the calibration and continue working Transfer error occurred device memory full Click on the option Create HEX file from the working page and flash the device RaceCon automatically saves the hex file and starts pro gramming ...

Page 19: ...fore memory limit reached and programming is lost 2 3 3 Handling of calibrations with parameter files To export parameter file DCM or PAR file right click on MS 25 Sport ECU in the project tree or ECU icon and select Export parameter file Dialog window opens for selection of calibration variables to be exported as parameter file Existing parameter file can be used as filter to select same variable...

Page 20: ...tree or in the ECU icon and select Import parameter file Dialog opens to select file Once parameter file successfully read to the importer check for Error description if all the parameters can be imported properly In case of porting calibration from older software with differences on table sizes etc it is important to pay attention if all values can be im ported properly ...

Page 21: ... of calibrations with HEX files Complete ECU calibrations can also be saved and opened as HEX files This works fine within same software version projects if no ECU software program archive a2l is changed HEX files can be saved or opened in the Project tree or under Calibration Measuring view ...

Page 22: ...linders Cylinder number Epm_num Cyl_C firing order Epm_numFireSeg_C cylinder angles CYLANGLE and spacing between cylinders TDCs in v engine Epm_phiTdcDst_C must be calibrated according the engine in the Engine Position Management EPM function See calibration guidelines for further information and examples of engine and calibration configurations 2 4 2 Engine Speed and Position Management The syste...

Page 23: ... for correct rail pres sure controller behavior under any engine operation conditions Either current less open or closed type metering units can be used ECU measures actual current for metering unit and the control strategy is current control Calibration example for typical CP3 pump 2 4 3 2 Injector Energizing Profile Injector energizing current profile must be correct for used solenoid injector t...

Page 24: ...njector Energizing Time Map Injector energizing time map TIINJ_ET_MAP is needed to convert the requested injection quantity corrected as volume to desired injection duration as function of rail pressure Energizing time map must be known for the used injector and nozzle and should be calib rated for the entire operation range of rail pressure Using wrong energizing time map may end in unexpected en...

Page 25: ...ct sensor curve PRAIL_CONV can result in incorrect in jection quantity which may lead to serious engine damages Maximum allowed system pressure should not be exceeded In a one actuator concept the mechanical pressure limiter valve PRV mounted directly in the fuel rail is only designed to open and protect the system very few times during its life time which must be considered in rail pressure setpo...

Page 26: ...al Sensor APS The accelerator pedal signal is a direct input for the drivability base map which scales the aps signal for driver requested torque into a percentage of the maximum limited torque specified as injection quantity from curve CL_QTLIM Before starting any new engine and application accelerator pedal position sensor signal has to be learned to achieve the range from 0 to 100 of torque req...

Page 27: ...e Limitations Quantity and torque limitations are split into two separate functions SLIM which is fuel quantity smoke limiting and TLIM which is engine torque limiting function Smoke limitation is defined as quantity limitation mg stroke based on mass air flow cor rected by ambient pressure Torque limitations are all correction factors based on engine temperature tmot intake temperature tint exhau...

Page 28: ...MP_QFRIC as a function of engine speed and engine temperature Correct calibration of friction quantity is important as it is used as a pre controller in sev eral other functions like low idle controller 2 4 4 5 Low Idle Controller Low idle controller LICO is a PID controller which is working directly with the friction map MP_QFRIC as a pre control input The base set point map for low idle is CL_NL...

Page 29: ...ntroller is a simple P controller The friction map MP_QFRIC calibration within the high idle controller engine speed range is important for the controller to function properly 2 4 4 7 Engine Start Fuel Quantity MP_QSTART is the fuel quantity map for engine start as a function of engine speed nmot and engine temperature tmot There is also a step limiter for ramping up and down when transitioning fr...

Page 30: ...o be injected See function definition for further information on the fuel quantity setpoint calculation includ ing where its output qfqsc is used and what the different function priorities are to take over the actual injected quantity under different engine operation conditions Additional pilot and post injections are also enabled and calibrated within this function Post1 injection is not calculat...

Page 31: ...d prioritization between mul tiple injections fuel density and finally outputs the actual desired injection time for the in jector driver If the calibrated injection timing for the desired fuel quantity and energizing time overlap the injection with higher priority wins Main injection is always the highest priority Injection naming and order with base timing and quantity calibration parameters are...

Page 32: ...ed in total qfqsc TDC MP_PHIBIMI_BASE MP_PHIBIPI1_BASE PHIBIPI1_LATEST MP_PHIBIPI2_BASE PHIBIPI2_LATEST Base Timing MP_PHIBIPO2_BASE MP_PHIBIPO1_BASE PHIBIMI_LATEST PHIBIPO2_EARLIEST PHIBIPO1_EARLIEST Post1 PO1 injection is not calculated as torque generating injection and is not included in the total injection quantity setpoint calculation qfqsc Timing before TDC is positive and after is negative...

Page 33: ..._CM_MAX Analog sensor inputs Inputs with fixed pull up resistors are prepared to handle passive sensor elements for in stance temperature sensors with integrated resistors NTC or PT100 sensors Inputs without any pull up resistors are prepared to handle active sensor elements which deliver 0 to 5 V signals for instance pressure potentiometer or acceleration sensors Each sensor input is mapped clear...

Page 34: ...3 Peripherals 34 40 Engine Control Unit MS 25 Sport Bosch Motorsport Example oil pressure sensor ...

Page 35: ...measurements The system offers many different temperature channels please see function description Input Signal Processing for details Sensor linearization curves for temperature sensors are applied directly as resistance for each temperature point Example engine temperature sensor ...

Page 36: ...ories Operation of the MS 25 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 is only permitted when they have been determ ined to be compliant from a performance and safety standpoint by a representative from Bosch Motorsport NOTICE For professionals only T...

Page 37: ...ue limitation given by engine mechanics based on material properties of e g crankshaft bearing forces cylinder head gasket etc All the other engine parameters which could have a destructive impact such as coolant temperature tmot oil pressure poil oil temperature toil and so on Basic engine calibration targets are Reliable engine start without big overshoots in engine speed when low idle speed set...

Page 38: ...irst start at dyno fine optimization at dyno or vehicle Software development update specification and implementation Fuel injection equipment upgrade component selection and delivery within a wide portfolio including series production and sample parts Engine management system technical definition engine control unit sensors actu ator selection and delivery within a wide portfolio including series ...

Page 39: ...Wiring Harness 7 Bosch Motorsport Engine Control Unit MS 25 Sport 39 40 7 Wiring Harness ...

Page 40: ...Bosch Engineering GmbH Motorsport Robert Bosch Allee 1 74232 Abstatt Germany www bosch motorsport com ...

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