Bosch DDU S2 Plus User Manual

Display DDU S2 Plus

Manual

Version 1.0 9/16/2016

Table of contents

1 Preparation ........................................................................................................................................................... 4

2 Power Supply ....................................................................................................................................................... 5

3 Onboard Network Concept ................................................................................................................................ 6

4 Technical Data ...................................................................................................................................................... 7

5 Inputs and Outputs ........................................................................................................................................... 11

5.1 Input channels ................................................................................................................................................................................ 11

5.2 Output channels ............................................................................................................................................................................ 11

5.3 Communication channels .......................................................................................................................................................... 11

6 Mechanical Drawing .......................................................................................................................................... 13

7 Starting up ......................................................................................................................................................... 14

7.1 Before starting ................................................................................................................................................................................ 14

7.2 First display configuration (Quick Start) ............................................................................................................................... 18

8 Display Configuration ....................................................................................................................................... 22

8.1 Display page setup ....................................................................................................................................................................... 22

8.2 Display element configuration ................................................................................................................................................. 23

8.3 LEDs .................................................................................................................................................................................................... 32

8.4 Page select ....................................................................................................................................................................................... 37

8.5 Display + LED brightness ........................................................................................................................................................... 48

8.6 Math + condition channels ....................................................................................................................................................... 59

8.7 Condition channels ....................................................................................................................................................................... 63

9 CAN Bus .............................................................................................................................................................. 66

9.1 CAN bus trivia ................................................................................................................................................................................. 66

9.2 CAN input ......................................................................................................................................................................................... 67

9.3 CAN output ...................................................................................................................................................................................... 75

10 Analog and Frequency Inputs .......................................................................................................................... 79

10.1 Features ............................................................................................................................................................................................. 79

10.2 Analog inputs .................................................................................................................................................................................. 79

10.3 Configuring inputs ........................................................................................................................................................................ 80

10.4 Configuring computed sources ............................................................................................................................................... 92

10.5 Hysteresis ......................................................................................................................................................................................... 94

11 Online Measurement ......................................................................................................................................... 98

11.1 Achieving an online connection .............................................................................................................................................. 98

11.2 Setting up an online measurement ..................................................................................................................................... 100

11.3 Online calibration of measurement channels ................................................................................................................. 106

11.4 Group adjustment ...................................................................................................................................................................... 108

11.5 Online calibration of multipoint adjustment channels ................................................................................................ 110

12 Error Memory .................................................................................................................................................. 113

12.1 General note ................................................................................................................................................................................. 113

12.2 Error memory representation in RaceCon ........................................................................................................................ 113

12.3 Information on errors available from the error memory ............................................................................................ 115

12.4 Configuration ............................................................................................................................................................................... 119

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13 Firmware .......................................................................................................................................................... 121

13.1 Firmware and configuration ................................................................................................................................................... 121

13.2 Firmware update ......................................................................................................................................................................... 121

14 Clone the Unit ................................................................................................................................................. 124

15 GPS Sensor ...................................................................................................................................................... 125

15.1 GPS (Global Positioning System) .......................................................................................................................................... 125

15.2 Protocol .......................................................................................................................................................................................... 125

15.3 Sensor recommendation ......................................................................................................................................................... 125

15.4 Measurement labels .................................................................................................................................................................. 128

15.5 GPS troubleshooting ................................................................................................................................................................. 129

16 Fuel Consumption Calculation ...................................................................................................................... 131

16.1 Setting up fuel consumption calculation and tank mangement ............................................................................. 131

16.2 Fuel consumption diagnosis/counter reset ..................................................................................................................... 132

16.3 Example .......................................................................................................................................................................................... 133

17 RaceCon Shortcuts ......................................................................................................................................... 134

Table of Contents

Bosch Motorsport DDU S2 PLUS Manual 3 / 136

Preparation

Use the DDU 8 only as intended in this manual. Any maintenance or repair must be performed by authorized and qualified personnel approved by Bosch Motor‐ sport.

Operation of the DDU 8 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 stand‐ point by a representative from Bosch Motorsport.

Read the manual carefully and follow the application hints step by step. Don’t hesitate to contact us, contact data can be found on the last page of this docu‐ ment.

Disclaimer:

Due to continuous enhancements we reserve the rights to change any illustra‐ tions, photos and technical data within this manual.

Please retain this manual for your records.

In this document all screenshots are created by way of example for other dis‐ plays.

Please consider this and replace the product names with the name of your prod‐ uct.

Notice

In this document all screenshots are created by way of example for other displays. Please consider this and replace the product names with the name of your product.

1 | Preparation

4 / 136 DDU S2 PLUS Manual Bosch Motorsport

Power Supply

Bosch Motorsport software is developed for Windows system software. Connect the Ethernet line to your computer and install the driver. Read the manual care‐ fully and follow the application hints step by step.

Please ensure that you have a good ground installation. That means:

▪ A ground that has a solid, low resistance connection to the negative battery

terminal

▪ Connection should be free from dirt, grease, paint, anodizing, etc..

▪ Use large diameter wire

▪ More metal‐to‐metal contact is better!

The following notations for power signals are used:

▪ KL 15 is a switched battery rail controlled by the IGN‐switch

▪ KL 30 is an unswitched battery positive rail (same as battery positive terminal)

▪ KL 31 is an unswitched ground rail (same as battery negative terminal)

Be careful to observe current limits of wires and connector pins!

Power Supply | 2

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Onboard Network Concept

Engine_GND

GND_Starpoint

Chassis

KL31

LS_GND_1 LS_GND_2

Main

Switch

UBAT

Star connection

(term30)

positive terminal

Electric Loads

IGN-

Switch

KL15

SENSPWR5

SENSGND

active

Sensor

ANA_IN(xx)

NTC

Sensor

ANA_IN(xy)

switched pos. terminal

Star connection dig. sensors (e.g. wheelspeed)

µC

As short as

possible

SENSPWR10

UBATT_FUSE

KL30

LS_SWITCH1…4

Bosch Motorsport diagnosis connector

DDU

3 | Onboard Network Concept

6 / 136 DDU S2 PLUS Manual Bosch Motorsport

Technical Data

The display DDU S2 PLUS integrates a programmable full color TFT screen for motorsport applications. It allows for synchronized acquisition and visualization of analogue and digital input channels as well as input via CAN. The DDU S2 PLUS can be used as stand alone display or in combination with the Bosch ECU family. It can be combined e.g. as copilot display with Bosch DDU 7 or DDU 8. Additional devices can be connected via Ethernet and CAN buses. CAN in and out is freely configurable.

Application

Display ▪ 5,7” graphic color display

▪ 12 user configurable display pages

▪ 10 multicolor freely configurable

(RGB) LEDs

Resolution 640 x 480 pixel

Supported image file formats bmp, gif, jpg, png, tif

Converters 8 kHz AD converters with digital low

pass filter

Configurable math channels

User configurable CAN in/out messages

Sampling rate Max. 1,000 Hz for all channels

RS232 GPS input

Mechanical Data

Size 148 x 126 x 32 mm

Technical Data | 4

Bosch Motorsport DDU S2 PLUS Manual 7 / 136

Weight 440 g

Protection Classification IP54 to DIN 40050, Section 9, Issue

2008

Operating temperature internal ‐20 to 85°C

Operating temperature Display ‐20 to 70°C

Max. vibration Vibration profile 1 (see Appendix or

www.bosch‐motorsport.com)

Electrical Data

Supply voltage 8 to 18 V

Max. power consumption (w/o loads) 14 W at 14 V

Inputs

Page/brightness selection Configurable

Analog channels 6

Speed inputs (Hall) 2

Input range 0 to 5 V

Resolution 12 bit

Switchable pull up resistor 3 kOhm

Outputs

Sensor supply 5 V ± 1 % (350 mA) 1

Sensor supply 10 V ± 1 % (350 mA) 1

Environment

External switch for page selection, 12 steps

B 261 209 658‐01

External switch for brightness adjust‐ ment or page selection, 6 steps

B 261 209 659‐01

Connectors and Wires

Motorsport connector

AS 2‐14‐35PN at DDU S2 PLUS

37 pins

Mating connector

AS 6‐14‐35SN

F 02U 000 453‐01

Communication

CAN interfaces 2

Ethernet 100BaseT 2

Sync 1

RS232 1 GPS

4 | Technical Data

8 / 136 DDU S2 PLUS Manual Bosch Motorsport

Configuration via RaceCon Over Ethernet or MSA‐Box II

Pin Assignment

1 Ethernet 2 RX ‐

2 Ethernet 2 RX +

3 Terminal 15

4 Ground

5 Unused

6 Unused

7 Unused

8 Unused

9 Ethernet 1 RX ‐

10 Ethernet 1 TX ‐

11 REV_IN

12 REV_IN

13 Sensor supply 10 V

14 Sensor supply 5 V

15 ANA_IN_1

16 ANA_IN_2

17 ANA_IN_3

18 ANA_IN_4

19 Ethernet 2 TX ‐

20 Ethernet 2 TX +

21 RS232 GPS TX

22 Screen Ethernet

23 ANA_IN_5

24 Ethernet 1 RX +

25 Ethernet 1 TX +

26 ANA_IN_6

27 Unused

28 Synchronization

29 CAN1_H

30 CAN1_L

31 RS232 GPS RX

32 Terminal 30

33 Unused

34 Unused

35 CAN2_H

36 CAN2_L

37 Sensor ground

Technical Data | 4

Bosch Motorsport DDU S2 PLUS Manual 9 / 136

Installation Notes

The required software (.pst file) for this device is available in the download area of our homepage www.bosch‐motorsport.com.

4 | Technical Data

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Inputs and Outputs

Input channels

Analog inputs

The DDU 8 analog inputs accept an input signal of 0 to 5 V. A 3.01 kOhm pull‐up resistor can be activated by software.

Digital inputs

The digital inputs of the DDU 8 accept 0 V to 5 V signals of Hall‐effect sensors by default. Connect the output of the Hall‐effect sensor to the REVn.

Output channels

Sensor power supply

The DDU 8 has two types of sensor power supply: 5 V and 10 V regulated volt‐ age. The regulated 5 V and 10 V outputs can deliver 350 mA each. They are short circuit protected to battery voltage and GND.

Communication channels

CAN bus

The DDU 8 has two CAN buses configurable as input and output. Different baud rates are selectable. Please note that the DDU 8 does not contain any CAN termi‐ nation resistors. Thus the CAN termination resistors need to be integrated into the wiring loom.

Ethernet channels

The DDU 8 has two 100 MBit full duplex Ethernet communication port. The port is internally connected with an Ethernet switch. The Ethernet port has 'cable auto crossover' functionality.

RS232 ports

The DDU 8 has one RS232 serial port. Baud rate for the port is programmable. RS232 port is reserved for GPS receiver.

5.1

5.1.1

5.1.2

5.2

5.2.1

5.3

5.3.1

5.3.2

5.3.3

Inputs and Outputs | 5

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Vehicle diagnoses connector

The Bosch Motorsport vehicle diagnosis connector is used as a standard inter‐ face to connect the vehicle to a PC e.g. via a MSA‐Box II. Loom connector: AS 0‐12‐35SN

Pin Name Description Used for DDU 8

Pin 1 Terminal 30 Permanent positive +

Pin 2 Terminal 15 Switched positive +

Pin 3 Terminal 31 GND +

Pin 4 CAN High Diagnostic CAN bus

Pin 16 CAN Low Diagnostic CAN bus

Pin 10 K‐Line ECU diagnosis

Pin 8 Ethernet RxD + Ethernet interface +

Pin 9 Ethernet RxD ‐ Ethernet interface +

Pin 11 Ethernet TxD + Ethernet interface +

Pin 12 Ethernet TxD ‐ Ethernet interface +

Pin 22 Screen Cable screen +

5.3.4

5 | Inputs and Outputs

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Mechanical Drawing

Mechanical Drawing | 6

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Starting up

Before starting

Install the software required DDU 8 operation. It is developed for Windows 2000/XP/Vista/7.

Following software versions are used in this manual:

▪ DDU 8 setup, configuration and calibration: RaceCon later than 2.5.0.400.

Set up the 100 Mbit Ethernet connection to the DDU 8.

▪ The Ethernet port has ‘cable auto crossover’ functionality

Minimum wiring loom of the Life connector (red):

Pin Description

Pin 1+2+3 12 V supply voltage

Pin 4+5 GND supply voltage

Pin 6 Ethernet Tx+

Pin 7 Ethernet Tx‐

Pin 8 Ethernet Rx+

Pin 9 Ethernet Rx‐

Pin 10 Ethernet Screen

Setting up the network interface

The DDU 8 contains a DHCP server, network addresses can be assigned automat‐ ically to the configuration PC. The IP address of DDU 8 is 10.10.0.208.

1. Switch off the PC’s firewall.

2. Set up the PC’s network interface as shown in the screenshots.

Select 'Internet Protocol (TCP/IP)'

Click 'Properties'

Select 'Obtain an IP adress automatically'

Click 'OK' when done

Starting the unit

The DDU 8 powers up by turning on the ignition of the car. At startup the DDU 8 will display a Bosch logo.

7.1

7.1.1

7.1.2

7 | Starting up

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After a moment the DDU 8 shows a display element screen.

The ‘Link LED’ at the PC’s network adapter will illuminate. If the LED is off, check the wiring harness.

About RaceCon

RaceCon is an all integrated software tool for configuration and calibration of Bosch Motorsport hardware products. It is used to set up, configure and calibrate the DDU 8.

For better understanding, Bosch Motorsport offers a video tutorial that explains many functions of RaceCon. The video tutorial is available in the ‘Software Down‐ load’ section of www.bosch‐motorsport.com.

Connecting the Unit to RaceCon

The following screenshot shows an overview of the RaceCon Main Screen with its areas. All (sub‐) windows are resizable and dockable.

7.1.3

7.1.4

Starting up | 7

Bosch Motorsport DDU S2 PLUS Manual 15 / 136

Project

Tree

Data Area

Properties Message Area

Main Area

Toolbox

1. Start the RaceCon software.

2. In the ‘File’ menu select ‘New’ to create a new project.

7 | Starting up

16 / 136 DDU S2 PLUS Manual Bosch Motorsport

3. In the Toolbox select the DDU 8 and drag it into the Main Area. A pop up window to specify the DDU 8 program archive appears.

An information shows that the archive is valid or not.

4. Select the program archive delivered with the DDU 8 (.PST file).

5. Click ‘OK’.

RaceCon detects configuration differences between the DDU 8 and the Race‐ Con project and asks for permission for data download.

6. Click ‘OK’ to proceed.

Successful Ethernet connection, DDU 'talks' to PC

The download starts and the DDU 8 carries out a reset.

Starting up | 7

Bosch Motorsport DDU S2 PLUS Manual 17 / 136

After the reset RaceCon reconnects to the DDU 8. Local configuration on both the PC and DDU 8 match (Indicated by green background and dot). The DDU 8 is now connected to RaceCon.

Green background and dot indicate matching configuration

First display configuration (Quick Start)

This chapter explains the configuration of a display element showing the battery voltage.

See chapter ‘Display element configuration’ for a detailed instruction to config‐ ure display elements.

1. Expand the DDU 8 Project Tree by clicking ‘+’.

7.2

7 | Starting up

18 / 136 DDU S2 PLUS Manual Bosch Motorsport

2. Double‐click on ‘New Page’. The DDU 8 display configuration area opens.

Click '+'

Double-click 'New Page'

3. Drag a ‘Large Element’ from the Toolbox and drop it on the display page. A message in the ‘Large Element’ box shows that it is not linked to a measure‐ ment channel.

4. In the DDU 8 Project Tree, click on ‘DDU 8’ to display the available measure‐ ment channels.

5. In the data window, scroll down to ‘ub’ (measurement channel for battery voltage).

Starting up | 7

Bosch Motorsport DDU S2 PLUS Manual 19 / 136

6. Drag the ‘ub’ measurement channel from the Data Area and drop it on the ‘Large Element’.

7. Right‐click on ‘DDU 8’ in the DDU 8 Project Tree and choose ‘Download Con‐ figuration’.

The configurations download starts and the DDU 8 carries out a reset.

7 | Starting up

20 / 136 DDU S2 PLUS Manual Bosch Motorsport

The value of the battery voltage is displayed on the DDU 8.

Starting up | 7

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Display Configuration

▪ DDU 8 features: 640 x 480 full color TFT display + 10 color LEDs

▪ Display and LEDs are fully configurable

▪ ECU channels, analog channels, and CAN channels can be displayed

▪ Display elements: large numeric, medium numeric, bar graph style, alarm

messages, static elements, image element

▪ DDU 8 supports up to 12 display pages, 6 brightness settings for display and

LEDs

Display page setup

Organizing display pages

▪ All Pages: Display elements placed on this page are displayed on all pages.

Recommended for ‘Alarm’ display elements.

▪ Single Page: Display elements placed on this page are displayed only on this

page.

The priority of display elements placed on ‘All Pages’ is higher than the priority of display elements placed on single pages.

Example: An Alarm placed on ‘All Pages’ is displayed on all display pages and is always in front of other display elements.

Adding a new display page

Right‐click on ‘Display’ and click ‘Add Page’ in the menu.

8.1

8.1.1

8.1.2

8 | Display Configuration

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A new empty page opens.

Selecting display page

In the DDU 8 Project Tree, click on ‘DDU 8’, then on ‘Display’ and double‐click on the page you want to select (example: ‘New Page’).

In the Main Area, a representation of the DDU 8 opens.

Tabs to switch between different items / pages

Configurable LEDs

Display area

Display element configuration

Numeric display element

Adding a numeric display element to display page

The ‘Large Element’ and the ‘Medium Element’ numeric display elements differ in element and font size. The element and font size can be changed using the Nu‐ meric Wizard.

Notice

In this view the displayed values are random values and do not show the real values of the measurement channels.

8.1.3

8.2

8.2.1

Display Configuration | 8

Bosch Motorsport DDU S2 PLUS Manual 23 / 136

1. Drag a numeric display element from the Toolbox and drop it on the display page. A message in the numeric element box shows that it is not linked to a measurement channel.

Drag + Drop

2. Drag a measurement channel from the Data Area and drop it on the numeric display element.

Drag + Drop

The measurement channel is linked to the numeric display element.

Configuring a numeric display element

1. Double‐click on the numeric display element. The Numeric Wizard window opens.

8 | Display Configuration

24 / 136 DDU S2 PLUS Manual Bosch Motorsport

b) c) d)

a) Enter the title displayed on top of the numeric display element. b) Enter the text displayed in the middle of the numeric display element. The variable <channel value> displays the value of the measurement channel. c) Choose the measurement channel. d) Choose the type of input data:

- Value

- Gear

- Time (in different formats) e) Enter the number of decimal places of the measurement channel. f) Choose the font size, alignment, borderstyle, background and foreground color of the numeric display element. g) Click the Extended button to show further options to change the color of the title, border and text individually.

2. Click ‘OK’ when done.

'Bargraph' display element

Adding a ‘Bargraph’ display element to display page

Drag the ‘Bargraph’ display element from the Toolbox and drop it on the display page.

Drag + Drop

Configuring a ‘Bargraph’ display element

1. Double‐click on the ‘Bargraph’ display element. The Bargraph Wizard window opens.

8.2.2

Display Configuration | 8

Bosch Motorsport DDU S2 PLUS Manual 25 / 136

e) f) g) h) i) j) k) l)

a) Enter the title displayed on top of the 'Bargraph' display element. b) Choose the measurement channel. c) Define the tick text corresponding with the physical value. You can add more tix labels by entering values in the row labeled with *. d) Choose the orientation of the Bargraph (horizontal or vertical). e) Choose the color mode of the Bargraph:

- Solid: The whole Bargraph and tics are colored in one color

- Stacked: The Bargraph is subdivided in segments with different colors. The colors are set in the tab 'Conditional Formatting'. For details, see chapter 'Conditional Formatting'. f) Define if ticks and numbers are shown. g) Choose the style of the border lines. h) Enter the physical value where the Bargraph begins. i) Enter the physical value where the Bargraph ends. j) Choose the background color of the Bargraph. k) Choose the foreground color of the Bargraph. l) Click the Extended button to show further options to change the color of the title, border and text individually.

2. Click ‘OK’ when done.

Notice

The tab ‘Conditional Formatting’ is explained in chapter ‘Con‐ ditional formatting’.

'Alarm' display element

The ‘Alarm’ display element displays a warning message in case of a defined con‐ dition becoming ‘true’. In case of a condition becoming ‘false’, the ‘Alarm’ display element is not shown.

Two types of ‘Alarm’ display elements are available:

▪ Alarm: An alarm displaying a defined text

▪ Alarm Icon: An alarm displaying a defined image (e.g. a warning triangle)

8.2.3

8 | Display Configuration

26 / 136 DDU S2 PLUS Manual Bosch Motorsport

Adding an ‘Alarm’ display element to display page

Drag an ‘Alarm’ element from the Toolbox and drop it on the display page.

Drag + Drop

Configuring an ‘Alarm’ (text) display element

1. Double‐click on the ‘Alarm’ display element. The Alarm Wizard window opens.

a) b)

c) d)

a) Enter the title displayed on top of the 'Alarm' display element. b) Choose the condition when the alarm will be activated:

- Create a condition using the Condition Creator. For more information see chapter 'Creating a new condition channel'

- Choose an existing condition. The Alarm is displayed if function is 'TRUE', i.e. result of the calculation is >0. c) Enter the alarm message displayed in the middle of the 'Alarm' display element. Enter the variable <channel value> to display the value of the measurement channel. d) Choose the measurement channel. e) Choose the type of input data:

- Value

- Gear

- Time (in different formats) f) Enter the number of decimal places of the measurement channel. g) Choose the font size, alignment, borderstyle, background and foreground color of the 'Alarm' dislay element.

2. Switch to the tab ‘Alarm representation’.

Display Configuration | 8

Bosch Motorsport DDU S2 PLUS Manual 27 / 136

b) c)

a) Choose if the alarm can be reset or not. b) Choose if the alarm blinks slowly, fast or does not blink. c) Enter the minimum time the Alarm display element is displayed if an alarm is triggered. d) Enter the time until the Alarm resets automatically after the minimum display time entered in c). Only possible if Alarm is resettable. e) Enter the time until the Alarm can appear again after a reset.

3. Click ‘OK’ when done.

4. Copy alarm to all display pages by clicking ‘Move to’ ‐> ‘All Pages’.

8 | Display Configuration

28 / 136 DDU S2 PLUS Manual Bosch Motorsport

Configuring an ‘Alarm Icon’ (image) display element

Drag + Drop

1. Double‐click on the ‘Alarm Icon’ display element.

The Alarm Icon Wizard window opens.

a) Select the image from the hard drive that is shown in case of an alarm. b) Choose the condition when the alarm will be activated:

- Create a condition using the Condition Creator. For more information see chapter 'Creating a new condition channel'

- Choose an existing condition The 'Alarm Icon' is displayed if function is 'TRUE'; i.e. result of the calculation is >0. c) Enable the checkbox if you want to define parts of the image as transparent. d) Select the basic transparent color key. This means that any pixel of the amage near (depending of the tolerance value) to this color gets transparent. e) Select a tolerance in percent to define parts of the mage as transparent.

2. Switch to the tab ‘Alarm representation’. It is configured in the same way as the ‘Alarm’ text display element.

3. Click ‘OK’ when done.

Notice

If several active alarms in the display overlap, each alarm is in the foreground for 2 seconds.

Display Configuration | 8

Bosch Motorsport DDU S2 PLUS Manual 29 / 136

Other display elements

Two types of other display elements are available:

▪ Label: A label displaying a specified text

▪ Picture element: An element displaying a static picture (e.g. temperature

warning)

Adding a Label or picture display element to display page

Drag the Label or picture display element from the Toolbox and drop it on the display page.

Drag + Drop

Configuring a Label display element

1. Double‐click on the Label display element. The Label Wizard window opens.

a) Enter the title displayed on top of the Label display element. b) Enter the text displayed in the middle of the Label display element. c) Choose the font size, alignment, borderstyle, background and foreground color of the Label display element. d) Click the Extended button to show further options to change the color of the title, border and text individually.

2. Click ‘OK’ when done.

8.2.4

8 | Display Configuration

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+ 106 hidden pages