Bosch DDU 7 User manual

Display Unit DDU 7
Manual
V 02 2/4/2019

Display Unit DDU 7 Table of contents | en 3
Bosch Motorsport Manual 04.02.2019 | V 02 |
Table of contents
1Preparation 7
2Power Supply 8
3Onboard Network Concept 9
4Technical Data 10
5Inputs and Outputs 13
5.1 Input channels 13
5.2 Output channels 13
5.3 Communication channels 13
5.4 Pin layout connector 14
6Mechanical Drawing 16
7Starting up 17
7.1 Before starting 17
7.1.1 Starting the unit 17
7.1.2 Connecting the unit to RaceCon 17
7.1.3 Setting up a new RaceCon Project 18
7.2 First display configuration (Quick Start) 22
7.3 First recording (Quick Start) 24
7.4 Feature activation 28
8Display Configuration 30
8.1 Display page setup 30
8.1.1 Organizing display pages 30
8.1.2 Adding a new display page 30
8.1.3 Selecting display pages 30
8.2 Display element configuration 31
8.2.1 Numeric display element 31
8.2.2 Bargraph display element 33
8.2.3 'Alarm' display element 34
8.2.4 Other display elements 38
8.2.5 Conditional formatting 39
8.2.6 Context menu 40
8.3 LEDs 40
8.3.1 Configuring shift LEDs 40
8.3.2 Converting a gear channel to ASCII representation 41
8.3.3 Creating customized LED pattern 43
8.3.4 Assigning display pattern priority 43
8.4 Page select / Display brightness / LED brightness 44
8.4.1 General information 44
8.4.2 Option 1: 12 Hardwired position switch 45
8.4.3 Option 2: Up/Down switches 50
8.4.4 Option 3: CAN input signal, math channel or ANA_IN channel 54
8.5 Math and condition channels 56
8.5.1 Math channels 56
8.5.2 Creating a new math channel 56
8.5.3 Creating a new conditional function 57
8.6 Condition channels 59
8.6.1 Creating a new condition channel 60
8.6.2 Creating a new condition combination 61
8.7 CPU Load Limits 63

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9CAN Bus 64
9.1 CAN bus trivia 64
9.2 CAN input 65
9.2.1 Input configuration 65
9.2.2 Create new CAN channel 65
9.2.3 CAN channel configuration 66
9.2.4 Extracting data from CAN bus 66
9.2.5 Conversion to physical values 67
9.2.6 Special features 67
9.2.7 Online view of CAN channels in vehicle 68
9.2.8 Import a CAN database (DBC) file 69
9.2.9 Export RaceCon CAN configuration 69
9.2.10 Import RaceCon CAN configuration 70
9.2.11 Export to dbc file 71
9.3 CAN output 71
9.3.1 Output configuration 71
9.3.2 Create new CAN output message channel 71
9.3.3 Edit CAN Message Multiplexer settings 74
9.3.4 Export RaceCon CAN configuration 74
9.3.5 Import RaceCon CAN configuration 75
10 Analog and Frequency Inputs 77
10.1 Features 77
10.2 Analog inputs 77
10.2.1 Measurement channels 78
10.3 Configuring inputs 78
10.3.1 Configuring a predefined Bosch sensor with the 'Bosch Sensor Wizard' 78
10.3.2 Configuring a generic linear sensor 79
10.3.3 Configuring a generic non-linear sensor 81
10.3.4 Configuring a multipoint adjustment 84
10.3.5 Digital filter details 86
10.3.6 Configuring a frequency input 87
10.4 Computed sources 89
10.4.1 Configuring computed sources 89
10.5 Hysteresis 90
10.5.1 Special functionality: vehicle speed 91
10.5.2 Setting up calculated speed 91
10.6 Configuring PWM outputs 93
10.6.1 Configuring a PWM output 93
11 Online Measurement 96
11.1 Achieving an online connection 96
11.1.1 Set up the PC for access to the Unit 96
11.1.2 Going online 96
11.1.3 Configuration download 97
11.2 Setting up an online measurement 97
11.2.1 Automatic creation of measurement sheets 100
11.2.2 Using the measurement sheets 102
11.3 Online calibration of measurement channels 102
11.3.1 Enable online offset calibration for measurement channel 102
11.3.2 Performing the online offset calibration 103

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12 Error Memory 104
12.1 Error memory representation in RaceCon 104
12.1.1 Accessing the memory 104
12.1.2 Clearing the error memory 105
12.2 Information on errors available from the error memory 106
12.2.1 Error Memory Properties 106
12.2.2 Error Properties 108
12.3 Analog Input Diagnosis 110
12.3.1 Monitoring limits / Shortcut Detection / Cable Breakage 110
12.3.2 Open Line Detection 111
13 Recording and Telemetry 112
13.1 Features 112
13.2 Configuration of recordings 112
13.2.1 Adding a recording 114
13.2.2 Adding a recording group 114
13.2.3 Global settings 114
13.2.4 Recording statistics 115
13.2.5 Recording diagnosis 116
13.2.6 Displaying online recording diagnosis ('statectrl_ok') 117
13.3 Configuration of online telemetry 117
13.3.1 Long range telemetry system FM 40 117
13.3.2 Hardware setup 118
13.3.3 Software setup 118
13.3.4 Telemetry channels with special functionality 120
13.4 Setup for USB recording 121
13.4.1 Recording data on USB device 122
13.4.2 USB device handling hints 126
13.4.3 Troubleshooting 126
14 Lap Trigger 127
14.1 Lap trigger (timing beacon) 127
14.1.1 Electrical trigger signal 127
14.1.2 Prevention of false triggers 128
14.1.3 Forced triggers 128
14.1.4 Setting up a lap trigger 128
14.1.5 Lap trigger channel diagnosis/counter reset 130
14.1.6 Lap trigger presettings 130
14.2 Counting outing/laps/fragments 131
14.3 Lap timing 132
14.3.1 Time Based Retrigger Protection 132
14.3.2 Distance Based Retrigger Protection 132
14.3.3 Distance Based Forced Trigger 133
14.4 Segment timing 134
14.4.1 Sub Trigger Mode 134
14.4.2 Distance Mode 135
14.5 Countdown timer 136
15 Firmware 137
15.1 Firmware and configuration 137
15.2 Firmware update 137
15.2.1 Performing the firmware update 137

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16 Clone the Unit 140
17 GPS Sensor 142
17.1 GPS (Global Positioning System) 142
17.1.1 Serial interface characterization 142
17.2 Protocol 142
17.3 Sensor recommendation 142
17.4 Measurement labels 142
17.5 GPS troubleshooting 143
18 Fuel Consumption Calculation 145
18.1 Setting up fuel consumption calculation and tank management 145
18.2 Fuel consumption diagnosis/counter reset 146
18.3 Example 147
19 Enhancements 148
19.1 Modular sensor interface M 60 148
19.1.1 Technical data 148
19.1.2 Assign the mounting location 150
19.1.3 Feature activation 153
20 RaceCon Shortcuts 154

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1 Preparation
Use the DDU 7 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 DDU 7 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.
Read the manual carefully and follow the application hints step by step. Do not hesitate to
contact us, contact data can be found on the last page of this document.
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.
Notice!
In this document, all screenshots are created by way of example for a display. Please consider
this and replace the product names with the name of your device.

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2 Power Supply
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!

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3 Onboard Network Concept
G
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
PC
Device

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4 Technical Data
The display DDU 7 integrates a programmable full colour dash board display with a data
logging system for motorsport applications. This allows for synchronized acquisition and
visualization of engine data from the ECU and chassis data channels. Additional input devices
can be connected via Ethernet and CAN buses.
Recorded data from the internal 2 GB flash memory can be downloaded via high speed
Ethernet. Data Analysis Software WinDarab is available for free of charge as WinDarab V7 free
on our website.
Variations
F 02U V01 130-04 6 analog channels, 4 Hall speed inputs
F 02U V01 167-03 6 analog channels, 4 DF11 speed inputs
F 02U V02 010-01 10 analog channels, no speed inputs
Application
Display – 5,7” graphic colour 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
Online data compression
Logging rate Max. 100 kB/s

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Recording channels Up to 720 per connected device
Logged data download speed Max. 1,000 kB/s
Internal storage capacity 2 GB
FM 40 long range telemetry support, GSM telemetry support
RS232 GPS input
CCP-Master, data acquisition from ECU that support CAN calibration protocol (optional)
Mechanical Data
Size 148 x 126 x 32 mm
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 2
Analog channels 6 or 10: see Variations
Wheel speed inputs Hall-effect, DF11 or no: see Variations
Input range 0 to 5 V
Resolution 12 bit
Switchable pull up resistor 3 kOhm
DF 11 inputs On request
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 adjustment or
page selection, 6 steps
B 261 209 659-01
Software Upgrade 1

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USB-Port unlocked (Rugged USB flash drive 2
GB Bosch File System (BFS) format included,
works with Bosch File System (BFS)
preformatted USB Flash drive only)
F 02U V01 133-02
Adapter cable to USB-Port (included in
Upgrade)
F 02U V01 343-01
Adapter for wiring harness (included in
Upgrade)
F 02U 002 996-01
Software Upgrade 2
CCP-Master (ASAP2 file from ECU
manufacturer required)
F 02U V01 134-01
Connectors and Wires
Motorsport connector
AS2-14-35PN at DDU7
37 pins
Mating connector
AS 6-14-35SN
F 02U 000 453-01
Communication
CAN interfaces 2
Ethernet 100BaseT 1
Laptrigger input 1
RS232 Telemetry, GPS
Configuration via RaceCon Over Ethernet or MSA-Box II
Installation Notes
The required software (.pst file) for this device is available in the download area of our
homepage www.bosch-motorsport.com.

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5 Inputs and Outputs
5.1 Input channels
Analog inputs
The DDU 7 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 7 accept 0 V to 5 V signals of Hall-effect sensors by default.
Connect the output of the Hall-effect sensor to the REVn_P pin and leave the REVn_M pin
open.
5.2 Output channels
Sensor power supply
The DDU 7 has four sensor power supplies:2 x 5 V, 1 x 10 V and 1 x Ubat regulated voltage.
They are short circuit protected to battery voltage and GND.
5.3 Communication channels
CAN bus
The DDU 7 has 2 CAN buses configurable as input and output. Different baud rates are
selectable. Please note that the DDU 7 does not contain any CAN termination resistors. Thus
the CAN termination resistors need to be integrated into the wiring loom.
Ethernet channels
The DDU 7 has one 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 7 has two RS232 serial ports. Baud rate for both ports is programmable. RS232 port
1 is reserved for online telemetry, port 2 can be used for reception of data from a serial GPS
receiver.
Vehicle diagnosis connector
The Bosch Motorsport vehicle diagnosis connector is used as a standard interface 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 7
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 +

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5.4 Pin layout connector
Connector AS-2-14-35PN
Pin Name Description Direction Remark
1 ANA05 analog signal 5 input
2 ANA06 analog signal 6 input
3 switched positive Kl.15 switched power supply Ubat input
4 unit ground (Kl. 31) ground power supply input
5
6
7
8
USB_Power
USB_DP
USB_DM
USB_GND
USB power
USB data +
USB data -
USB ground
input
input
input
input
9
10
ETH1_RX-
ETH1_TX-
Ethernet interface 1
(10/100BaseT)
bidirectional
dataline
11 REV1 speed signal 1 input
12 REV2 speed signal 2 input
13 SENSPWR10 10 V power supply for
analog sensors
output
14 SENSPWR5 5 V power supply for analog
sensors
output
15 ANA01: Page select analog signal 1 input
16 ANA02: Brightness select analog signal 2 input
17 ANA03: Alarm select analog signal 3 input
18 ANA04 analog signal 4 input
19 ANA07 analog signal 7 input
20 ANA08 analog signal 8 input
21 RS232-GPS-TX RS232_GPS transmit data bidirectional
dataline
used for
GPS-sensor
22 ETH_SCR screen for Ethernet screen
23 REV3 speed signal 3 input
24
25
ETH1_RX+
ETH1_TX+
Ethernet interface 1
(10/100BaseT)
bidirectional
dataline
26 REV4 speed signal 4 input
27 LAP_TRIG laptrigger input input

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Pin Name Description Direction Remark
28 TimeSync signal of synchronisation input used for
timing of
system
component
s
29
30
CAN1_H
CAN1_L
CAN interface 1 (up to 1
MBit/s)
bidirectional
dataline
MS3/MS4
CardMemor
y
31 RS232_GPS_RX RS232_GPS receive data bidirectional
dataline
used for
GPS-sensor
32 UBATT (Kl. 30) power supply Ubat input
33
34
RS232_1_TX
RS232_1_RX
RS232_1 transmit data
RS232_1 receive data
bidirectional
dataline
used for
telemetry
link
35
36
CAN2_H
CAN2_L
CAN interface 2 (up to 1
MBit/s)
bidirectional
dataline
MS 3/MS 4
CardMemor
y
37 SENSGND sensor ground output

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6 Mechanical Drawing

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7 Starting up
7.1 Before starting
Install the software required for the operation of the DDU 7. It is developed for Windows
system software. The following software versions are used in this manual:
– DDU 7 setup, configuration and calibration: RaceCon Version 2.6.
– Measurement data analysis: WinDarab V7
Set up the 100 Mbit ethernet connection to the DDU 7.
– The ethernet port has “cable auto crossover” functionality
7.1.1 Starting the unit
The DDU 7 powers up by turning on the ignition of the car. At startup the DDU 7 will display a
Bosch logo.
After a moment the DDU 7 shows a display element screen.
7.1.2 Connecting the unit to RaceCon
For testing new device configurations, you can connect the device to your computer via MSA-
Box or ethernet cable.
Connection via MSA-Box
1. Reassure that the MSA-Box is installed properly on your computer. If needed, download
the MSA-Box Diver from www.bosch-motorsport.com.
2. Connect an ethernet line of the device to the ethernet line of the MSA-Box.
Please note, that the MSA-Box also requires power supply on the MSA-Box connector of
your wiring loom.
3. Open RaceCon and connect the MSA-Box to the computer.
In the ‘Info / Status’ Box of RaceCon you will receive messages that the connection was
successful.
4. Reassure that the device is switched on.
5. ‘Link LED’ at the computer’s network adapter will illuminate.
If the LED is off, check the wiring harness.
After you created a RaceCon project with the device, the status icon of the device will
switch from grey to one of the following colors: red, orange, green. For further
information on how to set up a project, see the chapter Setting up a new RaceCon Project,
page 18. For the status color, see chapter “Color indication”.
Connection via Ethernet Cable
1. Follow the steps above for a connection via MSA-Box.
2. Instead of connecting the ethernet line to the MSA-Box, Connect the ethernet directly to
your computer.
Troubleshooting while setting up the network interface
The DDU 7 contains a DHCP server, network addresses can be assigned automatically to the
configuration PC. In case of problems during the network connection, please try the following
steps:
1. Switch off the PC’s firewall.

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2. Reconfigure the PC or the MSA-Box network interface settings, to obtain an IP address
automatically as shown in the pictures below.
Select
'Internet Protocol
(TCP/IP)'
Click
'Properties'
Select 'Obtain
an IP adress
automatically'
Click 'OK'
when done
7.1.3 Setting up a new RaceCon Project
The following screenshot shows an overview of the RaceCon Main Screen with its areas. All
(sub-) windows are resizable and dockable. You can find them under the ‘Windows’ tab.
Project
Tree
Data Area Message Area
Main Area
Toolbox
1. Start the RaceCon software.

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2. In the ‘File’ menu select ‘New project’ to create a new project.
3. In the Toolbox select the DDU 7 and drag it into the Main Area. A pop up window to
specify the DDU 7 program archive appears.
4. Download the firmware for the DDU 7 from www.bosch-motorsport.com.
An information shows if the archive is valid or not.

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5. Click ‘Next’.
6. Select ‘Race track’ or ‘Testbench’ mode according to your application.
7. Click ‘Finish’.
The DDU 7 is inserted into the project and RaceCon tries to connect to the device.