Bosch DISBLAY DDU 7 User manual

Display DDU 7
Manual
V 1.2 11/14/2016

Table of contents
1Preparation ........................................................................................................................................................... 4
2Power Supply ....................................................................................................................................................... 5
3Onboard Network Concept ................................................................................................................................ 6
4Technical Data ...................................................................................................................................................... 7
5Inputs and Outputs ........................................................................................................................................... 10
5.1 Input channels ................................................................................................................................................................................ 10
5.2 Output channels ............................................................................................................................................................................ 10
5.3 Communication channels .......................................................................................................................................................... 10
5.4 Pin layout connector .................................................................................................................................................................... 11
6Mechanical Drawing .......................................................................................................................................... 14
7Starting up ......................................................................................................................................................... 15
7.1 Before starting ................................................................................................................................................................................ 15
7.2 Feature activation .......................................................................................................................................................................... 20
7.3 First display configuration (Quick Start) ............................................................................................................................... 22
7.4 First recording (Quick Start) ...................................................................................................................................................... 24
7.5 Set time and date .......................................................................................................................................................................... 28
8Display Configuration ....................................................................................................................................... 29
8.1 Display page setup ....................................................................................................................................................................... 29
8.2 Display element configuration ................................................................................................................................................. 30
8.3 LEDs .................................................................................................................................................................................................... 39
8.4 Page select ....................................................................................................................................................................................... 44
8.5 Display + LED brightness ........................................................................................................................................................... 45
8.6 Math + condition channels ....................................................................................................................................................... 46
8.7 Condition channels ....................................................................................................................................................................... 50
8.8 CPU Load Limits ............................................................................................................................................................................. 53
9CAN Bus .............................................................................................................................................................. 54
9.1 CAN bus trivia ................................................................................................................................................................................. 54
9.2 CAN input ......................................................................................................................................................................................... 55
9.3 CAN output ...................................................................................................................................................................................... 63
10 Analog and Frequency Inputs .......................................................................................................................... 67
10.1 Features ............................................................................................................................................................................................. 67
10.2 Analog inputs .................................................................................................................................................................................. 67
10.3 Configuring inputs ........................................................................................................................................................................ 68
10.4 Configuring computed sources ............................................................................................................................................... 80
10.5 Hysteresis ......................................................................................................................................................................................... 82
11 Online Measurement ......................................................................................................................................... 86
11.1 Achieving an online connection .............................................................................................................................................. 86
11.2 Setting up an online measurement ........................................................................................................................................ 88
11.3 Online calibration of measurement channels .................................................................................................................... 94
11.4 Group adjustment ......................................................................................................................................................................... 96
11.5 Online calibration of multipoint adjustment channels ................................................................................................... 98
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12 Error Memory .................................................................................................................................................. 101
12.1 General note ................................................................................................................................................................................. 101
12.2 Error memory representation in RaceCon ........................................................................................................................ 101
12.3 Information on errors available from the error memory ............................................................................................ 103
12.4 Configuration ............................................................................................................................................................................... 107
13 Recording and Telemetry .............................................................................................................................. 109
13.1 Features .......................................................................................................................................................................................... 109
13.2 Configuration of recordings ................................................................................................................................................... 109
13.3 Configuration of online telemetry ....................................................................................................................................... 115
13.4 Setup for USB recording .......................................................................................................................................................... 119
14 Lap Trigger ...................................................................................................................................................... 126
14.1 Lap trigger (timing beacon) ................................................................................................................................................... 126
14.2 Counting outing/laps/fragments ......................................................................................................................................... 132
14.3 Lap timing ..................................................................................................................................................................................... 133
14.4 Segment timing .......................................................................................................................................................................... 135
14.5 Countdown timer ....................................................................................................................................................................... 136
14.6 GPS Lap trigger ........................................................................................................................................................................... 137
15 Firmware .......................................................................................................................................................... 139
15.1 Firmware and configuration ................................................................................................................................................... 139
15.2 Firmware update ......................................................................................................................................................................... 139
16 Clone the Unit ................................................................................................................................................. 142
17 GPS Sensor ...................................................................................................................................................... 143
17.1 GPS (Global Positioning System) .......................................................................................................................................... 143
17.2 Protocol .......................................................................................................................................................................................... 143
17.3 Sensor recommendation ......................................................................................................................................................... 143
17.4 Measurement labels .................................................................................................................................................................. 146
17.5 GPS troubleshooting ................................................................................................................................................................. 147
18 Fuel Consumption Calculation ...................................................................................................................... 149
18.1 Setting up fuel consumption calculation and tank mangement ............................................................................. 149
18.2 Fuel consumption diagnosis/counter reset ..................................................................................................................... 150
18.3 Example .......................................................................................................................................................................................... 151
19 Enhancements ................................................................................................................................................. 152
19.1 Modular sensor interface M 60 ............................................................................................................................................. 152
20 RaceCon Shortcuts ......................................................................................................................................... 157
Table of Contents
Bosch Motorsport DDU 7 Manual 3 / 160

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 Motor‐
sport.
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 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
1 | Preparation
4 / 160 DDU 7 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!
2
Power Supply | 2
Bosch Motorsport DDU 7 Manual 5 / 160

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
DDU
3
3 | Onboard Network Concept
6 / 160 DDU 7 Manual Bosch Motorsport

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 synchron‐
ized 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
4
Technical Data | 4
Bosch Motorsport DDU 7 Manual 7 / 160

Online data compression
Logging rate Max. 100 kB/s
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
4 | Technical Data
8 / 160 DDU 7 Manual Bosch Motorsport

External switch for brightness adjust‐
ment or page selection, 6 steps
B 261 209 659‐01
Software Upgrade 1
USB‐Port unlocked (Rugged USB flash
drive 2 GB Bosch File System (BFS) for‐
mat included, works with Bosch File Sys‐
tem (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 manu‐
facturer 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.
Technical Data | 4
Bosch Motorsport DDU 7 Manual 9 / 160

Inputs and Outputs
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.
Display brightness switch
Pin 37 of the life connector is used as a dimmer switch for the display. The inter‐
nal pull‐up resistor is automatically activated. Different dim settings are selected
by a connecting the pin to SENSGND with different resistor values over a 6 posi‐
tion switch. The individual brightness settings for LEDs and the display are de‐
fined by RaceCon.
Dim Level Resistor Value
Level 1 43.9 Ohm
Level 2 142 Ohm
Level 3 264 Ohm
Level 4 409 Ohm
Level 5 609 Ohm
Level 6 846 Ohm
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 regula‐
ted voltage. They are short circuit protected to battery voltage and GND.
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 termi‐
nation resistors. Thus the CAN termination resistors need to be integrated into
the wiring loom.
5
5.1
5.2
5.3
5 | Inputs and Outputs
10 / 160 DDU 7 Manual Bosch Motorsport

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 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 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 +
Pin layout connector
Connector AS‐2‐14‐35PN
Pin Name Description Direction Remark
1ANA05 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
5.4
Inputs and Outputs | 5
Bosch Motorsport DDU 7 Manual 11 / 160

Pin Name Description Direction Remark
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 an‐
alog sensors
output
15 ANA01: Page select analog signal 1 input
16 ANA02: Brightness se‐
lect
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‐sen‐
sor
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
28 TimeSync signal of synchronisation input used for
timing of
system
compo‐
nents
29
30
CAN1_H
CAN1_L
CAN interface 1 (up to 1
MBit/s)
bidirectional
dataline
MS3/MS4
CardMe‐
mory
31 RS232_GPS_RX RS232_GPS receive data bidirectional
dataline
used for
GPS‐sen‐
sor
32 UBATT (Kl. 30) power supply Ubat input
5 | Inputs and Outputs
12 / 160 DDU 7 Manual Bosch Motorsport

Pin Name Description Direction Remark
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
CardMe‐
mory
37 SENSGND sensor ground output
Inputs and Outputs | 5
Bosch Motorsport DDU 7 Manual 13 / 160

Mechanical Drawing 6
6 | Mechanical Drawing
14 / 160 DDU 7 Manual Bosch Motorsport

Starting up
Before starting
Install the software required DDU 7 operation. It is developed for Windows sys‐
tem software. Following software versions are used in this manual:
▪ DDU 7 setup, configuration and calibration: RaceCon
▪ Measurement data analysis: WinDarab V7
Set up the 100 Mbit Ethernet connection to the DDU 7.
▪ The Ethernet port has ‘cable auto crossover’ functionality
Setting up the network interface
The DDU 7 contains a DHCP server, network addresses can be assigned automat‐
ically to the configuration PC. The IP address of DDU 7 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 7 powers up by turning on the ignition of the car. At startup the DDU 7
will display a Bosch logo.
7
7.1
7.1.1
7.1.2
Starting up | 7
Bosch Motorsport DDU 7 Manual 15 / 160

After a moment the DDU 7 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 7.
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
7 | Starting up
16 / 160 DDU 7 Manual Bosch Motorsport

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.
Starting up | 7
Bosch Motorsport DDU 7 Manual 17 / 160

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.
An information shows that the archive is valid or not.
4. Please find the firmware for the DDU 7 on www.bosch‐motorsport.com/
downloads/software.
5. Click ‘Next’.
6. Select ‘Race track’.
7. Click ‘Finish’. The DDU 7 is inserted into the project and RaceCon tries to
connect to the device.
7 | Starting up
18 / 160 DDU 7 Manual Bosch Motorsport

RaceCon detects configuration differences between the DDU 7 and the Race‐
Con project and asks for permission for data download.
8. Click ‘OK’ to proceed.
Successful Ethernet
connection,
'talks' to PC
DDU 7
The download starts and the DDU 7 carries out a reset.
Starting up | 7
Bosch Motorsport DDU 7 Manual 19 / 160

After the reset RaceCon reconnects to the DDU 7. Local configuration on both
the PC and DDU 7 match (indicated by green background and dot). The DDU 7 is
now connected to RaceCon.
Green background
and dot indicate
matching
configuration
Feature activation
▪ Optional software feature packages are available for the DDU 7.
▪ If you have purchased an optional software feature package, it must be acti‐
vated before it becomes operational.
▪ The feature activation status is stored permanently in the device and requires
activating once only.
▪ As the activation key is device specific, a key delivered with one DDU 7 does
not work on any other DDU 7.
▪ If you have not purchased an option package, the next steps can be skipped.
1. To activate a feature, double‐click on ‘DDU 7’ in the Project Tree and click on
the ‘Features info’ tab in the Main Area.
1st: Double-click
on
2nd: Click on
'Features Info'
DDU 7
The ‘DDU 7 features info’ window appears.
7.2
7 | Starting up
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