Bosch M 60 User manual

Modular Sensor Interface M 60
Manual
V 1.2 5/16/2018

Modular Sensor Interface M 60 Table of contents | en 3
Bosch Motorsport Manual 16.05.2018 | V 1.2 |
Table of contents
1Preparation 6
2Onboard Network Concept 7
3Installation 8
4Technical Data 9
5Inputs and Outputs 11
5.1 Input Channels 11
5.1.1 Analog Inputs 11
5.1.2 Digital Inputs 11
5.2 Output Channels 11
5.2.1 PWM Outputs 11
5.2.2 Sensor Power Supply 11
5.3 Communication Channels 11
5.3.1 CAN Bus 11
5.3.2 Ethernet Channels 11
5.3.3 RS232 Ports 12
5.3.4 Vehicle Diagnosis Connector 12
5.4 Pin Layout Connectors 13
5.4.1 Pin Layout Life Connector ASDD-2-12-41PN (Red) 13
5.4.2 Pin Layout Sensor Connector ASDD-2-12-41PA (Yellow) 14
6Mechanical Drawing 17
7Starting up 18
7.1 Before Starting 18
7.1.1 Setting up the Network Interface 18
7.1.2 Starting the M 60 19
7.1.3 About RaceCon 19
7.1.4 Connecting the M 60 to RaceCon 19
7.2 Assign the Mounting Location 23
7.3 Feature Activation 26
8Math and Condition Channels 29
8.1 Math Channels 29
8.1.1 Creating a new Math Channel 29
8.1.2 Creating a new Conditional Function 30
8.2 Condition Channels 34
8.2.1 Creating a new Condition Channel 34
8.2.2 Creating a new Condition Combination 36
9CAN Bus 38
9.1 CAN Bus Trivia 38
9.2 CAN Input 39
9.2.1 Input Configuration 39
9.2.2 Create new CAN Channel 39
9.2.3 CAN Channel Configuration 40
9.2.4 Extracting Data from CAN Bus 41
9.2.5 Conversion to Physical Values 42
9.2.6 Special Features 42
9.2.7 Online View of CAN Channels in Vehicle 43
9.2.8 Import a CAN Database (DBC) File 44
9.2.9 Export RaceCon CAN Configuration 45
9.2.10 Import RaceCon CAN Configuration 45

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9.3 CAN Output 46
9.3.1 Output Configuration 47
9.3.2 Create new CAN Output Message Channel 47
9.3.3 Set up of Word Length, Byte Order and Quantization 49
9.3.4 Export RaceCon CAN Configuration 49
9.3.5 Import RaceCon CAN Configuration 50
10 Analog and Frequency Inputs 51
10.1 Features 51
10.2 Measurement Channels 51
10.3 Configuring Inputs 51
10.3.1 Configuring a predefined Bosch Sensor with the 'Bosch Sensor Wizard' 51
10.3.2 Configuring a generic linear sensor 54
10.3.3 Configuring a generic nonlinear sensor 57
10.3.4 Configuring a Multipoint Adjustment 60
10.3.5 Digital Filter Details 62
10.3.6 Configuring a Frequency Input 63
10.4 Configuring computed Source 65
10.5 Hysteresis 66
10.5.1 Special Functionality: Vehicle speed 68
10.5.2 Setting up calculated Speed 68
10.6 Configuring PWM Outputs 70
11 Online Measurement 73
11.1 Achieving an online Connection 73
11.1.1 Set up the PC for Access 73
11.1.2 Going online 74
11.1.3 Configuration Download 74
11.2 Setting up an online Measurement 75
11.2.1 Automatic Creation of Measurement Sheets 79
11.2.2 Using the Measurement Sheets 81
11.3 Online Calibration of Measurement Channels 81
11.3.1 Enable online offset Calibration for Measurement Channel 82
11.3.2 Performing the online offset Calibration 82
11.4 Group Adjustment 83
11.5 Online Calibration of Multipoint Adjustment Channels 85
12 Error Memory 88
12.1 General Note 88
12.2 Error Memory Representation in RaceCon 88
12.2.1 Accessing the Memory 88
12.2.2 Cleaning the Error Memory 88
12.3 Information on Errors available from the Error Memory 88
12.3.1 Error Memory Properties 88
12.3.2 Error Properties 88
12.4 Configuration 88
12.4.1 Monitoring limits / Shortcut Detection / Cable Breakage 88
12.4.2 Open Line Detection 88
13 Firmware 89
13.1 Firmware and Configuration 89
13.2 Firmware Update 89
14 Clone the Unit 92

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15 GPS Sensor 94
15.1 GPS (Global Positioning System) 94
15.2 Protocol 94
15.3 Sensor Recommendation 94
15.4 Measurement Labels 95
15.5 GPS Troubleshooting 96
16 Disposal 97

6en | Preparation Modular Sensor Interface M 60
16.05.2018 | V 1.2 | Manual Bosch Motorsport
1 Preparation
Use the M 60 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 M 60 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. Don’t
hesitate to contact us, contact data can be found on the back 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.

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2 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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3 Installation
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).
Notice!
Be careful to observe current limits of wires and connector pins!

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4 Technical Data
The M 60 is a compact and light weight sensor interface unit for analog and digital sensors. Up
to eight M 60 can be used to expand the number of input channels of the data logger C 60 as
well as the display DDU 9. The M 60 are linked via high-speed Ethernet interface. This allows
for synchronized acquisition of data from the different units and the ECU.
The M 60 offers 26 analog inputs, four rotational inputs, four pwm outputs and two
independent CAN buses. Each analog input channel features an analog pre-filter, 8 x
oversampling and highly linear digital filtering. The cut-off frequency of the digital filter is
automatically adjusted to match the acquisition rate. The latency of the digital filters is
corrected during recording, yielding zero filter delay in the recorded data.
The evaluation of each M 60 measurement channel is individually configurable with the PC
configuration tool RaceCon.
Application
8 kHz AD converters with digital low pass filter
Configurable math channels
User configurable CAN in/out messages
Up to 1,000 Hz acquisition rate for all channels
3-port network switch
Mechanical Data
Size 105 x 34.5 x 137.5 (149) mm
Weight 495 g
Operating temperature internal -20 to 65°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) 10 W at 14 V

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Inputs
Analog channels 26
Input range 0 to 5 V
Resolution 12 bit
Switchable pull up resistor 3 kOhm
Rotational channels (default Hall, Inductive as
option)
4
Outputs
PWM outputs (low side switch 2 A each) 4
Sensor supply 5 V (350 mA each) 4
Sensor supply 10 V (350 mA each) 1
Sensor supply 12 V (1 A, non regulated) 1
Environment
Software Upgrade 1
CCP-Master (ASAP 2 file from ECU
manufacturer required)
F 02U V01 012-01
Connectors and Wires
Motorsport connectors double density 2 x 41 pins
Mating connector I
AS-DD 6-12-41SN
F 02U 002 216-01
Mating connector II
AS-DD 6-12-41SA
F 02U 004 180-01
Communication
Configuration via RaceCon over Ethernet or MSA-Box II
2 CAN interfaces
3 Ethernet 100BaseT
The required software for this device is available on our homepage www.bosch-
motorsport.com

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5 Inputs and Outputs
The following chapter introduces the Input and Output Channels.
5.1 Input Channels
The M 60 provides diverse analog inputs which allows the direct connection of a multiplicity
number of sensors.
5.1.1 Analog Inputs
The M 60 analog inputs accept an input signal of 0 to 5 V. A 3.01 kOhm pull-up resistor can be
activated by software.
5.1.2 Digital Inputs
The digital inputs of the M 60 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. Support of inductive speed sensors is available as a hardware option. Inductive sensors
are connected to the REVn_P and REVn_M pins.
5.2 Output Channels
This chapter describes the PMW Output and Sensor Power Supply of the M 60.
5.2.1 PWM Outputs
The M 60 has 4 low side switch outputs controlled by pulse width modulation (PWM). Each
switch is rated 1 A maximum current. Maximum PWM switch frequency is 1 kHz with a 0 % …
100 % duty cycle. Each output is short circuit protected to GND and battery voltage. It is
mandatory to connect the LS_PWM pins to vehicle GND as indicated in the circuit diagram
when using the PWM outputs.
5.2.2 Sensor Power Supply
The M 60 has three types of sensor power supply:
– 12 V unregulated battery voltage
– 5 V regulated voltage
– 10 V regulated voltage
The 12 V unregulated output is fused and rated 1 A max. The regulated 5 V and 10 V outputs
can deliver 350 mA each. They are short circuit protected to battery voltage and GND.
5.3 Communication Channels
This chapter describes the Communication Channels of the M 60.
5.3.1 CAN Bus
The M 60 has 2 CAN buses configurable as input and output. Different baud rates are
selectable. Please note that the M 60 does not contain any CAN termination resistors. Thus
the CAN termination resistors need to be integrated into the wiring loom.
5.3.2 Ethernet Channels
The M 60 has three 100 Mbit full duplex Ethernet communication ports. The ports are
internally connected with an Ethernet switch. The Ethernet ports have 'cable auto crossover'
functionality.

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5.3.3 RS232 Ports
The M 60 has two RS232 serial ports. The baudrate for both ports is programmable. Port 1 is
reserved for online telemetry, port 2 can be used for reception of data from a serial GPS
receiver.
5.3.4 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 M 60
1 Terminal 30 Permanent positive +
2 Terminal 15 Switched positive +
3 Terminal 31 GND +
4 CAN High Diagnostic CAN bus
16 CAN Low Diagnostic CAN bus
10 K-Line ECU diagnosis
8 Ethernet RxD + Ethernet interface +
9 Ethernet RxD - Ethernet interface +
11 Ethernet TxD + Ethernet interface +
12 Ethernet TxD - Ethernet interface +
22 Screen Cable screen +

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5.4 Pin Layout Connectors
5.4.1 Pin Layout Life Connector ASDD-2-12-41PN (Red)
PIN Name Description Direction Remark
1 UBATT (Kl. 30) power supply Ubat input
2 switched
positive Kl.15
switched power supply Ubat input
3 switched
positive Kl.15
switched power supply Ubat input
4 unit ground (Kl.
31)
ground power supply input
5 unit ground ground power supply input
6 ETH1_TX+ Ethernet interface 1
(10/100BaseT)
bidirectional
dataline
7 ETH1_TX- Ethernet interface 1
(10/100BaseT)
bidirectional
dataline
8 ETH1_RX+ Ethernet interface 1
(10/100BaseT)
bidirectional
dataline
9 ETH1_RX- Ethernet interface 1
(10/100BaseT)
bidirectional
dataline
10 ETH_SCR screen for Ethernet screen
11 ETH2_TX+ Ethernet interface 2
(10/100BaseT)
bidirectional
dataline
12 ETH2_TX- Ethernet interface 2
(10/100BaseT)
bidirectional
dataline
13 ETH2_RX+ Ethernet interface 2
(10/100BaseT)
bidirectional
dataline
14 ETH2_RX- Ethernet interface 2
(10/100BaseT)
bidirectional
dataline
15 ETH3_TX+ Ethernet interface 3
(10/100BaseT)
bidirectional
dataline
16 ETH3_TX- Ethernet interface 3
(10/100BaseT)
bidirectional
dataline
17 ETH3_RX+ Ethernet interface 3
(10/100BaseT)
bidirectional
dataline
18 ETH3_RX- Ethernet interface 3
(10/100BaseT)
bidirectional
dataline
19 CAN1_H CAN interface 1 (up to 1
Mbit/s)
bidirectional
dataline
MS 3/MS 4
CardMemory

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PIN Name Description Direction Remark
20 CAN1_L CAN interface 1 (up to 1
Mbit/s)
bidirectional
dataline
MS 3/MS 4
CardMemory
21 CAN2_H CAN interface 2 (up to 1
Mbit/s)
bidirectional
dataline
22 CAN2_L CAN interface 2 (up to 1
Mbit/s)
bidirectional
dataline
23 Not connected Unused Spare
24 Not connected Unused Spare
25 Not connected Unused Spare
26 Not connected Unused Spare
27 SENSPWR5_1 5 V power supply for analog
sensors
output
28 SENSGND_1 sensor ground 1 output
29 TimeSync signal of synchronisation input used for timing of
system
components
30 LS_GND_1 PWM ground output
31 LS_SWITCH_1 PWM lowside switch 1 input
32 LS_SWITCH_2 PWM lowside switch 2 input
33 LS_SWITCH_3 PWM lowside switch 3 input
34 LS_SWITCH_4 PWM lowside switch 4 input
35 LS_GND_2 PWM ground output
36 ANA01 analog signal 1 input
37 ANA02 analog signal 2 input
38 ANA03 analog signal 3 input
39 ANA04 analog signal 4 input
40 ANA05 analog signal 5 input
41 ANA06 analog signal 6 input
5.4.2 Pin Layout Sensor Connector ASDD-2-12-41PA (Yellow)
PIN Name Description Direction Remark
1 UBATT_FUSE1 battery voltage supply output
2 SENSPWR10_1 10 V power supply for
analog sensors
output
3 SENSPWR5_2 5 V power supply for analog
sensors
output

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PIN Name Description Direction Remark
4 SENSPWR5_3 5 V power supply for analog
sensors
output
5 SENSPWR5_4 5 V power supply for analog
sensors
output
6 SENSGND_2 sensor ground 2 output
7 SENSGND_3 sensor ground 3 output
8 Not connected Unused Spare Do not connect
9 Not connected Unused Spare Do not connect
10 RS232_2_TX RS232_2 transmit data bidirectional
dataline
used for GPS-
sensor
11 RS232_2_RX RS232_2 receive data bidirectional
dataline
used for GPS-
sensor
12 RS232_GND RS232 ground
13 REV1_P speed signal 1 positive (ind.
and hall)
input
14 REV1_M speed signal 1 negative
(ind.)
input
15 REV2_P speed signal 2 positive (ind.
and hall)
input
16 REV2_M speed signal 2 negative
(ind.)
input
17 REV3_P speed signal 3 positive (ind.
and hall)
input
18 REV3_M speed signal 3 negative
(ind.)
input
19 REV4_P speed signal 4 positive (ind.
and hall)
input
20 REV4_M speed signal 4 negative
(ind.)
input
21 ANA07 analog signal 7 input
22 ANA08 analog signal 8 input
23 ANA09 analog signal 9 input
24 ANA10 analog signal 10 input
25 ANA11 analog signal 11 input
26 ANA12 analog signal 12 input
27 ANA13 analog signal 13 input
28 ANA14 analog signal 14 input

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PIN Name Description Direction Remark
29 ANA15 analog signal 15 input
30 ANA16 analog signal 16 input
31 ANA17 analog signal 17 input
32 ANA18 analog signal 18 input
33 ANA19 analog signal 19 input
34 ANA20 analog signal 20 input
35 ANA21 analog signal 21 input
36 ANA22 analog signal 22 input
37 ANA23 analog signal 23 input
38 ANA24 analog signal 24 input
39 ANA25 analog signal 25 input
40 ANA26 analog signal 26 input
41 Not connected Unused spare

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6 Mechanical Drawing

18 en | Starting up Modular Sensor Interface M 60
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7 Starting up
The following chapter explains what you have to do before starting the M 60 and how to
connect it to RaceCon.
7.1 Before Starting
Install the software required for M 60 operation. It is developed for Windows 2000/XP/Vista/7.
Following software versions are used in this manual:
– M 60 setup, configuration and calibration: RaceCon 2.1.0
– Measurement data analysis: WinDarab V7
Set up the 100 Mbit Ethernet connection to the M 60.
– All three Ethernet ports of M 60 are internally connected by a network switch.
– All Ethernet ports have ‘cable auto crossover’ functionality.
Minimum wiring loom of the Life connector (red):
PIN Description
1+2+3 12 V Supply Voltage
4+5 GND Supply Voltage
6 Ethernet Tx+
7 Ethernet Tx-
8 Ethernet Rx+
9 Ethernet Rx-
10 Ethernet Screen
7.1.1 Setting up the Network Interface
The M 60 contains a DHCP server, network addresses can be assigned automatically to the
configuration PC.
1. Switch off the PC’s firewall.

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2. Set up the PC’s network interface as shown in the screenshots.
a) Select ‘Internet Protocol (TCP/IP)’.
b) Click ‘Properties’.
c) Select ‘Obtain an IP address automatically’.
d) Click ‘OK’ when done.
7.1.2 Starting the M 60
The M 60 powers up by turning on the ignition of the car.
The ‘Link LED’ at the PC’s network adapter will illuminate. If the LED is off, check the wiring
harness.
7.1.3 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 M 60.
For better understanding, Bosch Motorsport offers a video tutorial that explains many
functions of RaceCon.
The video tutorial is available in the ‘Software Download’ section of www.bosch-
motorsport.com.
7.1.4 Connecting the M 60 to RaceCon
The following screenshot shows an overview of the RaceCon main screen with its areas. All
(sub-)windows are resizable and dockable.

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1. Start the RaceCon software.