f3katalog

System Overview

19 Oct. 04 www.bosch-motorsport.com 3

ContentsSystem Overview

System Description .............................................................................................. 5Basic System Overview ....................................................................................... 9Motronic MS 3.1................................................................................................. 10Software Functions MS 3.1 ................................................................................ 12

Engine EquipmentRotary Potentiometer RP 86 .............................................................................. 14Rotary Potentiometer RP 100 ............................................................................ 15Inductive Speed Sensor IA-C............................................................................. 16Speed Sensor HA-P........................................................................................... 17Lambda Sensor LSU.......................................................................................... 18Knock Sensor KS-P ........................................................................................... 20Temperature Sensor NTC M12-H ...................................................................... 21Temperature Sensor NTC M12-L....................................................................... 23Thermocouple Probe TCP-NF ........................................................................... 25Absolute Pressure Sensor PSA ......................................................................... 27Absolute Pressure Sensor PSA-BF.................................................................... 28Pressure Sensor PSS ........................................................................................ 29Injection Valve EV 6........................................................................................... 30Injection Valve EV 12......................................................................................... 32Fuel Pressure Regulator Mini 50........................................................................ 33Single Fire Coil P ............................................................................................... 34Single Fire Coil SP............................................................................................. 35Relay 25 A ......................................................................................................... 36

Chassis EquipmentRotary Potentiometer RP 308 ............................................................................ 38Pressure Sensor PSS ........................................................................................ 39Accelerometer AM 600 ...................................................................................... 40Linear Potentiometer LP 10 ............................................................................... 41Linear Potentiometer LP 75 ............................................................................... 42Linear Potentiometer LP 100 ............................................................................. 43Gear Potentiometer............................................................................................ 44CardMemory C40 Plus + CAN ........................................................................... 45Laptrigger IR-02................................................................................................. 46Display DDU 5 ................................................................................................... 47Speed Box 4 (only for test, use in race forbidden!) ............................................ 48

Application ToolsApplication Equipment Overview........................................................................ 50KIC 2.................................................................................................................. 51Modas................................................................................................................ 52Potiboard POP................................................................................................... 53WinDarab........................................................................................................... 54

Sales terms and conditionsSales terms and conditions for motorsport products .......................................... 56

Offer drawings

System Overview

www.bosch-motorsport.com 19 Oct. 044

System Overview

System Overview


System DescriptionEngine Control

Sensors

Actuators

Set-up and Calibration

Data Logger

Lap Marker Beacon System

Data Evaluation

Display

System Overview


The MS 3.1 engine control unit is designed to provide sophisticated control capabilities in acost-effective package. The ECU itself is based on the latest Bosch production unit, beingthe first ECU design in full hybrid technology. This offers the benefits of compact size andsuitability for use in extreme environments, qualities very much appreciated in motorsportapplications. Even the ignition drive stages are integrated within the unit. The ECU ismanufactured on the BOSCH production site at Reutlingen, Germany. This ensures highquality control, identical specification for all pieces and short term availability. Additionally aspare part delivery time of at least seven years after end of production is guaranteed.

The complete on car system would comprise the MS3.1 ECU, Card Memory data loggingunit and dash board display, interfaced via a CAN bus. Where appropriate we have se-lected Bosch production sensors and actuators to enhance the cost-effectiveness of thepackage. Other parts have been specially developed for motorsport applications to provideimproved reliability and performance in the racing environment.

A special version of ECU firmware would be employed to provide the security, monitoringand tracking features required by the FIA. The Windows based application tool MODASwould also be modified to incorporate only the features and access levels required.

As a world-wide organisation we can provide technical and spares support to the enginebuilders, teams and series scrutineers via our local branch offices.

Engine Control

MS 3.1`s control functions are state of the art and proven in GT 3 and Formula 3. Physicallybased structure and ambient corrections reduce the need for trackside tuning during theevent to a minimum. Closed loop Lambda control using the latest Bosch wide band Lambdasensor is included as is a powerful closed loop knock control capability with up to twoacoustic knock sensors helping to prevent expensive engine damage even during change-able ambient conditions or poor fuel quality.

Sophisticated input and output self diagnostics help identify sensor, actuator or wiringfaults.

Sensors

Engine speed sensing is exclusively performed according to the well-tried method using aninductive sensor in combination with 60-2 tooth wheel for crankshaft angle and a hall sen-sor for cylinder 1 recognition at camshaft. Requirements are shown in the appendix.

Load determination is carried out via a single throttle position sensor. Modifications for abackup signal from a redundant sensor could be made.

Temperature measurement is carried out using Bosch series production parts. These areNTC sensors except exhaust temperature, which uses a thermocouple with integratedamplifier.

Pressure measurement is with amplified sensors.

System Overview


Actuators

The engine actuators have been selected from the extensive range of Bosch series pro-duction parts. The injectors can be supplied in a range of flow rates and spray angles to suitthe engine characteristics. The ignition coils are prepared with steel spring contacts forimproved reliability during repeated installation. They can be mounted either on top of thespark plug or remotely depending on the plug well dimensions.

Set-up and Calibration

Teams are able to use MODAS for calibrating initial parameters for data logging (e.g.length of lap), carrying out released engine parameter tuning (e.g. ignition angle offset) orhelping to provide engine diagnostics capability in the absence of the engine technician.

We have made provision for software modifications to be made to the ECU system toaccommodate the security and privacy features detailed in the tender. However it would notbe possible to finalise the details of these modifications without consultation with the FIA onhow the security and tracking features would be used by the individual series scrutineersand the most appropriate way of incorporating the changes in the MS3.1 system.

Data Logger

Card Memory is the data acquisition component (logger) that interfaces to the MS 3.1,providing a data logging capability for any of the engine channels and for a range of chassischannels.

Data is recorded by the logger on a removable Memory Card. This provides very highmemory capacities (up to 96 MB) at a very economical cost. There is the added benefit thatthere is no lengthy data transfer time from the car to the PC, the memory card is simplyremoved from the car and inserted into the PC`s card slot, a fresh memory card can bereplaced in to the Card Memory ready for the next session.

Engine data including corresponding sensor inputs are transferred from ECU to the CardMemory via CAN. Accordingly the maximum sampling rate is related to the calculationprocess in ECU (ignition synchronous, 10 ms grid, ...). Chassis data such as damper travelpotentiometers, which are sampled via analogue logger inputs, may be recorded with 200Hz. However, lower sampling rates for ECU and chassis data can be individually selectedby the user in order to reduce memory expense.

Lap marker beacon and front wheel speed sensor (hall effect) are measured by the ECUand transferred via CAN on to the logger.

Damper travel and steering angle potentiometers are equipped with military connectorsproviding improved durability during car rebuilds.

System Overview


Lap Marker Beacon System

The lap marker beacon uses coded infrared transmitter with 16 channels and car mountedreceiver. Section time measuring is also possible with additional transmitters. During officialevents we would propose coordinating the use of a single transmitter each for all teams.

Data Evaluation

Data is archived and analysed with WinDarab, this is a comprehensive Windows basedsoftware tool that provides data analysis functions to both the team and engine builder. Anoptional user-defined partition of memory allows the team and engine builder to have sepa-rate aquisition tables each recording parameters of interest, sharing channels where ap-propriate. The separate data files can be archived and analysed independently.

WinDarab includes also capabilities for the configuration of the logger via Memory Card(selection of channels, sampling rates ...) and for chassis sensor calibration.

For Formula 3 we would provide a special, cost optimised version, using a read in donglefor technical reasons, but giving the possibility for data analysing on a various number ofPCs.

Display

The DDU 5 is a light and compact, steering wheel mounted dashboard unit. It is eqippedwith a high contrast color display. Up to 5 customized display configurations can be pro-grammed to suit individual customer requirements. All illuminated components aredimmable.

System Overview


Basic System Overview

Application tool

MODAS

Dashboard

DDU 5

Data logging

Card Memory

Evaluation tool

WinDARAB

Control unit MS 3.1

Laptrigger

KIC 2

1. Ignition coils2. Injectors3. Fuel pump4. Throttle position sensor5. Camshaft sensor6. Crankshaft sensor7. Lambda sensor8. Knock sensor9. Intake air temperature sensor10. Water temperature sensor11. Oil temperature sensor12. Fuel pressure sensor13. Fuel pressure regulator14. Oil pressure sensor15. Ambient air pressure sensor16. Crankcase pressure sensor17. Fuel temperature sensor18. Exhaust temperature sensor19. Wheel speed sensor

19

14

11

10

7

1

3

125

13

4 9

8

615

2

18

16

17

System Overview


Motronic MS 3.1The MS 3.1 is the first Bosch enginemanagement system in full hybrid tech-nique and for engines up to 6 cylinders.Two independent circuits are available forvibration knock detection and knock con-trol. Injection time, injection end timingand ignition timing are calculated frombasic maps and can be corrected by dif-ferent engine parameters. Also two closedloop wide range lambda circuits are avail-able. Various engine parameters can bemeasured with different input channelsand transferred via CAN interface to anoptional flash card data logger.

FunctionalityEngine management system for 4- and 6-cylinderenginesSequential fuel injectionIgnition timingLambda controlKnock controlFuel cut offComponent diagnosis

Mechanical dataExtremely small and flat aluminium pressurecasting housingConnectors with high pin densityExtremely shock and vibration proof hybrid tech-nologyFour housing fixation pointsSize 120 x 90 x 40 mmWeight 250 g

Conditions for useECU temperature -40 125°CMax. power consumption 10 W at 14 VMax. vibration 50 g sinus

at 20 Hz 2 kHz for t < 5 h

Electronic dataIn general2 microcontrollers with 16 bit organisationcalculation capacity 20 MIPSInputs2 lambda LSU4 interfaces3 analogous inputs 0 5 V for water temperature,oil temperature, intake air temperature3 analogous inputs 0 5 V for oil pressure, fuelpressure, ambient pressure2 analogous input 0 5 V for throttle positionsensor and gear position sensor1 digital input for lap trigger2 digital input for wheel speed sensor1 input for inductive crankshaft sensor1 input for hall camshaft sensor2 knock sensor interfacesOutputs6 injection power stages with diagnosis interface2 high current power stages (8 A) with diagnosisinterface for LSU heating6 ignition power stagesSensors supply output 5 V/100 mASeparate supply outputfor throttle position sensor 5 V/100 mA2 power stages (1 A) for mainrelay and fuel pump relay control

System Overview


Cable harness connectorsOrder numbers:

Order numbersMS 3.1 incl. Modas for notebook

D 261 205 139D 261 205 140

B 261 208 245

Communication interfaces1 CAN interface1 K-Line interface

Necessary equipmentKIC2-diagnosis connector withignition bridgeKIC2-diagnosis connector withoutignition bridge

B 261 206 866

B 261 206 867

System Overview


Software Functions MS 3.1Injection timingSequential fuel injectionInjection end timing as a function of engine chargeand engine revoution3 basic lambda maps as a function of enginecharge and engine revolution, selectable by adashboard switchCorrection of injection time during engine opera-tion as a function of cylinder number, air tempera-ture, water temperature and ambient pressureEngine start parameter for injection time as afunction of water temperature, number of ignitionsafter first crankshaft rotation and revolutionPost start and warm up enrichmentAcceleration enrichmentFuel cut off as a function of throttle position andengine revolutionFuel cutin algorithm

Knock controlKnock detection operated by vibration measuringKnock detection limits as a function of cylindernumber and revolutionAdaptation maps for steady-state and transientoperation

Ignition timingBasic ignition angle map as a function of enginecharge and engine revolutionCorrection of ignition angle during engine opera-tion as a function of cylinder number, air-, watertemperature, ambient pressureEngine start parameter for ignition angle as afunction of water temperature, ambient tempera-ture and revolution

Lambda control1 independant circuit for wide range lambda con-trolLambda closed loop control with adaptation

Speed limitationEngine speed limitation by ignition timing and fuelcut coordinated by torque control

Gear controlGear shift function by torque control with fuel cutoff and ignition retard

Lap functionsLap time and lap distanceTime comparisonMain and section timing

AdditionalsComplete engine data acquisition via CAN with anexternal Card MemorySelf diagnosis functions for input and output chan-nels with limp home functionalityGear detectionLifetime memoryFuel consumption calculation4 wheelspeeds via CAN

Engine Equipment


Engine Equipment

Engine Equipment


Rotary Potentiometer RP 86Possible range: 86°

This sensor is designed to measure rota-tional movement, especially throttle posi-tions. Each sensor is individually laser-calibrated.

Electronic dataNominal resistance 2,5 kΩResistance tolerance 20 %Non-linearity 0,9 %Repetitive accuracy 0,01 %Temp. coefficient < 5 ppm/°CMax. power supply 42 VUsual power supply 5 V

Mechanical dataMounting 2 x M4Length 160 300 mmMech. range < 86°Max. rotation speed 120 x 1/minTightening torque 1,5 2,5 NmWeight 60 gLife expectancy > 2 x 105 rotations

Conditions for useTemperature range -40 130°CVibration 40 g/5 Hz 2 kHz

ConnectorCable harness connector

Order number

Offer drawing

1 928 402 868

0 280 122 016A 280 121 252

Engine Equipment



This sensor is designed to measure rota-tional movement. Each sensor is individu-ally laser-calibrated. It is manufactured ina DR-25 sleeve, various connector op-tions are available.

Electronic dataNominal resistance 3 kΩResistance tolerance 20 %Non-linearity 0,9 %Repetitive accuracy 0,01 %Temp. coefficient < 5 ppm/°CMax. power supply 42 VUsual power supply 5 V

Mechanical dataMounting 2 x M4Length 160 300 mmMech. range 360°Max. rotation speed 120 x 1/minTightening torque 0,5 NmWeight 60 gLifetime > 50 x 105 rotations


Order numbersASL 6-06-05PA-HEOffer drawing

B 261 209 127A 261 209 127

Engine Equipment


Inductive Speed Sensor IA-CThis sensor is designed for incrementalmeasurement of revolutions at engineapplications.

Electronic dataResistance 860 Ω/20° ± 10 %Inductance 370 ± 60 mH/1 kHz

Mechanical dataMagnetic pole roundFixing M6 x 12Length 510 mmTightening torque 8 NmWeight 80 gInstallation depth 24 mm

Conditions for useTemperature range -40 130°CVibration 80 g/max. 80 h


Order number

Offer drawing

1 928 402 868

0 261 210 136A 265 461 845

Engine Equipment


Speed Sensor HA-PThis sensor is designed for incrementalmeasurement of revolutions and angles atengine and chassis applications.

Electronic dataPower supply 4,5 24 VInput current 10 mA typ., 20 mA max.Signal output (active) 0,4 V max.Output current 20 mA max.

Mechanical dataFixing M6Drill hole 18 mmMax. distance 1,52 mmTightening torque 6 NmWeight 70 gInstallation dimensions 30 mm

Conditions for useTemperature range -30 130°CVibration 100 g/10 Hz 2 kHzAir gap max. 1,5 mm


Order number

Offer drawing

1 928 403 110

0 232 103 037A 232 090 314

Engine Equipment


Lambda Sensor LSUThe wide-band lambda sensor LSU is aplanar ZrO2 dual cell limiting current sen-sor with integrated heater. It is used tomeasure the oxygen content and thelambda value of engine exhaust gases. Itsoutput signal in the range of lambda = 0,7to air makes the LSU capable to be usedas an universal sensor for lambda = 1measurement as well as for other lambdaranges.

The connector module carries a trimmingresistor, which defines the characteristicsof the sensor and is necessary for thesensor function. The wide band sensorLSU operates only in conjunction with aspecial control unit.

Electronic dataHeater supply voltage 9 VHeater power 10 WSensor element ZrO2 (Zirconium-Oxide-Ceramic)Lambda measuring range 0,70 ∞

Mechanical dataLength 460 mm/600 mmThread M18 x 1,5Tightening torque 60 NmWrench size 22 mmWeight 120 gVibration 30 g/5 Hz 2 kHz

Fuel additivesIn accordance with DIN EN 228 for commerciallyavailable unleaded fuel.

Temperature rangesExhaust gas at sensor element 850°CHexagon of the sensor housing < 570°CCable grommet (PTFE formed house)-Sensor side < 250°C-Cable side < 200°CCable and protection sleeve < 250°CConnector < 120°C


Order numbersL: 600 mmOffer drawing

D 261 205 138

0 258 006 065A 258 400 021

Engine Equipment


Installation instructionsThe Lambda sensor should be installed at a pointwhich permits the measurement of a representa-tive exhaust-gas mixture, and which does notexceed the maximum permissible temperature.The sensor is screwed into a mating thread andtightened with 50 60 Nm.• Install at a point where the gas is as hot as

possible.• Observe the maximum permissible tempera-

tures.• As far as possible install the sensor vertically,

whereby the electrical connections shouldpoint upwards.

• The sensor is not to be fitted near to the ex-haust outlet so that the influence of the outsideair can be ruled out. The exhaust-gas passageopposite the sensor must be free of leaks inorder to avoid the effects of leak-air.

• Protect the sensor against condensationwater.

• The sensor body must be ventilated from theoutside in order to avoid overheating.

• The sensor is not to be painted, nor is wax tobe applied or any other forms of treatment.Only the recommended grease is to be usedfor lubricating the threads.

• The sensor receives the reference air throughthe connection cable. This means that theconnector must be clean and dry. Contactspray, and anti-corrosion agents etc. are for-bidden.

The connection cable must not be soldered. Itmust only be crimped, clamped, or secured byscrews.

Engine Equipment


Knock Sensor KS-PThis sensor is designed to measure thestructure borne noise resulted from ir-regular engine combustion. The robustsensor is suitable for use under extremeconditions.

Electronic dataMain resonance frequency > 20 kHzImpedance R: > 1MΩC 1100 ± 300 pFMeasuring range 0,1 400 gSensitivity at 5 kHz 26 ± 8 mV/gRange of frequency 1 20 kHz

Mechanical dataThread M8 x 30 (aluminium engine block)

M8 x 25 (cast iron engine block)Weight 48 gTightening torque 15 25 NmMounting position random

Conditions for useTemperature range -40 150°CVibration, constant ≤ 80 gVibration, short ≤ 400 g


Order number

Offer drawing

1 928 403 137

0 261 231 120A 261 230 170

Engine Equipment


Temperature Sensor NTC M12-HTemperature range: -40 150°C

A shockproof sensor for measurementsunder pressure up to 25 bar. Good ther-mal conductivity allows fast responsetemperature measurement. The integratedconnector provides a low-cost connectionfor automotive applications.

General fields of application: oil-, fuel-,water temperature measurement.

Electronic dataNominal resistance 2,5 kΩ/20°CMeasuring range -40 +150°CAccuracy ± 1,5 KResponse time 90 % < 10 s

Mechanical dataThread M12 x 1,5Tightening torque 18 NmWrench size 19 mmWeight 30 g

Conditions for useTemperature range -40 150°CVibration 30 g/5 250 Hz

CharacteristicNTC 2,5 kΩ


Order number

Offer drawing

1 928 403 137

0 281 002 170A 280 130 110

Engine Equipment


°C-40-35-30-25-20-15-10-5051015202530354045505560

R(Ω)45 31334 28126 11420 00315 46212 0029 3977 4155 8964 7123 7923 0692 5002 0571 7071 4121 175987,6833,9702,8595,5

°C65707580859095100105110115120125130135140145150155160

R(Ω)508,3435,7374,2322,5279,6243,2212,7186,6163,8144,2127,3112,7100,289,3079,6571,2063,8657,4151,8246,88

Engine Equipment


Temperature Sensor NTC M12-LTemperature range: -30 130°C

A shockproof sensor for measurementsunder pressure up to 25 bar. Good ther-mal conductivity allows fast responsetemperature measurement. The integratedconnector provides a low-cost connectionfor automotive applications.

General fields of application: oil-, fuel-, airtemperature measurement

Electronic dataNominal resistance 2,5 kΩ/20°CMeasuring range -30 130°CAccuracy ± 1,5 KResponse time 90 % < 10 s

Mechanical dataThread M12 x 1,5Tightening torque 15 NmWrench size 19 mmWeight 26 g


CharacteristicNTC 2,5 kΩ


Order number

Offer drawing

1 284 485 143

0 280 130 039A 280 130 206

Engine Equipment


°C-40-35-30-25-20-15-10-5051015202530354045505560

R(Ω)45 31334 28126 11420 00315 46212 0029 3977 4155 8964 7123 7923 0692 5002 0571 7071 4121 175987,6833,9702,8595,5

°C65707580859095100105110115120125130135140145150155160

R(Ω)508,3435,7374,2322,5279,6243,2212,7186,6163,8144,2127,3112,7100,289,3079,6571,2063,8657,4151,8246,88

Engine Equipment


Thermocouple Probe TCP-NFTemperature range: -40 1000°C

A flexible N-type thermocouple for meas-uring exhaust-gas temperatures.

Electronic dataPower supply 12 VFull scale output 0,5 4,5 VThermocouple NiCrSi-NiSiMeasuring range 40 1000°C

Sensor dataLength 630 mmWeight 60 g

Mechanical dataThread M12 x 1Tightening torque 15 NmWrench size 17 mm

Conditions for useVibration 80 g/5 500 Hz

CharacteristicDIN EN 60584

Order number

Offer drawingB 261 209 821A 261 209 821

Engine Equipment


Input °C-400

100200300400500

Output mV3724857901135151319122327

Input °C60070080090010001100

Output mV275231833615404644734845

Engine Equipment


Absolute Pressure Sensor PSAPressure range: 0,2 1,05 bar nominal

A piezoresistive pressure sensor for am-bient air pressure measurement.

Electronic dataPower supply 4,75 5,25 VFull scale output 0,4 4,65 VTime of reaction 10 ms (90 %)Max. current < 10 mAResistance > 50 kΩ


Order numbers0,2 1,05 barOffer drawing

1 237 000 039

0 261 230 004A 261 260 041

Mechanical dataMeasurement transducer piezoresistiveMax. pressure 5 barThread M6Weight 60 g

Conditions for useTemperature range -40 120°CMax. temp. of location 130°CMax. vibration 15 g /30 200 Hz

Characteristic0,2 1,05 bar:Sensitivity 5000 mV/barOffset -600 mV

Engine Equipment


Absolute Pressure Sensor PSA-BFPressure range: 0,1 1,15 / 0,2 2,5 bar nominal

A piezoresistive pressure sensor modifiedfor precision air pressure measurement,especially air box pressure. It is manu-factured in a DR-25 sleeve, various con-nector options are available.

Electronic dataPower supply 4,75 5,25 VFull scale output 0,1 4,65 VCompensated range 40 130°CNon linearity 0,25 %Therm. zero point drift < 0,5 %Therm. sensitivity drift < 0,5 %Long time drift < 0,5 %

Mechanical dataMax. pressure 3 [5] barFitting 11,85 mmWeight 45 gSealing O-ring 7,59 x 2,62

Conditions for useTemperature range -40 125°CMax. temp. of location 130°CMax. vibration 250 g/200 500 Hz

Characteristic0,1 1,15 bar:Sensitivity 4040 mV/barOffset -4,8 mV0,2 2,5 bar:Sensitivity 1848 mV/barOffset 30,4 mV

Order numbers0,1 1,15 bar:AS 6-06-05PC-HEOffer drawing0,2 2,5 bar:AS 6-06-05PC-HEOffer drawing

0 201 230 052A 261 260 163

0 281 002 510A 261 260 163

ExtraSensor Adapter B 261 209 725

Engine Equipment


Pressure Sensor PSSPressure range: 0 10 / 100 bar nominal

A M10 x 1 pressure sensor for measuringvarious fluid pressure. Gauge and abso-lute pressure sensors are available.

Electronic dataPower supply 5 6 VCompensated range 20 85°CNon linearity 1 %Therm. zero point drift < 1 %Therm. sensitivity drift < 1 %Long time drift < 1 %Full scale output 0,5 4,5 VTime of reaction 1 ms (90%)

Mechanical dataMeasurement transducer piezoresistiveMax. pressure 2 x nominalThread M10 x 1Tightening torque 10 NmWrench size 17 mmWeight 65 gSealing O-ring 7,65 x 1,63


CharacteristicSensitivity10 bar 400mV/bar100 bar 40 mV/barOffset10 bar 100 mV100 bar 500 mV

Order numbers10 barOffer drawing100 barOffer drawing

B 261 209 341A 261 209 341B 261 209 347A 261 209 347

Engine Equipment


Injection Valve EV 6The development of the EV 6 took intoaccount all the essential functional re-quirements which originate from injectoroperation in multipoint electronic fuelinjection systems (EFI).

This resulted in: low weight, dry solenoidwinding, plastic encapsulation, finelymatched flow-rate classes, good valve-seat sealing, excellent hot-start capabili-ties, close tolerances of the specifiedfunctional values, high level of corrosionresistance and long service life.

Mechanical dataSystem pressure max. 8 barWeight 45, 8 g

Electrical dataSolenoid resistance e.g. 12 ΩMax. power supply 16 V

Conditions for useFuel input axial (top-feed)Operating temperature -40 ... 110°CPermissible fuel temperatures ≤ 70°CClimate proofness corresponds to saline fog testDIN 53 167

Technical dataOrder numbers Design Type Flow rate at 3 bar

(N-Heptan)Spray angle α Impedance

B 280 431 126 Standard C 261,2 g/min 25° 12 ΩB 280 431 127 Standard C 261,2 g/min 70° 12 Ω0 280 155 737 Long C 261,2 g/min 15° 12 ΩB 280 431 128 Standard C 364,3 g/min 25° 12 ΩB 280 431 129 Standard C 364,3 g/min 70° 12 ΩB 280 431 130 Standard C 493,1 g/min 25° 1,2 ΩB 280 431 131 Standard C 493,1 g/min 70° 1,2 Ω0 280 156 012 Standard C 310,1 g/min 20° 12 Ω

Further injection valves on request

Engine Equipment


Engine Equipment


Injection Valve EV 12The EV 12 injector is a developmentbased on the EV 6. Its main feature is thefact that the position of its injection pointcan be varied. Compared with the EV 6,the EV 12 injection point can be movedforward up to 20 mm.

Mechanical dataSystem pressure max. 8 barWeight 40 g

Electronic dataSolenoid resistance e.g 12 ΩMax. power supply 16 V

Conditions for useFuel input axial (top-feed)Operating temperatures -40 ... 110°CPermissible fuel temperatures ≤ 70°CClimate proofness corresponds to saline fog testDIN 53 167

Technical dataOrder numbers Design Type Flow rate at 3 bar

(N-Heptan) αSprayβ

angle γ δ

Impedance

B 280 432 115 Medium E 217 g/min 15° 15° 10° 270° 12 Ω0 280 155 893 Medium E 269 g/min 15° 7° 10° 270° 12 Ω0 280 155 897 Medium E 217 g/min 15° 7° 10° 270° 12 Ω

Further special versions on request

Engine Equipment

Fuel Pressure Regulator Mini 50Pressure range: 5,0 bar

DescriptionSheet steel housing with manifold connection

Mechanical dataSupply 4 mm, tube connectorReflow 9,15 mm, O-ring

Order number

Offer drawingB 280 550 113A 280 550 058


Erledigung durch KundenEffect by customer

- O-Ringe leicht mit sauberem Moto-renöl einölenOil O-rings lightly with clean engine oil

- Nach der Montage an Kraftstoffzutei-ler ist Dichtheitsprüfung dur-chzuführenLeaktest after installation

- Bei Ausbau und Wiederverwendungdes Druckreglers müssen die O-Ringeüberprüft werdenWhen the pressure regulator is re-moved and will be reused, the O-ringsmust be checked

- Betrieb des Druckreglers mit Luft istunzulässigOperation with air is not allowed

Engine Equipment


Single Fire Coil PThis coil is low cost concept for cylinderhead installation.

Mechanical dataWeight 260 gVibration 40 g/5 Hz ... 2 kHz

Electronic dataHigh voltage 35 kVI prim. (stand.) 8,5 AInductivity (prim.) 2,8 mHInductivity (sec.) 16 HResistance (prim.) 0,37 ΩResistance (sec.) 8,8 kΩSpark energy 45 ... 55 mJU prim. (clamp.) 260 VVoltage gradient 1,6 kV/µs

Conditions for useTemperature range -40 ... 140°C


Order number

Offer drawing

1 928 402 868

B 261 208 315A 221 152 139

Dwell time (ms)Ubatt 4 A 5 A 6 A 7 A 8 A8 V 2,90 4,00 5,50 7,8010 V 2,00 2,70 3,50 4,40 5,2012 V 1,65 2,10 2,65 3,17 3,5214 V 1,35 1,75 2,15 2,55 2,9016 V 1,10 1,40 1,75 2,05 2,35

Engine Equipment


Single Fire Coil SPThis production type coil is low cost con-cept for cylinder head installation.

Electronic dataHigh voltage >30 kVI prim. (stand.) 7,3 AResistance (prim.) 0,5 ΩSpark energy 35 mJU prim. (clamp.) 300 VVoltage gradient 1,5 kV/µs

Dwell time (ms), Temperature of IC ca. 50°CUbatt 7,3 A8 V 6,210 V 3,212 V 2,414 V 1,816 V 1,5

Mechanical dataWeightVibrationDiameter

Conditions for useTemperature range

Order number

Offer drawing

189 g40 g/5 Hz ... 2 kHz

22 mm

-40 ... 140°C

0 221 504 460A 221 141 014_009

Engine Equipment


Relay 25 AA miniature DC-contactor for electricalpower control. The rated current is 25 Afor secondary power distribution with highinrush current like hydraulic- and fuelmotor loads. The base part allows a quickchange of the relay.

Mechanical dataDrill hole 3,1 mmWeight 61 g

Conditions for useTemperature range -30 125°CVibration 30 g/70 Hz ... 3 kHzShock 100 g (11 ms)

Electronic dataSupply voltageMax. currentMin. switches

Order numbersRelayOffer drawingBaseOffer drawing

12 ... 14,5 V25 A

20 000

Y 261 A20 597Y 261 A25 338Y 261 A20 598Y 261 A25 338

Chassis Equipment


Chassis Equipment

Chassis Equipment



This sensor is designed to measure rota-tional movement. Each sensor is individu-ally laser- calibrated. It is manufactured ina DR-25 sleeve, various connector op-tions are available.


Mechanical dataMounting 2 x M4Length 160 300 mmMech. range ± 360°Max. rotation speed 120 x 1/minTightening torque 0,5 NmWeight 60 gLifetime > 50 x 105 rotations


Order numbersKPSE 6E8-33P-DNOffer drawing

B 261 209 115A 261 209 115

Chassis Equipment


Pressure Sensor PSSPressure range: 0 10 / 100 bar nominal

A M10 x 1 pressure sensor for measuringvarious fluid pressure. Gauge and abso-lute pressure sensors are available.

Electronic dataPower supply 5 6 VCompensated range 20 85°CNon linearity 1 %Therm. zero point drift < 1 %Therm. sensitivity drift < 1 %Long time drift < 1 %Full scale output 0,5 4,5 VTime of reaction 1 ms (90%)

Mechanical dataMeasurement transducer piezoresistiveMax. pressure 2 x nominalThread M10 x 1Tightening torque 10 NmWrench size 17 mmWeight 65 gSealing O-ring 7,65 x 1,63


CharacteristicSensitivity10 bar 400mV/bar100 bar 40 mV/barOffset10 bar 100 mV100 bar 500 mV

Order numbers10 barOffer drawing100 barOffer drawing

B 261 209 341A 261 209 341B 261 209 347A 261 209 347

Chassis Equipment


Accelerometer AM 600This accelerometer is available to meas-ure two axes in a single, robust package.With reference to its fitting position, longi-tudinal and transversal acceleration up to4,5 g can be measured.

Manufactured in DR-25 sleeve; variousconnector options available.

Electronic dataSupply voltage 5 V DCMax. supply voltage 6 V DCSignal output 2,5 V = 0 g; 440 mV/gSupply current 7 mAMax. current 12 mATolerance of sensitivity ± 3 %Non-linearity of sensitivity ± 2 %

Mechanical dataWeight 30 gLength 150 1000 mmMeasuring range ± 4,5 gOverload ± 600 gDimensions2 axes 24,5 x 26,5 x 14,6 mmFixing 2 x M3Tightening torque 2 Nm

Conditions for useTemperature range -40 85°C

CharacteristicOffset x,y 2,5 V at 0 gSensitivity x,y 440 mV/g

Order numbersAS 6-06-05PA-HEOffer drawing

B 261 209 311A 261 209 311

Chassis Equipment


Linear Potentiometer LP 10Possible mechanical range: 10 mm

This sensor is designed to measure stabi-lizer movement. It is manufactured in aDR-25 sleeve. Various connector optionsare available.

Electronic dataNominal resistance 1 kΩ ± 20 %Max. current 1 mANon-linearity 1 %Usual power supply 5 VPower consumption 0,3 W

Mechanical dataMounting 2 x M3Cable length 150 1000 mmWeight 70 g


Order numberKPSE 6E8-33P-DNOffer drawing

B 261 209 535A 261 209 535

Chassis Equipment



This sensor is designed to measure gearposition, throttle position or suspensionmovement. It is manufactured in a DR-25sleeve, various connector options areavailable.

Electronic dataNominal resistance 3 kΩMax. current < 1 mANon-linearity 0,15 %Usual power supply 5 VMax. power supply 47 V

Mechanical dataCable length L 150 1000 mmMin. length L1 224 mmPossible mech. range L2 79 mmMounting 2 x M5Sealing O-ring shaft sealMax. shaft velocity 10 m/secWeight 52 g



B 261 209 852A 261 209 852

Chassis Equipment



This sensor is designed to measure gearposition, throttle position or suspensionmovement. It is manufactured in a DR-25sleeve, various connector options areavailable.

Electronic dataNominal resistance 4 kΩMax. current < 1 mANon-linearity 0,15 %Usual power supply 5 VMax. power supply 74 V

Mechanical dataCable length L 150 1000 mmMin. length L1 249 mmPossible mech. range L2 104 mmMounting 2 x M5Sealing O-ring shaft sealMax. shaft velocity 10 m/secWeight 62 g



B 261 209 853A 261 209 853

Chassis Equipment


Gear PotentiometerPossible range: 308°

This sensor is designed to measure rota-tional movement. Each sensor is individu-ally laser- calibrated. It is manufactured ina DR-25 sleeve, various connector op-tions are available.


Mechanical dataMounting 2 x M4Length 160 300 mmMech. range ± 360°Max. rotation speed 120 x 1/minTightening torque 0,5 NmWeight 60 gLifetime > 50 x 105 rotations


Order numbersKPSE 6E8-3AP-DNOffer drawing

B 261 209 585A 261 209 585

Chassis Equipment


CardMemory C40 Plus + CANThe CardMemory is a device used fordata acquisition. The shown model C40Plus is developed to read in 15 analogoussignals. The measured data are stored ona compact flash card.

Options15 analogous inputs with 10 bit resolution and5 ms sample rate time1 inductive crankshaft sensor interfaceSensor supply outputs 5 V/100 mA

10 V/100 mACalibration functions are realised with an

additional software tool

ConnectorCable harness connector C40 Plus AS0-14-35 SN

Cable harnessB 261 209 450

Mechanical dataDust and splashwater proof aluminium housingFlexible housing fixation pointsConnector with 40 pinsSize 150 x 90 x 22 mmWeight 330 g

Conditions for useECU temperature -40 75°CMax. power consumption 7 W at 14 VMax. vibration 15 g sinus

at 20 Hz 2 kHz for t < 5 h

Electrical data1 microcontroller with 16 bit organisation1 CAN interfaceReal time clockNon volatile flash card memoryTotal calculation capacity approximately 10 MIPS

Order numbersC40 Plus incl. chassis adjust B 261 206 880

Chassis Equipment


Laptrigger IR-02This laptrigger system consists of an infra-red transmitter station and a receiverinstalled in the car. The system allows anexact laptime measurement. Section timemeasurement for comparison of differentcar setups is also available if severaltransmitters are used.

Notice: our old laptrigger IR is not com-patible with IR-02. If both laptriggers areused at the same time, the transmittershave to be positioned with a minimumdistance of 5 m.

Electronic dataIR-02-ReceiverFrequency codes 16Supply voltage 8 16 VOutput voltage 5 VIR-02-TransmitterFrequency codes 16 plus 16 offset codes

for section timesSupply voltage 8 16 V

Mechanical dataIR-02-ReceiverSize 42 x 20 x 10 mmWeight 39 gDust and waterproof aluminium housingIR-02-TransmitterSize with diode 90 x 40 x 28 mmWeight 124 gDust and waterproof aluminium housing

Conditions for useWorking range 15 mAmbient temperature -25 70°CSame height between receiver and transmitterVisibility connection between receiver and trans-mitterAvoid direct exposure to sunlight

Order numbersIR-02-ReceiverKPSE 6E8 3AP DN A34IR-02-Transmitter

B 261 206 884B 261 206 890

Chassis Equipment


Display DDU 5The DDU 5 is a light and compact, steer-ing wheel mounted dashboard unit. It iseqipped with a high contrast color displayand three additional dot-matrix displays.Up to 5 customized display configurationscan be programmed to suit individualcustomer requirements. All illuminatedcomponents are dimmable.

For enhanced flexibility the DDU 5 can beinterfaced to a range of stand-alone I/Omodules that facilitate multiple functionslike switching, light indication, car andrace information display.

Electronic data1x CAN interface for communication with ECU1x CAN interface for communication with network1x RS 232 interface for display programming9 LED shift up indicators (5 drivers, open collector,2,2 A)2 LED warning lights (2 drivers, open collector,1,1 A)8 inputs 0 5 V (analogous/digital)

Order numberF 01E B01 455

DisplaysMain display1x active matrix TFT high contrast color displayActive area 49,2 x 38,1 mmResolution 480 x 234Dot size 0,1025 x 0,163 mmWeight 52 gSecondary displays2x high intensity LED dot-matrix, 8-characterActive area 42 x 12 mm1x hight density LED dot-matrix, 1-characterActive area 12 x 17 mm

Conditions for useVibration 6 g/20 Hz ... 2 kHzTemperature -10 ... 65°C

Chassis Equipment


Speed Box 4(only for test, use in race forbidden!)This box determines the speed signals offour wheels and converts them into aCAN-message. The message includes thetime between each tooth-gap. The box isoptimised for the MS 3-use.

Electronic dataPower supply 4 18 VCurrent consumption 120 mA at 12 VChannels 4 SpeedChannel input 1 150 V

Mechanical dataSize 70 x 40 x 19 mmWeight 90 g

Conditions for useOperating temperature 10 60°C

ConnectorAS0-10-35PN

Order numberSpeed Box 4 F 01E B01 626

Application Tools


Application Tools

Application Tools


Application Equipment Overview

Data modification

Data analysing

Potiboard

CardMemory Evaluation tool WinDarab

Enginge management

Control unit

Indirect datadownload via

flash card

Data transfer via CAN

Data transfer via K-Line/KIC 2

Application tool

MODAS

Application Tools


KIC 2(K-Line Interface Compact)KIC 2 is part of the INCA module family.Within this family, the KIC 2 is the low costunit for PC-supported application on theserial diagnosis interface of an ECU.

KIC 2 is coupled to the PC via the parallelprinter interface. This ensures a powerfuland universal link to all common PCs. Thecoupling to the ECU is effected via the K-line of the diagnosis interface. The func-tionality of KIC 2 is essentially determinedby the operating programs of the PC.

Electronic dataInput voltage 6 ... 30 VPower consumption typ. 1 W at 13,5 VPower consumptionin stand by 30 mW at 13,5 VProcessor µP 87C520, 12 kByteFlash Eprom 2 x 48 kByteCentronics Iinterface 40 g/5Hz ... 2kHzTemperature range -30 ... 70°CControl P-module outputOutput voltage 0 ... 4,096 VQuantisation !V=1,0 mVResolution 12 bit

DetailsCompact designFully suitable for motor vehicle usePower supply through the connection to the ECUfrom board mains with galvanic separationAll inputs and outputs to the PCgalvanically separatedFirmware update possible via PCAccording to ISO 9141-2 for diagnosis testerUp to 250 kBaud transfer ratePlug suitable for motor vehicles (VS 20)Protocols: McMess, KP 2000, Keyword 71

Mechanical dataSize 17 x 60 x 78 mm Order number

KIC 2,diagnosis connector without igni-tion bridge

B 261 206 867

Application Tools


ModasModas is a software tool for calibrating engine and chassis parameters. It is speciallydesigned for race track use. Developing Modas we set great store by easy handling andquick access to the ECU.

General functionsOnline measurement and calibrationUniversal use for different ECUsModas facilitates operating and working in byusing the Windows standard. In the office Modas iscontrolled by mouse or menue. If Modas is used ina mobile way a fast grip is possible by keyboardand shortcuts.

Required hardware components:PC:IBM PC/AT compatible, 586 processor or higher,166 MHzApprox. 64 Mbyte of RAMApprox. 30 Mbyte harddisc spaceVGA monitorOperating systems:Windows 98, 2000, NT and XP

Performance descriptionModas is a combination of• Project (Data) management:Visualisation, processing and management ofcalibration, measurement and documentation data• Programming system:Programming and management of calibration data• Calibration system:Visualisation and manipulation of parameters(Calibration data)• Diagnosis system:Visualisation, processing, documentation andevaluation of diagnosis data

Order numberB 261 206 441

Application Tools


Potiboard POP(Parameter Operating Panel)

POP is part of the INCA module family. Itis designed for online mapping on dynosupporting the INCA calibration function.POP is coupled to the PC via serial link onthe SMB bus.

Order numberB 261 206 428

DetailsRobust designExternal power supplyModification of calibration data by potentiometeroperation4 potentiometers, individual assignment to 4characteristic values (fixed values, characteristiclines or maps)Additive or multiplicative modification selectablePOP configuration saved together with the INCAdisplay

Application Tools


WinDarabData Recording, Analysing and Influencing

WinDarab is an evaluation tool for monitoring and analysing of logged data. It is Win-dows-based and specially designed for motorsport use. For selection of monitored datachannels and setting of sample rates the integrated configuration tool WinDCP is used.

FunctionsMin/max-calculationsHistogramsMathematical functionsFilter functions incl. FFTx/y-plots

Data comparisonCalculation of differences lap by lap

Order number

Data evaluationAuto load and auto storeAdjustable axis: time or distanceDirect read in of memory data without readerGraphic display of all measured and stored chan-nelsVarious displays available (analogous and digital)Number of displays availableVarious display set-ups selectable and storableLaptrigger signal included

FunctionalityCreating of race tracksSeveral segments adjustable for each race trackLap reports and lap comparisonInform displaysData extract and export

B 261 206 434

Sales terms and conditions





Sales terms and conditions for motor-sport products(as a supplement to the Terms and Conditions of Delivery A 17)

Scope of validity1.1 The following conditions are valid for the supply of various products to be used by

our customers (Buyer) in motor sport vehicles, including mass products for roadvehicles out of serial production, modifications thereof and products especially de-veloped and designed in accordance with the customer´s specifications;

1.2 Buyer hereby acknowledges that mass products for road vehicles are not designedto meet all of the requirements and demands of motor racing.

1.3 Buyer further acknowledges that modified mass products or products speciallydeveloped and designed in accordance with Buyer´s specifications cannot be testedto the same degreeas mass products for road vehicles and that production is not inevery case conducted in accordance with well-known and secured processes;

Territorial validityThe above provisions shall apply irrespective of where the products delivered by usare used.

Use of products3.1 Buyer undertakes to use the products only in the realm of motor racing and not in

general road traffic.

3.2 We assume no responsibility for the admissibility of these various products in publicgeneral road traffic.

3.3 Should a product be used in public general road traffic, we will grant no warranty orliability whatsoever for damages/injuries incurred.



Warranty4.1 Warranty covers, at our option, replacement or repair of the defective product, in

case a defective product has been delivered. Any further claims on the part of theBuyer - irrespective of the legal grounds - are excluded.

4.2 Insofar as modified mass products out of serial production or specially designedproducts be concerned, we shall not assume any warranty that such products dis-play the features - particularly for use in motor racing - requested and/or expectedby Buyer.

LiabilityIn the event that a third party be injured as a result of a defective product (error indesign, production or instruction), Buyer shall indemnify and hold us harmless fromand against any resulting third-party claims - irrespective of the legal grounds forsuch claims -, including any costs necessary for legal defense.

EffectivenessIn the event that any provision hereof be or becomes invalid, the validity of the re-maining provisions shall not be affected thereby. Any invalid provision shall bereplaced by that valid provision which most closely corresponds to the original in-tention or economic purpose of the invalid provision.

Bosch Engineering GmbHMotorsportAn der Bracke 9D - 71706 MarkgroeningenGermany

Offer drawings


Offer drawings

BOSCH INTERN: Gueltigkeit nur am 1/18/2001 garantiert (M/TT/JJJJ - GMT)

Copyright Robert Bosch GmbH

BOSCH INTERN: Gueltigkeit nur am 1/18/2001 garantiert (M/TT/JJJJ - GMT)

Copyright Robert Bosch GmbH

T:/K3ELA/LDF_CAL/A261260163-000

Bosch Engineering GmbHMotorsportAn der Bracke 971706 MarkgröningenGermany

Phone: 00 49 (0) 711/811-3981Fax: 00 49 (0) 711/811-3982

North American Office:Robert Bosch CorporationMotorsport, Dep. AP/EAP38000 Hills Tech DriveFarmington Hills, MI 48331-3417Phone: 00 1 248 848-2977Fax: 00 1 248 324-7373

E-mail: [email protected]

mailto:[email protected]

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