F3 Katalog

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System Overview
Contents
System Overview
System Description .............................................................................................. 5 Basic System Overview ....................................................................................... 9 Motronic MS 3.1................................................................................................. 10 Software Functions MS 3.1 ................................................................................ 12
Engine Equipment
Rotary Potentiometer RP 86 .............................................................................. 14 Rotary Potentiometer RP 100 ............................................................................ 15 Inductive Speed Sensor IA-C............................................................................. 16 Speed Sensor HA-P........................................................................................... 17 Lambda Sensor LSU.......................................................................................... 18 Knock Sensor KS-P ........................................................................................... 20 Temperature Sensor NTC M12-H ...................................................................... 21 Temperature Sensor NTC M12-L....................................................................... 23 Thermocouple Probe TCP-NF ........................................................................... 25 Absolute Pressure Sensor PSA ......................................................................... 27 Absolute Pressure Sensor PSA-BF.................................................................... 28 Pressure Sensor PSS ........................................................................................ 29 Injection Valve EV 6........................................................................................... 30 Injection Valve EV 12......................................................................................... 32 Fuel Pressure Regulator Mini 50........................................................................ 33 Single Fire Coil P ............................................................................................... 34 Single Fire Coil SP............................................................................................. 35 Relay 25 A ......................................................................................................... 36
Chassis Equipment
Rotary Potentiometer RP 308 ............................................................................ 38 Pressure Sensor PSS ........................................................................................ 39 Accelerometer AM 600 ...................................................................................... 40 Linear Potentiometer LP 10 ............................................................................... 41 Linear Potentiometer LP 75 ............................................................................... 42 Linear Potentiometer LP 100 ............................................................................. 43 Gear Potentiometer............................................................................................ 44 CardMemory C40 Plus + CAN ........................................................................... 45 Laptrigger IR-02 ................................................................................................. 46 Display DDU 5 ................................................................................................... 47 Speed Box 4 (only for test, use in race forbidden!) ............................................ 48
Application Tools
Application Equipment Overview........................................................................ 50 KIC 2.................................................................................................................. 51 Modas ................................................................................................................ 52 Potiboard POP ................................................................................................... 53 WinDarab........................................................................................................... 54
Sales terms and conditions

Sales terms and conditions for motorsport products .......................................... 56
Offer drawings 19 Oct. 04 www.bosch-motorsport.com 3
System Overview
System Overview
www.bosch-motorsport.com
19 Oct. 04
System Overview
System Description
Engine Control Sensors Actuators Set-up and Calibration Data Logger Lap Marker Beacon System Data Evaluation Display
19 Oct. 04
System Overview
The MS 3.1 engine control unit is designed to provide sophisticated control capabilities in a cost-effective package. The ECU itself is based on the latest Bosch production unit, being the first ECU design in full hybrid technology. This offers the benefits of compact size and suitability for use in extreme environments, qualities very much appreciated in motorsport applications. Even the ignition drive stages are integrated within the unit. The ECU is manufactured on the BOSCH production site at Reutlingen, Germany. This ensures high quality control, identical specification for all pieces and short term availability. Additionally a spare 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 logging unit and dash board display, interfaced via a CAN bus. Where appropriate we have selected Bosch production sensors and actuators to enhance the cost-effectiveness of the package. Other parts have been specially developed for motorsport applications to provide improved reliability and performance in the racing environment. A special version of ECU firmware would be employed to provide the security, monitoring and tracking features required by the FIA. The Windows based application tool MODAS would 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 engine builders, 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. Physically based structure and ambient corrections reduce the need for trackside tuning during the event to a minimum. Closed loop Lambda control using the latest Bosch wide band Lambda sensor is included as is a powerful closed loop knock control capability with up to two acoustic knock sensors helping to prevent expensive engine damage even during changeable ambient conditions or poor fuel quality. Sophisticated input and output self diagnostics help identify sensor, actuator or wiring faults.
Sensors
Engine speed sensing is exclusively performed according to the well-tried method using an inductive sensor in combination with 60-2 tooth wheel for crankshaft angle and a hall sensor 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 a backup signal from a redundant sensor could be made. Temperature measurement is carried out using Bosch series production parts. These are NTC sensors except exhaust temperature, which uses a thermocouple with integrated amplifier. Pressure measurement is with amplified sensors.
19 Oct. 04
System Overview
Actuators
The engine actuators have been selected from the extensive range of Bosch series production parts. The injectors can be supplied in a range of flow rates and spray angles to suit the engine characteristics. The ignition coils are prepared with steel spring contacts for improved reliability during repeated installation. They can be mounted either on top of the spark 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) or helping 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 to accommodate the security and privacy features detailed in the tender. However it would not be possible to finalise the details of these modifications without consultation with the FIA on how the security and tracking features would be used by the individual series scrutineers and 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 chassis channels. Data is recorded by the logger on a removable Memory Card. This provides very high memory capacities (up to 96 MB) at a very economical cost. There is the added benefit that there is no lengthy data transfer time from the car to the PC, the memory card is simply removed from the car and inserted into the PC`s card slot, a fresh memory card can be replaced in to the Card Memory ready for the next session. Engine data including corresponding sensor inputs are transferred from ECU to the Card Memory via CAN. Accordingly the maximum sampling rate is related to the calculation process in ECU (ignition synchronous, 10 ms grid, ...). Chassis data such as damper travel potentiometers, which are sampled via analogue logger inputs, may be recorded with 200 Hz. However, lower sampling rates for ECU and chassis data can be individually selected by the user in order to reduce memory expense. Lap marker beacon and front wheel speed sensor (hall effect) are measured by the ECU and transferred via CAN on to the logger. Damper travel and steering angle potentiometers are equipped with military connectors providing improved durability during car rebuilds.
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System Overview
Lap Marker Beacon System

The lap marker beacon uses coded infrared transmitter with 16 channels and car mounted receiver. Section time measuring is also possible with additional transmitters. During official events 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 based software tool that provides data analysis functions to both the team and engine builder. An optional user-defined partition of memory allows the team and engine builder to have separate aquisition tables each recording parameters of interest, sharing channels where appropriate. 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 dongle for technical reasons, but giving the possibility for data analysing on a various number of PCs.
Display
The DDU 5 is a light and compact, steering wheel mounted dashboard unit. It is eqipped with a high contrast color display. Up to 5 customized display configurations can be programmed to suit individual customer requirements. All illuminated components are dimmable.
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System Overview
Basic System Overview

Application tool Control unit MS 3.1 Evaluation tool
MODAS Dashboard
WinDARAB Data logging
KIC 2
DDU 5
Laptrigger
Card Memory
3 12 5 13 17 2 18 4 9 8 10 7 1
15
6 16 11 14
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Ignition coils Injectors Fuel pump Throttle position sensor Camshaft sensor Crankshaft sensor Lambda sensor Knock sensor Intake air temperature sensor Water temperature sensor Oil temperature sensor Fuel pressure sensor Fuel pressure regulator Oil pressure sensor Ambient air pressure sensor Crankcase pressure sensor Fuel temperature sensor Exhaust temperature sensor Wheel speed sensor
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System Overview
Motronic MS 3.1
The MS 3.1 is the first Bosch engine management system in full hybrid technique and for engines up to 6 cylinders. Two independent circuits are available for vibration knock detection and knock control. Injection time, injection end timing and ignition timing are calculated from basic maps and can be corrected by different engine parameters. Also two closed loop wide range lambda circuits are available. Various engine parameters can be measured with different input channels and transferred via CAN interface to an optional flash card data logger.
Functionality Engine management system for 4- and 6-cylinder engines Sequential fuel injection Ignition timing Lambda control Knock control Fuel cut off Component diagnosis Electronic data In general 2 microcontrollers with 16 bit organisation calculation capacity 20 MIPS Inputs 2 lambda LSU4 interfaces 3 analogous inputs 0 5 V for water temperature, oil temperature, intake air temperature 3 analogous inputs 0 5 V for oil pressure, fuel pressure, ambient pressure 2 analogous input 0 5 V for throttle position sensor and gear position sensor 1 digital input for lap trigger 2 digital input for wheel speed sensor 1 input for inductive crankshaft sensor 1 input for hall camshaft sensor 2 knock sensor interfaces Outputs 6 injection power stages with diagnosis interface 2 high current power stages (8 A) with diagnosis interface for LSU heating 6 ignition power stages Sensors supply output 5 V/100 mA Separate supply output for throttle position sensor 5 V/100 mA 2 power stages (1 A) for main relay and fuel pump relay control
Mechanical data Extremely small and flat aluminium pressure casting housing Connectors with high pin density Extremely shock and vibration proof hybrid technology Four housing fixation points Size 120 x 90 x 40 mm Weight 250 g
Conditions for use ECU temperature -40 125C Max. power consumption 10 W at 14 V Max. vibration 50 g sinus at 20 Hz 2 kHz for t < 5 h
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System Overview
Communication interfaces 1 CAN interface 1 K-Line interface
Cable harness connectors Order numbers:
D 261 205 139 D 261 205 140
Necessary equipment KIC2-diagnosis connector with ignition bridge KIC2-diagnosis connector without ignition bridge
Order numbers MS 3.1 incl. Modas for notebook B 261 206 866 B 261 206 867
B 261 208 245
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System Overview
Software Functions MS 3.1

Injection timing Sequential fuel injection Injection end timing as a function of engine charge and engine revoution 3 basic lambda maps as a function of engine charge and engine revolution, selectable by a dashboard switch Correction of injection time during engine operation as a function of cylinder number, air temperature, water temperature and ambient pressure Engine start parameter for injection time as a function of water temperature, number of ignitions after first crankshaft rotation and revolution Post start and warm up enrichment Acceleration enrichment Fuel cut off as a function of throttle position and engine revolution Fuel cutin algorithm Lambda control 1 independant circuit for wide range lambda control Lambda closed loop control with adaptation
Speed limitation Engine speed limitation by ignition timing and fuel cut coordinated by torque control
Gear control Gear shift function by torque control with fuel cut off and ignition retard
Knock control Knock detection operated by vibration measuring Knock detection limits as a function of cylinder number and revolution Adaptation maps for steady-state and transient operation
Lap functions Lap time and lap distance Time comparison Main and section timing Additionals Complete engine data acquisition via CAN with an external Card Memory Self diagnosis functions for input and output channels with limp home functionality Gear detection Lifetime memory Fuel consumption calculation 4 wheelspeeds via CAN
Ignition timing Basic ignition angle map as a function of engine charge and engine revolution Correction of ignition angle during engine operation as a function of cylinder number, air-, water temperature, ambient pressure Engine start parameter for ignition angle as a function of water temperature, ambient temperature and revolution
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Engine Equipment
Engine Equipment
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Engine Equipment
Rotary Potentiometer RP 86
Possible range: 86
This sensor is designed to measure rotational movement, especially throttle positions. Each sensor is individually lasercalibrated.
Mechanical data Mounting Length Mech. range Max. rotation speed Tightening torque Weight Life expectancy
2 x M4 160 300 mm < 86 120 x 1/min 1,5 2,5 Nm 60 g 5 > 2 x 10 rotations
Electronic data Nominal resistance Resistance tolerance Non-linearity Repetitive accuracy Temp. coefficient Max. power supply Usual power supply
2,5 k 20 % 0,9 % 0,01 % < 5 ppm/C 42 V 5V
Conditions for use Temperature range Vibration
-40 130C 40 g/5 Hz 2 kHz
Connector Cable harness connector
1 928 402 868
Order number Offer drawing 0 280 122 016 A 280 121 252
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Engine Equipment

Possible range: 100
This sensor is designed to measure rotational movement. Each sensor is individually laser-calibrated. It is manufactured in a DR-25 sleeve, various connector options are available.
Mechanical data Mounting Length Mech. range Max. rotation speed Tightening torque Weight Lifetime
2 x M4 160 300 mm 360 120 x 1/min 0,5 Nm 60 g 5 > 50 x 10 rotations
3 k 20 % 0,9 % 0,01 % < 5 ppm/C 42 V 5V
-20 150C 40 g/5 Hz 2 kHz
Order numbers ASL 6-06-05PA-HE Offer drawing
B 261 209 127 A 261 209 127
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Engine Equipment
Inductive Speed Sensor IA-C

This sensor is designed for incremental measurement of revolutions at engine applications.
Mechanical data Magnetic pole Fixing Length Tightening torque Weight Installation depth
round M6 x 12 510 mm 8 Nm 80 g 24 mm
Electronic data Resistance Inductance
860 /20 10 % 370 60 mH/1 kHz
1 928 402 868
Order number -40 130C 80 g/max. 80 h Offer drawing 0 261 210 136 A 265 461 845
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Engine Equipment
Speed Sensor HA-P

This sensor is designed for incremental measurement of revolutions and angles at engine and chassis applications.
Mechanical data Fixing Drill hole Max. distance Tightening torque Weight Installation dimensions
M6 18 mm 1,52 mm 6 Nm 70 g 30 mm
Electronic data Power supply Input current Signal output (active) Output current
4,5 24 V 10 mA typ., 20 mA max. 0,4 V max. 20 mA max.
1 928 403 110
Conditions for use Temperature range Vibration Air gap
-30 130C 100 g/10 Hz 2 kHz max. 1,5 mm
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Engine Equipment
Lambda Sensor LSU

The wide-band lambda sensor LSU is a planar ZrO2 dual cell limiting current sensor with integrated heater. It is used to measure the oxygen content and the lambda value of engine exhaust gases. Its output signal in the range of lambda = 0,7 to air makes the LSU capable to be used as an universal sensor for lambda = 1 measurement as well as for other lambda ranges. The connector module carries a trimming resistor, which defines the characteristics of the sensor and is necessary for the sensor function. The wide band sensor LSU operates only in conjunction with a special control unit.
Mechanical data Length Thread Tightening torque Wrench size Weight Vibration Electronic data Heater supply voltage 9V Heater power 10 W Sensor element ZrO2 (Zirconium-Oxide-Ceramic) Lambda measuring range 0,70 Connector Cable harness connector
460 mm/600 mm M18 x 1,5 60 Nm 22 mm 120 g 30 g/5 Hz 2 kHz
D 261 205 138
Fuel additives In accordance with DIN EN 228 for commercially available unleaded fuel.
Temperature ranges Exhaust gas at sensor element Hexagon of the sensor housing Cable grommet (PTFE formed house) -Sensor side -Cable side Cable and protection sleeve Connector
Order numbers L: 600 mm Offer drawing
0 258 006 065 A 258 400 021
850C < 570C < 250C < 200C < 250C < 120C
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Engine Equipment
Installation instructions The Lambda sensor should be installed at a point which permits the measurement of a representative exhaust-gas mixture, and which does not exceed the maximum permissible temperature. The sensor is screwed into a mating thread and tightened with 50 60 Nm. Install at a point where the gas is as hot as possible. Observe the maximum permissible temperatures. As far as possible install the sensor vertically, whereby the electrical connections should point upwards. The sensor is not to be fitted near to the exhaust outlet so that the influence of the outside air can be ruled out. The exhaust-gas passage opposite the sensor must be free of leaks in order to avoid the effects of leak-air. Protect the sensor against condensation water. The sensor body must be ventilated from the outside in order to avoid overheating. The sensor is not to be painted, nor is wax to be applied or any other forms of treatment. Only the recommended grease is to be used for lubricating the threads. The sensor receives the reference air through the connection cable. This means that the connector must be clean and dry. Contact spray, and anti-corrosion agents etc. are forbidden. The connection cable must not be soldered. It must only be crimped, clamped, or secured by screws.
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Engine Equipment
Knock Sensor KS-P

This sensor is designed to measure the structure borne noise resulted from irregular engine combustion. The robust sensor is suitable for use under extreme conditions.
Mechanical data Thread M8 x 30 (aluminium engine block) M8 x 25 (cast iron engine block) Weight 48 g Tightening torque 15 25 Nm Mounting position random
Electronic data Main resonance frequency Impedance R: C Measuring range Sensitivity at 5 kHz Range of frequency
> 20 kHz > 1M 1100 300 pF 0,1 400 g 26 8 mV/g 1 20 kHz
Conditions for use Temperature range Vibration, constant Vibration, short
-40 150C 80 g 400 g
1 928 403 137
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Engine Equipment
Temperature Sensor NTC M12-H

Temperature range: -40 150C
A shockproof sensor for measurements under pressure up to 25 bar. Good thermal conductivity allows fast response temperature measurement. The integrated connector provides a low-cost connection for automotive applications. General fields of application: oil-, fuel-, water temperature measurement.
Mechanical data Thread Tightening torque Wrench size Weight Electronic data Nominal resistance Measuring range Accuracy Response time 90 %
M12 x 1,5 18 Nm 19 mm 30 g
2,5 k/20C -40 +150C 1,5 K < 10 s
-40 150C 30 g/5 250 Hz
1 928 403 137
Order number Characteristic NTC 2,5 k Offer drawing 0 281 002 170 A 280 130 110
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Engine Equipment
C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
R() 45 313 34 281 26 114 20 003 15 462 12 002 9 397 7 415 5 896 4 712 3 792 3 069 2 500 2 057 1 707 1 412 1 175 987,6 833,9 702,8 595,5
C 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160
R() 508,3 435,7 374,2 322,5 279,6 243,2 212,7 186,6 163,8 144,2 127,3 112,7 100,2 89,30 79,65 71,20 63,86 57,41 51,82 46,88
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Engine Equipment
Temperature Sensor NTC M12-L

A shockproof sensor for measurements under pressure up to 25 bar. Good thermal conductivity allows fast response temperature measurement. The integrated connector provides a low-cost connection for automotive applications. General fields of application: oil-, fuel-, air temperature measurement
Mechanical data Thread Tightening torque Wrench size Weight Electronic data Nominal resistance Measuring range Accuracy Response time 90 %
M12 x 1,5 15 Nm 19 mm 26 g
2,5 k/20C -30 130C 1,5 K < 10 s
-30 130C 60 g/50 250 Hz
1 284 485 143
Order number Characteristic NTC 2,5 k Offer drawing 0 280 130 039 A 280 130 206
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Engine Equipment
C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
R() 45 313 34 281 26 114 20 003 15 462 12 002 9 397 7 415 5 896 4 712 3 792 3 069 2 500 2 057 1 707 1 412 1 175 987,6 833,9 702,8 595,5
C 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160
R() 508,3 435,7 374,2 322,5 279,6 243,2 212,7 186,6 163,8 144,2 127,3 112,7 100,2 89,30 79,65 71,20 63,86 57,41 51,82 46,88
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Engine Equipment
Thermocouple Probe TCP-NF

A flexible N-type thermocouple for measuring exhaust-gas temperatures.
Mechanical data Thread Tightening torque Wrench size
M12 x 1 15 Nm 17 mm
Electronic data Power supply Full scale output Thermocouple Measuring range
12 V 0,5 4,5 V NiCrSi-NiSi 40 1000C
Conditions for use Vibration
80 g/5 500 Hz
Characteristic DIN EN 60584
Sensor data Length Weight
630 mm 60 g
Order number Offer drawing B 261 209 821 A 261 209 821
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Engine Equipment
Input C -40 0 100 200 300 400 500
Output mV 372 485 790 1135 1513 1912 2327
Input C 600 700 800 900 1000 1100
Output mV 2752 3183 3615 4046 4473 4845
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Engine Equipment
Absolute Pressure Sensor PSA

Pressure range: 0,2 1,05 bar nominal
A piezoresistive pressure sensor for ambient air pressure measurement.
Mechanical data Measurement transducer Max. pressure Thread Weight
piezoresistive 5 bar M6 60 g
Electronic data Power supply Full scale output Time of reaction Max. current Resistance
4,75 5,25 V 0,4 4,65 V 10 ms (90 %) < 10 mA > 50 k
Conditions for use Temperature range Max. temp. of location Max. vibration
-40 120C 130C 15 g /30 200 Hz
1 237 000 039
Characteristic 0,2 1,05 bar: Sensitivity Offset
Order numbers 0,2 1,05 bar Offer drawing 5000 mV/bar -600 mV
0 261 230 004 A 261 260 041
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Engine Equipment
Absolute Pressure Sensor PSA-BF

Pressure range: 0,1 1,15 / 0,2 2,5 bar nominal
A piezoresistive pressure sensor modified for precision air pressure measurement, especially air box pressure. It is manufactured in a DR-25 sleeve, various connector options are available.
Mechanical data Max. pressure Fitting Weight Sealing
3 [5] bar 11,85 mm 45 g O-ring 7,59 x 2,62
Conditions for use Temperature range Max. temp. of location Max. vibration
-40 125C 130C 250 g/200 500 Hz
Electronic data Power supply Full scale output Compensated range Non linearity Therm. zero point drift Therm. sensitivity drift Long time drift
4,75 5,25 V 0,1 4,65 V 40 130C 0,25 % < 0,5 % < 0,5 % < 0,5 %
Characteristic 0,1 1,15 bar: Sensitivity Offset 0,2 2,5 bar: Sensitivity Offset Extra Sensor Adapter
4040 mV/bar -4,8 mV 1848 mV/bar 30,4 mV
Order numbers 0,1 1,15 bar: AS 6-06-05PC-HE Offer drawing 0,2 2,5 bar: AS 6-06-05PC-HE Offer drawing
0 201 230 052 A 261 260 163 0 281 002 510 A 261 260 163
B 261 209 725
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Engine Equipment
Pressure Sensor PSS

Pressure range: 0 10 / 100 bar nominal
A M10 x 1 pressure sensor for measuring various fluid pressure. Gauge and absolute pressure sensors are available.
Mechanical data Measurement transducer Max. pressure Thread Tightening torque Wrench size Weight Sealing
piezoresistive 2 x nominal M10 x 1 10 Nm 17 mm 65 g O-ring 7,65 x 1,63
Electronic data Power supply Compensated range Non linearity Therm. zero point drift Therm. sensitivity drift Long time drift Full scale output Time of reaction
56V 20 85C 1% <1% <1% <1% 0,5 4,5 V 1 ms (90%)
-40 125C 15 g/30 200 Hz
Characteristic Sensitivity 10 bar 100 bar Offset 10 bar 100 bar
Order numbers 10 bar Offer drawing 100 bar Offer drawing
B 261 209 341 A 261 209 341 B 261 209 347 A 261 209 347
400mV/bar 40 mV/bar 100 mV 500 mV
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Engine Equipment
Injection Valve EV 6
The development of the EV 6 took into account all the essential functional requirements which originate from injector operation in multipoint electronic fuel injection systems (EFI). This resulted in: low weight, dry solenoid winding, plastic encapsulation, finely matched flow-rate classes, good valveseat sealing, excellent hot-start capabilities, close tolerances of the specified functional values, high level of corrosion resistance and long service life.
Mechanical data System pressure Weight Conditions for use Fuel input axial (top-feed) Operating temperature -40 ... 110C Permissible fuel temperatures 70C Climate proofness corresponds to saline fog test DIN 53 167
max. 8 bar 45, 8 g
Electrical data Solenoid resistance Max. power supply
e.g. 12 16 V
Technical data Order numbers B 280 431 126 B 280 431 127 0 280 155 737 B 280 431 128 B 280 431 129 B 280 431 130 B 280 431 131 0 280 156 012
Design Standard Standard Long Standard Standard Standard Standard Standard
Type C C C C C C C C
Flow rate at 3 bar (N-Heptan) 261,2 g/min 261,2 g/min 261,2 g/min 364,3 g/min 364,3 g/min 493,1 g/min 493,1 g/min 310,1 g/min
Spray angle 25 70 15 25 70 25 70 20
Impedance 12 12 12 12 12 1,2 1,2 12
Further injection valves on request
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Engine Equipment
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Engine Equipment
Injection Valve EV 12
The EV 12 injector is a development based on the EV 6. Its main feature is the fact that the position of its injection point can be varied. Compared with the EV 6, the EV 12 injection point can be moved forward up to 20 mm.
Mechanical data System pressure Weight
max. 8 bar 40 g
Electronic data Solenoid resistance Max. power supply
Conditions for use Fuel input axial (top-feed) Operating temperatures -40 ... 110C Permissible fuel temperatures 70C Climate proofness corresponds to saline fog test DIN 53 167
e.g 12 16 V
Technical data Order numbers
Design
Type E E E
B 280 432 115 Medium 0 280 155 893 Medium 0 280 155 897 Medium
Flow rate at 3 bar (N-Heptan) 217 g/min 269 g/min 217 g/min
15 15 15
Spray 15 7 7
angle 10 10 10
Impedance 270 270 270 12 12 12
Further special versions on request
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Engine Equipment
Fuel Pressure Regulator Mini 50

Pressure range: 5,0 bar
Mechanical data Supply Reflow
4 mm, tube connector 9,15 mm, O-ring
Description Sheet steel housing with manifold connection
Erledigung durch Kunden Effect by customer

O-Ringe leicht mit sauberem Motorenl einlen Oil O-rings lightly with clean engine oil Nach der Montage an Kraftstoffzuteiler ist Dichtheitsprfung durchzufhren Leaktest after installation Bei Ausbau und Wiederverwendung des Druckreglers mssen die O-Ringe berprft werden When the pressure regulator is removed and will be reused, the O-rings must be checked Betrieb des Druckreglers mit Luft ist unzulssig Operation with air is not allowed
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Engine Equipment
Single Fire Coil P

This coil is low cost concept for cylinder head installation.
Electronic data High voltage I prim. (stand.) Inductivity (prim.) Inductivity (sec.) Resistance (prim.) Resistance (sec.) Spark energy U prim. (clamp.) Voltage gradient
35 kV 8,5 A 2,8 mH 16 H 0,37 8,8 k 45 ... 55 mJ 260 V 1,6 kV/s
Mechanical data Weight Vibration
260 g 40 g/5 Hz ... 2 kHz
1 928 402 868
Conditions for use Temperature range
-40 ... 140C
Dwell time (ms) Ubatt 8V 10 V 12 V 14 V 16 V
4A 2,90 2,00 1,65 1,35 1,10
5A 4,00 2,70 2,10 1,75 1,40
6A 5,50 3,50 2,65 2,15 1,75
7A 7,80 4,40 3,17 2,55 2,05
8A 5,20 3,52 2,90 2,35
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Engine Equipment
Single Fire Coil SP

This production type coil is low cost concept for cylinder head installation.
Electronic data High voltage I prim. (stand.) Resistance (prim.) Spark energy U prim. (clamp.) Voltage gradient
>30 kV 7,3 A 0,5 35 mJ 300 V 1,5 kV/s
Mechanical data Weight Vibration Diameter
189 g 40 g/5 Hz ... 2 kHz 22 mm
-40 ... 140C
Dwell time (ms), Temperature of IC ca. 50C Ubatt 7,3 A 8V 6,2 10 V 3,2 12 V 2,4 14 V 1,8 16 V 1,5
Order number Offer drawing 0 221 504 460 A 221 141 014_009
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Engine Equipment
Relay 25 A
A miniature DC-contactor for electrical power control. The rated current is 25 A for secondary power distribution with high inrush current like hydraulic- and fuel motor loads. The base part allows a quick change of the relay.
Mechanical data Drill hole Weight
3,1 mm 61 g
Electronic data Supply voltage Max. current Min. switches
12 ... 14,5 V 25 A 20 000
Conditions for use Temperature range Vibration Shock
-30 125C 30 g/70 Hz ... 3 kHz 100 g (11 ms)
Order numbers Relay Offer drawing Base Offer drawing
Y 261 A20 597 Y 261 A25 338 Y 261 A20 598 Y 261 A25 338
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Chassis Equipment
Chassis Equipment
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Chassis Equipment

Possible range: 308
This sensor is designed to measure rotational movement. Each sensor is individually lasercalibrated. It is manufactured in a DR-25 sleeve, various connector options are available.
5 k 20 % 0,9 % 0,01 % < 5 ppm/C 42 V 5V
-20 150C 40 g/5 Hz 2 kHz
Order numbers KPSE 6E8-33P-DN Offer drawing
B 261 209 115 A 261 209 115
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Chassis Equipment
Pressure Sensor PSS

Pressure range: 0 10 / 100 bar nominal
A M10 x 1 pressure sensor for measuring various fluid pressure. Gauge and absolute pressure sensors are available.
Mechanical data Measurement transducer Max. pressure Thread Tightening torque Wrench size Weight Sealing
piezoresistive 2 x nominal M10 x 1 10 Nm 17 mm 65 g O-ring 7,65 x 1,63
Electronic data Power supply Compensated range Non linearity Therm. zero point drift Therm. sensitivity drift Long time drift Full scale output Time of reaction
56V 20 85C 1% <1% <1% <1% 0,5 4,5 V 1 ms (90%)
-40 125C 15 g/30 200 Hz
Characteristic Sensitivity 10 bar 100 bar Offset 10 bar 100 bar
Order numbers 10 bar Offer drawing 100 bar Offer drawing
B 261 209 341 A 261 209 341 B 261 209 347 A 261 209 347
400mV/bar 40 mV/bar 100 mV 500 mV
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Chassis Equipment
Accelerometer AM 600
This accelerometer is available to measure two axes in a single, robust package. With reference to its fitting position, longitudinal and transversal acceleration up to 4,5 g can be measured. Manufactured in DR-25 sleeve; various connector options available.
Mechanical data Weight Length Measuring range Overload Dimensions 2 axes Fixing Tightening torque
30 g 150 1000 mm 4,5 g 600 g 24,5 x 26,5 x 14,6 mm 2 x M3 2 Nm
Electronic data Supply voltage Max. supply voltage Signal output Supply current Max. current Tolerance of sensitivity Non-linearity of sensitivity
5 V DC 6 V DC 2,5 V = 0 g; 440 mV/g 7 mA 12 mA 3% 2%
-40 85C
Order numbers AS 6-06-05PA-HE Offer drawing
B 261 209 311 A 261 209 311
Characteristic Offset x,y Sensitivity x,y
2,5 V at 0 g 440 mV/g
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19 Oct. 04
Chassis Equipment
Linear Potentiometer LP 10
Possible mechanical range: 10 mm
This sensor is designed to measure stabilizer movement. It is manufactured in a DR-25 sleeve. Various connector options are available.
Mechanical data Mounting Cable length Weight
2 x M3 150 1000 mm 70 g
Electronic data Nominal resistance Max. current Non-linearity Usual power supply Power consumption
1 k 20 % 1 mA 1% 5V 0,3 W
-25 75C Order number KPSE 6E8-33P-DN Offer drawing B 261 209 535 A 261 209 535
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Chassis Equipment
This sensor is designed to measure gear position, throttle position or suspension movement. It is manufactured in a DR-25 sleeve, various connector options are available.
Mechanical data Cable length L Min. length L1 Possible mech. range L2 Mounting Sealing Max. shaft velocity Weight
150 1000 mm 224 mm 79 mm 2 x M5 O-ring shaft seal 10 m/sec 52 g
Electronic data Nominal resistance Max. current Non-linearity Usual power supply Max. power supply
3 k < 1 mA 0,15 % 5V 47 V
B 261 209 852 A 261 209 852
-30 100C
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Chassis Equipment

This sensor is designed to measure gear position, throttle position or suspension movement. It is manufactured in a DR-25 sleeve, various connector options are available.
Mechanical data Cable length L Min. length L1 Possible mech. range L2 Mounting Sealing Max. shaft velocity Weight
150 1000 mm 249 mm 104 mm 2 x M5 O-ring shaft seal 10 m/sec 62 g
Electronic data Nominal resistance Max. current Non-linearity Usual power supply Max. power supply
4 k < 1 mA 0,15 % 5V 74 V
B 261 209 853 A 261 209 853
-30 100C
19 Oct. 04
43
Chassis Equipment
Gear Potentiometer
Possible range: 308
This sensor is designed to measure rotational movement. Each sensor is individually lasercalibrated. It is manufactured in a DR-25 sleeve, various connector options are available.
5 k 20 % 0,9 % 0,01 % < 5 ppm/C 42 V 5V
-20 150C 40 g/5 Hz 2 kHz
Order numbers KPSE 6E8-3AP-DN Offer drawing
B 261 209 585 A 261 209 585
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19 Oct. 04
Chassis Equipment
CardMemory C40 Plus + CAN

The CardMemory is a device used for data acquisition. The shown model C40 Plus is developed to read in 15 analogous signals. The measured data are stored on a compact flash card.
Mechanical data Dust and splashwater proof aluminium housing Flexible housing fixation points Connector with 40 pins Size 150 x 90 x 22 mm Weight 330 g
Options 15 analogous inputs with 10 bit resolution and 5 ms sample rate time 1 inductive crankshaft sensor interface Sensor supply outputs 5 V/100 mA 10 V/100 mA Calibration functions are realised with an additional software tool Connector Cable harness connector C40 Plus AS0-14-35 SN
Conditions for use ECU temperature -40 75C Max. power consumption 7 W at 14 V Max. vibration 15 g sinus at 20 Hz 2 kHz for t < 5 h
Cable harness B 261 209 450
Electrical data 1 microcontroller with 16 bit organisation 1 CAN interface Real time clock Non volatile flash card memory Total calculation capacity approximately 10 MIPS
Order numbers C40 Plus incl. chassis adjust
B 261 206 880
19 Oct. 04
45
Chassis Equipment
Laptrigger IR-02
This laptrigger system consists of an infrared transmitter station and a receiver installed in the car. The system allows an exact laptime measurement. Section time measurement for comparison of different car setups is also available if several transmitters are used. Notice: our old laptrigger IR is not compatible with IR-02. If both laptriggers are used at the same time, the transmitters have to be positioned with a minimum distance of 5 m.
Mechanical data IR-02-Receiver Size 42 x 20 x 10 mm Weight 39 g Dust and waterproof aluminium housing IR-02-Transmitter Size with diode 90 x 40 x 28 mm Weight 124 g Dust and waterproof aluminium housing Electronic data IR-02-Receiver Frequency codes Supply voltage Output voltage IR-02-Transmitter Frequency codes Supply voltage
16 8 16 V 5V 16 plus 16 offset codes for section times 8 16 V
Conditions for use Working range 15 m Ambient temperature -25 70C Same height between receiver and transmitter Visibility connection between receiver and transmitter Avoid direct exposure to sunlight
Order numbers IR-02-Receiver KPSE 6E8 3AP DN A34 IR-02-Transmitter
B 261 206 884 B 261 206 890
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Chassis Equipment
Display DDU 5
The DDU 5 is a light and compact, steering wheel mounted dashboard unit. It is eqipped with a high contrast color display and three additional dot-matrix displays. Up to 5 customized display configurations can be programmed to suit individual customer requirements. All illuminated components are dimmable. For enhanced flexibility the DDU 5 can be interfaced to a range of stand-alone I/O modules that facilitate multiple functions like switching, light indication, car and race information display.
Displays Main display 1x active matrix TFT high contrast color display Active area 49,2 x 38,1 mm Resolution 480 x 234 Dot size 0,1025 x 0,163 mm Weight 52 g Secondary displays 2x high intensity LED dot-matrix, 8-character Active area 42 x 12 mm 1x hight density LED dot-matrix, 1-character Active area 12 x 17 mm Electronic data 1x CAN interface for communication with ECU 1x CAN interface for communication with network 1x RS 232 interface for display programming 9 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 number F 01E B01 455
Conditions for use Vibration Temperature
6 g/20 Hz ... 2 kHz -10 ... 65C
19 Oct. 04
47
Chassis Equipment
Speed Box 4 (only for test, use in race forbidden!)

This box determines the speed signals of four wheels and converts them into a CAN-message. The message includes the time between each tooth-gap. The box is optimised for the MS 3-use.
Mechanical data Size Weight
70 x 40 x 19 mm 90 g
Conditions for use Operating temperature
Electronic data Power supply Current consumption Channels Channel input
4 18 V 120 mA at 12 V 4 Speed 1 150 V
10 60C Order number Speed Box 4 AS0-10-35PN F 01E B01 626
Connector
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19 Oct. 04
Application Tools
Application Tools
19 Oct. 04
49
Application Tools
Application Equipment Overview

Data modification Application tool
MODAS
Potiboard
Data transfer via K-Line/KIC 2
Enginge management Control unit
Data transfer via CAN
Indirect data download via flash card CardMemory Data analysing Evaluation tool WinDarab
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19 Oct. 04
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 cost unit for PC-supported application on the serial diagnosis interface of an ECU. KIC 2 is coupled to the PC via the parallel printer interface. This ensures a powerful and universal link to all common PCs. The coupling to the ECU is effected via the Kline of the diagnosis interface. The functionality of KIC 2 is essentially determined by the operating programs of the PC.
Details Compact design Fully suitable for motor vehicle use Power supply through the connection to the ECU from board mains with galvanic separation All inputs and outputs to the PC galvanically separated Firmware update possible via PC According to ISO 9141-2 for diagnosis tester Up to 250 kBaud transfer rate Plug suitable for motor vehicles (VS 20) Protocols: McMess, KP 2000, Keyword 71 Electronic data Input voltage Power consumption Power consumption in stand by Processor Flash Eprom Centronics Iinterface Temperature range Control P-module output Output voltage Quantisation Resolution
6 ... 30 V typ. 1 W at 13,5 V 30 mW at 13,5 V P 87C520, 12 kByte 2 x 48 kByte 40 g/5Hz ... 2kHz -30 ... 70C 0 ... 4,096 V !V=1,0 mV 12 bit
Mechanical data Size
17 x 60 x 78 mm
Order number KIC 2, diagnosis connector without ignition bridge
B 261 206 867
19 Oct. 04
51
Application Tools
Modas
Modas is a software tool for calibrating engine and chassis parameters. It is specially designed for race track use. Developing Modas we set great store by easy handling and quick access to the ECU.
General functions Online measurement and calibration Universal use for different ECUs Modas facilitates operating and working in by using the Windows standard. In the office Modas is controlled by mouse or menue. If Modas is used in a mobile way a fast grip is possible by keyboard and shortcuts.
Required hardware components: PC: IBM PC/AT compatible, 586 processor or higher, 166 MHz Approx. 64 Mbyte of RAM Approx. 30 Mbyte harddisc space VGA monitor Operating systems: Windows 98, 2000, NT and XP
Performance description Modas is a combination of Project (Data) management: Visualisation, processing and management of calibration, 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 and evaluation of diagnosis data
Order number B 261 206 441
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Application Tools
Potiboard POP
(Parameter Operating Panel)
POP is part of the INCA module family. It is designed for online mapping on dyno supporting the INCA calibration function. POP is coupled to the PC via serial link on the SMB bus.
Details Robust design External power supply Modification of calibration data by potentiometer operation 4 potentiometers, individual assignment to 4 characteristic values (fixed values, characteristic lines or maps) Additive or multiplicative modification selectable POP configuration saved together with the INCA display
19 Oct. 04
53
Application Tools
WinDarab
Data Recording, Analysing and Influencing
WinDarab is an evaluation tool for monitoring and analysing of logged data. It is Windows-based and specially designed for motorsport use. For selection of monitored data channels and setting of sample rates the integrated configuration tool WinDCP is used.
Data evaluation Auto load and auto store Adjustable axis: time or distance Direct read in of memory data without reader Graphic display of all measured and stored channels Various displays available (analogous and digital) Number of displays available Various display set-ups selectable and storable Laptrigger signal included
Functions Min/max-calculations Histograms Mathematical functions Filter functions incl. FFT x/y-plots
Data comparison Calculation of differences lap by lap
Functionality Creating of race tracks Several segments adjustable for each race track Lap reports and lap comparison Inform displays Data extract and export
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19 Oct. 04
55
Sales terms and conditions for motorsport products

(as a supplement to the Terms and Conditions of Delivery A 17)
Scope of validity
1.1 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 road vehicles out of serial production, modifications thereof and products especially developed and designed in accordance with the customers specifications; Buyer hereby acknowledges that mass products for road vehicles are not designed to meet all of the requirements and demands of motor racing. Buyer further acknowledges that modified mass products or products specially developed and designed in accordance with Buyers specifications cannot be tested to the same degreeas mass products for road vehicles and that production is not in every case conducted in accordance with well-known and secured processes;
1.2 1.3
Territorial validity
The above provisions shall apply irrespective of where the products delivered by us are used.
Use of products
3.1
Buyer undertakes to use the products only in the realm of motor racing and not in general road traffic. We assume no responsibility for the admissibility of these various products in public general road traffic. Should a product be used in public general road traffic, we will grant no warranty or liability whatsoever for damages/injuries incurred.
3.2 3.3
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19 Oct. 04
Warranty
4.1 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 the Buyer - irrespective of the legal grounds - are excluded. Insofar as modified mass products out of serial production or specially designed products be concerned, we shall not assume any warranty that such products display the features - particularly for use in motor racing - requested and/or expected by Buyer.
4.2
Liability
In the event that a third party be injured as a result of a defective product (error in design, production or instruction), Buyer shall indemnify and hold us harmless from and against any resulting third-party claims - irrespective of the legal grounds for such claims -, including any costs necessary for legal defense.
Effectiveness
In the event that any provision hereof be or becomes invalid, the validity of the remaining provisions shall not be affected thereby. Any invalid provision shall be replaced by that valid provision which most closely corresponds to the original intention or economic purpose of the invalid provision.
Bosch Engineering GmbH Motorsport An der Bracke 9 D - 71706 Markgroeningen Germany
19 Oct. 04
57
Offer drawings
Offer drawings
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19 Oct. 04
Copyright Robert Bosch GmbH
BOSCH INTERN: Gueltigkeit nur am 1/18/2001 garantiert (M/TT/JJJJ - GMT)
T:/K3ELA/LDF_CAL/A261260163-000
Bosch Engineering GmbH Motorsport An der Bracke 9 71706 Markgrningen Germany Phone: 00 49 (0) 711/811-3981 Fax: 00 49 (0) 711/811-3982 North American Office: Robert Bosch Corporation Motorsport, Dep. AP/EAP 38000 Hills Tech Drive Farmington Hills, MI 48331-3417 Phone: 00 1 248 848-2977 Fax: 00 1 248 324-7373 E-mail: motorsport@bosch.com www.bosch-motorsport.com

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

Set-up and Calibration

Lap Marker Beacon System

Basic System Overview

WinDARAB Data logging

Communication interfaces 1 CAN interface 1 K-Line interface

Cable harness connectors Order numbers:

D 261 205 139 D 261 205 140

B 261 208 245

Software Functions MS 3.1

2 x M4 160 300 mm < 86 120 x 1/min 1,5 2,5 Nm 60 g 5 > 2 x 10 rotations

2,5 k 20 % 0,9 % 0,01 % < 5 ppm/C 42 V 5V

Conditions for use Temperature range Vibration

-40 130C 40 g/5 Hz 2 kHz

Connector Cable harness connector

1 928 402 868

Rotary Potentiometer RP 100

2 x M4 160 300 mm 360 120 x 1/min 0,5 Nm 60 g 5 > 50 x 10 rotations

3 k 20 % 0,9 % 0,01 % < 5 ppm/C 42 V 5V

Conditions for use Temperature range Vibration

-20 150C 40 g/5 Hz 2 kHz

Order numbers ASL 6-06-05PA-HE Offer drawing

B 261 209 127 A 261 209 127

Inductive Speed Sensor IA-C

Electronic data Resistance Inductance

860 /20 10 % 370 60 mH/1 kHz

Connector Cable harness connector

1 928 402 868

Conditions for use Temperature range Vibration

Speed Sensor HA-P

4,5 24 V 10 mA typ., 20 mA max. 0,4 V max. 20 mA max.

Connector Cable harness connector

1 928 403 110

Conditions for use Temperature range Vibration Air gap

-30 130C 100 g/10 Hz 2 kHz max. 1,5 mm

Lambda Sensor LSU

460 mm/600 mm M18 x 1,5 60 Nm 22 mm 120 g 30 g/5 Hz 2 kHz

D 261 205 138

Order numbers L: 600 mm Offer drawing

0 258 006 065 A 258 400 021

Knock Sensor KS-P

> 20 kHz > 1M 1100 300 pF 0,1 400 g 26 8 mV/g 1 20 kHz

Conditions for use Temperature range Vibration, constant Vibration, short

-40 150C 80 g 400 g

Connector Cable harness connector

1 928 403 137

Temperature Sensor NTC M12-H

2,5 k/20C -40 +150C 1,5 K < 10 s

Conditions for use Temperature range Vibration

-40 150C 30 g/5 250 Hz

Connector Cable harness connector

1 928 403 137

C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60

Temperature Sensor NTC M12-L

2,5 k/20C -30 130C 1,5 K < 10 s

Conditions for use Temperature range Vibration

-30 130C 60 g/50 250 Hz

Connector Cable harness connector

1 284 485 143

C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60

Thermocouple Probe TCP-NF