User Manual TTT802 Gearshift Controller – Firmware
Contents
1. Sy First Revision Sign and Date Documnent File name Document Type Revision Updated Revision Sign and Date Document Status and Sign Page Bin 2009 03 19 Bln 2010 04 29 Approved Lan 1 10 Document and Product Description User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 TTT802 Gearshift Controller Part 12 620 9 R1N S Standard P Paddleshift Overview Gearshift Controller for 4 5 6 or 7 speed sequential gearboxes with gear sequence R 1 N 2 3 4 5 6 7 Large 58 mm red gear indicator display and Rpm shift light bar with green yellow red and white Leds Key features Gear Position Indicator Rpm Shift light Led bar Closed Loop Paddle shift control optional Closed Loop Flat shift control Measuring Gearshift times in 1 1000 sec Measuring Gearbox Race time Oil change indicator Rpm limiter Launch control Automatic display intensity Special functions on request Calibrating the gearbox barrel sensor is an easy task There is no need for computers or even buttons It is done in seconds and the Rpm Shift light bar turns into a voltmeter to guide the user to the right position when fixing the gearbox barrel sensor to the box Built in computer port gives user access to all parameters for flat shift and Rom limiter as well as other functions such as measured gear shift times gearbox race time gear shift counter etc We supply an easy to use Windows application TT2. 360 degr barrel sensor Gear Lever sensor Proximity sensor M8 x 1 Speed sensor Hal sensor M12 x 1 Mounting bracket for proximity sensor M8 x 1 on Tractive gearlever TTT Racing Products Sweden www flatshift com First Revision Sign is e Updated Revision Sign and Date Document Status and Sign Page Bln 2009 03 19 Bln 2010 04 29 Approved Lan 9 10 Document and Product Description Documnent File name Document Type o 2 User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 Connections A 16 pole Matching Connector Molex Microfit 3 0 430251600 Ground PC Com interface Tx PC Com interface RS232 level Transmit data Rx PC Com interface RS232 level Receive data DO1 Digital FET output RPM out Ignition pulses to RPM meter DI1 Ground DI1 Digital input Ignition Pulse DO2 Galvanic Isolated ground for output ECU Ignition Cut DO2 Galvanic Isolated output open collector for ECU Ignition Cut Ground DO5 Digital FET output active low to control Blip Ground DO4 Digital FET output active low to control Paddleshift Valve Shift Down Ground DO3 Digital FET output active low to control Paddleshift Valve Shift Up Powersupply Ground Powersupply 12 VDC Vbat Note Fuse 0 5 Max 1 Amp must be installed in the powerline B 22 pole Matching Connector Molex Microfit 3 0 480252200 DI5 DI6 DI7 Gnd DIZ Digital input 12VDC Spare DI6 input on prototypes DI6 Di
3. bar types One dot from left amp right two dots from left amp right or the default one fill from left amp right Rpm Limiter The Gearshift Controller limits the rom to the maximum allowed rom corresponding to the setting for the particular gear position The maximum rpm setting can be individually entered for each gear position Launch Control Holding down the Start switch being in 1 gear position limits the rom to a preset start value By connecting a Start Rom limit adjust potentiometer it can then be used to increase or decrease the actual start rom limit When the Start switch is released the allowed rpm increases with time until it has reach the rpm limit setting for 1 gear How fast it increases depends on the start ramp time setting By connecting a Ramp time adjust potentiometer it can then be used to increase or decrease the actual start ramp time Positions of the potentiometers are indicated when being adjusted on the Rom Shift light bar When Ramp Time is being adjusted the character shows a small T and the potentiometer position is indicated on the bar When Start Rpm is being adjusted the character shows a and the potentiometer position is indicated on the bar Closed Loop Flat shift Control The main sensor used by the control is the high resolution calibrated gear barrel sensor which continuously informs the controller about the exact position of the barrel The reading from the gear barrel sensor is m
4. computer A3 Rx Data RS232 Input Mini SureSeal Male 0 9 m AWG22 Connect directly to A8 DO2 Isolated Cut Output Ignition interface or use A5 Gnd Ign Pulse Extension cable to A6 DI1 Ign Pulse Input connect to ECU A7 Gnd Cut Mini SureSeal Male 4 0 m AWG22 B1 Gnd Lever Proximity sensor B5 12 Volt to sensor B4 DI5 Lever sensor Input Mini SureSeal Male 2 1m AWG22 VGX360 Gearbox B21 Gnd Barrel Position sensor B22 5 Volt to sensor B20 Al Analog Barrel Position Input TTT802 BAL Add on Part 12 640 7 1 4m AWG22 Mini SureSeal Male B17 Gnd Analog Lever sensor B19 5 Volt to sensor B18 Al2 Analog Lever sensor Input Mini SureSeal Male Connect directly to Blip a A11 Gnd solenoid valve Powered A10 DOS FET Blip Output from Vbat or use Extension cable to connect to ECU TTT802 QT Add on Part 12 639 9 0 4 m AWG22 Start Switch B7 Di4 Start Switch Input B9 Gnd Connect directly to Mini SureSeal Male i i i 0 6 m AWG22 E E EE B14 Al4 A Ramp Time Adjust or use Extension cable to B16 AIl3 B Rpm Adjust separate dual B13 Gnd potentiometers with B15 5 Volt to potentiometers series resistors www ttt racing com TTT Racing Products Sweden www flatshift com
5. T802R1N Manager that supports all these functions The installation of the program is done thru our website www ttt racing com Housing Black anodized aluminium with polycarbonate front panel Size amp Weight 65 x 110 x 30 mm 220 grams Power Supply TTT 802 Gearshift Controller 12 620 9 12 14 Volt DC Average current 100mA max 300mA Recommended fuse 0 5 Max 1 Amp must be installed In the power supply line Connections There are 2 conneciors located on the rear one 16 pole A and one 22 pole B www ttt racing com TTT Racing Products Sweden www flatshift com Documnent File name Document Type ae MANTTT802RINE docx External a First Revision Sign is e Updated Revision Sign and Date Document Status and Sign Page Bln 2009 03 19 Bln 2010 04 29 Approved Lan 2 10 Document and Product Description User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 Functions Gear Position Indicator The calibrated gear barrel sensor is continuously sensed and the controller converts the reading into gear in position The 9 different possible positions are R 1 N 2 3 4 5 6 7 Rpm Shift light Bar By measuring the connected ignition pulses the rom is calculated and compared to the settings for each level of the bar The result of the comparison then controls how many Leds are lit The setting for each bar level can be individually entered for each gear position It is possible to chose 3 different
6. VDC B 15 Signal A Sianal B B 14 B 16 AGND B 13 www ttt racing com TTT Racing Products Sweden www flatshift com Documnent File name Document Type Revision MANTTT802RINE docx External 1 First Revision Sign and Te Updated Revision Sign and Date Document Status and Sign Page Bin 2009 03 19 Bln 2010 04 29 Approved Lan 7 10 Document and Product Description User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 Digital Pulse Output Rpm x 1 DO1 12V 1K2 BSP 78 i U Gnd Normally connected to input on rev counter with low level input Does not work with high voltage ignition type input Output pulse range 0 12 Volts Vbatt Digital Outputs x 3 DO3 DO5 BSP 78 Gnd Low side switch normally connected to load sourced from 12 Volts Vbatt Maximum allowed current 2 Amp Outputs have built in protection for short circuit overload and high temperature Digital Output Ignition Cut x 1 DO2 PC3H7DJ00000F Gnd Galvanic isolated open collector output type NPN normally connected to cut input on ECU or ignition interface Recommended load resistance is 4k7 47000hm Maximum load 10mA 12 Volts Vbatt Note Units with Serial Numbers 1001 1028 maximum load 5mA 12 Volts Vbaitt www ttt racing com TTT Racing Products Sweden www flatshift com First Revision Sign is e Updated Revision Sign and Date Document Status and Sign Page Bln 2009 03 19 Bln 2010 04 29 Ap
7. duct Description User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 Input Output schematic and specification Digital Inputs x 6 DI2 DI7 12V 4n Gnd For sensor with open collector tyoe NPN or mechanical switch Active low when input lt 1 5 Volts Input range 0 12 Volts Vbaitt Digital Pulse Input Ignition Pulse x 1 DI1 5V 4k7 47 100k 4n Gnd Normally connected to output on ECU ignition amplifier Rom out or ignition interface with open collector type NPN Active low when input lt 1 1 Volts Input range 0 12 Volts Vbatt Note For units with serial numbers 1001 1028 the input must be lt 0 8 Volts to guarantee low www ttt racing com TTT Racing Products Sweden www flatshift com Documnent File name Document Type Revision MANTTT802RINE docx External 1 First Revision Sign and Te Updated Revision Sign and Date Document Status and Sign Page Bln 2009 03 19 Bln 2010 04 29 Approved Lan 6 10 Document and Product Description User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 Analog Inputs x 4 Al1 Al4 Input resolution 11 bits 100nF Gn 5V Ali amp Al2 For potentiometers or sensors with an output within the range 0 5 Volts Al3 amp Al4 For Launch Control setting adjustment potentiometers Potentiometers needs a series resistor to Gnd See schematics below This is how the TTT905 Quick Trim unit is built 5
8. gital input 12 VDC Speed sensor Gnd on prototypes DI5 Digital input 12 VDC Gear Lever sensor 12 VDC for sensors and switches Gnd on prototypes 12 VDC for sensors and switches DI4 input on prototypes DI4 Digital input 12VDC N R Interlock Start switch Gnd on prototypes DI3 Digital input 12VDC Paddle Shift Down sensor DI2 DI3 DI4 Ground DI2 Digital input 12VDC Paddle Shift Up sensor Al4 Analog Ground Al4 5VDC Al3 Analog Ground Al4 Analog input Start Ramp time adjust potentiometer Al3 5VDC Al3 Analog input Start Rom limit adjust potentiometer Al2 Analog Ground Al2 Analog input Analog Lever Al2 5VDC Al1 Analog input Gearbox Barrel Position Ali Analog Ground Al1 5VDC Different functions compared to prototype units www ttt racing com TTT Racing Products Sweden www flatshift com Documnent File name Document Type Revision MANTTT802RINE docx External 1 f First Revision Sign and Date Updated Revision Sign and Date Document Status and Sign Page Bln 2009 03 19 Bln 2010 04 29 Approved Lan 10 10 Document and Product Description User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 TTT802 S Cable harness Part 12 630 8 0 5 m AWG20 12 Volt Vbat A16 12 Volt Su Eni pply A15 Gnd 0 4 m AWG22 33 A4 DO1 FET Rpm Output Ignition pulses to Rpm meter A9 Gnd Mini SureSeal Male 1 0 m AWG22 Use Com cable to A1 Gnd A2 Tx Data RS232 Output connect to
9. mand is considered valid or not depends on several different circumstances All to ensure a safe shift function Thanks to the closed loop system the shifting is both fast and reliable which is a big advantage compared to more simple timing controlled paddle shift systems Shifting fast really means fast Gear shift time measurement The shortest gear shift up and down for each gear 1 2 3 top gear are measured in milliseconds and can be read in the TT T802R1N Manager Gearbox race time The race time in gear 1 2 3 top gear total and on each gear are measured and can be read and cleared using the TTT802R1N Manager Gear Shift counter The total number of gear shifts up gear 1 2 3 to top gear is counted and can be read and cleared using the TTT802R1N Manager Display test Show Firmware version When the TTT802 is powered up with the gear in Neutral the display shows V 7 0 if firmware 7 0 and then the display and bar segments are toggled for aprox 4 second If there is no Rpm input the display test will appear even in other gears than Neutral Oil change Interval During the first 10 15 seconds after the TTT802 has been powered up the N for Neutral position will be replaced with a 0 if the Oil change interval has been reached The interval can be setup and the oil change confirmed using the TTT802R1N Manager www ttt racing com TTT Racing Products Sweden www flatshift com Docu
10. mnent File name Document Type ae i MANTTT802R1INE docx External First Revision Sign is e Updated Revision Sign and Date Document Status and Sign Page Bln 2009 03 19 Bln 2010 04 29 Approved Lan 4 10 Document and Product Description User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 Setting up Gear Barrel sensor and Calibrate Gear Positions Initiate To initiate the calibration procedure just wave with a magnet in front of the rom shift light bar within the first 10 seconds after the Gearshift Controller has been turned on By doing so the display will indicate R with a flashing dot The bar turns into a voltmeter where the top white led indicates the barrel sensors mid position Setup Gear Barrel sensor It is important that all Gear positions fits in the sensors measuring range 0 360 degrees and that the sensor is approximately the same amount of degrees from its end positions on R and Top Gear On a 6 speed gearbox where the Neutral is in the middle of 1 and 2 on half the angle that is between all other gears the ci gear should be close to 180 degrees This is when the white dot in the bar indicates the barrel sensors mid position The barrel sensor can also be read in the TT T802R1N Manager and after calibration the calibrated positions can be read Calibrate Gear Positions When the sensor is fixed the actual calibration procedure can be performed Select Reverse gear then confirm thi
11. onitored and if the sensor gives a false reading the flat shift function is disabled Barrel sensor error is indicated with an E on the display and when the fault disappears the display goes back to indicate actual Gear Position If the software detects a small barrel sensor misalignment that might depend on bad calibration or mechanical wear in the sensor or gearbox the display indicates a small N in the Neutral Gear Position Both these error detections can be individually enabled disabled using the TTT802R1N Manager Flatshift function cut gearing up down and blip gearing down can be selected individually for each gear When the controller detects a beginning shift up or shift down the ignition pulses are manipulated and they are not completely activated again until the barrel sensor indicates that we are in a safe position to do so In the TT T802R1N Manager the user can chose if the Gear Position Indicators decimal dot should indicate the flatshift functions cut and blip There are several possible ways that the controller can detect a beginning shift up or shift down sequence One is using a digital or analog Lever sensor or just using the barrel position or both Setting up the limit s for the sensor etc is done in the TTT802R1N Manager There are also user settings to set barrel sensitivity individually on each gear When puiting the gear in Neutral the ignition cut if active will remain active for 1 second and the blip
12. output if active will stay active until timer Blip Timeout deactivates the output The Blip Timeout value is setup in the TTT802R1N Manager Thanks to the closed loop system the driver can shift fast or slow just the way he likes which is a big advantage compared to more simple timing controlled flat shift systems Shifting fast really means fast www ttt racing com TTT Racing Products Sweden www flatshift com Documnent File name Document Type ae i MANTTT802R1INE docx External First Revision Sign is e Updated Revision Sign and Date Document Status and Sign Page Bln 2009 03 19 Bln 2010 04 29 Approved Lan 3 10 Document and Product Description User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 Closed Loop Paddle shift control Optional Only in P The main sensor used by the control is the high resolution calibrated gear barrel sensor which continuously informs the controller about the exact position of the barrel The reading from the gear barrel sensor is monitored and if the sensor gives a false reading the paddle shift function is disabled Se flatshift function When a valid shift up or shift down command is present the corresponding digital FET output activates the shift valve to start the shift sequence and at the same time the ignition pulses are manipulated and is not completely activated again until the barrel sensor indicates that gears are in a safe position to do so If the shift com
13. proved Lan 8 10 Document and Product Description Documnent File name Document Type ae User Manual TTT802 Gearshift Controller Firmware for R 1 N 2 Related products Part Part Part Part Part Part Part Part Part Part Part Part Part Part Part Part Part 12 625 4 12 630 8 12 635 3 12 627 2 12 639 9 12 640 7 12 649 8 12 650 6 12 651 5 12 660 5 12 671 3 12 675 9 12 678 6 20 615 6 30 521 9 30 510 1 40 110 4 www tit racing com TTT802 Sun Visor TTT802 S Cable harness TTT802 P Cable harness paddleshift TTT802 Cable kit with flying wires TTT802 QT Cable harness add on for Start Switch and Quick Trim or custom mounted potentiometers for adjusting Launch control settings TT T802 BAL Cable harness add on for Blip output and analog lever sensor Communication cable RS232 for TTT802 1 5m Extension cable 500mm 4 pole DR25 Extension cable 500mm 2 pole DR25 TTT905 Quick Trim Can be used to adjust Launch Control settings TTT748 Ignition Interface for carburettor motors with Hal sensor distributors TTT924 1 6 Channel Ignition Interface ignition cut when used with ECU without cut input Handles from 1 to 6 coils with integrated amplifiers TTT937 Power Switch Ignition Interface ignition cut when used with ECU without cut input Interrupts ignition coil power Vbat VGX360 5KP Contact less high resolution
14. s gear position using the magnet Dot stops flashing The display should now indicate R with the dot turned on Shift to 1 gear The display changes to 1 with a flashing dot Confirm using the magnet Dot stops flashing Shift to Neutral The display changes to N with a flashing dot Confirm using the magnet Dot stops flashing Shift to 2 gear The display changes to 2 with a flashing dot Confirm using the magnet Dot stops flashing Continue like this until the last gear is confirmed If you have a 5 speed gearbox the display should now indicate 5 with the dot turned on and if you have a 6 speed gearbox it should indicate 6 with the dot turned on Up until this point the user can cancel the calibration procedure by turning of the power supply to the Gearshift Controller By doing so nothing has been altered in the memory and the status of the Controller is the same as before the calibration procedure were initiated To finalize the calibration and to set the last confirmed gear as the top gear just confirm using the magnet one last time and the calibration procedure is ready The dot turns off and the display indicates the actual gear in position www ttt racing com TTT Racing Products Sweden www flatshift com Documnent File name Document Type ae MANTTT802RINE docx External First Revision Sign is e Updated Revision Sign and Date Document Status and Sign Page Bln 2009 03 19 Bln 2010 04 29 Approved Lan 5 10 Document and Pro
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