Callisto is a cost-effective product representing the new generation of our mid-range products. It is sold in three dedicated versions:
- Engine Control Unit (ECU)
- Transmission Control Unit (TCU)
- Throttle-by-Wire Controller (TxW)
These versions are not interchangeable.
Each application group contains the correct electronic components, such as diodes and resistors, required for that specific application. This eliminates complicated harness modifications where these components would otherwise have to be installed in the wiring loom. It also reduces unnecessary component count inside the product, which helps keep the unit cost-effective.
Callisto includes both negative and positive drivers, allowing the system to drive many devices directly. This reduces costs because Callisto does not require external coil drivers when using basic coils.
The unit can connect directly to most sensors found on engines and transmissions.
Callisto is supplied with a wide range of firmware developed by Spitronics to support many applications used so far. This makes it a versatile product to keep in stock.
Units can be purchased unprogrammed, allowing the correct firmware to be loaded when the sale is made. This is very useful for dealers who wish to keep inventory without needing to stock many different variants.
Harness systems are simplified and each product group is supplied with specialised wiring looms.
Overview
This versatile standalone automotive controller is designed as a cost-effective and durable replacement for modern vehicle electronic control units. It can be used on a wide variety of engines, transmissions, and other automotive control applications.
The system includes unique and practical features that make installation and tuning straightforward. It has been designed with both novice and professional installers in mind.
This South African-developed product can easily be customised for various engines, transmissions, and throttle-by-wire systems. Typical applications include:
- racing engines
- vehicle conversions
- custom-built vehicles
- replacement controllers for production vehicles
- entertainment features such as pops and bangs
The unit is compact and reliable and may be epoxy-filled to create a rugged and water-resistant controller suitable for harsh environments. It can easily be mounted inside the driver’s compartment.
Firmware Protection
Callisto is intentionally not reprogrammable by the end user. This design decision was made to prevent support issues experienced with earlier systems.
Instead, the ECU is programmed with the correct firmware for the specific engine configuration. Certain settings that could cause damage if changed incorrectly are locked to simplify the setup procedure and improve reliability.
Because drivers are shared across many possible applications, this controlled firmware system is necessary to ensure correct operation.
Dealer Stock Model
Callisto can be supplied as an open box unit if a qualified dealer wishes to keep stock. This allows the dealer to keep fewer variants on hand and configure the unit when the sale is made.
The product is sold in a Commercial class, with an optional RacePack that unlocks advanced features such as launch control, spinning, and drifting functions.
This makes the system suitable for both:
- everyday vehicles
- performance applications
Qualified dealers may purchase systems at reduced prices in an unactivated status. This allows better control of cash flow within their businesses.
Activation of additional features can be performed online. Once activated, the remaining balance is paid and the full functionality becomes available.
Hardware and System Design
The Callisto unit is designed to connect directly to most sensors and actuators used on engines, transmissions, and other automotive systems without modification.
It uses modern high-speed microcontrollers and surface-mount technology. All components are machine-soldered to minimise human assembly errors.
The system supports features such as:
- Lambda control
- idle control
- launch control
- cam control
- stepper motor control
- throttle-by-wire control
- boost control
- line pressure control
- fuel pressure control
- Tiptronic transmission control
The controller can directly drive intelligent coils, injectors, solenoids, and throttle-by-wire motors. It can also read signals from sensors such as:
- coolant temperature
- intake air temperature
- throttle position
- manifold pressure
- crank position
- cam position
- lambda sensors
- fuel pressure sensors
Tuning Software
The Cosmos tuning software is designed to be user-friendly and allows the tuner to configure the various features of the system. This makes the Callisto adaptable to a wide variety of applications.
To learn more about the system, browse through the features and specifications provided in the following sections.
Features
Callisto TCU Features
Callisto firmware is dedicated to each transmission model. Firmware is not interchangeable between models. Refer to the selection chart for the capabilities of the different classes.
Tiptronic or Paddle Shift
- Automatic Mode – The driver sets the maximum target gear allowed.
• Semi-Automatic Mode – The driver has greater control over gear selection while automatic features remain active.
• Manual Mode – The driver has full control over the transmission with built-in protection against engine over-revving.
Tune or Map Selection Switch
This switch allows the driver to select four different transmission profiles, for example:
- Automatic
• Tiptronic
• Towing
• Off-road
• Racing
Shifter Position Input
- The TCU can detect many types of shifter sensors to operate correctly in all lever positions. Different sensing boards may be connected to detect serial or parallel switch configurations.
• Switches with common positive or common negative signals may be connected using the Level Shifter board.
• If no shifter sensor is available, the reverse light signal may be used to lock out shifting while in reverse. This method is not recommended for more complex transmissions.
Gear Profile Adjustments
Each gear can be individually configured for upshift or downshift behaviour.
Shift control can be tuned using:
- RPM
• Vehicle speed
• Throttle position (TPS)
Line Pressure Adjustments
Line pressure can be adjusted using graph-based control, where TPS represents engine load.
- Multiple graphs may be used depending on transmission requirements.
• The software supports up to four different pressure graphs.
Sensors
- TPS sensor – Indicates driver throttle demand so the TCU can adjust shift behaviour accordingly.
• RPM signal – Used to shift the transmission to optimize engine performance and economy.
• Speed sensor – Protects against downshift over-revving and supports other shift algorithms.
• Transmission oil temperature sensor – Adjusts line pressure during cold conditions to soften gear shifts.
• Low-range sensor – Automatically adjusts transmission speed settings when low range is engaged.
• Shifter position sensor – Indicates which gear position is selected and which gears are permitted.
• 4-position map profile switch – Adjusts shift behaviour based on driver-selected profiles.
Sensors can be calibrated within the software to suit most engines and transmission systems.
Solenoids
- Shift solenoids select the required gear.
• Duty or PWM control solenoids control line pressure, lock-up and shift control solenoids to ensure smooth and comfortable gear changes.
General Purpose Outputs
General-purpose outputs can be used for custom features, for example:
- speed warning
• sirens
• dashboard LEDs
• other auxiliary functions
Speedometer Output
The speedometer output drives electronic speedometers and can be calibrated within the software.
Selectable Lock-Up
Torque converter lock-up can be enabled in all gears, where supported by the transmission, to improve fuel economy and reduce heat.
Standard Harness
A universal harness system reduces the need to keep multiple harnesses in stock.
Level 2 harnesses include relays and fuses to simplify installation and save time.
All input harness wiring uses screened cables to reduce electromagnetic interference that may cause unstable TCU behaviour.
Additional interface boards are available to support different transmission wiring configurations.
Compact Electronics
The TCU is compact and can easily be mounted under the dashboard, requiring minimal installation space.
Complete Firmware for Most Transmissions
Firmware is available for a wide range of transmission types.
Cost Effective
All required transmission control features are included, removing the need for expensive additional systems.
Standard Tuning Software
All Spitronics products use the same tuning software platform. Features not available in the firmware are automatically hidden to simplify the interface.
Easy DIY Instructions
Installation instructions are provided for users who wish to install the system themselves.
Start-Up Maps Included
Base maps are included to assist with initial setup and tuning.
User-Friendly Tuning Software
The tuning software is fully explained in the manual.
Map Locking
Tuning maps can be locked to prevent tampering. This is useful for transmission builders providing guarantees.
No Dyno Required
Transmissions can be tuned using the built-in tools by following the instructions in the manual.
(The last five points are intended for users who understand transmission wiring and operation. If unsure, download the software, maps, manual and drawings and experiment first. These are available free of charge.)
Specifications
Power Supply
12V Ignition power – 100 mA, filtered on board
12V Battery ignition power – 100 mA, filtered on board
12V Driver power – up to 14 A, depending on the load of connected devices
2.5 mm² earth strap for internal negative drivers
1.5 mm² battery earth for electronic components
Fixed Inputs
- 2 × Digital inputs for Magnetic, Hall, or Optical sensors (jumper selectable)
• 1 × Digital input for Dual Map, FlatShift, or RapidFire
• 4 × Analogue inputs (0–5 V) for MAP, TPS, POT, and Lambda
• 1 × Built-in 1.15 bar altitude sensor input (0–5 V) – optional, installed at purchase
• 1 × Water temperature input – 1k, 2k, and 2.5k NTC sensor selectable
• 1 × Air temperature input – 1k, 2k, 2.5k, and 10k NTC sensor selectable
• 1 × UART communication port for Spitronics USB cable interface
Fixed Outputs
- 12 × 20 A 400 V High-Voltage Negative Drivers for coils, injectors or GP outputs
(ground or floating output)
- 6 × 6 A 36 V Positive Drivers for smart coils and GP outputs
(+12 V or floating output)
- 2 × 9 A 100 V Negative Drivers for relay and RPM output
(ground or floating output)
Communication
Software UART connection via USB2 converter cable
Bootloader installed for firmware programming during production via USB cable
Physical Specifications
Size: 144 mm × 68 mm × 22 mm
Weight: 187 g (non-resin filled)
Connector type: Plastic Molex connectors
3–5 connectors depending on model: 12, 10, 8, 6, and 4 pin
* The unit can be resin-filled. Weight will increase depending on the resin used.
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