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BODAS
RC36-20 Controller
Series 30
Data sheet
RE 95203/03.12 1/24
Replaces: 02.11
For the closed and open loop control of hydraulic components
Contents
Connection diagram RC36-20/30 part 1
Connection diagram RC36-20/30 part 2
Features
– High performance thanks to ultra-modern 32-TriCore technology with 150 MHz
– Component of BODAS system for mobile applications
– Robust design meeting specifications for mobile applications
– High electromagnetic compatibility (EMC)
– Inputs and outputs with fault detection
– Central deactivation of all outputs
– Pulse-width-modulated (PWM) solenoid currents for minimum hysteresis
– Closed-loop control of solenoid currents, i.e. not dependent on voltage and temperature
Main components
– W atchdog supervised processor for program run monitoring
– Two independent sensor power supplies
– Four independent CAN bus interfaces
– Two-channel stop function
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Ordering code
RC
01
36-20
02
/
01
Type
BODAS controller
Version
1. Position: number of proportional outputs
02
2. Position: number of switched outputs
30
03
RC
36-20
03
Series
Series 3, index 0
30
Notes:
The BODAS controllers are not functional without software.
In order to use the BODAS controllers, you also need:
– BODAS standard software or
– application-specific software
If there is a sample label on the name plate, it is a prototype or sample, i.e., components not released for series production.
Possible sample labels are:
– SC: A
– SC: B
– SC: C
– SC: S (Software prototypes)
Optional accessories
–
BODAS-design software
The windows-based BODAS-design PC software
(RE 95112) is used for programming the BODAS RC controllers. All graphical and textual programming languages specified according to IEC 61131-3 are available for the programming.
–
BODAS-service software
The windows-based BODAS-service PC software
(RE 95086) is used for displaying functions, errors and system variables as well as for setting parameters via a PC.
–
C programming interface C-API
The C-API programming interface (RE 95115) is used for programming the BODAS RC controllers in the C programming language. All required functions that are needed for the configuration and the reading of the inputs, the control of the outputs, the use of the communication interfaces and the creation of the diagnostics information for BODAS-service are available to the user.
Additionally, the user needs a C-compiler, with which the created program is translated into a machine code that is readable for the BODAS controller.
–
BODAS measuring adapter MA6
The BODAS measuring adapter MA6 (RE 95090) is used for measuring all electrical signals at the inputs, outputs and interfaces of the BODAS controller. For testing purposes, it is connected in series between the controller and the vehicle or device wiring.
–
BODAS TB3 test box
(2 pieces) and adapter kit (1 piece)
The BODAS TB3 test box (RE 95092) is used for simulation of vehicle and device functions for development and testing purposes with BODAS controllers. The BODAS TB3 test boxes are connected to the controller via the adapter cable TAK4/10.
–
BODAS CAN I/O extension module RCE12-4/22
The BODAS CAN I/O extension module RCE12-4/22
(RE 95220) is used for the I/O extension of a controller if the number of inputs and outputs of the controller is not sufficient for the specified application.
All products mentioned here are available from Bosch Rexroth.
Further information can be found on the Internet at: www.boschrexroth.com/mobile-electronics.
RE 95203/03.12 RC36-20 Series 30 Bosch Rexroth AG
3/24
Description
The BODAS controller RC36-20 is designed as a universal central controller for complex mobile working machines. Thanks to the ultra-modern 32-bit TriCore technology, a clock frequency of 150 MHz and parallel processing, the RC36-20 pushes into completely new performance dimensions that were previously reserved for larger PLC systems. The fields of application of the RC36-20 extend from the programmable control of proportional solenoids and additional switching functions to travel drives and gear shiftings as well as coordination of highly complex control circuits in mobile working machines. With
67 input channels, 56 output stages and an additional output
(4 to 20 mA), as well as four CAN buses for communication in the vehicle, the RC36-20 provides a high-performance platform for all functions of mobile working machines.
Simple and flexible programming of the BODAS controller according to the industry standard IEC 61131-3, which enables a very convenient and rapid introduction to the programming of the RC36-20, is possible with the BODAS-design software.
Comprehensive and complex applications can be conveniently developed and clearly represented with BODAS-design.
An application interface in the form of a C-API interface is available for the development of the full performance capability of the RC36-20 BODAS controller when the C programming language is used. By using it, the software developer can concentrate on the important functions of his machine without having to become immersed in the details of the TriCore technology.
Internally, the series 30 BODAS RC controllers contain a highperformance 32-bit TriCore microprocessor and all input and output circuits. Analog voltages in the range from 0 to 10 V and 0 to 32 V, currents from 0 to 20 mA, frequencies from
0 Hz to 10 kHz and switching information are processed as input signals. As well, the RC36-20 offers special inputs for intelligent Bosch Rexroth sensors, like the speed sensor
DSM1-10 with integrated diagnostics function or resistor inputs from 700 to 2000 Ω, for example for the direct connection of temperature sensors. The inputs are protected against overvoltage and electrical interference. The voltage inputs can be monitored for the detection of a cable break or short circuit.
The current-controlled proportional solenoid outputs are pulsewidth-modulated (PWM) and are compensated for temperature and voltage for high accuracy and minimum hysteresis.
They are optimally harmonized with the electrical proportional control of the axial piston units and valves of Bosch Rexroth.
The switched outputs are designed for direct switching of relay and switching solenoids. Moreover, the outputs have integrated voltage and current monitoring.
With the BODAS-service software, the programs can be quickly and simply downloaded to the controller via the Flash module. Extensive service functions, such as diagnostics, parameter setting or display of process variables are available via the graphical Windows interface of BODAS-service. This enables simple parameter setting and diagnostics in order to place the machine in service quickly and safely.
The BODAS RC controllers were developed specifically for use in mobile working machines and satisfy corresponding safety requirements regarding ambient temperatures, water and dust ingression, shock and vibration as well as electromagnetic compatibility (EMC).
BODAS RC controllers and corresponding software in combination with pumps, motors, valves, sensors, input devices and actuators from Bosch Rexroth make for complete system solutions.
CAN bus interfaces are available with all BODAS controller RC for exchanging data with other bus users or electronic systems
(e.g. RC or RCE, joystick, diesel engine injection, display).
Four independent CAN bus interfaces, each of which can be operated with various protocols, are available in the RC36-20
BODAS controller for communication. Communication with the
BODAS-design and BODAS-service software is likewise done via CAN bus and is based on the Standard Key Word Protocol 2000 (KWP 2000).
With the RC36-20, it is possible to realize two-channel deactivation (stop function). To do this, the corresponding development guidelines, which are available on request, need to be observed.
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Block circuit diagram
Controller
External inhibit
1)
Power supply output stages and electronics
+
-
Power supply with intelligent watchdog
Ignition switch
(terminal 15)
+
Activation pulse
Inputs
Deactivation channel
2)
Frequency inputs
Voltage inputs
1
2...6
7...8
9...10
1...2
3...9
Current inputs
1...12
Temperature inputs
Switch inputs
1...4
1...32
SW-INH
Frequency
DSM
Frequency inductive
Frequency active
Voltage
0 to 32 V
Voltage
0 to 10 V
Current
0 to 20 mA
Temperature
(resistance)
Switch
External inhibit 1 )
Power supply
Watchdog
SPI bus
Power supply
Central deactivation
TriCore™ microcontroller 32 bit
µC microcontroller
DSP digital signal processing
Risc µC reduced instruction set computer
Flash
EPROM
6 MByte
RAM
1 MByte
Power outputs
Measuring
PWM output stage
Switching end stage
1...36 High-side proportional solenoid outputs 2.0 A
1...12 Switched outputs 1.8 A
Switching end stage
13...20 Switched outputs 0.5 A
Status
Digital input
Two separate
A/D converters
12-bit
Controller for outputs
Interface controller
Current
4 to 20 mA
1 Analog output
4 to 20 mA
Voltage
5 V
Voltage
10 V
Interface drivers
1 Sensor supply 5 V
1 Sensor supply 10 V
1...4 CAN bus interface
1) Input that is independent of the microcontroller, for the central enabling/deactivation of the power outputs.
2)
Input for the central enabling/deactivation of the power outputs in software
Abbreviations:
μC = micro controller
DSP = digital signal processing
RISC = reduced instruction set computer
RE 95203/03.12 RC36-20 Series 30
Notes
Bosch Rexroth AG
5/24
6/24
Bosch Rexroth AG
Technical data
Controllers RC
Nominal voltage
Residual ripple (DIN 40839, part 1)
Supply voltage, permissible range
Current consumption
standby, in the 12 V vehicle electrical system
12 and 24 V max. ± 2 V
8 to 32 V standby, in the 24 V vehicle electrical system loaded, in the 12 V vehicle electrical system loaded, in the 24 V vehicle electrical system
Fuses
internal: external: in the supply path
4)
Controllers enabling pin
Constant voltage sources
3) e.g. for setpoint potentiometer
1000 mA
500 mA
Digital voltage inputs, diagnostics-capable
Analog voltage inputs, pulldown
380 mA
290 mA max. 50 A max. 50 A
50 A
Terminal 15
10 V ± 350 mV
5 V ± 150 mV
0 to 10 V
0 to 32 V
0 to 20 mA Analog current inputs, diagnostics-capable
Resistor inputs
e.g. for temperature sensors resistance measuring range
Frequency inputs total
DSM
700 to 2000 Ω
Inductive sensors
Active sensors
0 to 9 kHz level 7 mA/14 mA
0 to 10 kHz level > 1 V eff
0 to 10 kHz level low < 1 V level high > 6 V
Analog current outputs
for 200 Ω load (burden) for 150 Ω load (burden)
Proportional solenoid outputs (PWM)
High side current range
Pulsation frequency
Digital output stages total
4 to 20 mA
0 V (off), 0.5 to 5.0 V
0 to 2.0 A 2)
0 Hz, 83 to 250 Hz
High side current range
High side current range
Interfaces
CAN 2.0 B, ISO 11898
Fault detection in the event of cable break and short circuit
max 1.8 A 2) max 0.5 A
Analog inputs
Proportional solenoid outputs
Switching solenoid outputs
Short circuit resistance when energized
to supply voltage and ground for all inputs and outputs
1) 3)
Reverse-connect protection
Power supply/battery
1)
2)
3)
4)
Exception: GND, sensor GND, sensor supplies and CAN interfaces to battery
Max. total current per group: 5 A
Sensor voltage inputs are released when there is a short circuit to battery.
A correct reading of sensor signals is no longer ensured.
Cable protection. The wiring has to be rated according to the fuse protection.
RC36-20 Series 30 RE 95203/03.12
2
1
10
6
2
32
7
2
12
4
36
20
12
8
4
–
36-20
RE 95203/03.12 RC36-20 Series 30
Technical data
Controllers RC
Microcontroller
Clock frequency
Memory capacities
RAM
Flash EPROM
EEPROM
Software installation
Download in Flash memory
Electromagnetic compatibility
Spurious interference (ISO 11452-2)
Spurious interference (ISO 11452-5)
Electrostatic discharge ESD (according to ISO 10605)
Out of service
In service
Max. dissipation power
Electronics
Output stages
Operating temperature, case
with mounting point on cooling surface
Storage temperature, case
Vibration resistance
Broadband noise vibration
(IEC 60068-2-34)
Sinusoidal vibration (IEC 60068-2-6)
Random-shaped vibration
(IEC 60068-2-36)
Shock resistance
Transport shock (IEC 60068-2-27)
Continuous shock
(IEC 60068-2-29)
Type of protection (DIN/EN 60529)
1) with assembled mating connector
Resistance to moisture
(IEC 60068-2-30Db; variant 2)
Resistance to salt spray
(IEC 60068-2-11, part 2, test Ka)
Case material
Mass
Outer dimensions
Mating connector
1)
While following the installation instructions
MHz
MByte
MByte kByte
Bosch Rexroth AG
7/24
200 V
RMS
/m;
100 V
RMS
/m;
8 kV
15 kV
W at 32 V
W at 32 V
-40 to +85 °C (-40 to +185 °F)
Maximum permissible case temperature in the short-term passive:
-40 to +105 °C (-40 to +221 °F)
34 m/s 2 , 10 to 1000 Hz,
20 cycles per axis
Values on request
1.5 mm, 5 to 57 Hz,
10 g, 58 to 2000 Hz,
8 cycles per axis
15 g; 11 ms per spatial axis x, y, z and in each direction
(pos./neg. )
25 g, 6 ms per spatial axis x, y, z and 1000x in each direction (pos./neg.)
IP65
95 % (+25 °C to +55 °C)
72 h, 35 °C, 5 % NaCl
Diecast aluminum approx. kg
Length (in mm)
Width (in mm)
Height (in mm)
96-pin
58-pin
1.5 kg
303.4
210
50.8
1
1
8.5
60
36-20
TC1796
150
1
6
32
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Connection diagram RC36-20 part 1
3 A 3 )
Optional voltage circuit breaker
+12 V/
+24 V
Ignition switch
1 A
30 15
30
0 V
Masse
31
Stop switch
UBat
Optional two-channel stop switch, pins must be connected
2
DSM
3
DSM
4
10
DSM
5
6
7
Ind
8
DSM
Ind
9
DSM
Aktiv
Aktiv
High/low digital inputs switch active
VSS_1
VSS_2
11
12
13
9
10
7
8
14
5
6
3
4
1
2
201
203
204
205
206
245
258
240
202
207
220
233
246
122
123
124
228 INH
112
IN_58
113 IN_59
110 IN_60
111
IN_61
109 IN_62
108
IN_63
133
IN_64
132 IN_65
213
IN_66
208 IN_67
157
252
238
222
148
159
158
214
210
250
236
209
147
223
IN_7
IN_8
IN_9
IN_10
IN_11
IN_12
IN_13
IN_14
IN_1
IN_2
IN_3
IN_4
IN_5
IN_6
15
16
17
18
136
137
135
134
IN_15
IN_16
IN_17
IN_18
19
20
211
144
IN_19
IN_20 low active
24
25
26
27
21
22
23
28
29
30
31
32
247
234
225
212
248
237
239
251
224
143
142
235
IN_21
IN_22
IN_23
IN_24
IN_25
IN_26
IN_27
IN_28
IN_29
IN_30
IN_31
IN_32
Switch-on signal
INH
13 )
SW-INH
14 )
VSS_2
0 V/+5 V 6 )
0 V/+5 V 6 )
0 V/+5 V 6 )
0 V/+5 V 6 )
VSS_1 10 )
VP_2
15 )
OUT_37
OUT_38
OUT_39
OUT_40
OUT_41
OUT_42
OUT_43
OUT_44
OUT_45
OUT_46
OUT_47
OUT_48
OUT_49
OUT_50
OUT_51
OUT_52
OUT_53
OUT_54
OUT_55
OUT_56
192
191
190
189
2 )
1
2 )
2
2 )
3
2 )
4
Power circuit breaker outputs 12)
1.8 A
1.8 A
1.8 A
1.8 A
194
193
188
187
2 )
7
2 )
8
2 )
5
2 )
6
1.8 A
1.8 A
1.8 A
1.8 A
249
172
195
196
115
243
241
242
114
256
244
257
2 )
17
2 )
18
2 )
19
2 )
20
2 )
13
2 )
14
2 )
15
2 )
16
2 )
9
2 )
10
2 )
11
2 )
12
1.8 A
1.8 A
1.8 A
1.8 A
Small signal outputs
0.5 A
0.5 A
0.5 A
0.5 A
0.5 A
0.5 A
0.5 A
0.5 A
OUT_57
4...20 mA
221
8 )
Analog signal output
4 to 20 mA
255
215
216
CAN 1
253
254
CAN 2
163
162
CAN 3
161
160
CAN 4
CAN bus interface
CAN bus interface
CAN bus interface
4)
4)
4)
CAN bus interface 4)
Connection diagram part 2, see next page
1 )
1)
2)
3)
4)
5)
6)
Short, low-resistance connection from a case screw to the device ground or vehicle ground
Separate ground connection from solenoid return line to battery (chassis possible)
Separate fuse needed for switches and sensors
CAN bus: 120
Ω termination resistor needed
Outputs 5 V/10 V can alternatively also be used as sensor supply.
Jointly switchable between high/low active via software. Maybe switched to sensor ground or constant voltage source VSS_1 or VSS_2 externally.
For additional footnotes, see next page
RE 95203/03.12 RC36-20 Series 30 Bosch Rexroth AG
9/24
Connection diagram RC36-20 part 2
Active sensors/ potentiometer
0 to 32 V
Active sensors/ potentiometers
0 to 10 V
6
7
8
9
3
4
5
1
2
5 )
219
VSS_1
5 )
232 VSS_2
Constant voltage source
10 V/1000 mA
119
120
IN_33
IN_34
141
231
217
226
139
166
164
IN_35
IN_36
IN_37
IN_38
IN_39
IN_40
IN_41
Constant voltage source
5 V/500 mA
VP_1
15 )
OUT_1
OUT_2
OUT_3
OUT_4
OUT_5
OUT_6
OUT_7
OUT_8
OUT_9
OUT_10
OUT_11
OUT_12
153
177
154
178
179
180
181
182
183
184
185
186
2 )
1
2 )
2
2 )
3
2 )
4
2 )
5
2 )
6
2 )
7
2 )
8
2 )
9
2 )
10
2 )
11
2 )
12
OUT_13
OUT_14
OUT_15
OUT_16
151
175
152
176
2 )
13
2 )
14
2 )
15
2 )
16
Proportional solenoids
12)
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
Connection see page 8
PTC 1000
Temperature sensor
Current source
0 to 20 mA or alternative voltage source
0 to 10V
1
9 )
2
9 )
3
9 )
4
9 )
146
121 IN_54
116
IN_55
117 IN_56
118 IN_57
145
138
IN_42
1
8 )
168 IN_43
2
8 )
218
IN_44
3
8 )
229 IN_45
4
8 )
171
IN_46
5
8 )
227 IN_47
6
8 )
167
IN_48
7
8 )
169 IN_49
8
8 )
170
IN_50
9
8 )
165 IN_51
10
11
8 )
230
IN_52
8 )
140
IN_53
12
8 )
Sensor ground
5V constant voltage
Sensor ground
11)
11)
11)
OUT_17
OUT_18
OUT_19
OUT_20
149
173
150
174
OUT_21
OUT_22
OUT_23
OUT_24
130
131
156
155
OUT_25
OUT_26
OUT_27
OUT_28
126
101
125
129
OUT_29
OUT_30
OUT_31
OUT_32
128
103
127
102
OUT_33
OUT_34
OUT_35
OUT_36
107
106
105
104
2 )
33
2 )
34
2 )
35
2 )
36
2 )
29
2 )
30
2 )
31
2 )
32
2 )
25
2 )
26
2 )
27
2 )
28
2 )
21
2 )
22
2 )
23
2 )
24
2 )
17
2 )
18
2 )
19
2 )
20
1 )
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
2.0 A
7)
8)
9)
10)
11)
12)
13)
14)
15)
Observe max. current consumption when the proportional solenoids and the switched outputs are simultaneously activated
Independent ground connection of the current source to the battery, GND controllers possible
Usable as switch inputs if there is an external connection to GND
If voltages are applied to these inputs that are higher than 5 V and simultaneously the sensor supply VSS_1 is unloaded, then VSS_1 during no-load operation may deviate from 5 V.
For use as voltage inputs (0 to 10 V), the load is switchable via software in groups for these inputs. Groups: inputs 1 to 6, inputs 7 to 10, inputs 11 to 12
Outputs arranged in groups, each having 4 output stages. Maximum permissible output current of a group: 5 A
First deactivation channel (in hardware): unlock of the output stages Level > 4.5 V/deactivation of the output stages < 1V/centrally switches the power supply of all proportional and switched outputs/cable break leads to the deactivation of all output stages
Second deactivation channel (in software): unlock of the output stages level < 5 V/deactivation of the output stages > 9 V/switches all proportional and switched outputs/cable break leads to the deactivation of all output stages.
Power supply is switchable via software
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Connection variants
Monitored potentiometer 2.5 to 5 kΩ
Error monitoring of the potentiometer
– Internal measurements of the sensor voltage (5 V)
– Connection of the potentiometer to a current input, via which the current of the potentiometer is checked.
– Checking the loop voltage. It must be within a valid range (software).
Switch input with fault detection
Error monitoring of the switch inputs
– Switching of the input voltage between 10 V and 5 V
– Reading the switching level and checking the valid range (software)
232
219
RE 95203/03.12 RC36-20 Series 30 Bosch Rexroth AG
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Overview of functions
Pin
250, 236, 209, 147, 223,
148, 159, 158
214, 157, 252, 238, 222,
210
136, 137, 135, 134
211, 144
Pin
To
ADC
Description
Digital input with switchable pullup/ down to 5 V/GND switchable in 4 pullup/pulldown groups:
IN_1 to IN_8
Main function
Digital input
Operating point, settable via software
Pullup/pulldown resistance, switchable via software
Switch externally to GND or VSS_x
IN_9 to IN_14
Alternative functions
Analog voltage input
Measuring range 0 to 10 V
Resolution
Input resistance
12 bit (2.7 mV/bit)
DC to 5 V
DC to GND
21.5 kΩ (pullup)
15.0 kΩ (pulldown)
(21.5 kΩ II 49.5 kΩ)
Filter limit frequency 330 Hz
Basic setting with open terminal 5 VDC
5 VDC
GND
GND GND
IN_15 to IN_18
From
CPU
I N_19 to IN_20
224, 143, 142, 235, 247,
234, 225, 212, 248, 237,
239, 251
IN_AIV10V_PUPD
VSS_1
Digital input
IN_21 to IN_32
These inputs have a pullup of 21.5 kΩ to the voltage
VSS_1 (5 V)
Digital input
Switching threshold settable by software.
To connect externally to
GND
Analog voltage input
Measuring range 0 to 10 V
Resolution input resistance
12 bit (2.7 mV/bit)
DC to GND 49.5 kΩ
Filter limit frequency 330 Hz
To
ADC
Pin
112
Pin
113
Pin
GND GND
VSS_2
IN_AIV10V_PU
CPU
Port
ADC
Digital input
IN_58 (SW-INH)
This input has an internal pullup resistance of 200 Ω to VSS_2 (10 V)
Default usage as secondary input
enabling
Enabling of the output stages via basic software
Functions like pin 113, including DSM frequency input
Configuration in application software is required for usage as frequency input
Phase measurement in combination with
IN_59 (pin 113)
GND GND
VSS_2
IN_FI_DSM_ANA
GND GND
CPU
Port
ADC
DSM frequency input
IN_59
This input has an internal pullup resistance of 200 Ω to VSS_2 (10 V)
Frequency input for
Bosch Rexroth DSM sensors
Frequency evaluation up to a maximum of 9 kHz.
Evaluation of additional information such as direction of rotation and error monitoring.
Frequency input for active sensors type NPN (e.g. HDD1)
Frequency evaluation of active speed sensors, that switch to ground.
Level low < 5 V (< 7 mA)
Level high > 9 V (> 13 mA)
Caution: short circuit current up to 47 mA
Phase measurement in combination with
IN_58 (pin 112)
IN_FI_DSM_ANA
Analog voltage input
Measuring range
Resolution
0 to 10 V
12 bit (2.7 mV/bit) input resistance
DC to GND 49.5 kΩ
Filter limit frequency 330 Hz
Digital input switching to GND
Evaluation possibilities
• Threshold adjustable via software
• Digital current threshold 10 mA ±3 mA
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Overview of functions
Pin
110, 111, 109, 108
Pin
VSS_2
IN_FI_DSM
CPU
Port
Description
DSM frequency input
IN_60 to IN_63
This input has an internal pullup resistance of
200 Ω to VSS_2 (10 V)
Main function
Frequency input for Bosch
Rexroth DSM sensors
Frequency evaluation up to a maximum of 9 kHz.
Evaluation of additional information such as direction of rotation and error monitoring.
Alternative functions
Frequency input for active sensors
type NPN (e.g. HDD1)
Frequency evaluation of active speed sensors, that switch to ground.
Level low < 5 V (< 7 mA)
Level high > 9 V (> 13 mA)
Caution: short circuit current up to 47 mA
Phase measurement between IN_60
(pin 110) and IN_61 (pin 111).
Phase measurement between IN_62
(pin 109) and IN_63 (pin 108)
133, 132
Pin
4.64 kΩ
GND
GND GND
IN_FI_IND
ADC
Inductive frequency input
IN_64 to IN_65
CPU
Port
Frequency input for inductive and active sensors type PNP
and NPN (e.g. HDD1)
Frequency evaluation up to
10 kHz input resistance
DC to GND 44 kΩ required signal amplitude min. 1 Veff (sinus)
Digital input switching to GND
Evaluation possibilities
• Digital current threshold 10 mA
±3 mA
Digital input active high
Evaluation possibilities
• Threshold adjustable via software
• max. 30 V
• Filter limit frequency depends on
amplitude
Analog voltage input
Measuring range 0 to 30 V
Resolution 12 bit (7.65 mV/bit)
Input resistance
DC to GND 44 kΩ
213, 208
Pin
119, 120
Pin
VSS_2
GND GND
IN_FI_AKTIV
GND GND
CPU
Port
ADC
To
ADC
Active frequency input
IN_66 to IN_67
This input has an internal pullup resistance of
6.81 kΩ to VSS_2 (10 V)
Frequency input for active
sensors type NPN (e.g. HDD1)
Frequency evaluation of active speed sensors, that switch to ground.
Short circuit current up to
1.37 mA
Frequency evaluation up to
10 kHz
Digital input switching to GND
Evaluation possibilities
• Threshold adjustable via software
• Digital current threshold
• Filter limit frequency 13.21 kHz
Level low < 1 V switch to GND with low resistance
Level high > 6 V switch open
Phase measurement between
IN_66 (pin 213) and IN_67
(pin 208)
Analog voltage input
Measuring range 0.5 to 5 V
Resolution
510 Hz
12 bit (1.78 mV/bit)
Filter limit frequency
Analog voltage input
IN_33 to IN_34
Analog voltage input
Measuring range 0 to 32 V
Resolution: 12 bit
Input resistance
(8.8 mV/bit)
DC to GND 51 kΩ
Filter limit frequency 800 Hz
Digital input active high
Evaluation possibilities
• Threshold adjustable via software
• max. 32 V
IN_AIV32V
RE 95203/03.12 RC36-20 Series 30 Bosch Rexroth AG
13/24
Overview of functions
Pin
139, 166, 164, 141, 231, 217,
226
Description
Analog voltage input
IN_35 to IN_41
To
ADC
Pin
GND GND
Main function
Analog voltage input
Measuring range 0 to 10 V
Resolution: 12 bit
(2.7 mV/bit)
Input resistance
DC to GND 49.5 kΩ
Filter limit frequency 330 Hz
Alternative functions
Digital input active high
Evaluation possibilities
• Threshold adjustable via software
• max. 10 V
138, 168, 218, 229, 171,
227
230, 140
Pin
To
ADC
Analog current input
with switchable load
(input resistance)
IN_42 to IN_53
Switchable in three groups between analog current and voltage input
GND
GND GND
From
CPU
Over voltage protection only if ECU is energized
IN_AIC_AIV10V
121, 116, 117, 118
Temperature input
IN_54 to IN_57
3.3 VDC
Analog current measurement input
Measuring range 0 to 20 mA
Load 488 Ω
Resolution 12 bit
(2.71 mV/bit)
Filter limit frequency 330 Hz
Analog voltage input
Measuring range 0 to 10 V
Resolution 12 bit
(2.71 mV/bit)
Input resistance
DC to GND 12.38 kΩ
Filter limit frequency 330 Hz
In 12 V applications two current inputs may be connected in parallel to halve the input resistance
Digital input active high
Evaluation possibilities
• Threshold adjustable via software
• max. 10 V
Pin
GND GND
To
ADC
Temperature measurement via resistance measurement of connected temperature sensors
Evaluation of passive temperature sensors with PTC measuring shunts from 700 to 2000 Ω
Support of
Bosch Rexroth sensors:
TSF (RE 95180)
TSA (RE 95181)
Digital input switching to GND
Evaluation possibilities
• Threshold adjustable via software
• max. 3.3 V
Analog voltage input
Measuring range 0 to 3 V
Resolution 12 bit
(1.26 mV/bit)
Input resistance
DC to GND 156.2 kΩ
Filter limit frequency 94 Hz
IN_TEMP_PTC_FTG
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Overview of functions
Pin
183, 184, 185, 186, 179, 180, 181, 182, 153,
177, 154, 178, 151, 175, 152, 176, 149, 173,
150, 174, 130, 131, 156, 155, 126, 101, 125,
129, 128, 103, 127, 102, 107, 106, 105, 104
From main switch
(battery voltage)
From main switch
(battery voltage)
PWR_ON
HS switch
Free wheeling diode
R068
22 kΩ
Pin
Description Main function Alternative functions
PWM output stage
OUT_1 to OUT_36
PWM output stage
High side switch clock frequency adjustable via software
Spark suppression diode for switching of inductive loads integrated
Max. current 2.0 A
Pulse duty factor 0 to 100 %
Power supply centrally switchable via VP_1
Switching output stage
diagnostics-capable actuated time 100 %
From
CPU current measurement to ADC
State to CPU
GND
GND
GND current
Sense to ADC
From
CPU
State to CPU
192, 191, 190, 189, 194, 193, 188, 187, 196,
249, 172, 195
From main switch
(battery voltage)
From main switch
(battery voltage)
22 kΩ
HS switch
Pin
PWR_ON
GND
Free wheeling diode
Power switching output stage
OUT_37 to OUT_48
Switching output stage
High side switch max. current 1.8 A
Spark suppression diode for switching of inductive loads integrated
Power supply centrally switchable via VP_2
GND
GND
115, 243, 241, 242, 114, 256, 244, 257
From main switch
(battery voltage)
HS switch
Pin
From
CPU
State to CPU
PWR_ON
Small signal switching output stage
OUT_49 to OUT_56
Switching output stage
High side switch max. current 0.5 A
Power supply centrally switchable via VP_2
GND
GND
221 current measurement to ADC
From
CPU voltage measurement to ADC
PWR_ON
VSS_2
HS switch
Reverse
Battery
Diode
Pin
Analog current output
OUT_57
Analog current output
Output signal at 200 Ω load
4 to 20 mA output is supplied via VSS_2
Analog voltage output,
Output signal 0 V (off),
0.5 to 5.0 V
150 Ω load required
GND GND
RE 95203/03.12 RC36-20 Series 30
Overview of functions
Pin
219
232
228
Pin
GND GND
Disable VP_1 and VP_2
CPU
Port
240
Pin
GND
215, 216
Pin
IN_KL15
CAN high
CAN low
TxD
RxD
GND
Pin
253, 254
Pin
CAN high
CAN low
TxD
RxD
Pin
163, 162
Pin
GND
CAN high
CAN low
TxD
RxD
Pin
161, 160
Pin
GND
CAN high
CAN low
TxD
RxD
GND
Pin
To Logic
Description
Sensor supply
VSS_1
Bosch Rexroth AG
15/24
Main function
Sensor supply, deactivatable
Output voltage precision
Load capacity
5.0 V
± 0.15 V
500 mA
Alternative functions
Sensor supply
VSS_2
Sensor supply, deactivatable
Output voltage 10.0 V
(max. Ubat -1 V) precision
Load capacity
± 0.35 V
1000 mA
External inhibit
INH
Digital input
Isolation of the output stages
Level > 4.5 V <= Ubat,
Deactivation of output stages < 1 V (Proportional and switched outputs), cable break leads to the deactivation of all output stages input resistance
DC to GND 33.6 kΩ
Ignition switch KL 15
Power on control unit
Switch-on signal
Switch to battery voltage to power on the control unit
Input resistance
DC to GND 7.9 kΩ
From
CPU
To
CPU
CAN interface
CAN1_H, CAN1_L
From
CPU
To
CPU
CAN interface
CAN2_H, CAN2_L
CAN interface
factory setting 250 kBaud,
Standard diagnostics interface
CAN 2.0 B, up to 1 Mbaud termination resistor in the cable harness required
CAN interface
CAN 2.0 B, up to 1 Mbaud termination resistor in the cable harness required
From
CPU
To
CPU
CAN interface
CAN3_H, CAN3_L
CAN interface
CAN 2.0 B, up to 1 Mbaud termination resistor in the cable harness required
From
CPU
To
CPU
CAN interface
CAN4_H, CAN4_L
CAN interface
CAN 2.0 B, up to 1 Mbaud termination resistor in cable harness required
16/24
Bosch Rexroth AG
Dimensions
Long-side side view
RC36-20 Series 30 RE 95203/03.12
Side view of connector side with pulled connector
Contact surface
Plan view
37 ± 2 45 ± 2
(303.4 ± 5)
267 ± 3
1)
View from below
214.5
94.7
11.5
333.9 ± 5
2)
6 x Ø 7
Ø 0.6
Fixing:
– The BODAS controller must be fixed at 6 positions (1 to 6).
– Tightening torque MA = 8 ± 2 Nm for fixing the BODAS controller with M6 screws.
– Tightening torque applies for fitting without washer. The equivalent tightening torque must be calculated when using washers.
– Bosch Rexroth’s consent is required if fixing is different from above.
– Installation point: flatness of the mounting surface
0.5
– The cable harness should be mechanically fixed in the area in which the controller is installed (spacing < 150 mm).
The cable harness should be fixed such that the assembly has sufficient room to exit the controller without putting too much force on the mating connectors.
If the mounting surface is not sufficiently even, place flexible compensating elements
(e.g. rubber washers) between the fixing points of the BODAS controller and the mounting surface.
– Space required for mating connector
– Space required for plugging and unplugging the mating connector
Display without scale, dimensions in mm
RE 95203/03.12 RC36-20 Series 30
Installation position
90°
360°
Bosch Rexroth AG
17/24
90°
Note:
Installation position only permissible with specified angular range.
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Mating connector
Order designations for the connector set with the Bosch Rexroth material number R902603622
Designation Number
Contact carrier code: A
Cover pre-assembled
Secondary lock 1.2
Secondary lock 2.8
Wire tie (cable tie)
Contacts
BDK 2.8 contact
Surface: SN
Insulation cross-section: 2.2 to 3.0 mm
Line cross section: 1.5 to 2.5 mm
Matrix 1.2 contact
Surface: SN
Insulation cross-section: 1.2 to 1.6 mm
Line cross section 0.35 to 0.5 mm
Matrix 1.2 contact
Surface: SN
Insulation cross section: 1.2 to 1.6 mm
Line cross section: 0.35 to 0.5 mm
Individual cross-section
White for BDK 2.8
Cross section: 2.2 to 3.0 mm
1 per connector
1 per connector
1 per connector
1
1 per connector
6 (8)* )
52 (55)* )
96 (100)*
)
6 (8)* )
Bosch part numbers of the individual parts
Module 58-pin Module 96-pin
1 928 404 780
1 928 404 774
1 928 404 760
1 928 404 761
1 928 498 057
1 928 498 137
–
1 928 300 600
1 928 401 713
1 928 404 781
1 928 404 773
1 928 404 762
–
–
–
1 928 498 137
–
* ) The number in the brackets indicates how many contacts or individual seals are included in the Bosch Rexroth connector set.
The number without brackets indicates the requirement.
View of connector strip
RE 95203/03.12 RC36-20 Series 30 Bosch Rexroth AG
19/24
Mating connector
Notes regarding assembly
In the assembly of the connectors, heed the assembly instructions for plug connections (1 928 A00 48M), BDK 2.8 contacts
(1 928 F00 025) and Matrix 1.2 contacts (1 928 A00 47M).
These assembly instructions are available on request from Rexroth.
Caution:
In the installation of the connector in the vehicle, observe the following:
The fixation of the cable harness must be done at a distance ≤ 150 mm after the outgoing cable unit at the same vibration level of the controller.
Recommended lines
Recommended connection lines for contacts 201 to 206:
– Cross section 1.5 mm² to 2.5 mm² (16 to 14 AWG, 14 AWG with thin electric insulation)
– Outer diameter: 2.2 mm to 3.0 mm
Recommended connection lines for contacts 101-105, 124, 125-129, 148, 149-153, 172, 173-177, 196, 207, 220, 233, 246
– Cross section 1.0 mm² to 1.5 mm² (18 to 16 AWG)
– Outer diameter: 1.9 mm to 2.1 mm for 1.0 mm², 2.2 mm to 2.4 mm for 1.5 mm²
Lines with 0.35 mm² to 0.5 mm² cross section (see other contacts below) may be used for these contacts, too.
However, cross sections 1.0 mm² to 1.5 mm² can ease the insertion of these contacts into the connector.
Recommended connection lines for other contacts not mentioned above:
– Cross section 0.35 mm² to 0.5 mm² (22 AWG)
– Outer diameter: 1.2 mm to 1.6 mm
Required tools
Bosch part numbers for tools*)
Contact (terminal)
Crimping tool with matrix
Quick change tool
Wear part set
Disassembly extraction tool
10 Replacement needles fort he extraction tool
Line cross sections for cable type FLK-R
BDK 2.8 contacts Matrix 1.2 contacts
1.5 to 2.5 mm 2
1 928 498 057
1 928 498 162
1 928 498 164
1 928 498 166
1 928 498 167
1 928 498 168
0.35 to 0.5 mm
1 928 498 137
1 928 498 212
1 928 498 200
1 928 498 206
2 1.0 mm 2
1 928 498 138
1 928 498 213
1 928 498 201
1 928 498 207
1 928 498 218
1 928 498 219
1.5 mm 2
1 928 498 139
1 928 498 214
1 928 498 202
1 928 498 208
*) The tools may be purchased from Bosch dealers or Bosch Service (www.bosch-service.com)
Drawings and further information about Bosch connectors and tools can be found on the internet: www.bosch-connectors.com
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Safety instructions
General instructions
– Reliable operation cannot be guaranteed if samples or prototypes are used in series production machines.
– The proposed circuits do not imply any technical liability for the system on the part of Bosch Rexroth.
– Incorrect connections could cause unexpected signals at the outputs of the controller.
– Incorrect programming or parameter settings on the controller may create potential hazards while the machine is in operation.
It is the responsibility of the machine manufacturer to identify hazards of this type in a hazard analysis and to bring them to the attention of the end user. Rexroth assumes no liability for dangers of this type.
– The component firmware/software must be installed and removed by Bosch Rexroth or by the authorized partner concerned in order to uphold the warranty.
– It is not permissible to open the controller or to modify or repair the controller. Modification or repairs to the wiring could result in dangerous malfunctions.
Repairs to the controller may only be performed by Bosch Rexroth or by an authorized partner.
– To switch off the system in emergencies, the stop switch (two-channel stop function) or the optional de-energize switch may be used. The switch must be in an easily accessible position for the operator. The system must be designed in such a way that safe braking is ensured when the outputs are switched off.
– When the electronics is not energized no pins must be connected to a voltage source. Thus, when the current supply is switched off, the supply for the electronics, the power outputs and the external sensor supply have to be switched off together.
– Make sure that the controller´s configuration does not lead to safety-critical malfunctions of the complete system in the event of failure or malfunction. This type of system behavior may lead to danger to life and/or cause much damage to property.
– System developments, installations and commissioning of electronic systems for controlling hydraulic drives must only be carried out by trained and experienced specialists who are sufficiently familiar with both the components used and the complete system.
– While commissioning and maintenance the controller (with BODAS Tools) the machine may pose unforeseen hazards. Before commissioning the system, you must therefore ensure that the vehicle and the hydraulic system are in a safe condition.
– Make sure that nobody is in the machine‘s danger zone.
– No defective or incorrectly functioning components may be used. If the components should fail or demonstrate faulty operation, repairs must be performed immediately.
– Controller used to develop software may only be installed in series production machines if it can be guaranteed that these controller have not been flash-programmed with new software more than 500 times. Controller that have been programmed more than 1000 times are not to be installed in series production machines!
Notes on the installation point and position
– Do not install the controller close to parts that generate considerable heat (e.g. exhaust).
– Radio equipment and mobile telephones must not be used in the driver‘s cab without a suitable antenna or near the control electronics.
– A sufficiently large distance to radio systems must be maintained.
– All connectors must be unplugged from the electronics during electrical welding and painting operations.
– Cables/wires must be sealed individually to prevent water from entering the device.
– The controller must not be electrostatically charged, e.g. during painting operations.
– The controller will heat up beyond normal ambient temperature during operation. To avoid danger caused by high temperatures, it should be protected against contact.
– Install the control unit in such a way that the electrical plug is facing downwards. This ensures that any condensation water that may form can flow out.
– Standing and permanently running water are not permitted anywhere near the circumferential groove (lid/base connector) or the pressure balance element (DAE).
– The case must be wired to vehicle ground in order to comply with EMC guidelines. Metallic screws are used to create a connection to vehicle ground.
RE 95203/03.12 RC36-20 Series 30 Bosch Rexroth AG
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Safety instructions
Notes on transport and storage
– If it is dropped, the controller must not be used any longer as invisible damage could have a negative impact on reliability.
– Control units must be stored with a mean relative humidity of 60% and at a temperature between -10 °C and +30 °C.
Storage temperatures between -20 °C and +40 °C are briefly permissible, for up to 100 hours.
– After a storage time of more than 5 years, the controller must be examined by the manufacturer.
Notes on wiring and circuitry
– The electronics and the power outputs of a controller must be fed from the same power source.
– When wiring the output stages, the maximum cumulative output current for each output stage group should be noted. The cumulative output current means a permanent, simultaneous actuation of the output stages.
– Lines to the speed sensors are so short as possible and be shielded. The shielding must be connected to the electronics on one side or to the machine or vehicle ground via a low-resistance connection.
– The product may only be wired when it is de-energized.
– Lines to the electronics must not be routed close to other power-conducting lines in the machine or vehicle.
– The wiring harness should be fixated mechanically in the area in which the controller is installed (spacing < 150 mm). The wiring harness should be fixated so that in-phase excitation with the controller occurs (e.g. at the controller bolting point).
– If possible, lines should be routed in the vehicle interior. If the lines are routed outside the vehicle, make sure that they are securely fixed.
– Lines must not be kinked or twisted, must not rub against edges and must not be routed through sharp-edged ducts without protection.
– Lines are to be routed with sufficient spacing to hot or moving vehicle parts.
– PWM outputs must not be linked or bridged.
– PMW outputs ( OUT_1 to OUT_36) must not be used to power lamps.
– The sensor supplies can be „pulled up“ by external connection, e.g., the application of a higher voltage, because they operate only as a voltage source but not as a voltage sink! Pulling up a sensor supply may result in unexpected malfunctions and damage of the controller in lasting operation.
– The „high side“ outputs may not be externally connected to battery.
– If the stop function is used in an application, the contact 228 (INH) of the controller must be connected to the stop switch in the vehicle. For a dual channel switch off function the contact SW-INH has to be connected to the stop switch, too. Refer to the connection diagram.
Note on proportional and switching solenoids and other wired inductive consumers
– The proportional solenoids must not be wired with spark-suppression diodes.
– Switching solenoids at the outputs of the control unit do not need to be connected to spark-suppression diodes.
– The electronics may only be tested with the proportional solenoids connected.
– Other inductive loads that are in the system but not connected to the controller must be connected to spark-suppression diodes. This applies to relays (e.g. for de-engergizing the controller) that have the same supply as the controller, too.
Intended use
– The controller is designed for use in mobile working machines provided no limitations / restrictions are made to certain application areas in this data sheet.
– Operation of the controller must generally occur within the operating ranges specified and released in this data sheet, particularly with regard to voltage, current, temperature, vibration, shock and other described environmental influences.
– Use outside of the specified and released boundary conditions may result in danger to life and/or cause damage to components which could result in consequential damage to the mobile working machine.
Improper use
– Any use of the controller other than that described in chapter „Intended use“ is considered to be improper.
– Use in explosive areas is not permissible.
– Damage resulting from improper use and/or from unauthorized interference in the component not described in this data sheet render all warranty and liability claims void with respect to the manufacturer.
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Safety instructions
Use in functions relevant to safety
– The customer is responsible for performing risk analysis of the mobile working machine and determining the possible safetyrelated functions.
– In safety-related applications, the customer is responsible for taking suitable measures for ensuring safety (sensor redundancy, plausibility check, emergency switch, etc.)
For example, a suitable assignment of input variables (e.g. by connecting the acceleration pedal signal to two independent analog inputs) can be used to detect faults and to activate specially programmed reactions.
Special measures may be initiated if the plausibility check shows deviations between the setpoint values and the values read back by the microcontroller.
– Product data that is necessary to assess the safety of the machine can be provided on request or are listed in this data sheet.
For all control units, the notes found in the API description and in the online help section of BODAS design must be observed.
Safety features in the BODAS controller
– The input circuits for speed and analog signals partially feature circuits that are mutually electrically isolated. Through appropriate input connections, the microcontroller and, when used, the software diagnostic function can detect faults.
– Faults in the supply voltage are detected by internal monitoring.
– All output signals can be monitored by the microcontroller with the appropriate software.
– For service purposes, the controllers can be operated with all power outputs de-energized.
– The internal watchdog module decentrally switches off the power supply of all proportional and switched outputs when there are malfunctions in the program run.
Further information
– In addition, the application-specific documents (connection diagrams, software descriptions, etc.) are to be observed.
– More detailed information on BODAS controllers may be found at www.boschrexroth.com/mobile-electronics.
RE 95203/03.12 RC36-20 Series 30
Notes
Bosch Rexroth AG
23/24
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Bosch Rexroth AG RC36-20 Series 30 RE 95203/03.12
Bosch Rexroth AG
Mobile Electronics
Glockeraustraße 2
89275 Elchingen, Germany
Phone +49 (0) 73 08 82-0
Fax +49 (0) 73 08 72 74 [email protected] www.boschrexroth.com/mobile-electronics
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.
Subject to change.
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