Assembly Technologies
Pneumatics
ServiceAutomationMobileHydraulics
Electronic Control Unit RC
RE 95200/11.03 1/16Replaces: 09.03
Series 20
For open and closed-loop controlof hydraulic componentsContents
Ordering CodeDescription
Block Circuit DiagramTechnical DataTerminal ConnectionsTerminal Connection VersionsUnit Dimensions
Installation Position, Mating ConnectorSettings and Displays, Test AdapterSafety Concept
2234...56...8910...12
131415
Features
– Robust design meeting specifications for mobile applications– High electromagnetic compatibility (EMC)–Inputs and outputs with fault detection
–Safety features such as redundant inputs and central safetycut-off for all outputs
–Pulse-width-modulated (PWM) solenoid currents forminimum hysteresis
–Closed-loop control of solenoid currents, i.e. not dependenton voltage and temperature–Sturdy, sealed aluminum housing–Watertight with suitable mating connector
Main components
–Powerful 16-bit microcontroller module–Protected watchdog for program run monitoring
–Serial data interface for diagnostics, parameterization anddisplay of process variables–CAN bus interface
–Power supply and ground connections for potentiometersand sensors
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Ordering Code
RCTypeElectronic control unitDesign1. digit = no. of proportional outputs2. digit = no. of switch outputs2-24-46-9Series2Index0Note:
The electronic control units cannot operate without software.
Standard software and programs for specific applications are available from Rexroth.
RC/20Description
The RC electronic control units are used for the programmablecontrol of proportional solenoids and additional switchingfunctions. They can therefore be used for both simple andcomplex open and closed-loop control, e.g. for hydrostatictravel drives, work hydraulics or transmission control in mobilemachinery.
RC electronic control units were specially developed for use inmobile machinery, and satisfy the relevant safety requirementswith regard to ambient temperature, tightness, resistance toshock and vibration, as well as electromagnetic compatibility(EMC).
Internally, RC electronic control units comprise a powerful 16-bit microcontroller and all input and output circuitry on a singlecircuit board.
Analog voltages in the range 0...5 V, currents from 0...20 mA,frequencies from 0 Hz...10 kHz and switching information areprocessed as input signals. The inputs are protected againstovervoltage and electrical interference. The voltage inputs canbe monitored to detect any broken wires or short circuits.The proportional solenoid outputs are pulse-width-modulated(PWM) and optimally adapted for proportional electrical controlof axial piston units and valves to ensure high accuracy andminimum hysteresis.
The switch outputs are designed for the direct switching ofrelays, lamps and switch solenoids. The serial interface RS232permits the connection either of the BB-3 control panel(RE 29 798 and RE 95 080) or a laptop with BODEMsoftware for personal computers (RE 95 085) for servicefunctions such as diagnostics, parameterization or display ofprocess variables.
CAN bus interfaces are available with all RC electronic controlunits for exchanging data with other bus users or electronicsystems (e.g. MC or RC electronic control units, joysticks,diesel engine injection, display). The CAN bus interfaces caneach be run with different protocols.
Standard programs are available for the electronic control unitsoftware.
If more extensive functions are required, special program
packages for specific applications can also be compiled usinga program library and adapted to the application in questionwith the aid of service tools. Programming with BODAS(RE 95 110) is also possible.
Combined with pumps, motors, valves, sensors, transducersand actuators from Rexroth, RC electronic control units andcorresponding software can be used to create completesystem solutions.
RE 95 200/11.03 | RC
Mobile Hydraulics | Bosch Rexroth AG3/16
Block Circuit Diagram
Enable3)
output stagesPower supply,output stages
+-WatchdogPower supplyunitPower forelectroniccircuits&Centralsafety cut-offPower supply for+electronic circuits-Ignition lock
+Switch-onpulsePoweroutputs16-bit microcontrollerFlashEPROMEEPROMRAMPWM outputProportionalsolenoidoutputs1)Switchoutputs1
InputsDigital output)
Frequencies1)Analogvoltage1)Analog current1)Switchinginformation1)Flash
programming
FrequencyVoltageCurrentEvaluationof switchesFlashevaluationCounterinputA/D converter10-bitDigital inputsElectroniccontrol unit foroutputsSignaloutputsInterfacecontrollerEnableoutput stagesExternal ECUEnable
3)output
stagesExternalelectroniccontrol unit
3)Analog
voltageoutputSerialinterfaceRS232CAN businterface
InterfacedriverInterfacedriverLEDred / green2)1)
The inputs and outputs are partially mutually isolated by the technical circuitry.In the RC2-2/20 only3)Not in the RC2-2/20
2)
4/16Bosch Rexroth AG | Mobile HydraulicsRC | RE 95 200/11.03
Technical Data
RC2-2RC4-4RC6-9
Nominal voltage
Residual ripple (DIN 40839, Part 1)Supply voltage, permitted rangeCurrent consumption
without loadwith load, max.
Fuse
internal:
external:for switch and proportional solenoid outputs
for electronics and sensorsStabilized voltage source
e.g. for setpoint potentiometer 1-5 kΩwith current monitoring:with voltage monitoring:Analog voltage inputs
(may also be used as switch input)1)Analog current inputs
(may also be used as switch input)1)Switch inputs
(may be used as analog voltage input)High active only
Switch between high/low activeFrequency inputs
(may also be used as switch input)1)Proportional solenoid outputs (PWM)
Current range
Pulse frequencySwitch outputs (MOSFET)
max. 1.3 Amax. 2 Amax. 2.6 A
Analog voltage outputsInterfaces
RS 232 CCAN 2.0 BLED indicators
Fault detection for broken wires and short circuit
Analog inputs
Proportional solenoid outputsProtection against short circuit
to supply voltage and groundfor all inputs and outputsReverse polarity protection
supply/battery
1) switched with supply voltage
12 and 24 Vmax. ± 2 V8...32 VmAA
2508–8122––22424–22–22–2–2––112
40015–1512––252661534–44–42–2112–
40018–2014–228488265624–696–3112–
A TA T5 V ± 0.1 V15 mA20 mA100 mA0...5 V0...20 mA
low <1.5 V; high >4.5 V
0...10 kHz; > 1 Vrms0...1.8 A0...2.3 A100...400 Hz
100, 160 or 220 Hz
0...5 V
ISO 11898red / green
RE 95 200/11.03 | RC
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Technical Data
RC2-2
MicrocontrollerClock frequencyMemory capacities
RAM
Flash EPROMEEPROM
Software installation
Download to flash memory
Electromagnetic compatibility
Spurious interference
(motor vehicles directive 95/54/EG)
Line-bound interference(ISO 7637-1/-2/-3)Load dumpMax. dissipated loss
Operating temperature, housingStorage temperature, housingVibration resistance:
Sinusoidal vibration(IEC 60086-2-6)
Random vibration(IEC 60086-2-36)Shock resistance:
Transport shock(IEC 60068-2-27)
Continuous shock(IEC 60068-2-29)Resistance to moistureResistance to salt spray
(IEC 60068-2-11)
Type of protection (DIN / EN 60529)
with fitted mating connectorHousing materialWeight
Outer dimensions
100 Vrms/m; (details on request)Values on requestmax. 70 VW at 32 V-40...85°C-40...105°C10 g / 57...2000 Hz20 cycles per axis0.05 g2 / Hz30 min per axis
15 g / 11 ms
3x in each direction (pos./neg.)and in each axis
25 g / 6 ms
1000x in each direction (pos./neg.)and in each axis95 % (+25°C to +55°C)72 h, 35°C, 5% NaClIP 65, with supplementarymeasures IP 69KDiecast aluminumapprox. kgLength (in mm)Width (in mm)Height (in mm)52-pin28-pinMHzKbytesKbytesKbytes
RC4-4
RC6-9
C164CIC167CSC167CS2012825628.0
4025651288.0
4025651288.25
0.5114204411–
0.7182202411–
0.71822024111
Mating connector
6/16Bosch Rexroth AG | Mobile HydraulicsRC | RE 95 200/11.03
Terminal Connections RC2-2
1A3)Ignition lockEmergencyOFF1A4142Power supplyfor electronicsSupply for prop. andswitch outputs8AOutputsON127+12 V/+24 VGroundSpeed sensor10 V228Frequency inputs33324443Proportionaloutputs312)12.3 A2.3 AProportional solenoids302)22Stabilized voltagesource 5V 2x15 mA29Switchoutputs2)12.0 A2.0 ASwitch outputs152)25)36+5V 3847+5V 5)2464934Voltage inputsCurrent inputs51TxD50RS 232RxD17Potentiometer135Current source0...20 mA1452Reserved52CDBEAGFHDiagnosticconnectorfor BB-3or BODEM
Switches123437481011Switch inputsCAN HCAN L4039CAN bus 4)Ground connection,housing 1)1)2)3)
4)5)
Short, low-resistance connection from a housing screw to the unit or vehicle groundSeparate ground connection from solenoid return lead to battery (chassis also possible)Separate fuses recommended for switches and sensors
CAN bus: terminating resistor 120 Ω recommended (see installation instructions in RDE 90 300-01)Alternatively, 5V/ground outputs may also be used to supply the sensors
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Terminal Connections RC4-4
1A3)Ignition lockEmergencyOFFOutputsON1A4142Power supplyfor electronicsSupply for prop. andswitch outputs3115A127+12 V/+24 VFrequency inputsGroundProportional outputs0 V22833324443181712)2,3A2,3A2,3A2,3AProportional solenoidsSpeed sensor123302)232)4Stabilized voltage source5 V / 2x100 mA162)4Potentiometer123455)36+5V 35 38Voltage inputsSwitch outputs4746498+5V 5)292)122)2,6A2,6A1,3A1,3ASwitch outputs1552)20346 192)340...20 mA245Current inputsCurrent source10 V...5 V227Analog signal output0 V...5 V DC9321TxDRS232 RxD5024514Reserved52Switches1234563748101123128)8)8)6)CDBEAHGFDiagnosticconnectorfor BB-3or BODEM
Switch inputs6)CAN H1CAN L14039CAN businterfaces 4)CAN H2CAN L22625Enable externaloutput stages1314INH7)OE1)1)2)3)4)5)6)7)8)
Short, low-resistance connection from a housing screw to the unit or vehicle groundSeparate ground connection from solenoid return lead to battery (chassis also possible)Separate fuses recommended for switches and sensors
CAN bus: terminating resistor 120 Ω recommended (see installation instructions in RDE 90 300-01)Alternatively, 5V/ground outputs may also be used to supply the sensorsSwitched together between high/low active by means of softwareLevel >3V enable output stages (proportional and switch outputs)Switched together between high/low active by means of software
8/16Bosch Rexroth AG | Mobile HydraulicsRC | RE 95 200/11.03
Terminal Connections RC6-9
1A3)Ignition lockEmergencyOFFOutputsON1A4142Power supplyfor electronicsSupply for prop. andswitch outputs31220A1272281234562,3A2,3A2,3A2,3A1,8A1,8A)Proportional solenoids302+12 V/+24 VGround0 VProportional outputs)42Speed sensor12345333244431817735553543635384746498+5V 5)Frequency inputs)162)682)Stabilized voltage source5 V / 2x100 mA692)292)Potentiometer12341234562,6A2,6A1,3A1,3A2,6A1,3A1,3A1,3A1,3ASwitch outputsVoltage inputs+5V 5)152)52)20Stabilized voltagesource 5 V / 2x20 mA62)Switch outputs56788019626579645663+5V 5)722)712)Voltage inputs+5V 5)7472)752)897634Current source0...20 mA1452)Current inputs290 V...5 V227Analog signal output0 V...5 V DCCDBEAHGF3214TxD50RS232 RxD2451Switches123457637481011236112606)6)8)8)8)8)52Diagnosticconnectorfor BB-3or BODEM
Switch inputsCAN H1CAN L1CAN H2CAN L2ReservedReserved4039262558591)CAN businterfaces4)Enable externaloutput stages81314INH7)OE1)2)3)4)5)6)7)8)
Short, low-resistance connection from a housing screw to the unit or vehicle groundSeparate ground connection from solenoid return lead to battery (chassis also possible)Separate fuses recommended for switches and sensors
CAN bus: terminating resistor 120 Ω recommended (see installation instructions in RDE 90 300-01)Alternatively, 5V/ground outputs may also be used to supply the sensorsSwitched together between high/low active by means of softwareLevel >3V enable output stages (proportional and switch outputs)Switched together between high/low active by means of software
RE 95 200/11.03 | RC
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Terminal Connection Versions
(other versions on request)
Monitored potentiometers
If all three connecting points of the potentiometer are to bemonitored for broken wires, the potentiometer must beconnected as illustrated in the section of the terminalconnection diagram below.
The existing current inputs are used for this purpose.
Monitoredpotentiometer1...5 kΩ1)1)1)Internal pull-down resistance
CurrentinputVoltageinputSensorsupply10/16Bosch Rexroth AG | Mobile HydraulicsRC | RE 95 200/11.03
Unit Dimensions RC2-2
120max. 341)max. 4137,3max. 17c552)301)7d0,2LEDa17,55987104,4max. 96max. 114b204180188Mounting:–The electronic control unit must be secured at four points(a, b, c, and d).–Tightening torque MA = 8 ± 2 Nm for securing theelectronic control units with M6 screws.–Tightening torque applies for screws without washer. Theequivalent tightening torque must be determined whenusing washers.–Rexroth’s consent is required if mounting is different fromabove.Note:If the mounting surface is not sufficiently even, place flexiblecompensating elements (e.g. rubber washers) between themounting points of the electronic control unit and themounting surface.1)2)Space required for mating connectorSpace required for plugging and unplugging the matingconnectorRE 95 200/11.03 | RC
Mobile Hydraulics | Bosch Rexroth AG11/16
Unit Dimensions RC4-4
119max. 341)max. 4136,16,8c301)d180552)a19,559–0,592172max. 181,8bMounting:–The electronic control unit must be secured at four points(a, b, c, and d).–Tightening torque MA = 8 ± 2 Nm for securing theelectronic control units with M6 screws.–Tightening torque applies for screws without washer. Theequivalent tightening torque must be determined whenusing washers.–Rexroth’s consent is required if mounting is different fromabove.1)2)188Space required for mating connectorSpace required for plugging and unplugging the matingconnector202212/16Bosch Rexroth AG | Mobile HydraulicsRC | RE 95 200/11.03
Unit Dimensions RC6-9
119max. 341)max. 4136,16,8c301)d18031,1552)19,5a59–0,592172max. 181,8bMounting:–The electronic control unit must be secured at four points(a, b, c, and d).–Tightening torque MA = 8 ± 2 Nm for securing theelectronic control units with M6 screws.–Tightening torque applies for screws without washer. Theequivalent tightening torque must be determined whenusing washers.–Rexroth’s consent is required if mounting is different fromabove.1)2)188Space required for mating connectorSpace required for plugging and unplugging the matingconnector2022RE 95 200/11.03 | RC
Mobile Hydraulics | Bosch Rexroth AG13/16
Installation Position
-130PermittedVisible rangeof LED’s70300NotpermittedInstallationposition0+190Mating Connector
Order designations for female connector, comprising:
Number for AMP-Tyco MT2/JPT 52-pin28-pinID No. 02602414ID No. 02602415
4448481–1–40
––2828–1–1–
Designation
Junior-Power-Timer contactsSingle-wire seals JPTMicro-Timer-2 contactsSingle-wire seals MT2Basic unit MT2/JPT; 52-pinBasic unit MT2/JPT; 28-pinCoverCover
Blanking plugs F.D3.6-MT2
AMP No.0-0964285-20-0963293-10-0964275-20-0964972-10-1393450-30-1393436-20-1393454-70-1393454-20-0963531-1
The female connector is not included in the delivery volume.
The AMP-Tyco MT2/JPT 52-pin female connector is available from Rexroth with Mat. No. 02602414 and the AMP-Tyco MT2/JPT28-pin female connector with Mat. No. 02602415.
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Settings and Displays
All settings and the display of functions, faults and system variables are performed using the BB-3 control panel (RE 29798 andRE 95080) or a PC with BODEM software (RE 95085) via the serial interface.
Test Adapter
The MA test adapter (RE 95090) is used to measure all electrical signals at the inputs, outputs and interfaces of the electroniccontrol unit. It is connected in series between the electronic control unit and the vehicle or unit wiring.The BB-3 control panel, BODEM software and MA test adapter are all available from Rexroth.
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Safety Concept
Safety features in the electronic control unit
–The input circuits for speed and analog signals partially feature circuits that are mutually electrically isolated. The switch signalsare electrically separated into mutually independent groups (see block circuit diagram). The microcontroller can detect faults bymeans of duplicate (redundant) input function assignments.
–Broken wires or short circuits at potentiometers can be detected by circuit logic.(See circuit version: Monitored potentiometers)
–Faults in the power supply are detected by internal monitoring.
–All output signals can be monitored by the microcontroller with the appropriate software.
–The power outputs are supplied by separate connections independently of the electronics.
For service purposes, the electronic control units can be operated with all power outputs de-energized.
–The internal watchdog module centrally cuts off all proportional and switch outputs in the event of disturbances to the programexecution.
Safety measures during use of the electronic control unit(See also safety instructions in RDE 90 301-01)
–Faults can be detected and specially programmed safety functions activated by means of duplicated input variable assignments(e.g. connection of the drive pedal signal to two independent analog inputs).
–Special safety functions can be initiated if the plausibility check reveals discrepancies between the setpoints and the values readback by the microcontroller.
Note:
–The suggested circuits do not imply any technical liability of Rexroth for the system.–The safety instructions contained in RDE 90 301-01 must be observed.
–To switch off the system in emergencies, the power supply to the electronics must be disconnected by an emergency stopswitch. The emergency stop switch must be installed in an easily accessible position for the operator.Safe braking must be ensured when the emergency stop function is activated.
–Cables to speed sensors must be shielded. The shield must be connected to the electronics on one side or to the machine orvehicle ground via a low-resistance connection.
–Cables to the electronics must not be routed close to other power-conducting cables in the machine or vehicle.–A sufficiently large distance to radio systems must be maintained.
–All connectors must be unplugged from the electronics during electrical welding operations.–The electronics may only be tested with the proportional solenoids connected.
–The proportional solenoids must not be connected to spark suppression diodes.
Switching solenoids at the outputs of the RC electronics need not be connected to spark suppression diodes.
Other inductive loads that are in the system but not connected to the RC must be connected to spark suppression diodes.–In order to preserve the warranty, any installation or replacement of the software (flash EPROM) must be performed bypersonnel from Rexroth.
–Cables/wires must be sealed individually to prevent water from entering the unit.
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Bosch Rexroth AGMobile Hydraulics
Product Unit Mobile ElectronicsElchingen PlantGlockeraustrasse 2
89275 Elchingen, GermanyTelephone+49 (0) 73 08 82-0Facsimile+49 (0) 73 08 72 74info.brm-ak@boschrexroth.de
www.boschrexroth.com/mobile-electronics
© 2003 by Bosch Rexroth AG, Mobile Hydraulics, 89275 Elchingen
All rights reserved. Neither this document nor any part of it may be reproduced orstored, processed, duplicated of circulated e. g. by using electronic systems inany form or by any means without the prior authorisation of Bosch Rexroth AG. Incase of infringements the infringing party will be obliged to compensate for alldamages incurred.
The data specified in this brochure (data sheet) is intended to describe theproducts. No warranty or statement, whether express or implied with regard tofitness for particular purposes or merchantability may be derived from our
information (data sheet). The information provided in this brochure (data sheet)does not release the user from any of its obligations of own judgement andverification for the specific purposes. Please note that our products are subjectto a natural process of wear and tear and aging.
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