BODAS VAC – Application software Electronic valve control

RE 95352/2020-09-22, Bosch Rexroth AG

BODAS VAC – Application software Electronic valve control

RE 95352/2020-09-22

Contents1 Introduction 22 Typical applications and variants 23 System description 24 Functional description 45 Electrical interfaces 6

5.1 General information 65.2 CAN signals 65.3 Inputs 75.4 Outputs 105.5 Power supplies 105.6 Connection diagram RC12-10/30 11

6 Parameter setting and diagnostics 157 Functional safety in accordance with EN ISO 13849 16

7.1 Approach 167.2 Concept 167.3 Safety functions 177.4 Example of using a BODAS VAC safety function 19

8 Project engineering and ordering information 218.1 Ordering code 21

9 Valid standards and separate documentation 2210 Abbreviations 2311 Safety Instructions 24

Features The valve control system in combination with the

BODAS controller RC12-10/30 has the option to con-trol up to six directional valves and two on-off valves.

The valve control system can be easily adapted by the user to various joysticks, valve and control block confi-gurations by means of adjustment parameters.

Support of CAN J1939 bus communication, DM1/DM2 diagnosis as well as freely configurable CAN messages.

The BODAS VAC application software is designed for use with hydraulic valves.

The BODAS VAC application software is suitable for joysticks with CAN bus interface (SAE J1939 protocol: BJM1 or BRM) or with analog inputs (Voltage or cur-rent).

Diagnostics and parameter settings are performed with the BODAS-service PC software.

Inputs/Outputs are monitored for wire breakage, short circuits, range feasibility and consistency.

Ready-to-use safety functions developed in accordance with the standards EN ISO 13849 are part of the soft-ware.

Bosch Rexroth AG, RE 95352/2020-09-22

2 Electronic valve control | BODAS VAC – Application softwareIntroduction

1 Introduction

The BODAS VAC is a standard software solution embed-ded on a RC12-10/30 Rexroth Controller to control valve solenoids in a control block.Hydraulic operating functions are controlled via valves whose positions are specified by target value generators, such as joysticks.Directional valves are in charge of the flow distribution between pump and actuators, such as motors or cylin-ders. Each control block can consists several valves, or so-called axes. In this case, BODAS VAC can control up to six directional valves and two on-off valves independently. Each axis (or valve) controls both speed and movement direction of actuators.Two digital outputs can be controlled directly by digital inputs. Digital output 1 can be controlled optionally by axis 1, by enabling/disabling it when the valve is operated. This can be used for e.g. brake release functions.BODAS VAC supports both 12 V and 24 V systems. The software solution supports CAN messages for inputs, outputs and diagnosis based on SAE J1939.The software is created with a modular design that can be easily adapted to various joystick, valve and control block configurations according to customer-specific require-ments. For more information about customer-specific extensions, please consult your Bosch Rexroth contact.

2 Typical applications and variants

Typical applications are wheel loader, driller, telehandler, forklift, sweeper or generic valve control.In combination with fixed displacement or variable dis-placement hydraulic pumps, BODAS VAC can be used in sweepers to control rotations of main broom, side brooms, and conveyors. A part of hydraulic flow can be shared for rotating hydrau-lic motors to achieve constant vehicle speed, if no high driving dynamics are required.Driver can send request via joysticks. The signals are then evaluated by BODAS VAC and converted into electrical signals for the actuators.For drilling rig application, BODAS VAC can be used to move the drilling rig to vertical position. Then, the driver can start sharing the hydraulic flow to the drilling motor via a joystick.Combination with different hydraulic actuators can create variety of control functions.

3 System description

The electronic valve control, is an easily configurable software application for valves control. The hydraulic system consists of a fixed or variable pump, a control block and the actuators in the form of hydraulic motors or hydraulic cylinders.

In this way, the volume flow in hydraulic cylinders or hydraulic motors is controlled via directional valves.

The electronic valve control system in the ASrun software variant is designed for up to six valves in open circuit with electric proportional control. For additional requirements the ASopen software variant allows the customer to modify or extend the software according to his needs.

The following joysticks are supported: THEC5 CAN joystick THES5 analog joystick EJC CAN joystick Analog joysticks with 2 or 3 roller or rockers

(Voltage or current signals).

The following control blocks are supported: Load-sensing control block M4/RM with proportion

pressure reduction valve FTDRE2K/FTDRE4K LUDV control block RS with proportion pressure reduc-

tion valve FTDRE2K/FTDRE4K

The proportional valves are controlled via the proportional outputs of the controller.

The on-off valves are controlled via the switch outputs of the controller.


3 BODAS VAC – Application software | Electronic valve control Introduction

Typical configuration for the BODAS VAC (figure shows all possible connected, not mandatory inputs)

1)

CAN1: BODAS-serviceCAN2: SAE J1939 / BRM JoystickCAN3: SAE J1939 / BRM JoystickCAN4: CCP

Emer

genc

y st

op

Dri

ver

on-b

oard

sw

itch

(op

t.)

Wor

k re

leas

e sw

itch

(op

t.)

CAN

bus

/ana

log

joys

tick

(w

ith

dir

ecti

on s

wit

ch, o

pt.)

Com

pre

ssio

n sw

itch

(C

AN b

us o

pt.)

Pos

itiv

e/ne

gati

ve e

nd

pos

itio

n sw

itch

(op

t.)

Angl

e se

nsor

(op

t.)

Faul

t la

mp (

opt.

)

Control block

1) Connections for each axis of movement

BODAS controller RC12-10/30

BODAS display (optional)

BODAS- service

Diesel engine Variable or fixed pump

Cable harness

On-offvalve

On-offvalve

Valv

e… ×

12

The following electronic components are required: RC12-10/30 controller with mating connector (95204) Software BODAS VAC, Release 40

At least one of the following joysticks is required: THEC5 CAN joystick THES5 analog joystick with direction switch Analog joysticks with 2 or 3 direction switches (Voltage

or current signals).

The following additional electronic components can be used, but are not mandatory:

Safety switch (emergency stop) Implement release switch for working release Driver on board switch to detect if the driver is sitting

on the seat Direction switches to detect lever operation direction Compression buttons Fault lamp BODAS display of DI4

The following hydraulic components are required:

Variable or fixed pump Control block:

– M4/RM–12/15/22 with FTDRE2K/FTDRE4K or – RS–8/12/14/15/20/22/32 with FTDRE2K/FTDRE4K

The following components are required for commissioning and service:

BODAS-service PC software (95086) BODAS-service connection cable Diagnostics socket


4 Electronic valve control | BODAS VAC – Application softwareFunctional description

4 Functional description

The electronic valve control system BODAS VAC Version 40 allows the pressure in pressure reduction valves to be controlled via signals from a joystick in accordance with a parameterizable characteristic curve. Target angle value from joystick will be converted into electrical signal, which controls proportional solenoid in each valve. The position of spool can be moved by the solenoid and hence, the movement of actuators can be controlled.

Operating behaviorThe following explains how a valve is controlled in a con-trol block.The position of the connected joystick is detected via the analog input or CAN connection. The valve control behavior is controlled by various variables:

The set point is defined with the joystick. The output value for the set point is specified in the

parameterizable control characteristic. The valve control curve shape can be changed from

linear to progressive The time ramps on all inputs and outputs determine

how quickly the output value is changed.It is possible to automatically switch to counter operation depending on the joystick signals.

Control behavior The joystick is in the neutral position if it is positioned

within a user-definable range around the zero position. This is called the dead band. It can be set in the para-meters.

When the joystick is in the neutral position, the out-puts for controlling the valve are deactivated and the mechanical springs inside the valve ensure this posi-tion.

If the joystick is moved to a position outside the dead band, the value at the respective output (for movement direction A or B) increases according to the position of the joystick and the set characteristic. The valve is actuated. In addition, the acceleration behavior can be selected via a parameterizable time ramp.

All the movements can be blocked by a system release switch. When the release switch is not switched on, no movement is allowed.

A driver on board function is used to detect whether the driver is available. When the driver is not on board, no movement is allowed.

Special functionA “detent” function is used to detect “detent” operation, which means the driver release the joystick from the left/down end quickly. Quickly means less than 1 second.When this operation is active, the relevant axes of sole-noid current will keep constant until the cylinder reaches a preset position even joystick is in neutral position. „End Position Damping“ activates a stop ramp to avoid a mechanical shock, when the end stroke is detected by an end switch. „Curves function“ allows changing control curve shape from linear to progressive. A progressive behavior will improve the machine handling for small movements. The curve gradient (Max Stroke) is used for a linear reduction of the maximum flow to the actor. This feature can be used to reduce the speed of a machine movement online during work cycle.

Error detection and reactionVarious options are available for monitoring the operating behavior:

Start condition – The start condition is used to prevent the valves

from being opened unintentionally. – After the controller is switched on (ignition switch

active), all activated joysticks must be in the neutral position. In addition, the safety switch must be closed in order for the valves to be controlled.

– To acknowledge faults, all activated joysticks must be moved to the neutral position.

Monitoring of inputs and outputs The lines for the target value inputs and proportional

solenoid outputs are monitored for wire breaks and short circuits.

In the event of an error or if the emergency-stop switch is actuated, the valve control system is switched off immediately.

In the event of an error, an error lamp is also cont-rolled.

Important features Various joystick types are available for set point specifi-

cation. The ramp times can be set for each movement direc-

tion and axis. There are various characteristic types (linear to pro-

gressive) which can be set for each movement direc-tion and axis.


5 BODAS VAC – Application software | Electronic valve control Functional description

The characteristics can be temporarily compressed for each axis to facilitate more precise operation.

Valves are automatically damped at the end of the movementby means of limit switch or position sensor.

Diagnostic function All errors that occur are stored in the controller and

can also be read later in plain text with the aid of the PC software BODAS-service.

Control logic diagram

Important parameters Configuration of the analog or CAN joystick signals Adjustable ramps Selection of the control characteristic Minimum and maximum solenoid current for each

movement direction.

Joystick positionsignal

Compressionsignal

Work releaseswitch

Drive onboard switch

Angle sensor

Digital switch

Switch

Angle sensor

Switch

Switch

Swich / CAN

Positive end positionswitch

Negative end positionswitch

Switch

Switch

Driver on board &Work release

Detent End positiondampingValve controlCompression

Positive valve

Digital valve

Negative valve

Dev_inp

Dev_Outp

Veh


6 Electronic valve control | BODAS VAC – Application softwareElectrical interfaces

5 Electrical interfaces

5.1 General information

Check for maximum output currents.The maximum allowed current per output pin is individu-ally indicated in the connection diagram.Within the ECU, one output stage drives the current for two output pins. The total current for both pins must remain below the maximum allowed current of each out-put stage.

For additional information, also refer to Rexroth data sheet 95204 for BODAS controller RC series 30.

5.2 CAN signals

Up to four CAN channels are supported:

CAN 1 250 kBaud Communication with BODAS-service or BODAS-design.

CAN 2 250 kBaud J1939 Standard.CAN joystick with BRM protocolDiesel engine and other ECUs

CAN 3 250 kBaud J1939 Standard.CAN joystick with BRM protocol

CAN 4 1000 kBaud 1000 kBaud Communication via CAN cali-bration protocol (CCP). Supporting deve-lopment tools like CANape, INCA or equi-valent for advancedCaution: CCP must not be used for para-meter setting or calibration..

Input and output signals for the driver and machine inter-face are sent on both CAN 2 and CAN 3 in accordance with the J1939 standard.For each joystick the CAN bus (2 or 3) and the CAN ID can be configured. This allows 2 joysticks use the same CAN ID on two different CAN busses.

For details, see the CAN database, which is part of the BODAS VAC documents and tools container.

Supported message interfaces

CANSAE J1939

Signal is contained in a standard J1939 message.

Standard

CANSAE J1939

Signal is contained in a proprietary J1939message. All proprietary messages have achecksum and message counter forincreased safety. All proprietary messageidentifiers can be commonly shifted via anoffset parameter for free choice of identifier space

Proprietary


7 BODAS VAC – Application software | Electronic valve control Electrical interfaces

5.3 Inputs

Range inputs

Discrete CAN bus

Supported electrical interfaces

Signal range

Remarks Supported CAN

messages

Remarks

Joystick

0 100%-100%

V

X

0 … 5 V or

0 … 10 V

Joystick without direction switches. Signal range of voltage channel can be learned via trimming func-tionality of BODAS-service

CANSAE J1939/

BJM1

BODAS THE5 CAN joystick with 3 direc-tion switches with BJM1, Standard Pro-tocol. Function safety supported.

0 100%-100%

V

X

0 … 5 V or

0 … 10 V

Joystick with 2 direction switches. Signal range of voltage channels can be learned via trimming func-tionality of BODAS-service

0 100%-100%

V

X

0 … 5 V or

0 … 10 V

Joystick with 3 direction switches. Signal range of voltage channel can be learned via trimming func-tionality of BODAS-service

0 100%-100%

V

X

0 … 5 V or

0 … 10 V

THE5 analog Joystick with 2 redundant direction swit-ches. Functional safety supported. Signal range of voltage channels can be learned via trimming func-tionality of BODAS-service

0 100%-100%

VVmon

X

0 … 5 V or

0 … 10 V

Redundancy analog joy-stick. Function safety sup-ported. Signal range of vol-tage channel can be learned via trimming func-tionality of BODAS-service

Angle sensor

0

α (1) α (2)α

U1

U2U1(1)

U1(2)

U [mV]

0 … 5 V

Angle sensor providing two voltage signals with cons-tant sum (Inverse curves).Signal range of voltage channel can be learned via trimming functionality of BODAS-service

0 20000

20000

–20000

–20000

αbus

α

V

Angle sensor connec-ted via fieldbus

0

α (1) α (2)α

U1

U1(1)

U [mV]

0 … 5 V

Angle sensor providing a voltage signal only. Signal range of voltage channel can be learned via trim-ming functionality of BODAS-service




0 100%-100%

V

X

This interface expects one analog voltage signal in the range from 0 V … 5 V or 0 V … 10 V When Joystick is in neutral position, the voltage should be 2.5 V or 5 V The details of the signal characteristics including start and end point can be configured via parameters.

0 100%-100%

V

X

This interface expects one analog voltage signal in the range from 0 V … 5 V or 0 V … 10 V 2 direction switch signals indicate the operation direction (Positive or Negative).When Joystick is in neutral position, the voltage should be minimal and both direction sig-nals are false. The details of the signal characteristics including start and end point can be configured via parameters.

0 100%-100%

V

X

This interface expects one analog voltage signal in the range from 0 V … 5 V or 0 V … 10 V 2 direction switch signals indicate the operation direction (Positive or Negative).When Joystick is in neutral position, the voltage should be 2.5 V or 5 V The details of the signal characteristics including start and end point can be configured via parameters.

0 100%-100%

V

X

This interface expects one analog voltage signal in the range from 0 V … 5 V or 0 V … 10 V 3 direction switch signals indicate the operation direction (Positive, Neutral or Negative).When Joystick is in neutral position, the voltage should be minimal and only Neutral sig-nals set to true. The details of the signal characteristics including start and end point can be configured via parameters.

0 100%-100%

VVmon

X

This interface expects 2 analog voltage signal in the range from 0 V … 5 V or 0 V … 10 V. One control signal and one test signal. For example, the range is 5 V, control signal = 5 V – test signal.The details of the signal characteristics including start and end point as well as the allo-wed tolerances can be configured via parameters.

0

α (1) α (2)α

U1

U2U1(1)

U1(2)

U [mV] This interface expects 2 analog voltage signal in the range from 0 V … 5 V One control signal and one test signal. For example, the range is 5 V, control signal = 5 V – test signal.The details of the signal characteristics including start and end point as well as the allo-wed tolerances can be configured via parameters.

0

α (1) α (2)α

U1

U1(1)

U [mV]This interface expects one analog voltage signal in the range from 0 V … 5 V The details of the signal characteristics including start and end point can be configured via parameters.



Switch inputs

Discrete CAN bus


Closed and open switch voltage

Remarks Supported CAN messages

Remarks

Driver-on-board switch

GND or VSSx (5 V, 10 V)

or Ubat

Switches may be normally opened or closed

CANSAE J1939

Standard SAE J1939 message

Implement release switch

Switch sensor

Switched input


This interface expects an on/off signal coming from a push button or switch with normally open contact.

This interface expects an on/off signal coming from a push button or switch with normally closed contact.

This interface expects two redundant on/off signals coming from a push button or switch with two normally open contacts.

This interface expects two redundant on/off signals coming from a push button or switch with one normally open and one normally closed contact. Function safety supported.

This interface expects two redundant on/off signals coming from a push button or switch with two normally closed contacts.



5.4 Outputs

Discrete CAN bus


Default output logic

Remarks Supported CAN messages

Remarks

Proportional control block (valves)

Center closedMinimum and maximum control current can be ad-just via BODAS-service

CANSAE J1939

Standard SAE J1939 message

Switch control block (valves) Center closed

Fault lamp

Lamp is on

Lamp signals from lowestto highest priority:off, on, slow flash, fast flash


V This high-side output expects a solenoid connected to a low-side switch. The low-side switch is an addi-tional switch off path for switching off the output in case of external short circuits. Up to four high-side switches can be connected to one low-side switch. The proportional output current is generated via PWM closed-loop control. The details of the solenoid characteristics including minimum and maximum resistance can be configured via parameters.

V This high-side output expects a solenoid connected to ground potential. The output voltage is switched to battery voltage or ground. The details of the solenoid characteristics including.Minimum and maximum resistance can be configured via parameters.

V This high-side output expects a resistance (e.g. a lamp) connected to ground potential. The output vol-tage is switched to battery voltage or ground. The details of the resistance characteristics including mi-nimum and maximum resistance can be configured via parameters.

5.5 Power supplies

Battery power supply 12 V and 24 V batteries are supported. Different solenoids are to be used depending on the

battery voltage. Thus different load resistances are expected for error detection.

The BODAS controller RC is using an after-run functiona-lity. Therefore, battery power supply must not be discon-nected within a time period of 2 seconds after switching of ignition.

Sensor suppliesUBat

This potential is connected to battery voltage and is protected by a 5 A fuse.

It is solely used for power supply of ECU electronics and the emergency stop switch.

UIgn

This potential is connected to the ignition switch and is protected by a 1 A fuse.

It is used for sensors requiring battery voltage as power supply and for some switches.

VSS_1, VSS_3 These potentials are connected to 5 V constant voltage

sources supplied by the ECU. It is used for sensors requiring a 5 V power supply, for

potentiometers and for some switches.

VSS_2 This potential is connected to a 10 V constant voltage

source supplied by the ECU.



5.6 Connection diagram RC12-10/30

1 A

1530

0 V/+5V8)

VSS_2

IN_2

IN_3

IN_1

IN_5

IN_6

IN_4

IN_8

IN_9

IN_7

IN_11

IN_12

IN_10

IN_14

IN_15

IN_13

IN_17

IN_18

IN_16

IN_20

IN_21

IN_19

IN_23

IN_24

IN_22

IN_26

IN_27

IN_25

IN_29

IN_30

IN_28

IN_32

IN_31

IN_73

IN_74

IN_72

IN_66

IN_67

IN_75

IN_69IN_70

IN_68

IN_71

+24 V+12 V/

30

31

5 A

50 A5)

BB

BA

A

A

A

A

A

A

B

A

A

B

A

A

A

B

A

A

B

A

A

A

B

A

A

B

B

A

A

A

A

A

A

A0 V/+5V

8)

8)

OUT_2

OUT_1

OUT_4

OUT_3

OUT_6

OUT_5

VP_110)

OUT_38

OUT_37

OUT_40

OUT_39

OUT_41

OUT_42

Connection diagram part 2, see page 12

See 3:Angle sensor or end switch in part 3

See 1: Joystick in part 3

Axis1: Angle sensoror end switch

Joystick 1Y Axis

Part 1

Proportionaloutputs

Proportionaloutputs

Proportionaloutputs

Axis1Positive actuator

Negative actuator


Negative actuator


Negative actuator

Power supply electronics

Proportionaloutput

Power supply

Power outputs

Switch-on-signal

Proportionaloutput

Proportionaloutput

Proportionaloutput

Proportionaloutput

Proportionaloutput

Axis1Actuator valvelowside






Sw

itch

input

sVo

ltag

e in

put

sFr

eque

ncy

input

s

Optionalde-energizeswitch

Ignition switch

0 VGround

WAKE4)

See 2: Switch in part 3

See 2: Switch in part 3








Joystick 1X Axis

Joystick 2Y Axis

Joystick 2X Axis

Joystick 3Y Axis

Joystick 3X Axis

Driver on board switch

Work release switch

Footer see page 14



IN_41

OUT_20

OUT_19

OUT_22

OUT_21

OUT_24

OUT_23

OUT_26

OUT_25

OUT_28

OUT_27

OUT_34

OUT_33

OUT_36

OUT_35

OUT_474...20 mA

CAN H1CAN L1

CAN H2CAN L2

CAN H3CAN L3

CAN H4CAN L4

VP_110)

VP_210)

1)

VP_110)

IN_48

IN_50

IN_51

IN_49

IN_63

IN_64

IN_62

IN_52

IN_53

IN_65

IN_55

IN_56

IN_54

IN_58

IN_59

IN_57

IN_61

IN_60

IN_44

IN_46

IN_47

IN_45

IN_42

IN_43

IN_36

IN_38

IN_39

IN_37

IN_40

IN_34

IN_35

IN_33

VSS_1

VSS_2

VSS_3

INH7)INH

SW-INH9)

6,5V

UBat

B

C

B

B

B

A

B

B

A

A

A

A

A

A

A

C

C

C

C

C

C

C

C

C

B

B

BAAAAAA

3)

6)

6)

6)

2)

2)

2)

2)

VSS_1 or UBatVSS_1 or UBat

VSS_1 or UBat

3)

3)

Connection diagram part 1, see page 11

See part 3 for connection

Part 2

Proportionaloutputs


Negative actuator


Negative actuator


Negative actuator

Volt

age

input

s

Proportionaloutputs

Switch outputs

Switch outputs

Switch outputs

Switch outputs

Switch outputs

Sw

itch

input

sTe

mper

atur

e in

put

sC

urre

nt /

vol

tage

input

s

Constant voltagesource 5 V/150 mA

Stop switch



On-off valve 1

On-off valve 2

Error lamp

3,3 VConstant voltage

Sensor ground 5 A

Sensor ground 5 A



See Part 3

B-s commissioning

(BJM/BRM joystick)

(BJM/BRM joystick)

CCP







Compression input 1Digital input 1Digital input 2Compression input 2Compression input 3Compression input 4Compression input 5

Footer see page 14

Compression input 6



Joystick

VSS_1Pin 219 Part 2

GNDPin 146 Part 2

VSS_1Pin 219 Part 2

GNDPin 146 Part 2

VSS_1Pin 219 Part 2

GNDPin 146 Part 2

VSS_1Pin 219 Part 2

GNDPin 146 Part 2

VSS_1

VSS_1

Switch (Driver on-board and work release)

UBat or VSS_1 Pin 219 Part 2 UBat or VSS_1 Pin 219 Part 2UBat or VSS_1 Pin 219 Part 2 UBat or VSS_1 Pin 219 Part 2

UBat or VSS_1 Pin 219 Part 2 UBat or VSS_1 Pin 219 Part 2


Part 3

Not approved for safety Safety supported


Joystick:

1 U analog for 2 direction

Joystick:

2x high switch and 1 U analog

Not approved for safety Not approved for safety


Safety supported Not approved for safety

Switch:

1 Signal

Switch:

1 Signal(Inverted)

Switch:

2 Signals

Switch:

2 Signals(1st Inverted)

Switch:

2 Signals(2nd Inverted)

Switch:

2 Signals(Both Inverted)

Joystick:

3x high switch and 1 U analog

Joystick:

2x U; Constant sum

1 2

3 4

Neutral direction switch


Positive direction switch


Positive direction switch

1 2

3 4

5 6



Angle sensor or end switch

Angle sensor

WS1

WS1

WS1

VSS_1Pin 219 Part 2

GNDPin 146 Part 2

VSS_1Pin 219 Part 2

GNDPin 146 Part 2

End switch


Notice No safety function designed for the following devices

in BODAS VAC_V1.0 For each hydraulic axis customer can select either

angle sensor or end position switch for the damping feature

1) Short, low-resistance connection from a housing screw to the vehicle ground.

2) CAN bus: termination resistor 120 Ω required. 3) Outputs 5 V/10 V can also be used as sensor supply alternatively.4) Temporary wake up of the controller when a signal > 9 V is

applied for more than 1 sec. 5) Note max. current consumption with simultaneous actuation of

proportional solenoids and switching outputs.6) For use as voltage inputs (0 … 10 V), the load can be switched by

the software in groups for these inputs. Groups: inputs 1 … 4, inputs 5 … 8, inputs 9 … 10.

7) Enable the output stages with level > 5 V (proportional and switched outputs).

8) Input groups may be switched to pull down or pull up in software.

9) Switching off (in Software): Enable output stages with level < 5 V. Switch off output stages with level > 9 V. Switches all proportional and switched output. Cable brake causes all output stages to switch off.

10) Supply can be switched by the software.

Footnotes for pages 11 and 12

Neutral end switch

Positive end switchEnd switch:

1 signal

End switch:

1 signal(inverted)

Angle sensor:

2x U; Constant sum

Angle sensor:

1x U



1 2

3 4

Neutral end switch

Positive end switch


15 BODAS VAC – Application software | Electronic valve control Parameter setting and diagnostics

6 Parameter setting and diagnostics

The parameters to be set during the commissioning of the Valve Control BODAS VAC can be easily adjusted using BODAS-service PC software.

BODAS-service could be configured to display the most important process variab-les and the error messages for fault diag-nostics and troubleshooting purposes.


16 Electronic valve control | BODAS VAC – Application softwareFunctional safety in accordance with EN ISO 13849

7 Functional safety in accordance with EN ISO 13849

7.1 ApproachBODAS VAC uses a subsystem approach as stated in the figure below.

SubsystemDriver interface

+ Machine sensors

Subsystem Hydraulics

+ Mechanics

Valve control system

The machine manufacturer can use the BODAS controller RC + BODAS VAC subsystem within the machine safety design to realize safety functions for the hydraulic system. The described characteristics within this data sheet refer to the BODAS controller RC + BODAS VAC subsystem.Ready-to-use safety functions developed according to the standards EN ISO 13849 are part of the software. If the performance level for the BODAS VAC subsystem is suffici-ent to reach the required overall performance level, BODAS VAC can be used based on the customer- specific risk assessment. In any case, the requirements of the relevant safety standard must be fulfilled at the machine level.

7.2 ConceptThe software of the BODAS controller RC + BODAS VAC subsystem utilizes an inherent safety concept. This means that all noted safety functions are realized not by dedica-ted monitoring software, but by a safe implementation of the safety relevant software program parts. The BODAS VAC software has been completely developed according to PL d (7.4). The software comes with 5 prede-fined safety functions, but is not limited to these. For additional safety functions, contact your Bosch Rexroth sales partner.This inherent approach is combined with a safe diagnosis system within the BODAS VAC software, fulfilling the requirements of category 2: Detection of and appropriate reaction to hardware faults.

As BODAS VAC represents a safety element out of context (SEooC), the machine manufacturer must verify whether it is the right product for the specific application. In any case, the machine manufacturer is responsible to fulfill the overall safety requirements at the machine level.

The following approach shows how the machine manufac-turer can reach the required performance level for a speci-

fic application applying BODAS VAC.

1 Risk assessment Performance of risk assessment Identification of the safety functions Determination of the required performance level (PLr)

2 Safety concept and category selection: Category 2 is pre-defined for BODAS controller RC + BODAS VAC subsystem

Comparison of risk assessment results with safety functions offered within BODAS VAC

If the safety requirements of the application cannot be fulfilled with the existing safety functions of BODAS VAC, the product must not be used. In this case, consult your Bosch Rexroth contact regarding a customized solution. Otherwise go on with the next step.

Developing a safety concept for the complete machine – Applying BODAS VAC inherent safety approach – Creating block diagrams – Calculation of the overall performance level. The

SISTEMA tool from IFA may be used. A calculation example is provided. Once the safety function groups and the characteristics of the sensors and actuators have been provided, it can directly calcu-late the probability of failure per hour and the performance level achieved.

3 Integration and parameterization of BODAS VAC in the machine

Integrate BODAS VAC in the machine environment interfacing the wiring harness and devices which are selected according to the safety requirements.

Set parameters with BODAS-service according to the application-specific requirements

4 Validation Creation of an appropriate application-specific appro-

val test specification. The BODAS VAC approval test specification is part of the documents and tools container and can be used as a starting point. An application-specific adaptation is required in any case.

Performance of approval tests specific to application and project as well as documentation of the results.

Subsystem BODAS controller

RC +

BODAS VAC


17 BODAS VAC – Application software | Electronic valve control Functional safety in accordance with EN ISO 13849

7.3 Safety functionsAll Safety functions of the BODAS VAC subsystem have been developed according to PL d (DIN EN ISO 13849). The software has been developed to fulfil the require-ments of PL d (DIN EN ISO 13849) The ECU hardware fulfils the requirements of category 2 according DIN EN ISO 13849. For example, to know which components have a dependency for e.g. the safety function “safe forward“

and Reverse with CAN joystick”, the “x” marks in the line of “Safe Forward and Reverse with CAN joystick” show which components have to be regarded. In this case, these are:

CAN bus Joystick Solenoid axis forward Solenoid axis backward

Relationship between safety functions and input/output functionsThe following table shows, which input and output com-ponents are related to each declared safety function.

Inputs Outputs

CAN

(BR

M/B

JM)

Joys

tick

Anal

og v

olta

ge jo

ysti

ck f

or c

ontr

ol c

hann

el

Anal

og v

olta

ge jo

ysti

ck f

or t

est

chan

nel

Joys

tick

pos

itiv

e sw

itch

for

axi

s

Joys

tick

neg

ativ

e sw

itch

for

axi

s

Joys

tick

neu

tral

sw

itch

for

axi

s

Dri

ver

on b

oard

sw

itch

Wor

k re

leas

e sw

itch

Sol

enoi

d a

xis

forw

ard

Sol

enoi

d a

xis

reve

rse

Faul

t la

mp

Safe forward and reverse with a CAN Joystick x x x

Safe stand still x x x x

Safe forward and reverse with an analog voltage Joystick with analog voltage redundancy x x x x

Safe forward and reverse with an analog voltage Joystick with digital input redundancy x x x x x x

Safe forward and reverse with end position damping x x x x x x x x

x = mandatory for safety function

Relationship between safety functions and vehicle functionsThe following tables show the dependencies between safety functions and configured functionality.The following table shows, which functionality is related to each declared safety function. For example, to know which functionality has a dependency for e.g. the safety function

“Safe stand still”, the “x” marks in the line of “Safe stand still” show which functionality is affected. In this case, these are

Valve control Driver on board Work release

Valv

e co

ntro

l

Det

ent

End p

osit

ion

dam

pin

gIm

ple

men

t m

anag

emen

t

Com

pre

ssio

n

Safe forward and reverse with a CAN Joystick x x x x x

Safe stand still x x

Safe forward and reverse with an analog voltage Joystick with analog voltage redundancy x x x x x

Safe forward and reverse with an analog voltage Joystick with digital input redundancy x x x x x

x = mandatory for safety function



SF1: Safe stand stillThis function prevents unintentional start of movement as long as the operator is not present at the operator’s posi-tion.

Driver-on-bord switch

Subsystem Driver interface +

machine sensorsSubsystem Hydraulics

+ MechanicsSubsystem

ECU + BODAS VAC

Solenoid valve

Work release switch

PFH value for the BODAS controller RC + BODAS VAC subsystem for this function is about 2.6E-6. This value depends on the connected sensors and the type of con-nection (such as analog or CAN…).

SF2: Safe forward and backward with CAN joystickThis safety function ensures the axis move forward and backward and stops the movement without CAN signal:

CAN Jostick




ECU + BODAS VAC

Solenoid valve

PFH value for the BODAS controller RC + BODAS VAC subsystem for this function is about 3E-6. This value depends on the connected sensors and the type of con-nection (such as analog or CAN…).

SF3: Safe forward and backward with analog joystick with redundant direction switchesThis safety function ensures the axis move forward and backward and stops the movement with joystick switches state abnormal.

Analog Jostick




ECU + BODAS VAC

Solenoid valve × 2

Positive switch

Negative switch

Neutral switch


SF4: Safe forward and backward with analog joystick with redundant analog inputThis safety function ensures the axis move forward and backward and stops the movement with joystick redun-dant input abnormal.

Analog Jostick




ECU +BODAS VAC

Solenoid valve

PFH value for the BODAS controller RC + BODAS VAC subsystem for this function is about 2E-6. This value depends on the connected sensors and the type of con-nection (such as analog or CAN…).


19 BODAS VAC – Application software | Electronic valve control Functional safety in accordance with EN ISO 13849

SF5: Safe forward and backward with end position damping detectionThis safety function ensures axis move with ramp to stop when position switch or sensor detected.

CAN Jostick




ECU + BODAS VAC

Solenoid valve × 2End positive switch

End positive sensor


7.4 Example of using a BODAS VAC safety functionThis chapter uses an example based on SF1 Safe Forward and Reverse with CAN joystick to show how to use the standard BODAS VAC safety functions depending on the machine configuration.

First step: Develop a block diagramDevelop the block diagram based on the machine configu-ration and desired functionality. The usable blocks of the BODAS controller RC are defined within the safety-rele-vant project instructions, Rexroth document 95451-01-B of the chosen ECU. The appropriate blocks of the subsys-tem of sensors and hydraulics have to be chosen accor-ding to the machine configuration.The example shows a block diagram for the safety func-tion SF1, “Safe Forward and Reverse with CAN joystick”. It makes use of a CAN joystick on the sensor side and an electrically controlled valve on the hydraulic side.The block diagram shows the connection of all blocks relevant for this safety function. It also shows the chosen category, here category 2 with a function channel and a test channel.

Category 2 shall be validated by demonstrating the fol-lowing:1. They meet the requirements of Category B.2. The well-tried safety principles used are in accordance

with 9.2.2 c.3. The checking equipment detects all relevant faults

applied, one at a time, during the checking process and generates an appropriate control which initiates a safe state or when this is not possible and provides a warning of the hazard.

4. The check provided by the checking equipment do not introduce an unsafe state.

5. The initiation of the check is carried out at the machine start-up and prior to the initiation of a hazar-dous situation, and periodically during operation in accordance with the design specification and if the risk assessment and the kind of operation necessary.

6. Common-cause failures are sufficiently reduced.7. The maximum PL achievable with category 2 is PL = d.



Block diagram

S... Sensor/HMIK... ControlblockA... Actuator

S3 K7 K11 K6Joystick,(CAN)

Processor,RAM

K5 K9PWM output,

LS

Sensor,supply

Circuit board /supply

AxisForward

AxisReverse

HW-Monitoring

PWM output,HS

K4 2*K8

A1 A2

Out Ena /Inhibit

K13

CAN-module

Second step: Calculate metricsThe metrics of MTTFD and DC value from ECU subsystem are calculated in the second step. Bosch Rexroth recom-mends using the SISTEMA tool for that purpose.

Result for the BODAS controller RC + BODAS VAC subsystem is:

According to the BODAS controller RC + BODAS VAC subsystem, the calculation for the full system has to be done based on the respective machine. The database of the used values can be found within the safety-relevant project planning instruction for BODAS controller RC, Rexroth document 95451-01-B. Since the sensor and system structures vary, a concrete calculation has to be done within each project. Also, the machine-specific tem-perature profile has to be taken into account when perfor-ming the MTTFD value calculation.

Subsystem Driver interface + machine sensors

SubsystemECU + BODAS VAC

Subsystem Hydraulics + Mechanics

Test

Cha

nnel

Saf

ety

(Fun

ctio

n) C

hann

el

RC12-10/30


21 BODAS VAC – Application software | Electronic valve control Project engineering and ordering information

8 Project engineering and ordering information

The way from machine prototyping to serial production The outputs of the BODAS controller RC+BODAS VAC

are deactivated in the initial delivery status. The scope of supply (as described above) must be

applied and each controller has to be parameterized. Access to the parameters is password-protected. The password is part of the documents and tools container.

The machine manufacturer must verify and validate BODAS-valve control in regard to the machine-specific requirements

Important: The details in chapter 7 „Functional safety in

accordance with EN ISO 13849”, must be taken into account.

Please take into account the Rexroth brochure „10 steps to performance level“.

A customer-specific parameter file has to be transfer-red to each controller for serial production. For a customer-specific software solution please con-tact your Bosch Rexroth sales partner

Required tools BODAS-service Version 3.5 or higher; for the latest

version see www.boschrexroth.com/p-BODAS-service CANalyzer or similar tool for CAN data commissioning

Recommended tools SISTEMA, software tool for the application of the

standard EN ISO 13849-1 Vector CANalyzer version 7.6 or higher – required for

full functionality including virtual test box and plant model.

8.1 Ordering code

01 02 03

ASrun – VAC 40

Type

01 Application software ASrun

Application

02 Open and closed loop valve control VAC

Version

03 Release number of the software 40

Ordering informationThe ASrun-VAC40 application software may only be opera-ted with the controller RC12-10/30 and other additional components described in following chapters. When orde-ring, link the hardware and software type codes with a „+“:Example: RC12-10/30+ASrun-VAC40

http://www.boschrexroth.com/p-BODAS-service


22 Electronic valve control | BODAS VAC – Application softwareValid standards and separate documentation

9 Valid standards and separate documentation

Document

SAE J1939-21 December 2010 Data Link Layer

SAE J1939-71 May 2012 Vehicle Application Layer

Standard DIN ISO 13849-1 2006-11 Safety of machinery – Safety-related parts of control systems Part 1: General principles for designPart 2: Validation

Standard DIN ISO 13849-2 2012-10

95204 BODAS Controller RC series 30RC12-10, RC20-10, RC28-14

95451-01-B BODAS controller RC 12-10, RC20-10, RC28-14Safety-relevant project planning instruction

08511 10 Steps to Performance Level

Compatible Rexroth products

Components Data sheet Relevant type code

BODAS Pressure sensor PR3 95155 PR3 600MD36/10, PR3 600GS05/10

BODAS Pressure sensor PR4 95156

BODAS Controller RC series 30 95204 RC12-10/30

BODAS-service 95086

BODAS-service connection cable 95086

BODAS measuring adapter MA6 95090

CAN-USB interface 95086

Diagnostics socket 95086

Load-sensing control block M4 64276

LUDV control block RS14 64136

4THE5 CAN joystick 29696

BODAS display DI4 95272

FTDRE2K 58034

FTDRE4K 58040

MHDRE 04K 64666


23 BODAS VAC – Application software | Electronic valve control Abbreviations

10 Abbreviations

Abbreviation Meaning

ASrun Application Software

BODAS Bosch Rexroth Design and Application System

CAN Controller Area Network

CCF Common Cause Failure

CCP CAN Calibration Protocol

DA Automatic control speed-related

DC Diagnostic Coverage

DHC Diesel Hydraulic Control

DIN Deutsches Institut fuer Normung

ECU Electronic Control Unit

EN European Norm

EP Proportional control electric

ET Electric control, direct-controlled

FNR Forward/Neutral/Reverse

GND Ground

HA Automatic control high-pressure related

HS High-Side

IFA Institute for work protection of the German

ISO International Organization for Standardization

IVS Idle Validation Switch

LED Light Emitting Diode

LS Low-Side

MCR Radial piston motors

MTTFD Mean Time To dangerous Failure

PFH Probability of dangerous Failure per Hour

PL Performance Level

PLr Required Performance Level

PWM Pulse-Width Modulation

RC Rexroth Controller

SAE Society of Automotive Engineers

SEooC Safety Element out of Context

SF Safety Function

SISTEMA Safety Integrity Software Tool for the Evaluation of Machine Applications

SRL Software Requirement Level

VAC Valve Control

BJM Bosch Rexroth Joystick

BRM Bosch Rexroth Mobile protocol


24 Electronic valve control | BODAS VAC – Application softwareSafety Instructions

11 Safety Instructions

BODAS VAC represents a safety element out of context (SEooC). The machine manufacturer must verify whether it is the right product for the specific application.

The machine manufacturer must perform a risk assessment.

The required safety functions and performance levels must be fulfilled with the product in order to use BODAS VAC in a specific application.

The machine manufacturer bears responsibility for applying the valid safety standards at the machine level.

The machine manufacturer is responsible for fulfilling all safety requirements at the drivetrain and machine level.

The machine manufacturer is responsible for validating the machine-specific configuration of BODAS VAC.

Configurations of BODAS VAC used for serial production must be validated.

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 BODAS controller RC.

Incorrect programming or parameter settings 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. Bosch Rexroth assumes no liability for dangers of this type.

The application software must be installed and removed only by Bosch Rexroth or an authorized partner to preserve the warranty.

It must be ensured that the vehicle is equipped with adequately dimensioned service and parking brakes.

Make sure that the software 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 put life in danger and/or cause great 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.

The machine may pose unforeseen hazards while commissioning and maintenance are carried out. 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.

The technical specifications and safety instructions of all involved components must be considered.

The machine manufacturer must follow the valid standards and separate documentation when using the product.

Intended use The control unit 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 control unit 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 hazard to persons and/or cause damage to components which could result in sub sequential damage to the mobile working machine.

Improper use Any use of the control unit other than as described

under “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.

More detailed information Observe the instruction manual for BODAS VAC. The safety measures are to be observed. In addition, the application-specific documents

(connection diagrams, software descriptions, etc.) are to be observed.

More detailed information on BODAS controller RC BODAS VAC may be found at www.boschrexroth.com/mobile-electronics.

Pay regular visits to our home page for the latest product information and information about updates.

Copying, translation and distribution of Bosch Rexroth software is prohibited under copyright law.

http://www.boschrexroth.com/mobile-electronics


25 BODAS VAC – Application software | Electronic valve control Safety Instructions


26 Electronic valve control | BODAS VAC – Application softwareSafety Instructions

Bosch Rexroth AGGlockeraustraße 489275 ElchingenGermanyPhone +49 7308 [email protected]

© Bosch Rexroth AG 2020. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The data specified within only serves to describe the product. No statements concerning a certain condi-tion or suitability for a certain application can be derived from our informa-tion. 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.

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BODAS VAC – Application software Electronic valve control