Series 20 Features - Airline Hydraulics Hydraulics Electric Drives and Controls Linear Motion and Assembly Technologies Pneumatics Service Automation Mobile Hydraulics Features –

IndustrialHydraulics

Electric Drivesand Controls

Linear Motion andAssembly Technologies Pneumatics

ServiceAutomation

MobileHydraulics

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

RE 95200/11.03 1/16Replaces: 09.03Electronic Control Unit RC

Series 20

For open and closed-loop controlof hydraulic components

ContentsOrdering Code 2

Description 2

Block Circuit Diagram 3

Technical Data 4...5

Terminal Connections 6...8

Terminal Connection Versions 9

Unit Dimensions 10...12

Installation Position, Mating Connector 13

Settings and Displays, Test Adapter 14

Safety Concept 15

2/16 Bosch Rexroth AG | Mobile Hydraulics RC | RE 95 200/11.03

DescriptionThe 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.

Ordering Code

Note:

The electronic control units cannot operate without software.Standard software and programs for specific applications are available from Rexroth.

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 programpackages 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.

RC / 2 0

Type

Electronic control unit RC

Design

1. digit = no. of proportional outputs 2-2

2. digit = no. of switch outputs 4-4

6-9

Series

2

Index

0

RE 95 200/11.03 | RC Mobile Hydraulics | Bosch Rexroth AG 3/16

+

+-

+-

Block Circuit Diagram

1) The inputs and outputs are partially mutually isolated by the technical circuitry.2) In the RC2-2/20 only3) Not in the RC2-2/20

Centralsafety cut-off

Counterinput

PWM output

Enable3)output stages

Frequencies1)

Watchdog

FlashEPROM

Interfacedriver

Switchoutputs

SerialinterfaceRS232

CAN businterface

16-bit microcontroller

Switchinginformation1)

Flashprogramming

Power forelectronic

circuits

Inputs

Frequency

Evaluationof switches

Flashevaluation

LEDred / green

EEPROM RAM

Electroniccontrol unit for

outputs

A/D converter10-bit

Digital inputs Interfacecontroller

&

Poweroutputs

Current

VoltageAnalogvoltage1)

Power supply,output stages

Ignition lock Switch-onpulse

Interfacedriver

Proportionalsolenoidoutputs

Digital output

Power supplyunit

Enableoutput stagesExternal ECU

Signaloutputs

Analogvoltageoutput

Power supply forelectronic circuits

Analog current1)

2)

EnableoutputstagesExternalelectroniccontrol unit

3)

3)

1)

1)


Technical DataRC2-2 RC4-4 RC6-9

Nominal voltage 12 and 24 VResidual ripple (DIN 40839, Part 1) max. ± 2 V

Supply voltage, permitted range 8...32 V

Current consumptionwithout load mA 250 400 400with load, max. A 8 15 18

Fuseinternal: – – –external: for switch and proportional solenoid outputs A T 8 15 20

for electronics and sensors A T 1 1 1

Stabilized voltage sourcee.g. for setpoint potentiometer 1-5 kΩ 5 V ± 0.1 V 2 2 4with current monitoring: 15 mA 2 – –with voltage monitoring: 20 mA – – 2

100 mA – 2 2

Analog voltage inputs(may also be used as switch input)1) 0...5 V 2 5 8

Analog current inputs(may also be used as switch input)1) 0...20 mA 2 2 4

Switch inputs 4 6 8(may be used as analog voltage input) 2 6 8High active only low <1.5 V; high >4.5 V 4 1 2Switch between high/low active – 5 6

Frequency inputs(may also be used as switch input)1) 0...10 kHz; > 1 Vrms 2 3 5

Proportional solenoid outputs (PWM) 2 4 6Current range 0...1.8 A – – 2

0...2.3 A 2 4 4Pulse frequency 100...400 Hz 2 4 –

100, 160 or 220 Hz – – 6

Switch outputs (MOSFET) 2 4 9max. 1.3 A – 2 6max. 2 A 2 – –max. 2.6 A – 2 3

Analog voltage outputs 0...5 V – 1 1

InterfacesRS 232 C 1 1 1CAN 2.0 B ISO 11898 1 2 2

LED indicators red / green 2 – –

Fault detection for broken wires and short circuitAnalog inputs

Proportional solenoid outputs

Protection against short circuitto supply voltage and groundfor all inputs and outputs

Reverse polarity protectionsupply/battery

1) switched with supply voltage


RC2-2 RC4-4 RC6-9

Microcontroller C164CI C167CS C167CS

Clock frequency MHz 20 40 40

Memory capacitiesRAM Kbytes 128 256 256Flash EPROM Kbytes 256 512 512EEPROM Kbytes 2 8 8

Software installationDownload to flash memory

Electromagnetic compatibilitySpurious interference 100 Vrms/m; (details on request)

(motor vehicles directive 95/54/EG)

Line-bound interference Values on request

(ISO 7637-1/-2/-3)

Load dump max. 70 V

Max. dissipated loss W at 32 V 8.0 8.0 8.25

Operating temperature, housing -40...85°C

Storage temperature, housing -40...105°C

Vibration resistance:Sinusoidal vibration 10 g / 57...2000 Hz

(IEC 60086-2-6) 20 cycles per axis

Random vibration 0.05 g2 / Hz

(IEC 60086-2-36) 30 min per axis

Shock resistance:Transport shock 15 g / 11 ms

(IEC 60068-2-27) 3x in each direction (pos./neg.)and in each axis

Continuous shock 25 g / 6 ms

(IEC 60068-2-29) 1000x in each direction (pos./neg.)and in each axis

Resistance to moisture 95 % (+25°C to +55°C)

Resistance to salt spray(IEC 60068-2-11) 72 h, 35°C, 5% NaCl

Type of protection (DIN / EN 60529)with fitted mating connector IP 65, with supplementary

measures IP 69K

Housing material Diecast aluminum

Weight approx. kg 0.5 0.7 0.7

Outer dimensions Length (in mm) 114 182 182Width (in mm) 204 202 202Height (in mm) 41 41 41

Mating connector 52-pin 1 1 128-pin – – 1

Technical Data


Terminal Connections RC2-2

1) Short, low-resistance connection from a housing screw to the unit or vehicle ground2) Separate ground connection from solenoid return lead to battery (chassis also possible)3) Separate fuses recommended for switches and sensors4) CAN bus: terminating resistor 120 Ω recommended (see installation instructions in RDE 90 300-01)5) Alternatively, 5V/ground outputs may also be used to supply the sensors

8A

1A 3)

27

4241

3332

37

48

10

11

2

1

28

+12 V/+24 V

0 V

30

5150

17

40

52

39

TxDRxD

CAN H

RS 232

CAN L

CDBEAGFH

44

1

1

2

2

1

2

1

2

3

4

1

2

1

2

36

35

38

47

45

46

49

2)

31

34

15

29

1A

+5V 5)

+5V 5)

432)

2)

2)

Supply for prop. andswitch outputs

Power supplyfor electronics

Ground

Switches

Switch outputs

Proportional solenoids

Diagnosticconnectorfor BB-3or BODEM

CAN bus 4)

EmergencyOFF Outputs

ON

Speed sensor

Volta

ge in

puts

Current source

0...20 mA

Potentiometer

Pro

port

iona

lou

tput

sS

witc

hou

tput

s

Ground connection,housing 1)

Ignition lock

Reserved

Freq

uenc

y in

puts

Cur

rent

inpu

tsS

witc

h in

puts

Sta

biliz

ed v

olta

geso

urce

5V

2x1

5 m

A

2.3 A

2.3 A

2.0 A

2.0 A



22

7

51

50

24

40

39

2625

TxDRS232 RxD

0 V...5 V

CAN H1CAN L1

CAN H2CAN L2

CDBEA

1

2

3

6)

15A

1A3)

27

4241

2

1

28

+12 V/+24 V

0 V

1A

37

48

10

11

23

13

14

12

3332

4443

1817

H52

GF

1

2

3

4

2,3A

2,3A

2,3A

2,3A

31

30

4

16

1

2

3

4

2,6A

2,6A

1,3A

1,3A

29

15

5

6

INH

OE

1

2

3

4

5

35 36

38

474649

8

20

19

+5V 5)

+5V 5)

1

245

34

39

421

1

2

3

4

5

6

6)

8)

8)

8)

7)1)

2)

2)

2)

2)

2)

2)

2)

2)

Ground

Switch outputs


Volta

ge in

puts

Freq

uenc

y in

puts


CAN businterfaces 4)

EmergencyOFF

Ignition lock

Potentiometer

Switches

Analog signal output0 V...5 V DC

Cur

rent

inpu

tsS

witc

h in

puts



Sta

biliz

ed v

olta

ge s

ourc

e5

V /

2x1

00 m

A

Current source

0...20 mA

Enable externaloutput stages

Reserved

OutputsON

Speed sensor

1) Short, low-resistance connection from a housing screw to the unit or vehicle ground2) Separate ground connection from solenoid return lead to battery (chassis also possible)3) Separate fuses recommended for switches and sensors4) CAN bus: terminating resistor 120 Ω recommended (see installation instructions in RDE 90 300-01)5) Alternatively, 5V/ground outputs may also be used to supply the sensors6) Switched together between high/low active by means of software7) Level >3V enable output stages (proportional and switch outputs)8) Switched together between high/low active by means of software

Pro

port

iona

l out

puts

Sw

itch

outp

uts



1) Short, low-resistance connection from a housing screw to the unit or vehicle ground2) Separate ground connection from solenoid return lead to battery (chassis also possible)3) Separate fuses recommended for switches and sensors4) CAN bus: terminating resistor 120 Ω recommended (see installation instructions in RDE 90 300-01)5) Alternatively, 5V/ground outputs may also be used to supply the sensors6) Switched together between high/low active by means of software7) Level >3V enable output stages (proportional and switch outputs)8) Switched together between high/low active by means of software

5

515024

40

39

2625

TxDRS232 RxD

CAN H1CAN L1

CAN H2CAN L2

CDBEA

1

2

228

3748

101123

13

14

61

3332

4443

H52

GF

INH

OE

5859

2)

27

4241

1

1A

20A

1A3)

+12 V/+24 V

0 V

2)

8

31817

47355

55354

5

6

7

801962

65

56

63

6479

1

2

3

363538

46

20

8

49

4

47

12

60

1

2

3

4

2,3A

2,3A

2,3A

2,3A

31

30

4

16

2)

2)

2)

2)

5

6

1,8A

1,8A

68

69

2)

1

2

3

4

2,6A

2,6A

1,3A

1,3A

29

15

5

6

2)

2)

2)

2)

5

6

7

8

2,6A

1,3A

1,3A

1,3A

72

71

74

75

2)

2)

2)

2)

9 1,3A76

227

0 V...5 V

1

245

34

39

421

+5V 5)

+5V 5)

+5V 5)

+5V 5)

7)

6)12

34

7

6)

8)

8)

8)

6

8

8)

1)

Ground

Switch outputs


Volta

ge in

puts

Freq

uenc

y in

puts


CAN businterfaces4)

EmergencyOFF

Ignition lock

Potentiometer

Switches

Analog signal output0 V...5 V DC

Cur

rent

inpu

tsS

witc

h in

puts



Sta

biliz

ed v

olta

ge s

ourc

e5

V /

2x1

00 m

A

Volta

ge in

puts

Sta

biliz

ed v

olta

geso

urce

5 V

/ 2

x20

mA

Current source

0...20 mA

Enable externaloutput stages

ReservedReserved

OutputsON

Pro

port

iona

l out

puts

Sw

itch

outp

uts

Speed sensor


Monitored potentiometersIf 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.

1) Internal pull-down resistance

Terminal Connection Versions(other versions on request)

1)

1)

Monitoredpotentiometer1...5 kΩ

Sen

sor

supp

lyVo

ltage

inpu

tC

urre

ntin

put


Unit Dimensions RC2-2

Mounting:

– 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) Space required for mating connector

2) Space required for plugging and unplugging the matingconnector

120

7

5917,5

87

104,4max. 96

max. 114

552)

301)

0,2

max

. 41

max

. 341 )

max

. 17

37,3

180

188

204

dc

a

b

LED



119

max

. 41

36,1

2

max

. 341

)

180

6,8

188

202

301)

dc

59–0,5ba

552)

92

19,5

172max. 181,8

Mounting:









19,5

301)

119

max

. 41

36,1

2

max

. 341

)

180

6,8

188

202

dc

31,1

59–0,5ba

552)

92

172max. 181,8

Mounting:








Installation Position

70

30

0 0

-130

+190

Visible rangeof LED’s Installation

position

Permitted

Notpermitted

Mating ConnectorOrder designations for female connector, comprising:

Number for AMP-Tyco MT2/JPT 52-pin 28-pin

Designation AMP No. ID No. 02602414 ID No. 02602415

Junior-Power-Timer contacts 0-0964285-2 4 –

Single-wire seals JPT 0-0963293-1 4 –

Micro-Timer-2 contacts 0-0964275-2 48 28

Single-wire seals MT2 0-0964972-1 48 28

Basic unit MT2/JPT; 52-pin 0-1393450-3 1 –

Basic unit MT2/JPT; 28-pin 0-1393436-2 – 1

Cover 0-1393454-7 1 –

Cover 0-1393454-2 – 1

Blanking plugs F.D3.6-MT2 0-0963531-1 40 –

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.


Test AdapterThe 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.

Settings and DisplaysAll 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.


Safety ConceptSafety 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.


Bosch Rexroth AGMobile HydraulicsProduct Unit Mobile ElectronicsElchingen PlantGlockeraustrasse 289275 Elchingen, GermanyTelephone +49 (0) 73 08 82-0Facsimile +49 (0) 73 08 72 [email protected]/mobile-electronics

© 2003 by Bosch Rexroth AG, Mobile Hydraulics, 89275 ElchingenAll 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 ourinformation (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.

Documents

Series 20 Features - Airline Hydraulics Hydraulics Electric Drives and Controls Linear Motion and Assembly Technologies Pneumatics Service Automation Mobile Hydraulics Features –