Bodas Controller RC: Series 20

Blocked for new applications / Für Neuanwendung gesperrt
BODAS RE 95200/02.12
Replaces: 03.09
1/20
Controller RC
Series 20
Data sheet
For closed- and open-loop control

of hydraulic components
Contents Features
Ordering code 2 –– Component of BODAS system for mobile applications
Description 2 –– Robust design meeting specifications for mobile applications
Block circuit diagram 3 –– High electromagnetic compatibility (EMC)
Technical data 4 –– Inputs and outputs with fault detection
Connection diagram RC2-2 6 –– Safety features such as redundant inputs and central safety
cut-off for all outputs
Connection diagram RC4-4 7
–– Pulse-width-modulated (PWM) solenoid currents for
minimum hysteresis
–– Closed-loop control of solenoid currents, i.e. not dependent
Overview of functions 10 on voltage and temperature
Dimensions RC2-2 12 –– Sturdy, sealed aluminum housing
Dimensions RC4-4, RC6-9 13
Main components
Dimensions RC12-18 14
–– Powerful 16-bit microcontroller module
Installation position 15
–– Protected watchdog for program run monitoring
Mating connector 16
–– Serial data interface and CAN-bus interface for diagnostics,
Safety instructions 17 parameter setting and display of process variables
–– Supply voltage and ground connections for potentiometers
and sensors
2/20 Bosch Rexroth AG RC Series 20 RE 95200/02.12
Ordering code Description

The BODAS controllers RC are used for the programmable
RC / 20 control of proportional solenoids and additional switching func-
01 02 03 tions. They can therefore be used for both simple and complex
open- or closed-loop controls, e.g. for hydrostatic travel drives,
Type working hydraulics or transmission control in mobile working
01 BODAS controller RC machines.
BODAS controllers RC were specially developed for use
Version in mobile working machines, and satisfy the relevant safety
1st digit = no. of ▲ 2-2 requirements with regard to ambient temperature, tightness,
proportional outputs 4-4 resistance to shock and vibration, as well as electromagnetic
02 compatibility (EMC). Internally, BODAS controller RC consist
2nd digit = no. of ▲ 6-9
of a powerful 16-bit microcontroller and all input and output
switched outputs ▲ 12-18 circuitry.
Series Analog voltages, resistances frequencies and switching infor-

03 Series 2, index 0
mation are processed as input signals. The inputs are protec-
20
ted against overvoltage and electrical interference. The voltage
= Available ▲ = Not for new applications inputs can be monitored to detect any cable breaks or short
circuits.
Note:
The proportional solenoid outputs are pulse-width-modulated
The BODAS controllers are not functional without software. (PWM) and optimally adapted for electric proportional control
of axial piston units and valves to ensure high accuracy and
In order to use the BODAS controllers, you also need:
minimum hysteresis.
– BODAS standard software or
The switched outputs are designed for the direct switching of
– Application-specific software
relays, lamps and switching solenoids.
The RS232 serial interface enables the connection of a laptop
Optional accessories:
to the BODAS-service PC software for service functions,
–– BODAS-design software such as diagnostics, parameter setting or display of process
The Windows-based PC software BODAS-design variables.
(RE 95112) is used for programming the BODAS controller
CAN-bus interfaces are available with all BODAS controller
RC. All graphic and text-based programming languages
RC for exchanging data with other bus users or electronic sys-
specified in the IEC 61131-3 standard are available for
tems (e.g. RC or RCE, joystick valves, diesel engine injection,
programming.
display). The CAN-bus interfaces can each be operated with
–– BODAS-service software different protocols.
The Windows-based PC software BODAS-service
BODAS standard programs are available for the BODAS con-
(RE 95086) is used for displaying functions, errors and sys-
troller RC software. If more extensive functions are required,
tem variables as well as for setting parameters via a PC.
special program packages for specific applications can also be
–– BODAS measuring adapter MA compiled using a program library and adapted to the applica-
The BODAS measuring adapter MA (RE 95090) is used tion in question with the aid of service tools. Programming with
for measuring all electric signals at the inputs, outputs and BODAS-design is also possible.
interfaces of the BODAS controller. For test purposes, it is
Combined with pumps, motors, valves, sensors, input devices
connected in series between the controller and the vehicle
and actuators from Bosch Rexroth, BODAS controllers RC
or device wiring.
and corresponding software can be used to create complete
–– BODAS test box TB3 system solutions.
The BODAS test box TB3 (RE 95092) is used for simula-
ting vehicle and equipment functions for development and
test purposes with BODAS controllers. The BODAS test
box TB3 is connected to the controller with the adapter
cable TAK1/10.
–– BODAS CAN I/O extension module RCE12-4/22
The BODAS CAN I/O extension module RCE12-4/22
(RE 95220) is used for I/O extension of a controller in the
event that the number of controller inputs and outputs is
insufficient 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 95200/02.12 RC Series 20 Bosch Rexroth AG 3/20
Block circuit diagram

Controller
Note:
The block circuit diagram applies for controllers RC2-2/20, RC4-4/20, RC6-9/20.
For controller RC12-18/20, the respective block circuit diagrams for the master and slave apply.
Output enable
stages3)
Voltage supply,
Central
output stages Watchdog
safety cut-off
Power supply &
Voltage + Power supply
supply - unit electronics
Power outputs
electronics
Proportional
PWM output solenoid outputs1)
Ignition switch + Switch-on
pulse Digital output Switched
outputs1)
+ Inputs
Microcontroller 16 bit Enable3)
Signal output stages
+ Flash
Frequencies1) - EEPROM RAM outputs of external
Frequency EPROM controller
Enable output Analog
Analog Control unit stages of external voltage
Voltage for outputs
voltage1) controller output3)
Counter
input Interface
Analog current1) Current
controller Serial
Evaluation A/D-converter interface RS-232
Switching 10 bit
information1) switch
LED2) CAN-bus
Digital Interface driver
Programming Evaluation red / green interface
inputs
1) The inputs and outputs are partially mutually isolated by the technical circuitry.
2) In the RC2-2/20 only
3) Not in the RC2-2/20
Technical data
Controller RC 2-2 4-4 6-9 12-18
Nominal voltage 12 and 24 V    
Residual ripple (DIN 40839, Part 1) max. ± 2 V    
Supply voltage, permitted range 8 - 32 V    
Current consumption
Without load, maximum mA 250 400 400 800
With load, maximum A 8 15 18 36
Fuse
Internal: – – – –
External: for switch and proportional
AT 8 15 20 2x20
solenoid outputs
For electronics AT 3 3 3 2x3
For sensors AT 1 1 1 2x1
Constant voltage source
E.g. for setpoint potentiometer 1 - 5 kΩ 5 V ± 0.1 V
With current monitoring 15 mA 2 – – –
With voltage monitoring 20 mA – – 2 4
100 mA – 2 2 4
Analog voltage inputs
(may also be used as switch input)1) 0-5V 2 5 8 16
Analog current inputs
(may also be used as switch input)1)4) 0 - 20 mA 2 4 4 8
Switch inputs low < 1.5 V; high > 4.5 V
(number of which can be used as frequency inputs for interval time measurement) – 4 4 4
High active only 4 1 2 –
Switch between high/low active – 5 6 12
(may be used as analog voltage input) 2 6 8 –
Frequency inputs
(may also be used as switch input)1) 0 - 10 kHz; > 1 VRMS 2 3 5 10
Proportional solenoid outputs (PWM)
Current range 0 - 1.8 A – – 2 4
0 - 2.3 A 2 4 4 8
Pulsation frequency 100 - 400 Hz 2 4 – –
100, 160 or 220 Hz – – 6 12
Switched outputs (MOSFET)
max. 1.3 A – 2 6 12
max. 2 A 2 – – –
max. 2.6 A – 2 3 6
Analog voltage outputs 0-5V – 1 1 2
Interfaces
RS232 C 1 1 1 2
CAN 2.0 B ISO 11898 1 2 2 2
LED indicators red / green 2 – – –
Fault detection for cable break and short circuit
Analog inputs    
Proportional solenoid outputs    
Protection against short circuit of the inputs and outputs
Against supply voltage and ground2)    
Reverse-connect protection
Power supply / battery3)    
1) Switchable with supply voltage
2) Voltages greater than those applied to supply pins 1, 27, 41, 42 must not be applied to the outputs. Except GND, sensor GND,
constant voltage sources und CAN interfaces against battery voltage.
3) The external fuse trips in the event of voltage reversal.
4) The load of the current inputs is 220 Ω. Voltages > 5.5 VDC cause the load to increase to 22.2 kΩ.
Technical data
Controller RC 2-2 4-4 6-9 12-18
Microcontroller C164CI C167CS C167CS 2xC167CS
Clock frequency MHz 20 40 40 40
Memory capacities
RAM kByte 128 256 256 512
Flash EPROM kByte 256 512 512 1024
EEPROM kByte 2 8 8 16
Software installation
   
Download to flash memory
Electromagnetic compatibility
Spurious interference 100 VRMS/m;
   
(motor vehicles directive 95/54/EG) (details on request)
Line-bound interference
Values on request    
(ISO 7637-1/-2/-3)
Load dump 70 V    
Electrostatic discharge ESD
(acc. to ISO 10605)
Not in operation 8 kV    
In operation 15 kV    
Maximum dissipation power W at 32 V 8.0 8.0 8.25 16.5
Operating temperature, case -40…+85°C (-40...+185°F)    
Storage temperature, case -40…+85°C (-40...+185°F)    
Vibration resistance
Sinusoidal vibration 10 g; 57 - 2000 Hz
(IEC 60068-2-6) 20 cycles per axis    
Random-shaped vibration 0.05 g2 / Hz
   
(IEC 60068-2-36) 30 min per axis
Shock resistance
15 g; 11 ms
Transport shock per spatial axis
   
(IEC 60068-2-27) x, y, z and in each
direction (pos./neg.)
25 g; 6 ms
per spatial axis
Continuous shock
x, y, z and 1000x in    
(IEC 60068-2-29)
each direction
(pos./neg.)
Resistance to moisture
(IEC 60068-2-30Db; Variant 2) 95% (+25 to +55°C)    
Resistance to salt spray
(IEC 60068-2-11) 72 h, 35°C, 5% NaCl    
Type of protection (DIN / EN 60529)1)
IP54k / IP65    
Without / with mounted mating connector
Case material Diecast aluminum    
Weight Approx. kg 0.5 0.7 0.7 1.5
Outer dimensions Length (in mm) 114 187 187 187
Width (in mm) 204 202 202 202
Height (in mm) 45 45 45 83
Mating Connector 52-pin 1 1 1 2
28-pin – – 1 2
1) Taking installation notes into account
Connection diagram RC2-2

3)
1A
Safety switch
Ignition switch6)
3A 41 Switch-on signal
30 15 42
Electronic supply
10 A 1 Supply voltage of the

+12 V/+24 V
30 27 output stages
31 2
0V 28
Ground
Frequency inputs
31 max. 2.3 A Proportional
Proportional
Speed sensor 33
32 solenoids
outputs
2)
44
30 max. 2.3 A
43
2)
sources 5 V 2x15 mA
Constant voltage
29 max. 2.0 A Switched outputs

Switched
outputs
2)
15 max. 2.0 A
2)
5)
36 +5V
Potentiometer 35
Voltage inputs
38
5)
47 +5V
46
49
34
51
TxD
Current inputs
50
Current source RS 232 RxD C
17 D Diagnostics
0 - 20 mA B
E connector
45 A for
G
F BODAS-service
52
H
40
Switches CAN H
37 39
CAN L
Switch inputs
48 CAN-bus
10 interface4)
11
1)
1) Short, low-resistance connection from a case screw to the device ground or vehicle ground
2) Separate ground connection from solenoid return line to battery (chassis possible)
3) Separate fuses for switches and sensors necessary
4) CAN bus: termination resistor 2 x 120 Ω necessary
5) Alternatively, 5 V/ground outputs may also be used to supply the sensors
6) The terminals are labeled according to DIN 72 552. This does not apply for the controller.

3)
1A Safety switch
Ignition switch9)
30 15 42
Electronic supply
+12 V/+24 V
15 A 1 Supply voltage of the
30 27
output stages
31 2 31
0V 28 Proportional
Proportional outputs
max. 2.3 A
Frequency inputs
Ground 2)
solenoids
30
Speed sensor 33
32 max. 2.3 A
2)
44 4
43 max. 2.3 A
2)
Constant voltage sources

18 16
17 max. 2.3 A
5 V 2x100 mA
2)
36 +5V 5)
Potentiometer 35
38
29
47 +5V
5)
max. 2.6 A Switched outputs
46
Switched outputs
2)
Voltage inputs
49
15
max. 2.6 A
8 2)
5
max. 1.3 A
20 2)
6
max. 1.3 A
19
2)
34
22 Analog
Current source 0 V...5 V
signal outputs
Current inputs
7
0 - 20 mA
45 0 V - 5 V DC
51
9
TxD C Diagnostics
RS232 RxD 50 D connector
24
21 B for
E BODAS-service
A
52
H
Switches
37 G
6) F
48
40
Switch inputs
6)
CAN H1
10 39
CAN L1
11
8) CAN-bus
8) interfaces4)
23
8) 26
12
CAN H2
25
Enable external CAN L2
output stages
13 OE 14
INH 7)
1)
6) Can be switched together between high/low active by means of software
7) Enable the output stage level ≥ 5 V (proportional and switched outputs)
8) Switched together between high/low active by means of software

3)
1A
Ignition switch9) Safety switch

30 15 42
Electronic supply 31
max. 2.3 A Proportional
20 A 1 Supply voltage of the 2)
solenoids
+12 V/+24 V
Proportional outputs
27 30
30 output stages
max. 2.3 A
2)
31 2
Ground 0 V 28
4
max. 2.3 A
33 2)
Frequency inputs
Speed sensor 32 16
44 max. 2.3 A
2)
43
68
18

17 max. 1.8 A
2)
73 69
5 V 2x100 mA
55 max. 1.8 A
2)
53
54
36 +5V 5) 29
Potentiometer 35 max. 2.6 A Switched outputs
38 2)
5)
47 +5V 15
Voltage inputs
46
49
max. 2.6 A
2)
5
8
max. 1.3 A
2)
Switched outputs
6
20
max. 1.3 A
2)
5 V 2x20 mA
72
80 +5V 5)
19
max. 2.6 A
2)
62
71
max. 1.3 A
Voltage inputs
65
2)
74
79 +5V 5)
64 max. 1.3 A
56 2)
75
63 max. 1.3 A
2)
76
34 max. 1.3 A
Current source 2) Analog
0 - 20 mA signal output
Current inputs
45 22
0 V...5 V 0 V - 5 V DC
7
9
51
21 TxD C Diagnostics
50
RS232 RxD D connector
24
B
Switches E for
37
48 6) A BODAS-
52
6) H service
10 G
F
Switch inputs
8)
11 40
8) CAN H1
23
8) CAN L1 39 CAN-bus
61
8) interfaces4)
12 26
CAN H2
CAN L2 25
60 58
Enable external 59
output stages OE 14
13 INH 7)
1)
7) Enable the output stage level ≥ 5 V (proportional and switched outputs)

The connection of Master A and Slave B for the RC12-18/20 is to be performed as shown below.
All Master A and Slave B inputs and outputs that are not shown are identical in terms of function and specification to those of the
RC6-9/20.
RC 12-18/20 RC 12-18/20
3) Master A Slave B
1A
Safety
switch 13
Ignition switch6) INH 4) 13 4)
INH
3A 41 41
30 15 42 42
20 A 5)
20 A 5) 1 1
+12 V/+24 V 27 27
30
31 2 31 2
0V 28 28
0V
12 12
60 60
IN
CAN H2 26 26 CAN H
CAN L2 25 25 CAN L2
2)
2)
1) 1)
2) CAN bus: termination resistor 120 Ω necessary (see installation instructions RDE 90 300-01)
3) Supply voltage for external sensors and switches
4) Master A and Slave B interlock of the outputs by "cross" wiring terminals 13 and 14 at both controller units
5) The fuses function as line protection. The design is performed by the machine manufacturer.
Connection variants
Monitored
power supply
potentiometer
Sensor
1 to 5 kΩ
36/
47
35/
46
7)
Voltage
38/
input
49
34/
45
7)
Current
input
7) Internal pull-down resistor

Overview of functions
Pin Description Main function Alternative functions
33, 44, Inductive Frequency input for inductive Frequency input for active sensors
182) frequency input sensors Frequency evaluation of active
731) 531) FRQI_A1 - FRQI_A5 Frequency speed sensors
evaluation to 500 - 10 kHz FRQ_A1 - FRQ_A5
Vmin (sine) 1 Veff
DC to GND 110 kΩ Digital input
For sensors which switch to ≥ 5 V
DIG_FA1 - DIG_FA5
36, 47 Sensor supply Sensor supply
ANA_A1V, ANA_A2V Output voltage 5.0 V
Precision 5%
Load capacity 100 mA
801), 791) Sensor supply Sensor supply, can be switched off

ANA_A3V, ANA_A4V Output voltage 5.0 V
Precision 5%
Load capacity 20 mA
35, 46, Analog Analog voltage input Digital input

82), voltage input 5 V Measuring range 0 - 5.5 V Evaluation options
202), ANA_A1 - ANA_A8 Resolution 10 bit • Threshold programmable via software
192), (5.37 mV/bit)
651), 641), Input resistance
631) DC to GND 110 kΩ
Limit frequency
filter 160 Hz
34, 45, Analog Analog current measurement input Digital input
92), 212) current input 20 mA Measurement range 0 - 20 mA Evaluation options
with selectable load Load 220 Ω • Threshold programmable via software
(input resistance) Resolution 10 bit DC to GND 220 Ω
CUR_A1 - CUR_A4 Input resistance
On voltages > 5.5 V, the load automatically
Limit frequency
switches to 22 kΩ um
filter 75 Hz
At voltages > 5.5 V the load automa-
tically switches to 22 kΩ
37, 48, 10, Digital input 5 V Digital input Analog voltage input
11, with selectable Threshold, programmable via software Measurement range 0 - 5 V
232), 22 k pull-up / pull-down after Pull-up / pull-down resistance Resolution 10 bit
122) 5 V / GND partially switchable by means of (5.93 mV/Bit)
Pull-up/pull-down switched software Input resistance
in 2 groups: DC to GND 18.3 kΩ
DIG_A1 - DIG_A2 Limit frequency filter 3.5 kHz
switchable, group 1 (ANA_DA1 - ANA_DA4)
Limit frequency filter 90 Hz
DIG_A3 - DIG_A5
(ANA_DA5, ANA_DA6)
switchable, group 2
Frequency input for active sensors
DIG_A6 Frequency evaluation of active
permanent to GND speed sensors
FRQ_DA1 - FRQ_DA4
611), 601) Digital input 32 V Digital input Analog voltage input
DIG_A7 with selectable Threshold, programmable via software Measuring range 0 - 32 V
pull-up / pull-down Pull-up / pull-down resistance swit- Resolution 10 bit
after 5 V / GND chable by means of software (37 mV/bit)
DIG_A8 Pull-down Input resistance
permanently to DC to GND 19 kΩ
GND Limit frequency filter 120 kHz
1) RC6-9/20 and RC12-18/20 (for both master and slave)

2) RC4-4/20, RC6-9/20 and RC12-18/20 (for both master and slave)
Overview of functions
Pin Description Main function Alternative functions
132) External Inhibit Digital input
INH Levels ≥ 5 V cause output stages to release
Input resistance
DC to GND 10 kΩ
142) Output enable Digital output
OE Output voltage 7-8V
Load capacity approx. 5 mA
31, 30 PWM output stage PWM output stage Switch output stage
4, 16 PWM_A1 - PWM_A4 High-side switch Diagnostics-compatible
PWM-frequency programmable via software actuated time 100%
Integrated suppression diode DIGP_A1 - DIGP_A4
for inductive kickback
Max. current 2.3 A
Pulse duty factor 0 - 100%
681) PWM output stage PWM output stage Switch output stage
691) PWM_A5, PWM_A6 High-side switch Diagnostics-compatible
PWM-frequency programmable via software actuated time 100%
Integrated suppression diode DIGP_A5, DIGP_A6
Max. current 1.8 A
Pulse duty factor 0 - 100%
29, 15 Switch output stage 2.6 A Switch output stage Open loop
DIGL_A1 - DIGL_A2 High-side switch PWM 0 - 100%
Max. current 2.6 A without current measurement
Integrated suppression diode
52), Switch output stage 1.3 A Switch output stage
62), 721), DIGL_A3 - DIGL_A9 High-side switch
711), Max. current 1.3 A
741), Integrated suppression diode
751), 761) for inductive kickback
222) Analog Analog voltage output
voltage output Voltage range 0-5V
AOUT_A1 Resolution 10 bit
(4.9 mV)
Load capacity 3 mA
51, 50, RS232 interface Serial interface
TxD, RxD RC-232C to 56 kBaud
40, 39, CAN interface CAN interface
262), CAN1_H, CAN1_L, CAN 2.0B, 1 Mbaud
252) CAN2_H, CAN2_L Internal termination resistor not present
52 BST Boot strap for flashing via RS232 with
BODAS Flash adapter FA1
1) RC6-9/20 and RC12-18/20 (for both master and slave)

2) RC4-4/20, RC6-9/20 and RC12-18/20 (for both master and slave)
Dimensions RC2-2
120
max. 45
41 42 51 52
27 28 29 30 39 40
15 16 25 26
1 2
38
3 4 13 14
max. 17
0,2
7
c d
LED
204
180
188
90
Fixing:
–– The BODAS controller must be fixed at 4 points
(a, b, c and d).
a b 28 –– Tightening torque MA = 8 ± 2 Nm for fixing the
87 BODAS controller with M6 screws.
105 –– Tightening torque applies for mounting without washer. The
max. 114 equivalent tightening torque must be calculated when using
washers.
max. 1441)
min. 1692) –– Bosch Rexroth’s approval is required if mounting is different
from above.
–– Installation point: evenness of mounting surface 0.5
–– 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 such that a phase
excitation with the controller occurs (e.g. at the controller
mounting point).
If the mounting surface is not sufficiently even, place flexib-
le compensating elements (e.g. rubber washers) between
the fixing points of the BODAS controller and the mounting
surface.
1) Space required for mating connector

2) Space required for plugging and unplugging the mating
connector
Dimensions RC4-4, RC6-9
Chamber not used

for RC4-4/20
max.45
41 42 51 52 74 75 79 80
29 30 39 40 67 68 72 73
27 28
15 16 25 26 60 61 65 66
1 2 3 4 13 14 53 54 58 59
36
17
ø6.9
c d
max. 155 1)
max. 195 2)
202
188
180
158
a 59 b 94
Fixing:
172
187 –– The BODAS controller must be fixed at 4 points
max. 2121)
(a, b, c and d).
min. 2332) –– Tightening torque MA = 8 ± 2 Nm for fixing the
BODAS controller with M6 screws.
–– Tightening torque applies for mounting without washer. The
equivalent tightening torque must be calculated when using
washers.
–– Bosch Rexroth’s approval is required if mounting is different
from above.
mounting point).
surface.

connector
Dimensions RC12-18
41 42 51 52 74 75 79 80
29 30 39 40 67 68 72 73
27 28
15 16 25 26 60 61 65 66
1 2 3 4 13 14 53 54 58 59
max. 83
74
41 42 51 52 74 75 79 80
55
29 30 39 40 67 68 72 73
27 28
15 16 25 26 60 61 65 66
1 2 3 4 13 14 53 54 58 59
38
ø6.9
c d
max. 1551)
max. 1952)
202
180
188
158
a 59 b 94 Fixing:
172 –– The BODAS controller must be fixed at 4 points
187 (a, b, c and d).
max. 2121) –– Tightening torque MA = 8 ± 2 Nm for fixing the
min. 2332) BODAS controller with M6 screws.
–– Tightening torque applies for mounting without washer. The
equivalent tightening torque must be calculated when using
washers.
–– Bosch Rexroth’s approval is required if mounting is different
from above.
mounting point).
surface.

connector
Installation position
³®
®
®
®
®
®
Visible range of
LEDs at RC2-2/20
®
®
®
Note:
Installation position only permissible with specified angular range.
16/20 Bosch Rexroth AG RC RE 95200/02.12
Mating connector 1-headline

Order designations for mating connector, consisting of:
Number for AMP-Tyco MT2/JPT

52-pin 28-pin
Designation AMP No. ID No R902602414 ID No R902602415
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; 28-pin 0-1393436-2 – 1
Cover 0-1393454-7 1 –
Cover 0-1393454-2 – 1
Leakage dummy plugs F.D3,6-MT2 0-0963531-1 40 –
The mating connectors are not included in supply.
The mating connectors are available from Bosch Rexroth as a kit with all materials under the following material numbers.
–– Mating connector kit 52-pin: Mat. no. R902602414
–– Mating connector kit 28-pin: Mat. no. R902602415
Recommended line
Recommended connection lines for contacts 1, 2, 27 and 28:
–– Cross section 1.0 mm² (16 AWG with thin insulation)
–– Outer diameter: 2.0 mm - 2.7 mm
Recommended connection lines for the other contacts (except for 1, 2, 27 and 28):
–– Cross section 0.5 mm² (20 AWG)
–– Outer diameter: 1.9 mm - 2.1 mm
Tools needed
Tyco AMP order numbers for crimping and extractor tools

For crimping
Description Partlist number For connection
Hand-held crimping tool 169 400-0
Insert 539 612-1 MT-2 (Micro Timer)
Insert 539 614-1 JPT (Junior Power Timer)
For disassembly
Description Partlist number For connection
Extractor tool 539960-1 MT-2 (Micro Timer)
Extractor tool 1-1579007-6 JPT (Junior Power Timer)
Applicable documents
–– Applicable Tyco AMP specification No.: 114-18081
This document contains the recommended crimping data and crimping tools for Micro Timer contacts, model MT2.
–– Applicable Tyco AMP specification No.: 114-18050
This document contains the recommended crimping data and crimping tools for Junior Power Timer contacts, model JPT.
RE 95200/02.12 RC Bosch Rexroth AG 17/20
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. Bosch 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 safety 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 swit-
ched 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 con-
troller 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 con-
nection to vehicle ground.
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 should 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 secu-
rely 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.
–– Proportional outputs (PWM_Ax and DIGP_Ax) 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 dama-
ge of the controller in lasting operation.
–– The outputs may not be externally connected to battery.
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 dio-
des. 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 applica-
tion areas in this data sheet.
–– Operation of the controller must generally occur within the operating ranges specified and released in this data sheet, particular-
ly 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.
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 safety-
related 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 appropria-
te 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.
Bosch Rexroth AG © This document, as well as the data, specifications and other information set
Mobile Electronics forth in it, are the exclusive property of Bosch Rexroth AG. It may not be repro-
Glockeraustraße 4 duced or given to third parties without its consent.
89275 Elchingen, Germany The data specified above only serve to describe the product. No statements
Telephone +49 (0) 73 08 82-0 concerning a certain condition or suitability for a certain application can be de-
Telefax +49 (0) 73 08 72-74 rived 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
info.bodas@boschrexroth.de products are subject to a natural process of wear and aging.
www.boschrexroth.com/mobile-electronics
Subject to change.

Bodas Controller RC: Series 20

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Bodas Controller RC: Series 20

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Blocked for new applications / Für Neuanwendung gesperrt

For closed- and open-loop control

Ordering code Description

Series Analog voltages, resistances frequencies and switching infor-

Block circuit diagram

Connection diagram RC2-2

10 A 1 Supply voltage of the

29 max. 2.0 A Switched outputs

Connection diagram RC4-4

Constant voltage sources

Connection diagram RC6-9

Ignition switch9) Safety switch

Constant voltage sources

Connection diagram RC12-18

7) Internal pull-down resistor

801), 791) Sensor supply Sensor supply, can be switched off

35, 46, Analog Analog voltage input Digital input

1) RC6-9/20 and RC12-18/20 (for both master and slave)

1) RC6-9/20 and RC12-18/20 (for both master and slave)

1) Space required for mating connector

Dimensions RC4-4, RC6-9

Chamber not used

1) Space required for mating connector

1) Space required for mating connector

Mating connector 1-headline

Number for AMP-Tyco MT2/JPT

Tyco AMP order numbers for crimping and extractor tools

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