Bosch BODAS RC/3 Series User manual

Instruction manual
RE95240-01-B/2021-01-12, EN
BODAS controller
RC/3x and RC/4x

© BoschRexrothAG2021. 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 condition or suitability
for acertain application can be derived from
our information. The information given does
not release the user from the obligation of
own judgment and verification. It must be
remembered that our products are subject to
anatural process of wear and aging.
The cover shows an example application.
Theproduct delivered may differ from the
image on the cover.
The original instruction manual was created in
the German language.

RE95240-01-B/2021-01-12, Bosch Rexroth AG
Contents | BODAS controller RC/3x and RC/4x 3/24
1 About this documentation ........................................................................ 4
1.1 Validity of the documentation ......................................................................4
1.2 Required and supplementary documentation...............................................4
1.3 Representation of information......................................................................4
1.3.1 Safety instructions .......................................................................................4
1.3.2 Symbols .......................................................................................................5
1.3.3 Designations ................................................................................................5
1.3.4 Abbreviations ...............................................................................................6
2 Safety instructions ................................................................................... 7
2.1 About this chapter........................................................................................7
2.2 Intended use ................................................................................................7
2.3 Improper use................................................................................................7
2.4 Personnel qualifications ...............................................................................7
2.5 General safety instructions ..........................................................................8
2.6 Product-specific safety instructions .............................................................9
2.7 Personal protective equipment.....................................................................9
3 General instructions on property damage and product damage.............. 10
4 Scope of delivery....................................................................................11
5 About this product ................................................................................. 12
5.1 Product description ...................................................................................12
5.2 Product identification.................................................................................13
6 Transport and storage ............................................................................ 14
6.1 Storing the control unit ..............................................................................14
7 Installation............................................................................................. 15
7.1 Unpacking ..................................................................................................15
7.2 Installation conditions................................................................................15
7.3 Mounting the control unit...........................................................................16
7.4 Notice on wiring and circuitry ....................................................................17
8 Commissioning....................................................................................... 18
9 Operation ............................................................................................... 18
10 Maintenance and repair.......................................................................... 19
10.1 Cleaning and care ......................................................................................19
10.2 Inspection and maintenance ......................................................................19
10.3 Repair ........................................................................................................19
11 Removal and replacement ...................................................................... 20
12 Disposal ................................................................................................. 20
13 Extension and conversion....................................................................... 21
14 Troubleshooting ..................................................................................... 21
15 Technical data ........................................................................................ 22
16 Alphabetical index ................................................................................. 23
Contents

4/24 BODAS controller RC/3x and RC/4x | About this documentation
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1 About this documentation
1.1 Validity of the documentation
This documentation is valid for the following products:
• BODAS controller of series 3x and 4x
This documentation is intended for machine/system manufacturers, assemblers and
service engineers.
This documentation contains important information on the safe and proper
transport, installation, commissioning, operation, maintenance, disassembly and
simple troubleshooting of the product.
▶ Read this documentation completely, in particular chapter2 "Safety instructions"
on page7 and chapter 3 "General instructions on property damage and
product damage" on page10 before you start working with the product.
1.2 Required and supplementary documentation
▶ Only commission the product if the documentation marked with the book symbol
is available to you and you have understood and observed it.
Table 1: Required and supplementary documentation
Title Document number Document type
BODAS controller RC4-5, series 30 95205 Data sheet
BODAS controller RC28-14, RC20-10 and RC12-10,
series 30
95204 Data sheet
BODAS controller RC10-10, series 31 95206 Data sheet
BODAS controller RC5-6, series 40 95207 Data sheet
BODAS controller RC18-12 and RC27-18, series 40 95208 Data sheet
1.3 Representation of information
Uniform safety instructions, symbols, terms and abbreviations are used throughout
this documentation to ensure safe and proper use of the product. For clarification,
they are explained in the sections below.
1.3.1 Safety instructions
This documentation contains safety instructions in chapter2.6 "Product-specific
safety instructions" on page9 and in chapter3 "General instructions on property
damage and product damage" on page10, as well as before asequence of actions
or an instruction for action involving arisk of personal injury and property damage.
Always follow the measures for danger prevention associated with the use of this
product.

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About this documentation | BODAS controller RC/3x and RC/4x 5/24
Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger!
Consequences of noncompliance
▶ Danger prevention measures
•Warning sign: draws attention to the danger
•Signal word: identifies the degree of the danger
•Type and source of danger: indicates the type and source of the danger
•Consequences: describes what occurs if safety instructions are disregarded
•Precautions: states how the danger can be avoided
Table 2: Hazard classes as defined in ANSI Z535.6
Warning sign, signal word Meaning
DANGER Identifies adangerous situation that will result in death or serious
injury if it is not avoided.
WARNING Identifies adangerous situation that may result in death or serious
injury if it is not avoided.
CAUTION Identifies adangerous situation that may result in minor to
moderate injury if it is not avoided.
NOTICE
Property damage: The product or surrounding area may be damaged.
1.3.2 Symbols
The following symbols indicate notices that are not safety-relevant but increase
understanding of the documentation.
Table 3: Meaning of symbols
Symbol Meaning
If this information is disregarded, the product cannot be used and/or
operated to its full extent.
▶ Single, independent action
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions must be completed in order.
1.3.3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
RC BODAS controller
The designation "product" or "control unit" will be used as ageneric term for the
"BODAS controller".

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1.3.4 Abbreviations
This documentation uses the following abbreviations:
Table 5: Abbreviations
Abbreviation Meaning
ANSI American National Standards Institute is an organization that coordinates
the development of voluntary standards in the United States
DIN Deutsches Institut für Normung (German Institute for Standardization)
EMC Electromagnetic compatibility
ISO International Organization for Standardization
RE Rexroth document in the English language

RE95240-01-B/2021-01-12, Bosch Rexroth AG
Safety instructions | BODAS controller RC/3x and RC/4x 7/24
2 Safety instructions
2.1 About this chapter
The product has been manufactured in accordance with generally accepted
engineering standards. There is still, however, adanger of personal injury or
property damage if this chapter and the safety instructions in this documentation are
not observed.
▶ Read this documentation completely and thoroughly before working with the
product.
▶ Keep this documentation in alocation where it is accessible to all users at all
times.
▶ Always include the required documentation when passing the product on to third
parties.
2.2 Intended use
The control unit is designed for use in mobile working machines provided
no limitations / restrictions are made to certain application areas in data
sheets95204,95205, 95206, 95207 and 95208.
▶ Operation of the control unit must generally occur within the operating ranges
specified and released in data sheets95204, 95205, 95206, 95207 and 95208.
This applies in particular to voltage, current, temperature, vibration, shock and
other described environmental influences.
▶ Its use outside of these specified and approved boundary conditions may result
in danger to life and/or cause damage to components which could result in
sequential damage to the mobile working machine.
2.3 Improper use
Any use other than that described as intended use is considered improper.
BoschRexroth AG is not liable for damages resulting from improper use. The user is
solely responsible for any risks arising from improper use.
2.4 Personnel qualifications
The activities described in this documentation require basic mechanical,
electronical/electrical and hydraulic knowledge, as well as knowledge of the
associated technical terms. In order to ensure safe use, these activities should only
be performed by skilled personnel or an instructed person under the direction and
supervision of skilled personnel.
Skilled personnel refers to persons who possess the professional training,
knowledge and experience, as well as the understanding of the regulations relevant
to the work to be done that are necessary to recognize possible dangers and take
the appropriate safety measures. Skilled personnel must follow the rules relevant
to their field and have the necessary expert knowledge of mechatronics, electronics
and hydraulics, if applicable.
Expert knowledge means, for instance:
• Being able to read and fully understand electrical circuit diagrams and hydraulic
diagrams, if applicable,

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• in particular, fully understanding the relationships with regard to safety devices,
• as well as to carry out the wiring of electronic components correctly and
• to have knowledge of the function and interaction of electronic, mechanical and
hydraulic components.
Only trained and experienced specialists who are adequately familiar with both the
components used and the complete system should implement system developments
or install and commission electronic systems for controlling hydraulic drives.
BoschRexroth offers you measures supporting training in specific areas.
You can find an overview of the training contents on the Internet at:
www.boschrexroth.com/training.
2.5 General safety instructions
• Reliable operation cannot be guaranteed if samples or prototypes are used in
series production machines.
• The possible circuits for the system do not imply any technical liability for
BoschRexroth.
• Incorrect connections could cause unexpected signals at the outputs of the
controlunit.
• Incorrect programming or parameterization of the control unit may lead to dangers
when operating the machine. It is the responsibility of the machine manufacturer to
identify this type of hazard within the scope of ahazard analysis and to bring them
to the attention of the end user. Rexroth is not liable for any hazards of this kind.
• The component firmware/software must be installed and removed by
BoschRexroth or the responsible authorized partner in order to ensure that the
warranty does not expire.
• It is not permissible to open, modify or repair the control unit. Modifications to or
repairs on the wiring can lead to dangerous malfunctions. Repairs to the control
unit may only be performed by BoschRexroth or by an authorized partner.
• The stop switch (two-channel deactivation) can be used for deactivation in
emergency situations. The switch must be installed 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.
• Make sure no pins are charged with avoltage source when the electronics are not
receiving power.
• Make sure that the control unit's configuration does not lead to safety-critical
malfunctions of the complete system in the event of failure or malfunction. Such
system behavior could result in death or serious property damage.
• Only trained and experienced specialists who are adequately familiar with
both the components used and the complete system should implement system
developments or install and commission electronic systems for controlling
hydraulic drives.
• The machine may cause unforeseen hazards during control unit start-up and
maintenance. The vehicle and hydraulic system must therefore be in asafe state
during such work.
• Therefore, make sure that nobody is in the machine's danger zone.

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Safety instructions | BODAS controller RC/3x and RC/4x 9/24
• Do not use defective components or components which are configured incorrectly.
Failed or incorrectly operating components must be repaired immediately.
• Control units used to develop software must not be installed in series production
machines as the number of flash cycles is limited and may have been reached or
exceeded.
2.6 Product-specific safety instructions
The following safety instructions apply to chapters 6 to 14.
WARNING
System/machine under pressure!
Risk of death or serious injury when working on unsecured machines/systems!
Property damage!
▶ Switch off the relevant machine/system part and secure it against reactivation
according to the parameters by the machine/system manufacturer.
CAUTION
Improper cable and line routing!
Risk of stumbling and property damage! Improper routing of cables and lines
can cause arisk of stumbling as well as damage to equipment and components,
e.g.due to lines and connectors being torn off.
▶ Always install cables and lines in away that nobody can fall over them, that
they are not bend or twisted, do not chafe on edges and are not guided through
ducts with sharp edges without sufficient protection.
Danger due to malfunctions!
Risk of injury and property damage as well as machine damage due to malfunctions
of the sensor!
▶ Carry out arisk assessment of your machine and determine the possible
safety-relevant functions.
▶ Take suitable measures to ensure safety in applications relevant to safety,
e.g.sensor redundancy, plausibility check, emergency switch, etc.
▶ Product data that is required for the safety assessment of the machine is
included in datasheets95204, 95205, 95206, 95207 and 95208.
2.7 Personal protective equipment
The personal protective equipment is the responsibility of the user of the product.
Observe the safety regulations in your country.
All pieces of personal protective equipment should be intact.

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Bosch Rexroth AG, RE95240-01-B/2021-01-12
3 General instructions on property
damage and product damage
The following notices apply to chapters 6 to 14.
NOTICE
Environmental pollution due to incorrect disposal!
Careless disposal of the product and the packaging material could lead to
environmental pollution!
▶ Dispose of the product and packaging in accordance with the national
regulations in your country.
Electrical voltage!
Damage to property due to electrical voltage!
▶ Always disconnect the voltage supply to the relevant machine/system part
before installing the product and/or connecting or disconnecting the connector.
Secure the machine/system against being turned back on.
The warranty exclusively applies to the delivered configuration.
The warranty will be voided if the product is incorrectly installed, commissioned or
operated, or if it is used or handled improperly.

RE95240-01-B/2021-01-12, Bosch Rexroth AG
Scope of delivery | BODAS controller RC/3x and RC/4x 11/24
4 Scope of delivery
Only the control unit is included in the scope of delivery. In Fig. 1, the control unit
RC5-6/40 is shown as an example.
Fig. 1: RC5-6/40

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5 About this product
5.1 Product description
The BODAS controllers are designed as auniversal control unit for mobile
working machines. The control units are used for the programmable control of
proportional and switching solenoid and of additional electrical switching functions.
Typicalapplications are electro-hydraulically actuated work functions, travel drives
and transmission controls. The microcontroller, all input and output circuits,
communication interfaces, voltage supplies for the sensors and apower supply
unit for operation with 12 or 24V supply voltages are integrated in acompact
housing. The control units have several power outputs, which are partially
current-controlled. Several independent CAN bus interfaces are available in the
BODAS controllers. The BODAS controllers RC were developed specifically for use in
mobile working machines and satisfy corresponding safety requirements regarding
ambient temperatures, water and dust ingression, shock and vibration as well as
electromagnetic compatibility (EMC). BODAS controllers RC and corresponding
software in combination with pumps, motors, valves, sensors, input devices and
actuators from BoschRexroth make for complete system solutions.

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About this product | BODAS controller RC/3x and RC/4x 13/24
5.2 Product identification
The product can be identified using the material number on the label of the
packaging unit.
In addition, the material number(1) and the designation of the control unit(2) can
be found on the name plate. The following example shows aRC5-6/40 name plate:
2
1
Fig. 2: RC5-6/40 name plate
Table 6: Material number of the control units
Designation Material number
RC4-5, series 30 R917008015
RC12-10, series 30 R917008181
RC20-10, series 30 R917008180
RC28-14, series 30 R917007683
RC10-10, series 31 R917010287
RC5-6, series 40 R917011700
RC18-12, series 40 R917013300
RC18-12E, series 40 R917013042
RC27-18, series 40 R917013301
RC27-18E, series 40 R917013043

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6 Transport and storage
Check the control unit for transport damage. If there are obvious signs of damage,
please inform the transport company and BoschRexroth immediately.
If the control unit is dropped, continued use is not permissible because unseen
damage may affect its reliability.
6.1 Storing the control unit
• Store control units at an average relative humidity of 60% and at atemperature
between -10°C and +30°C. Momentary, astorage temperature of -20 °C to +40 °C
is permissible for up to 100hours.
• After astorage time of more than 5years, the control unit must be checked by the
manufacturer before use.
Requirement

RE95240-01-B/2021-01-12, Bosch Rexroth AG
Installation | BODAS controller RC/3x and RC/4x 15/24
7 Installation
Prior to installation, the following documents should be to hand:
• Product-specific data sheet (contains the permissible technical data,
main dimensions and circuit diagrams of standard versions), see Table 1
"Required and supplementary documentation" on page4.
7.1 Unpacking
NOTICE! Danger due to electrostatic discharge!
When unpacking the control unit, there is adanger of damage to the electronic
components of the control unit due to electrostatic discharge.
▶ During unpacking, the control unit is to be protected against electrostatic
discharge.
▶ Remove the packaging from the control unit.
▶ Check the control unit for transport damage and completeness, see chapter4
"Scope of delivery" on page11.
▶ Dispose of the packaging in accordance with the regulations in your country.
7.2 Installation conditions
▶ Do not install the control unit near parts which 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 transmission systems must be maintained.
▶ All connectors must be unplugged from the electronics during electrical welding
or painting operations.
▶ Cables/wires must be sealed individually to prevent water from entering the
control unit.
▶ The control unit must not be electrostatically charged, e.g.during painting.
▶ The control unit will heat up beyond normal ambient temperature during
operation. Protect the control unit from being touched in order to avoid hazards
caused by high temperatures.
▶ Install the control unit in such away that the electrical plug is not facing upwards.
This ensures that any condensation water is drained.
▶ Standing and permanently running water are not permitted anywhere near the
circumferential groove (lid/base connector) or the pressure equalizing element
(DAE).
▶ The control unit must be fastened with metal screws in order to establish agood
thermal connection between the housing and the cooling surface (heat sink).

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7.3 Mounting the control unit
• The BODAS controller must be mounted in the vehicle so that it does not bounce
against other vehicle parts and additional mounting elements of the control unit.
• This tightening torque applies for fitting without washer. The equivalent tightening
torque must be calculated when using washers. For recommended screw sizes and
tightening torques, refer to the following table.
Table 7: Screw size and tightening torques
Designation Recommended screw size Maximum tightening torques
RC4-5, series 30 M4, head diameter > 7mm 3.0 Nm (with washer),
2.5 Nm (without washer)
RC12-10, series 30 M6 10.0 Nm (without washer)
RC20-10, series 30
RC28-14, series 30
RC10-10, series 31
RC5-6, series 40
RC18-12, series 40
RC18-12E, series 40
RC27-18, series 40
RC27-18E, series 40
• Rexroth's consent is required if mounting is different from above.
• The minimum distance between the underside and the mounting surface of the
vehicle is 1mm.
• For the RC4-5-30 control unit, the following applies: The distance between the
underside and the mounting surface should be less than 10mm. If the control
unit is not mounted with aholder, it should be mounted with four distance bolts
guaranteeing this distance and preventing bending of the base plate in the area of
the screw holes.
• The evenness of the mounting surface between points a, b, c and d
(drawing see data sheets95204, 95205, 95206, 95207 and 95208) is 0.5.
• The wiring harness should be fixated in the area in which the control unit is
installed (spacing<150mm) in such away that the in-phase excitation with the
control unit occurs (e.g.at the control unit tightening point).
• The wiring harness should be mounted in such away that there is enough space for
the mating connector to be unplugged without having too much force acting on the
mating connector.
• If the mounting surface is not sufficiently even, place flexible compensating
elements between the mounting points of the BODAS controller and the mounting
surface.

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7.4 Notice on wiring and circuitry
• Electrical isolation is required for connections with systems with adifferent
electrical ground or power source.
• Lines to the speed sensors are to be shielded and kept as short as possible and be
shielded. The shielding must be connected to the electronics or to the device or
vehicle ground via alow resistance connection (only on one side).
• Twisted pair cables are to be used for CAN and ISOBUS.
• The product may only be wired when it is de-energized.
• Cables to the electronics must not be routed close to other power-conducting
cables in the machine or vehicle.
• The wiring harness must be mechanically fastened in the area in which the
controlunit is installed (distance<150mm). The wiring harness must be mounted
in such away that an in-phase excitation with the control unit occurs (e.g.at the
control unit fixing point).
• If possible, lines are to be routed inside the vehicle. If lines have to be routed
outside the vehicle, ensure secure mounting.
• 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 distance from hot or moving vehicle parts.
• PWM outputs must not be connected to one another or bridged.
• The outputs must not be used to operate incandescent lamps due to the inrush
current properties of these loads. Exceptions are permitted for signal lamps with
low power if it is ensured that the inrush current does not exceed the limit values
of this data sheet.
• The sensor supplies can be "pulled up" by an external connection, e.g.,the
application of ahigher voltage, because they operate only as avoltage source
but not as avoltage sink. Pulling up asensor supply may result in unexpected
malfunctions and damage the control unit in continuous operation.
• There are restrictions for the operation of LEDs with internal electronics at the
outputs. The input current must be below the diagnostic threshold values.
• If LEDs are operated at power outputs, the diagnostic current may cause the
LEDsto flash.
• The "high-side" outputs may not be externally connected to battery.
• Loads connected to low-side outputs (both power outputs and outputs with
lowpower) must be supplied by ahigh-side output and not directly by the battery.

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8 Commissioning
During all work for commissioning the control unit, observe the general
safetyinstructions and intended use detailed in chapter2"Safety instructions" on
page7.
▶ When commissioning the control unit, the machine may pose unforeseen dangers.
Before commissioning the system, you must therefore ensure that the vehicle and
the hydraulic system are in asafe condition.
▶ The control unit is generally commissioned via asoftware application. Please
refer to the software manual for the respective series.
9 Operation
Use the control unit only within the performance range specified in the technical
data.

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Maintenance and repair | BODAS controller RC/3x and RC/4x 19/24
10 Maintenance and repair
10.1 Cleaning and care
NOTICE
Damage to seals and electronics/electrics due to mechanical effects!
The water jet of ahigh-pressure cleaner may damage the seals and
electronics/electrics of the control unit!
▶ Do not point the high-pressure cleaner directly towards the control unit.
For cleaning and care of the control unit, observe the following:
▶ Check whether all the seals and fittings on the plug-in connections are securely
seated to ensure that no moisture can penetrate into the control unit and the
installation space during cleaning.
▶ Use only very small amounts of water and, if necessary, amild cleaning agent to
clean the control unit. Never use solvents or aggressive cleaning agents.
10.2 Inspection and maintenance
No special activities are necessary.
10.3 Repair
The control unit cannot be repaired.
When replacing the control unit, make sure that no contamination can penetrate the
mating connector.
▶ Only use an original spare control unit from Rexroth, otherwise the functional
reliability cannot be guaranteed, and the warranty will be voided.
▶ Control units can be found online at www.boschrexroth.com/eshop
Address all questions regarding repair to your responsible BoschRexroth service.

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Bosch Rexroth AG, RE95240-01-B/2021-01-12
11 Removal and replacement
▶ Only remove the control unit when completely de-energized.
12 Disposal
Careless disposal of the control unit can lead to environmental pollution.
▶ The control unit and its packaging must be disposed of according to the
national environmental regulations of the country in which the control unit is
used.