REXROTH PR4 280 GB05 User manual

RE 95156/12.2015, Bosch Rexroth AG
BODAS Pressure sensor
PR4 series 10
RE 95156
Edition: 12.2015
Features
▶ Thin-film measurement principle
▶ Compact dimensions for all pressure ranges
▶ Shock and vibration resistant
▶ EMC characteristics better than 150V/m
▶ High resistance to pressure spikes
▶ Very good resistance to temperature shock
▶ High accuracy over the complete measuring range
▶ Maximum tightening torque 45 Nm
▶ Measurement range
0 to 280 bar
0 to 420 bar and
0 to 600 bar
▶ Ratiometric output signal 0.5 to 4.5V with 5V
supply voltage
▶ Type of protection IP67 and IP69K
Contents
Ordering code 2
Description 2
Technical data 3
Characteristics 4
Dimensions 4
Connector Bosch Compact 5
Installation instructions 6
Safety instructions 7

Bosch Rexroth AG, RE 95156/12.2015
2PR4 series 10 | BODAS Pressure sensor
Ordering code
Ordering code
01 02 03 04 05 06
BODAS PR4 / 10
Type
01 Pressure sensor PR4
Measurement range
02 0 to 280 bar1) 280
0 to 420bar 420
0 to 600bar 600
Mechanical connection 280 420 600
03 G1/4A nach DIN EN ISO 1179-2 ● ● – G
M14x1.5 nach ISO6149-2 – – ● M
Electrical connection
04 Bosch Compact B
Supply Output signal
05 5 ±0.25V 0.5 to 4.5V ratiometric 05
Series
06 10
Available variants
Type Material number
PR4 280 G B 05 / 10 R9170055621)
PR4 420 G B 05 / 10 R917009842
PR4 600 M B 05 / 10 R917010105
●= Available –= Not available
Description
This sensor is used for measuring pressure in hydraulic
circuits. Due to its outstanding characteristics, it is also
ideally suited for use in mobile hydraulics: shock and
vibration resistance, type of protection, resistance
topressure spikes, resistance to temperature shock,
EMCcharacteristics better than 150 V/m. The measurement
principle uses a hermetically welded thin-film measurement
cell, which ensures long-term leak resistance. The sensor
signal can be directly evaluated by a BODAS controller RC.
1) Start of production: Mid of 2016

RE 95156/12.2015, Bosch Rexroth AG
BODAS Pressure sensor | PR4 series 10
Technical data
3
Technical data
Type PR4 280
GB05
420
GB05
600
MB05
Measurement range 0 to 280 bar 0 to 420 bar 0 to 600 bar
Overload limit1) 400 bar 560 bar 800 bar
Bursting pressure2)4) 2500 bar 3750 bar 5250 bar
Output signal 0.5V to 4.5V, ratiometric
Supply voltage Usup 5V ±0.25V
Maximum supply voltage 18V (maximum 1h)
Connector Bosch Compact 1.1a
Short circuit signal output to GND or supply
(maximum 8h) with supply at the same time of
UsatUs, kurz
0 to 18 V
Sensor output impedance Rdifferntial at
0.1Us<Uout<0.9Us
typical: 5 Ω
maximum: 10 Ω
Current consumption
Typical at 5V supply voltage 12 mA
Maximum without load ≤15mA
Maximum at reverse connection 260 mA
Parts contacting measuring cell materials X5CrNiCuNb16-4
Housing material PBT-GF30/CrNi steel
Response time (10 to 90%) ≤1.0 ms
Overall accuracy ≤1.5%, refer to table "tolerance over temperature, pressure and life time"
Medium temperature range3) –40 °C to +150°C
Ambient temperature range –40°C to +100°C
Storage temperature range –30°C to +60°C at 0 to 80% relative humidity and 5 years
Transportation conditions
Conditions deviating from the storage conditions are allowed for the transport:
Duration, max. 48 h temperature –40 °C to +80 °C
Relative humidity 0 % to 80 %
CE conformity Pressure vessel directive 97/23/EC
UN ECE 10 Rev4 and ISO 11452-2, -4, -5 as well as according to IEC61000
Service life 10000 operating hours or 10 years
Pressure cycles over service life 10 million cycles
Shock resistance 50g (DIN EN 60068-2-27, 11ms), 500g (DIN EN 60068-2-27, 1ms)
Vibration resistance
Amplitude of the deflection s = 0.35 mm in the range 70 Hz to 147 Hz
Amplitude of the acceleration a = 300 m/s2in the range 147 Hz to 1350 Hz
a = 250 m/s2in the range 1350 Hz to 2000 Hz
Frequency change 0.5 octave/min
Duration of excitation 100 h in each spatial direction with the same test specimen
Drop test
Controlled drop from 1 m height onto concrete in accordance with ISO 16750-3. One drop
event per axial direction.
Electromagnetic compatibility EMC
BCI up to 200 mA open and closed loop according ISO 11452-4 up to 400 MHz.
Antenna > 150 V/m according ISO 11452-2 from 200 MHz - 3.2 GHz
Electrical protection Protection from voltage reversal, short circuits and undervoltage;
protection from overvoltage in the defined supply voltage range
Type of protection with installed mating connector IPX6K and IPX9K according to ISO 20653 (2006-08-15)
Weight approx. G 1/4: 48g, M14: 52 g
1) maximum 15 minutes at Pnto Pmax
2) maximum 15 minutes at Pnto Pberst
3) 150°C: 250h over live time
4) The specifield bursting pressure is valid for the device only.
This value does not included the mechanical interface - the thread between the sen-
sor and the hydraulic component

Bosch Rexroth AG, RE 95156/12.2015
4PR4 series 10 | BODAS Pressure sensor
Characteristics
Dimensions [mm]
Characteristics
Output voltage as function of the pressure
The signal output voltage is (up to the nominal pressure)
calculated from the actual pressure as follows:
UOUT = (c1p+c0) US
where
UOUT = Signal output voltage
US= Supply voltage (typ. 5 V)
p= Pressure [MPa]
c0= 0.1
c1= 0.8 / Pn MPa-1
pn= Nominal pressure [MPa]
0 MPA pn
0.96 US(4.8 V)
0.90 US(4.5 V)
0.10 US(0.5 V)
0.04 US(0.2 V)
Upper range for signal range check (SRC)
Lower range for signal range check (SRC)
Values for US= 5 V
in brackets
Pressure p
Tolerance over temperature, pressure and life time
0
new condition / after life time
pnenn
pnenn/2
Temperature
−40°C
1.10
%/1.50 %
0.90
%/1.30 %
0.70 %/1.10 %
−0°C
0.70
%/1.20 %
0.60
%/1.10 %
0.50 %/1.00 %
100°C
0.70
%/1.20 %
0.60
%/1.10 %
0.50 %/1.00 %
150°C
1.10
%/1.50 %
0.90
%/1.30 %
0.70 %/1.10 %
Pressure
The tolerance for the pressure measurement is given in
%FS = "full scale". FS denotes the sensor nominal pressure
pnenn or the usable range. The relative tolerance is depen-
dent on the pressure and temperature, and increases over
the service lifetime. Here, the service lifetime encompasses
the entire lifetime. The tolerances for new parts are statisti-
cally observed with 3Sigma per manufacturing batch.
Delivery of 100 % sorted products is permitted. After life-
time the tolerance for new parts can broaden to the values
given in the diagram. Here the given tolerances also repre-
sent the 3Sigma limit.
Dimensions
Sensor with mechanical connection G 1/4
according DIN EN ISO 1179-2
12.35
19.9
SW 27
+2 –2
12+0.5
–0.5
+0.5 –0.5
54.25+2
–2
26+0.4
–0.4
G 1/4 DIN
EN ISO 228-1
16.5×11.5×1.5
DIN EN ISO 1179-2
Sealing
Stud end for
threaded fitting
Sensor with mechanical connection M14 × 1.5
according DIN EN ISO 6149-2
12.35
19.9
SW 27
+2 –2
11+0.5
–0.5
+0.5 –0.5
54.25+2
–2
26+0.4
–0.4
M14×1.5
DIN ISO 261
11.3×2.2
EN ISO 6149-2
Sealing
Stud end for
threaded fitting

RE 95156/12.2015, Bosch Rexroth AG
BODAS Pressure sensor | PR4 series 10
Connector Bosch Compact
5
1) The mating connectors are not included in the scope of supply.
These are available from Bosch Rexroth under the corresponding
material numbers.
2) The tools may be purchased from Bosch dealers or Bosch Service
(www.bosch-service.com)
Drawings and further information about Bosch connectors and
tools can be found on the internet: www.bosch-connectors.com
Connector Bosch Compact
Pin assignment
321
1 Ground GND
2 Output
3 Supply voltage Usup
Mating connector 1)
Mating connector sets with the following content are
available under Rexroth part number R917009890 for the
manual assembly of wiring harness connectors for laboratory
or small-series requirements:
Designation Number Material number
Bosch Compact 1.1a Connector 1 1928403966
BDK Terminal Gold for 18-20 AWG,
0.5-1.0 mm2
3 1928498054
Bosch compact cap straight 1 1928300527
Single seal, BDK, blue, ROHS 3 1928300599
End clip 1 1928403423
Required tooling2)
Designation Number Material number
Bosch crimping tool
for BDK 2.8 terminal
0.5, 0.75, 1.0 sq mm wire
1 1928498161
Bosch terminal extraction tool
for BDK 2.8 terminals
1 1928498167
Assembly example
3
2
1
1 Compact 1.1a
2 End clip
3 Cap straight
Notes regarding assembly
In the assembly of the connectors, respect the assembly
instructions for plug connections (Y 928 P00 222) and
BDK2.8 contacts (1 928 F00 025).
These assembly instructions are available on request from
Rexroth.
Caution:
In the installation of the connector in the vehicle, observe
the following:
The fixation of the cable harness must be done at a dis-
tance ≤ 150 mm after the outgoing cable unit at the same
vibration level of the sensor.

Bosch Rexroth AG, RE 95156/12.2015
6PR4 series 10 | BODAS Pressure sensor
Installation instructions
Installation instructions
Mounting
Mounting process of sensor must be ensured by customer
by adequate validation.
Rexroth recommends to wet the surface of thread and
tightening plane of pressure sensor completely with Oil or
Molykote WI5 prior to mounting.
To prevent accumulation of lubricant in the pressure port
application of lubricant by spraying while pressure port
facing downwards is recommended.
Pressure vessel directive
▶ Devices with MEV (measurement range end value)
600bar correspond to directive 97/23/EC and are not
designed for overheated fluids of fluid group 2. These
devices are manufactured and inspected according to
module A.
▶ Devices with measurement rang end value 280 to
420bar correspond to article 3 paragraph (3) of direc-
tive
97/23/EC and are not designed and manufactured for
overheated fluids of fluid group 2, in accordance with
good engineering practice.
Electrical connection
▶ The device may only be installed by a trained electrician.
▶ The national and international specifications regarding
the installation of electro-technical systems must be
followed.
▶ Voltage supply according to SELV, PELV.
▶ De-energize the system.
Mechanical connection
▶ Before installing and removing the device, make certain
that the system is not pressurized.
Tightening torque
Before mounting the PR4 pressure sensor, check the speci-
field tightening torque of the hydraulic pump, motor or valve
block.
If the torque for mounting the sensor in the respective
hydraulic component is not specifield use a torque of
35±5Nm.
Do not exceed the maximum tightening torque of: 45 Nm.
Risk of injury!
Overload pressures that exceed the specified maximum
permissible pressure are to be prevented through appro-
priate measures. The specified bursting pressure must not
be exceeded. Even exceeding the bursting pressure for
brief periods can destroy the device.
Operating conditions - temperatures
The sensor is designed for use in hydraulic components
(direct motor attachment) and the corresponding ambient
temperatures with a typical temperature distribution:
Temperature
‒40 °C 6 %
23 °C 20 %
85 °C 65 %
135 °C 8 %
140 °C 1 %
Storage conditions
The pressure sensor is to be stored under the following
conditions:
Temperature range ‒30 °C to +60 °C
Rel. humidity 0 to 80 % r. h.
Maximum storage duration after the delivery 4 years
The sensor has to be kept under dry and dust-free storage
conditions. It is important to ensure that there is no con-
tamination due to liquid or solid media in the connector
area or on the threaded fitting. Sulfurous atmospheres have
to be avoided for silver-plated connector pins.
These storage conditions do not lead to any change in the
properties and the functioning of the high-pressure sensor.
After the maximum storage duration is exceeded, the sen-
sors must be sent back to Bosch Rexroth AG for inspection
or testing.
Transportation conditions
Conditions deviating from the storage conditions are
allowed for the transport:
Duration max. 48 h
Temperature ‒40 °C to +80 °C
Relative humidity 0 % to 80 %

RE 95156/12.2015, Bosch Rexroth AG
BODAS Pressure sensor | PR4 series 10
Wiring and error diagnostic of the sensor
7
Wiring and error diagnostic of the sensor
Recommended wiring of the sensor
The sensor is to be connected to the ECU according to the
following wiring diagram and provided with a supply volt-
age of 5 V.
▼ Sensor wiring in the ECU
Pressure sensor ECU
Signal
(UOUT)
+5 V (US)
A/D
converter
and μC
Pull up
resistance
GND
Supply voltage
Ground
The assignment of the connector pins of the high-pressure
sensor is described in the offer drawing.
The pressure sensor delivers an analog output signal that
has a ratiometric relationship with the supply voltage.
Specification of the pull-up resistor:
Quantity Symbol Value Unit
min typ max
Pull-up resistor
as per US
RPull-up 4.41 4.64 4.87 kΩ
In addition to this, a low-pass filter with a time constant of
maximum 0.7 ms is to be provided in the signal path.
The electrical output of the sensor is designed such that
malfunctions through cable breaks or short-circuits can be
detected with the wiring shown in the representation with
a pull-up resistor of 4.64 kΩ ±5 % against supply voltage.
Behavior after reset and initialization
In case of certain errors, a reset is triggered in the sensor.
These are then generated every 400 ms. After a reset, and
during the subsequent initialization of the sensor, the
output is pulled to ground. If the error is still present, the
output signal either remains in the lower error band, or the
output signal rises to the upper error band. In case, the
error is no longer present, the output signal controls its
value into the applicable operating range. The course of the
output signal and the related typical time at room tempera-
ture, after the reset, are shown in diagram below.
▼ Representation of the time after reset and initialization
V
0 t1 t2 t3 t4 t
Reset
Operating range
Power-
up Lower
error band
Upper
error band
Typicals [ms] t1 t2 t3 / t4
CRC OK 0.03 0.9 1.1 / 1.2
CRC NOK 0.03 2.1 2.3 / 2.4
Behavior after undervoltage and overvoltage
In case of undervoltage <4.75 V or overvoltage >5.25 V
detection, the output is pulled to ground. The upper error
band (if the error is still present), as shown in the diagram,
is reached after time t4.

Bosch Rexroth AG, RE 95156/12.2015
8PR4 series 10 | BODAS Pressure sensor
Safety instructions
Safety instructions
General instructions
▶ Before finalizing your design, request a binding installation
or offer drawing.
▶ The proposed circuits do not imply any technical liability
for the system on the part of Bosch Rexroth.
▶ It is not permissible to open the sensor or to modify or
repair the sensor. Modifications or repairs to the wiring
could result in dangerous malfunctions.
▶ Only allow pressure measurement devices to be
installed by trained and specialist personnel who are
authorized by the system owner.
▶ Connections must only be opened while in a
depressurized state!
▶ System developments, installation 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 with the complete system.
▶ While commissioning the sensor, 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.
▶ Make sure that nobody is in the machine’s danger zone.
▶ No defective or incorrectly functioning components may
be used. If the sensor should fail or demonstrate faulty
operation, it must be replaced.
▶ Residual measurement materials in unmounted pressure
measurement devices could endanger people, the
environment and equipment. Take appropriate
precautionary measures.
▶ In spite of taking great care in preparing this document,
all conceivable application cases could not be taken into
account. If information is lacking for your specific
application, please contact Bosch Rexroth.
Notes on the installation location and position
▶ Do not install the sensor close to parts that generate
considerable heat (e.g. exhaust).
▶ Lines are to be routed with sufficient distance from hot
or moving vehicle parts.
▶ A sufficiently large distance to radio systems must be
maintained.
▶ The connector of the
sensor is to be unplugged during
electrical welding and painting operations.
▶ Electrostatic painting of the sensor is not allowed
(hazard: ESD damage).
▶ Cables/wires must be sealed individually to prevent
water from entering the device.
▶ Make sure, by appropriate installation of the sensor, that
no water is gathering the sensor measuring element.
This might result to a malfunction of the measuring
signal (freezing condition, in worst case: crack of
measuring element).
Notes on transport and storage
▶ Please inspect the device for any damages which may
have occurred during transport. If there are obvious
signs of damage, please immediately inform the trans-
port company and Bosch Rexroth.
▶ If it is dropped, the
sensor must not be used any longer
as invisible damage could have a negative impact on
reliability.
Notes on wiring and circuitry
▶ Use twisted pair wires to connect the pressure sensor.
▶ Use short wires to avoid voltage drop along the lines
and choose wires with bigger gauge in case of longer
distances between the sensor and the electronic.
▶ We recommend to use shielded wire to increase the
signal quality. Connect the shield on one side, either to
the machine or the vehicle ground or to the electronic
via a short low resistance connection.
▶ The mating connector of the sensor must not be plugged
or unplugged, if the electrical system of the machine is
energized.
▶ The sensor lines are sensitive to radiation interference.
For this reason, the following measures should be taken
when operating the sensor:
– Sensor lines should be attached as far away as
possible from large electric machines.
– If the signal requirements are satisfied, it is possible
to extend the sensor cable.
▶ Lines from the
sensor 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 sensor is installed (spacing < 150mm).
The wiring harness should be fixated so that in-phase
excitation with the sensor occurs (e.g. at the sensor
mounting points).
▶ If possible, lines should be routed in the vehicle interior.
If the lines are routed outside the vehicle, make sure
that they are securely fixed.

RE 95156/12.2015, Bosch Rexroth AG
BODAS Pressure sensor | PR4 series 10
Safety instructions
9
▶ Lines must not rub against edges and must not be
routed through sharp-edged ducts without protection.
▶ Bosch Rexroth warranty will cover the function of the
connector system only in the case of combination with
harness connector system parts according to this data
sheet.
▶ Use only the appropriate tooling to crimp and mount the
mating connector.
Attention:
Use harness connector for protection against water
ingress.
▶ First cable mounting point max. 150 mm after the plug
(straight cable length). It must be located on the sensor
carrier.
▶ Angle of bending the cable (deviation from straight line)
between cable exit at sensor and first mounting point,
20° to 90°.
▶ Admissible bending radius of the cable up to the first
cable mouting point: R≥ 50 mm.
▶ Installation instructions see also corresponding offer
drawing.
Intended use
▶ The
sensor is designed for use in mobile working
machines provided no limitations/restrictions are made
to certain application areas in this data sheet.
▶ Prior to installation, commissioning and operation,
make certain that the correct pressure measurement
device was selected with respect to measurement
range, design and – based on the specific measurement
conditions – parts which are in contact with measuring
materials (corrosion). Furthermore, the respective
national safety regulations are to be observed.
▶ Operation of the
sensor must generally occur within the
operating ranges specified and released in this data
sheet, particularly with regard to voltage, temperature,
vibration, shock and other described environmental
influences.
▶ If required, install a throttle, that limit possible pressure
peaks. Attention should be also paid to side effects e.g.
cavitation. Ensure that there will be no cavitation in any
point of operation.
▶ 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 conse-
quential damage to the mobile working machine.
▶ Failure to observe the respective specifications may
result in serious bodily injury and/or property damage.
Improper use
▶ Any use of the
sensor other than that described in chap-
ter “Intended use” is considered to be improper.
▶ Use in explosive areas is not permissible.
▶ Damages which result from improper use and/or from
unauthorized, interference in the component not
described in this data sheet render all warranty and
liability claims with respect to the manufacturer void.
Use in safety-related functions
▶ The customer is responsible for performing a risk analy-
sis of the mobile working machine and determining the
possible safety-related functions.
▶ In safety-related applications, the customer is respon-
sible for taking suitable measures for ensuring safety
(sensor redundancy, plausibility check, emergency
switch, etc.).
▶ Product data that is necessary to assess the safety of
the machine can be provided on request or are listed in
this data sheet.
Further information
▶ Further information about the
sensor can be found at
www.boschrexroth.com/mobile-electronics.
▶ The sensor must be disposed according the national
regulations of your country.

10
Bosch Rexroth AG, RE 95156/12.2015
Bosch Rexroth AG
Mobile Applications
Robert-Bosch-Straße 2
71701 Schwieberdingen, Germany
Tel. [phone]
[e-mail]
www.boschrexroth.com
© This document, as well as the data, specifications and other information
set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
reproduced or given to third parties without its consent. The data specified
above only serve 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.
PR4 series 10 | BODAS Pressure sensor