re95300_2011-08

Linear Motion andAssembly Technologies ServicePneumaticsHydraulics

Electric Drives and Controls

ContentsOrdering code 2

Variant SPCC 2

SPCC Connection Diagram 7

Variant SPCD 9

SPCD Connection Diagram 13

Safety instructions 16

Data sheet

Application SoftwareOpen and Closed Loop Speed Control SPC

RE 95300/08.11 1/18Replaces: 12.07

Electronic open and closed loop speed control for hydraulic drives

FeaturesHydraulic drives are often operated on diesel engines whose speed in operation cannot be kept constant due to different driving profiles.

The electronic open and closed loop speed control is an easily configurable software application for the open and closed loop control of hydraulic drives. It is used to keep the output speed constant independently of diesel engine and pump speeds.

Following variants are available:

Variant C - for open loop and closed loop speed control (SPCC)

Variant D - for open loop and closed loop speed control in concrete mixer vehicles (SPCD)

The SPC software is designed for use with Rexroth hydraulic pumps and hydraulic motors.

The user can easily configure the SPC software for various combinations of pumps, combustion engines, sensors and equipment.

The SPC software is suitable for diesel engines with or without a CAN bus interface (SAE J1939 protocol).

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

2/18 Bosch Rexroth AG Open and closed loop speed control SPC RE 95300/08.11

NoteVariant C is described on page 2Variant D is described on page 9

Ordering information

The AS/SPC application software may only be operated with the controller RC2-2/21 and other additional components de-scribed in following chapters. When ordering, link the hardware and software type codes with a +:

Example: RC2-2/21+AS/SPCD20

Variant SPCCThe electronic speed control, variant C (SPCC) is an easily configurable software application for the open and closed loop control of hydraulic drives. The hydraulic drive consists of a pump and a motor. The speed control serves to keep the drive speed constant, independent of the speeds of the diesel engine and the hydraulic pump.

The SPCC electronic speed control is designed to control a variable pump in a closed or open hydraulic circuit.

The following hydraulic concept is used in an open hydraulic circuit:

A variable pump A11VO, A7VO or A17VO with electroproportional control EP together with fixed motors A2FM, A2FE, A4FM, A10FM or MCR

In a closed hydraulic circuit, the following hydraulic concept is used:

A variable pump A4VG or A10VG with electroproportional control EP together with fixed motors A2FM, A2FE, A4FM, A10FM or MCR

For an open loop control either diesel engine speed or pump speed needs to be measured. For realization of an open loop control two different designs of diesel engine can be used:

In case of diesel engines without a CAN bus interface (mechanically controlled), the actual speed of the diesel engine is sent to the speed control by a speed sensor mounted at the starter gear ring or at the hydraulic pump.

In diesel engines with a CAN bus interface, the speed control receives the actual speed of the diesel engine via the CAN bus.

Type01 Application software AS

Software02 Open and closed loop speed control SPC

Variants

03Speed control C

Speed control for concrete mixer vehicles D

Version04 Variants C and D 20

AS / SPC 2001 02 03 04

Ordering codeFor the SPCC closed loop speed control neither the set speed nor the actual speed of diesel engine is necessary and there-with no CAN signal or speed sensor signal from starter gear ring or hydraulic pump needed. Closed loop control is solely dependent on the set and actual speed of hydraulic motor. Therefore a speed sensor needs to be mounted at hydraulic motor.

Functional descriptionIn order to keep the output speed of hydraulic drives constant and independent of the diesel engine and the pump speed, the swivel angle of the variable pump is adjusted by electropropor-tional control.

Proportional speed control

This operation mode could be selected using a separate switch. In this case given set point value defines directly pump dis-placement. The output target speed therewith will be propor-tional in dependence to the diesel engine speed. Proportional control will be also be active, if neither open nor closed loop control are set active (using a parameter in BODAS-service).

Open loop speed control

When the open loop speed control is set active (using a para-meter in BODAS-service), the following applies: Target output speed can be set in various ways, described in chapter Setpoint specification. An external speed sensor or the CAN bus provides the actual speed of the diesel engine. As an alternative also hydraulic pump speed can be measured. If the actual speed of the diesel engine exceeds a defined mini-mum speed (start of control), open loop speed control starts to work. If the diesel engine speed further increases, the electric control current (PWM signal) to the hydraulic pump is reduced. This reduction is inversely proportional to the increasing diesel engine speed. The pump flow and, as a result, the hydraulic motor speed, remain constant. Thus output speed is kept at the value specified by the target output speed independent of the diesel engine speed.

Open loop speed control can be used for variable pumps in both open and closed hydraulic circuits.When a pump is used in an open hydraulic circuit, only one direction of rotation can be used for the drive (either forward or backward).

Closed loop speed control

When the closed loop speedcontrol is set active (using a para-meter in BODAS-service), the following applies: Target output speed can be set in various ways, described in chapter Setpoint specification. The actual speed of the drive is measured by a speed sensor mounted on the hydraulic motor. When the actual speed changes, the pump control and, thus, the swivel angle of the variable pump are regulated in such a way that the flow stays constant. As a result, the output speed of a hydraulic motor connected to the hydraulic pump is kept constant.

In case a very dynamic system has to be controlled, it may help using a combination of open and closed loop control to a closed loop control with pilot control. Therefore knowledge of hydraulic pump or diesel engine speed and hydraulic motor speed is necessary. Then at first open loop compensation is base for closed loop control.

RE 95300/08.11 Open and closed loop speed control SPC Bosch Rexroth AG 3/18

Variant SPCC

BODAS-designBOD

AS-service

I/O

CAN

RS-232

RC2-2/21

PLC (opt)

PotentiometerOther electronic

controlDirection Release

Special function

Angle sensor (opt)

CAN bus J1939 - setpoint

CAN bus J1939 - diesel engine speed - DM1/2 messages - setpoint

Diesel engine Hydraulic pump (variable displacement), i.e. A11VO..EP or A7VO..EP or A17VO..EP

Hydraulic motor (fixed displacement), i.e. A2FM or A2FE or A4FM or A10FM or MCR

Start release

Proportional control

(opt)

Electronic engine control unit

(EECU)Diagnostics and parametrization

Diesel engine speed (opt.)

Hydraulic pump speed

(opt.)

Pressure sensor

(opt.)

Hydraulic motor speed

(opt.)

Figure 1: Typical configuration for the SPCC for an open hydraulic circuit (figure shows all possible connected, not mandatory inputs)

BODAS-designBOD

AS-service

I/O

CAN

RS-232

RC2-2/21

PLC (opt)

PotentiometerOther electronic

controlDirection Release

Special function

CAN bus J1939 - setpoint

CAN bus J1939 - diesel engine speed - DM1/2 messages - setpoint

Diesel engine Hydraulic pump (variable displacement), i.e. A4VG..EP or A10VG..EP

Hydraulic motor (fixed displacement), i.e. A2FM or A2FE or A4FM or A10FM or MCR

Start release

Electronic engine control unit

(EECU)Diagnostics and parametrization

Diesel engine speed (opt.)


(opt.)

Pressure sensor

(opt.)


(opt.)

Angle sensor (opt)

Proportional control

(opt)

Figure 2: Typical configuration for the SPCC a closed hydraulic circuit (figure shows all possible connected, not mandatory inputs)


Setpoint specificationType of set-point specification for target output speed can be selected using

potentiometer (signed / unsigned can be defined using parameter, including current measurement for failure check)

PLC-demand (0..5V / 0..10 V can be defined using para-meter),

CAN-message J1939, freely configurable using parameter set

constant parameter value,

release or direction switches ( 2 switches: forward / backward),

angle sensor, i.e. mounted at drive pedal.

Additionally reference value characteristics can be chosen (progression).

A ramp influencing adaption of set-point values can be set using parameters.

Two direction switches in the vehicle are used to set the direc-tion of drive rotation (forward or backward).

Working behaviorThe working behavior of the drive is controlled by three para-meters:

Setpoint for the output speed is received (see chapter Set- point specification).

The direction switch determines the direction of rotation (forward or backward).

The acceleration behavior selected by the time ramp settings determines how fast the control changes at the PWM out-put. The time ramps can be adjusted separately for accelera-tion and deceleration and for forward and backward rotation.

The drive potentiometer is in neutral position if it is positioned within an adjustable range around the zero position. This range is called the dead band.

When the drive potentiometer is in neutral position, the PWM outputs for controlling the proportional solenoids of the hydrau-lic pump are switched off.

When it is moved to a position outside of the dead band, the current at the respective PWM output (for forward or backward rotation) increases depending on the position of the potentio-meter, the direction switch and the set time ramp. The corresponding proportional solenoids of the hydraulic pump are activated.

Special functionSPCC enables the control of a special function. This can be any other function, for example another drive. When the speed of the hydraulic motor exceeds a selected switching level, which can be set using a parameter in BODAS-service, the special function switches on.

Figure 3: Operation principle of speed control SPCC

Variant SPCC

x

y

p

Volumetricefficiency curve

Controlspecification

Pump pressure

Proportional controlOpen loop controlClosed loop controlPilot control

Engine / hydraulic pump speedHydraulic motor speed

Parameter valueCAN J1939 messagePLC (0..5V / 0..10 V)

Potentiometer(single / redundant)

Release input

Setpointspecification

Curve Time ramps

time

proportional

open loop

open loop

closed loop

closed loop

Correction calculation pump control

Direction ofrotation hydraulic pump

Em

erge

ncy

switc

h


Security functionsVarious options are available for monitoring the working beha-viour:

Start conditions Start conditions are used to prevent the drive from starting unintentionally.Switching on the controller for the first time (ignition on), following start conditions are checked:

Setpoint value for hydraulic motor speed needs to be set -to 0.

Hydraulic motor needs to be in stand still and diesel engine -is running (diesel engine speed shows a needed minimum value).

Direction switches are in neutral position. -

Release input is active / not active. Requested status of -release input can be defined by parameter settings.

If one or all start conditions are not needed (result of a risk analysis), each of the start conditions can be deactivated separately using according parameter in BODAS-service.

Monitoring the diesel engine speed (if open loop control is used).At diesel engine speeds below idle speed, the drive is swit-ched to a fixed low out-put speed.

Monitoring the inputs and the outputs. The inputs and outputs are monitored for wire breaks and short circuits.In case of an error or if the emergency switch is actuated, the drive is turned off immediately.If connected, an error lamp will be switched on, when an error becomes active.

Important featuresA BODAS-service parameter can switch between several different possibilities to provide set-point.

A BODAS-service parameter can switch between open loop, closed loop or pilot control.

A switch installed in the vehicle can be used to switch proportional control on or off.

Progressive curves for set-point handling can be used.

The acceleration and deceleration times can be set separately for both directions of drive rotation.

For open loop control: actual value of diesel engine or pump speed is provided either by a speed sensor or via CAN bus.

For closed loop control: actual value of hydraulic motor speed is provided by a speed sensor.

The behavior of the drive is monitored by additional measures such as start conditions, set-point and diesel engine speed monitoring.

The inputs (e.g. drive pedal) and outputs (e.g. solenoids) of the controller are monitored for cable breaks and short circuits. In case of a failure or if an emergency switch is actuated, the drive is turned off immediately.

Failures can be displayed via connected error lamp.

All errors that occur can be send as DM1 and DM2 (on demand) messages on CAN bus interface using J1939 protocol.

All errors that occur are stored in the controller and can also be read out using BODAS-service diagnostic tool.

Important parametersHydraulic motor, diesel engine or hydraulic pump data (actual speed)

Set-point definition

Configuration (chosen progressive curve, dead band, speed regulator, special function, control type)

Minimum and maximum solenoid current for hydraulic pump forwards and backwards

Parameter Settings and DiagnosticsThe parameters to be set for commissioning the SPCC speed control are easy to adjust with the BODAS-service PC soft-ware.

For diagnostics and troubleshooting, you can use BODAS-service to display the most important process variables and error messages.

Required ComponentsThe following electronic components are required:

RC2-2/21 controller with mating connector (RE 95201)

Software SPCC, Version 20

For closed loop control: speed sensor HDD2 (RE 95135) or DSM (RE 95132) or DSA (RE 95133) with mating connec-tor, each installed at hydraulic motor,

For open loop control: speed sensor IDR (RE 95130) or HDD2 (RE 95135) or DSM (RE 95132) or DSA (RE 95133) with mating connector at diesel engine gear ring (only, if no CAN diesel engine available)

For open loop control: speed sensor HDD2 (RE 95135) or DSM (RE 95132) or DSA (RE 95133) with mating connec-tor at hydraulic pump (only, if no sensor at diesel engine installed and no CAN diesel engine available)

Safety switch (emergency stop)

Release switch for start release

Variant SPCC


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

Potentiometer for setpoint specification

PLC (0..5V / 0..10 V) for set-point specification

Angle sensor, i.e. mounted at drive pedal for set-point specification

Switch for turning proportional speed control on and off

Direction switches

The following hydraulic components are required:

Variable pump with corresponding control device A4VGEP (RE 92003) orA10VGEP (RE 92750) orA11VO..EP (RE92500) orA7VO..EP (RE92202) orA17VO..EP (RE92260)

Fixed motors A2FM (RE 91001) orA2FE (RE 91008) orA4FM (RE 91120) orA10FM (RE 91172) orMCR (RE 15205 15209)

The following components are required for commissioning and service:

BODAS-service PC software (RE 95086)

BODAS-service connection cable

Diagnostics socket

Variant SPCC


SPCC Connection diagramVersion with HDD / DSA / DSM sensor + potentiometer + pressure sensor (hydraulic pump)

1) Short, low-resistance connection from a case screw to the device ground or vehicle ground2) Separate ground connection from solenoid return line to battery (chassis possible)3) Separate fuses for switches and sensors necessary4) CAN bus: termination resistor 120 necessary5) Sensor supply voltage for potentiometers and active sensors6) Can be switched together between high/low active by means of software - pull-up or pull-down for these inputs7) If 5V is applied to the input, all power outputs are off8) Can be used as switch inputs if externally switched to GND9) The terminals are labeled according to DIN 72552. This does not apply for the controller

120

2)1

2)2

2)1

29

2)

4)40

39

2526

52

245051 C

DBEAH

FG

3

31

30

1)

3 A

9)

3)1 A

8)

8)

10 A

1530

30

31

4

1

2

3

13

41

42

27

228

36

7)

5)

8)

8)

8)

8)

2

3

4

38/49

8

20

9

21

34

45

48

10

11

6)

6)1

PLC

pU

4

37

1

3233

4344

17

7

18

22

494647

3835

15

+12V/+24V

+L

+L

DIGL_A3PMI_A1

RS 232 RxDTxD

DIGL_A1PWM_A3

PWM_A4DIGL_A2

PWM_A1 DIGP_A1

PWM_A2 DIGP_A2

FRQI_A3 FRQ_A3 DIG_F A3



FRQI_A4 DIG_FA4

ANA_A1V

T

T_A2 DIG_

T

T_A4 DIG_

CUR_A2 ANA_A2I DIG_

CUR_A1 ANA_A1I DIG_

ANA_A2

ANA_A1

ANA_A2V

T_A1 DIG_ A1

A2

T_A3 DIG_ A3

T A4

CA2

CA1

T

DIG_A1 ANA_DA1 F R Q_DA1

DIG_A4 ANA_DA4 FR Q_DA4



CAN L

CAN N

0V

2.3 A

2.3 A

2,0 A

2.0 A

2)2 2.0 A

Ignition switch Safety switch

Ground

ShutdownOutputs

Switch-on signalElectronic supply

Supply voltage ofthe output stages

PWM-output

PWM-output

Switchedoutputs

Proportional solenoidhydraulic pump forward

Proportional solenoidhydraulic pump backward

special function

start release

Battery supply

error lamp

Low-side measure-ment input

Diagnostics connectorfor BODAS-service

CAN-Businterface

Output drive direction backward

Output drive direction forward

Prop. drive on/off

Diesel engine clamp W+ (opt.)

Release (opt.)

Termination

Dig

ital i

nput

sTe

mpe

ratu

re in

puts

Cur

rent

in

puts

5V C

onst

ant

volta

geVo

ltage

inpu

tsS

enso

r sup

ply

volta

ge2

x 5V

/30

mA

Freq

uenc

y in

puts

n, hydraulic motor(opt. HDD, DSA sensor)

n, diesel engine/hydraulic pump(opt. HDD, DSA sensor)

n, hydraulic motor(opt. DSM sensor)n, diesel engine/ hydraulic pump(opt. DSM sensor)

Potentiometer

Pressure sensor hydraulic pump

only DSM

only DSM

Diagnostics(KWP 2000) +CAN communication(J1939 + standard protocol)


1) Short, low-resistance connection from a case screw to the device ground or vehicle ground2) Separate ground connection from solenoid return line to battery (chassis possible)3) Separate fuses for switches and sensors necessary4) CAN bus: termination resistor 120 necessary5) Sensor supply voltage for potentiometers and active sensors6) Can be switched together between high/low active by means of software - pull-up or pull-down for these inputs7) If 5V is applied to the input, all power outputs are off8) Can be used as switch inputs if externally switched to GND9) The terminals are labeled according to DIN 72552. This does not apply for the controller

SPCC Connection diagramVersion with IDR sensor (diesel engine) + angle sensor at drive pedal

2)1

2)2

2)1

29

2)

4)40

39

2526

52

245051 C

DBEAH

FG

3

31

30

1)

3 A

9)

3)1 A

8)

8)

10 A

1530

30

31

4

1

2

3

13

41

42

27

228

36

7)

5)

8)

8)

8)

8)

2

3

4

38/49

8

20

9

21

34

45

48

10

11

6)

6)1

PLC

U

4

37

1

3233

4344

17

7

18

22

494647

3835

15

+12V/+24V

+L

+L

DIGL_A3PMI_A1

RS 232 RxDTxD

DIGL_A1PWM_A3

PWM_A4DIGL_A2

PWM_A1 DIGP_A1

PWM_A2 DIGP_A2




FRQI_A4 DIG_FA4

T

T_A2 DIG_

T

T_A4 DIG_

ANA_A2ANA_A2V

T_A1 DIG_ A1

A2

T_A3 DIG_ A3

T A4

CUR_A2 ANA_A2I DIG_CA2


T





CAN L

CAN N

120

ANA_A1ANA_A1V

0V

2,3 A

2,3 A

2,0 A

2.0 A

2)2 2.0 A

5

A


Ground

ShutdownOutputs



PWM-output

PWM-output

Switchedoutputs

Proportional solenoidhydraulic pump forward

Proportional solenoidhydraulic pump backward

special function

start release

Battery supply

error lamp



CAN-Businterface

Output drive direction backward

Output drive direction forward

Prop. drive on/off

Diesel engine clamp W+ (opt.)

Release

Termination

Dig

ital i

nput

sTe

mpe

ratu

re in

puts

Cur

rent

in

puts

5V C

onst

ant

volta

geVo

ltage

inpu

tsS

enso

r sup

ply

volta

ge2

x 5V

/30

mA

Freq

uenc

y in

puts

n, hydraulic motor(opt. HDD, DSA sensor)

n, diesel engine(opt. IDR)

n, hydraulic motor(opt. DSM sensor)n, diesel engine/ hydraulic pump(opt. DSM sensor)

Angle sensordrive pedal

only DSM

only DSM



Figure 5: Typical configuration for the SPCD closed loop speed control

The electronic speed control, variant D (SPCD) is an easily configurable software application for the drum speed control of concrete mixer vehicles. The hydraulic drive consists of a pump and a motor. It is used to turn the drum of the concrete mixer vehicle. The SPCD open or closed loop speed control is used to keep the hydraulic drive speed constant, independent of the speeds of the diesel engine and the hydraulic pump.

The SPCD is designed to control a variable pump in a closed hydraulic circuit.

The following hydraulic concept is used:

An A4VTG, A4VG or A10VG variable pump with electroproportional control EP together with an A2FM, A2FE, A4FM, A10FM or MCR fixed motor

For an open loop control either diesel engine speed or pump speed needs to be measured. For realization of an open loop control two different versions of diesel engine can be used:

In case of diesel engines without a CAN bus interface (mechanically controlled), the actual speed of the diesel engine is sent to the speed control by a speed sensor mounted at the starter gear ring or at the hydraulic pump.

In diesel engines with a CAN bus interface, the SPCD speed control receives the actual speed of the diesel engine via CAN bus.

For closed loop speed control neither the set speed nor the actual speed of diesel engine is necessary and therewith no CAN signal or speed sensor signal from starter gear ring or hydraulic pump needed.

Closed loop control is solely dependent on the set and actual speed of hydraulic motor. Therefore a speed sensor needs to be mounted at hydraulic motor.

Functional DescriptionIn order to keep the output speed of hydraulic drives constant and independent of the diesel engine speed and the pump speed, the swivel angle of the hydraulic variable pump is adjus-ted by electroproportional control.

Open and closed loop speed controlThe set speed of the drum is set by means of two push-buttons (charge / discharge) in the vehicle. The actual speed of the drum, depending on chosen control type, is measured by a speed sensor mounted at the hydraulic motor, at the hydraulic pump, at the diesel engine starter gear ring or provided via CAN. When the actual speed changes, the pump control and, thus, the swivel angle of the variable pump are regulated in such a way that the flow stays constant. As a result, the output speed of a hydraulic motor connected to the hydraulic pump is held constant at the set speed value. This keeps the drum rotating at a constant speed independent of the diesel engine speed and pump speed.

This is achieved by regulating the swivel angle of the hydraulic variable pump in the closed circuit by electroproportional con-trol. The pump control varies according to the time ramp that has been set for the working behavior.

In case of an error (i.e. speed sensor or solenoid error) open or closed loop control is deactivated. In an emergency mode drum speed then can set using a proportional control, with a limited variable pump angle.

Variant SPCD

BODAS-designBOD

AS-service

I/O

CAN

RS-232

RC2-2/21

Charge/discharge

Funnel fill-upsensor(opt.)

Pump/funnel(opt.)

Gear boxin

neutral(opt.)

Accelerate/deacceleratediesel engine

(opt.)

CAN bus J1939- diesel engine speed- DM1/2 messages

Diesel engine Hydraulic pump(variable displacement), i.e. A4VG..EP orA10VG..EP

Hydraulic motor(fixed displacement), i.e. A2FM or A2FE orA4FM orA10FM orMCR

Park brake(opt.)

Electronic enginecontrol unit

(EECU)Diagnostics andparametrization

Accelerate /diesel engine

(opt.)

Deaccelerate /diesel engine

(opt.)GND relay

Diesel enginespeed (opt.)


(opt.)

Pressure-sensor

(opt.)


(opt.)


Figure 6: Operation principle of speed control SPCD

Setpoint specificationTwo push-buttons in the vehicle (charge/discharge) are used to select the drum set-point speed.

They also set the direction of the drive (clockwise/counter-clockwise) and therefore the direction in which the drum rotates.

Working behaviorThe working behavior of the drum when mixing and delivering the concrete is controlled by two variables:

The push-buttons (charge/discharge) set the setpoint for the output speed and direction in which the drum rotates.

The acceleration and deceleration behavior selected by the time ramps determine how quickly the control changes at the PWM output.

If the drum is at a downtime and one of the buttons (e.g. charge) is pressed, the drive starts to move in the appropriate direction (clockwise) and the drum rotates clockwise and mixes the concrete.

Pressing the same button (charge) again increases the output speed in this direction according to the selected time ramp.

Pressing the other button (the discharge button in this ex-ample) reduces the output speed in the selected direction of rotation (clockwise in this example) according to the selected time ramp.

The time ramps for increasing and reducing the output speed for concrete mixing are set at the same time.

If the drum speed is reduced to stand-still, while button is still actuated, drum will stop and remain in stand-still for a defined period of time. Under consideration of defined time ramps, afterwards drum starts to rotate in corresponding opposite direction.

Stop functionIf both push-buttons (charge/discharge) are pressed simulta-neously, the drum speed will be reduced until standstill under consideration of the corresponding time ramp (stop function).

The time ramp used for the stop function is set separately from the time ramp for the working behavior.

Additional functionsThe SPCD open and closed loop speed control offers the following additional functions:

Memory functionIf the stop function is used to bring the drum to a downtime, the most recent speed and direction of rotation (that were used immediately before the stop function was activated) are stored.

Variant SPCD

1) Automatic dieselengine speedmanagement

Error monitoring

Push button charge / mix

Eco mode

Funnel function

Fill level sensor 1

Fill level sensor 2

Engine / hydraulic pump speedHydraulic motor speed

Diesel engine acceleration

Setpointspecification(ramps, funnel,

memory and eco mode)

Funnel control

open loop1) Limiter 20 %

closed loop

Correction calculation pump control

Accelerate diesel engine

Hydraulic pump

Em

erge

ncy

switc

h

Decelerate diesel engine

Eco function

Push button discharge

Diesel engine decelerationPark brake

Gear box in neutral


When the button used to select the direction of rotation is pressed once more, the drum starts to move again. The drive uses the stored speed and direction of rotation. This takes place with an adjustable time ramp.

If the other button is pressed, the stored speed and direction of rotation are erased. This also happens if both buttons are pressed together. The drum drive must then be started as described under "working behavior".

Funnel functionThe funnel function is an optional function and usually used with combination machines (mixer & pump on one truck) to control delivery from the mixer, for example into the funnel of a concrete pump. A switch in the vehicle is used to switch it on and off. The function must be activated during commissioning.

When the funnel function is switched on and the "discharge" button is pressed, the function starts up and the drum starts moving counter-clockwise. Only counter-clockwise rotation is used for delivery. The speed is preset and stored with the button. The concrete then flows from the drum on the vehicle into the funnel.

A sensor monitors the fill level in the funnel. When the funnel is full, the fill level sensor opens (input voltage at the controller is 0 V) and the drum is stopped according to the preset time ramp.

While the fill level sensor is open, only the clockwise direction of rotation can be used. This is used to maintain the mixing function while the funnel function is stopped. The speed can then be increased using the right button and reduced with the left one. The speed of clockwise rotation is not stored at this time.

When the funnel is empty, the fill level sensor closes (the input voltage at the controller is 24 V) and the following applies:

If the drum is at a downtime, it starts moving counter-clockwise under consideration of the defined time ramp, in order to continue discharging. The drive uses the stored speed.

If the drum is moving clockwise, it stops and restarts discharging in the counter-clockwise direction.

The stop ramp for the funnel function is set separately from the time ramps for mixing operation.

While the funnel function is active, the failure LED remains on all the time. It acts as a status LED in this case.

Automatic diesel engine speed managementThe automatic diesel management enables an automatic diesel speed adaption to actual system needs to optimize fuel consumption.

When drum speed is set like usual, at first hydraulic pump is adapted without a diesel adaption. When pump displacement is at Vg = max, then diesel speed is automatically adapted to reached demanded drum speed. This can happen by actuation of digital inputs at ECU or via CAN communication to ECU.

With buttons diesel engine speed can be influenced manually, then automatic diesel engine speed management is switched off.

This function is only available for open loop control and when truck is in stand-still. To assure that this condition is active, the park brake must be actuated and gear box set to neutral. Those signals can be read as digital inputs or via CAN.

This functionality has to be activated during commissioning using a BODAS-service parameter.

Eco modeThe eco mode is an optional function and can be used, when truck is travelling between construction sites or concrete bat-ching plant. Main intention is to reduce fuel consumption.

Mode can be separately activated and deactivated by pressing button eco mode.

Operator can set a limited drum speed which will be active for a parameterized time before it is reduced for another parame-terized time. Afterwards drum speed returns to set value and cycle starts again.

For eco mode a memory functionality is available: last set speed is saved and can be recalled by simply pressing button eco mode without any other button actuated. Set speed can be changed by pressing button eco mode simultaneously with buttons charging or discharging. Memorized speed is also available after reset of RC.

This mode has to be activated during commissioning using a BODAS-service parameter.

Security functionsVarious options are available for monitoring working behavior:

Start conditionThe start condition is used to prevent the drive from starting unintentionally.

After switching on the controller (ignition on), the starting con-dition must be satisfied in order for the drive to be started. The starting condition is met if no buttons are pressed.

Monitoring the actual speedThe speed sensor is monitored for wire breaks and short circuit

In case of an error, the maximum swivel angle for each adjust-ment is limited and speed control is switched off. Maximum allowed pump displacement can be set using a parameter. Then drum speed control acts proportional and is therewith no longer indepentent of set diesel engine speed.

Monitoring the inputs and outputsThe inputs and outputs and the proportional solenoid outputs are monitored for wire breaks and short circuits.

In case of an error or if the emergency switch is actuated, the drive is turned off immediately.

An failure LED also flashes if there is an error.

Variant SPCD


Important featuresTwo buttons (charge / discharge) are used for the setpoint specification.

The setpoints for speed and direction of rotation can be stored using the memory function.

The funnel function can control delivery from the mixer drum into the funnel of a concrete pump.

For open loop control: actual value of diesel engine speed is provided by a speed sensor or via CAN bus.

For closed loop control: actual value of hydraulic motor speed is provided by a speed sensor.

Accurate speed control is possible even at low speeds.

The working behavior of the drive is monitored by security functions such as the starting condition and the actual speed monitor.

The inputs and outputs of the controller (e.g. push-buttons, solenoids) are monitored (for cable breaks and short circuit). In case of an error or if the emergency switch is actuated, the drive is turned off immediately.

All errors that occur are stored in the controller and can also be read out later in plain text using the BODAS-service diagnostic tools.

Important parametersHydraulic motor, diesel engine or hydraulic pump data (actual speed, gearbox ratio)

Configuration (acceleration and deceleration times, dead band, speed regulator, memory function, funnel function, eco mode, automatic diesel engine speed management)

Minimum and maximum solenoid current for hydraulic pump in both directions

Parameter Settings and DiagnosticsThe parameters to be set for commissioning the SPCD are easy to adjust with the BODAS-service PC software.

For diagnostics and troubleshooting, BODAS-service can be used to display the most important process variables and error messages.

Required ComponentsThe following electronic components are required:

RC2-2/21 controller with mating connector (RE 95201)

Software SPCD, Version 20

Push-buttons (single-pole changeover switches) for setpoint specification

For closed loop control: speed sensor HDD2 (RE 95135) or DSM (RE 95132) or DSA (RE 95133) with mating connec-tor, each installed at hydraulic motor,

For open loop control: speed sensor IDR (RE 95130) or HDD2 (RE 95135) or DSM (RE 95132) or DSA (RE 95133) with mating connector at diesel engine starter gear ring (only, if no CAN diesel engine available)

For open loop control: speed sensor HDD2 (RE 95135) or DSM (RE 95132) or DSA (RE 95133) with mating connec-tor at hydraulic pump (only, if no sensor at diesel engine installed and no CAN diesel engine available)

Emergency switch (emergency stop)

The following additional electronic components can be used optional:

Switch for activation of the funnel function

Fill level sensor (switch on funnel)

Button for eco mode activation

Switch signal for park brake active

Switch signal for gear box in neutral

Button for diesel engine speed acceleration (manually)

Button for diesel engine speed deceleration (manually)

The following hydraulic components are required:

Variable pump with appropriate control device A4VTGEP (RE 92012)or optionally:A4VGEP (RE 92003) orA10VGEP (RE 92750)

Fixed motor A2FM (RE 91001) or optionally:A2FE (RE 91008) orA4FM (RE 91120) orA10FM (RD 91172) orMCR (RE 15205 15209)

The following components are required for commissioning and service:

BODAS-service PC software (RE 95086)

BODAS-service connection cable

Diagnostics socket

Variant SPCD


SPCD Connection diagram Option using IDR speed sensor at engine/pump and/or DSM speed sensor at hydraulic motor (feed forward control)

120



2)

2)

29

4)40

39

2526

52

245051 C

DBEAH

FG

3

31

30

1)

3 A

10)

3)1 A

9)

9)

10 A

1530

30

31

1

3

13

41

42

27

228

36

8)

5)

9)

9)

9)

9)

38/49

8

20

9

21

34

45

48

10

11

6)

6)37

1

3233

4344

17

7

18

22

494647

3835

15

+12V/+24V

+L

+L

DIGL_A3PMI_A1

RS 232 RxDTxD

DIGL_A1PWM_A3

PWM_A4DIGL_A2

PWM_A1 DIGP_A1

PWM_A2 DIGP_A2

FRQI_A3 FRQ_A3 DIG_ FA3



FRQI_A4 DIG_ FA4

T

T_A2 DIG_

T

T_A4 DIG_

T_A1 DIG_ A1

A2

T_A3 DIG_ A3

TA4

T

CAN L

CAN N

2

1

24V = min

OV = max

ANA_A2

ANA_A1

ANA_A2V

ANA_A1V

7)

7)

7)

DIG_A4 ANA_DA4 FRQ_DA4




0V

2.3 A

2.3 A

2.0 A

2.0 A

15

EECU

EECU

1) Short, low-resistance connection from a case screw to the device ground or vehicle ground2) Separate ground connection from solenoid return line to battery (chassis possible)3) Separate fuses for switches and sensors necessary4) CAN bus: termination resistor 120 necessary5) Sensor supply voltage for potentiometers and active sensors6) Can be switched together between high/low active by means of software - pull-up or pull-down for these inputs7) Separate ground connection fpr the sensors to controller GND possible (p. e. pins 38/49)8) If 5V is applied to the input, all power outputs are off9) Can be used as switch inputs if externally switched to GND10) The terminals are labeled according to DIN 72552. This does not apply for the controller


Ground

ShutdownOutputs



PWM-output

PWM-output

Switchedoutputs

Proportional solenoidhydraulic pump charge

Digital outputaccelerate diesel engine (opt.)

clamp 15

Digital outputGND relay



CAN-Businterface

Button discharge

Button charge

Termination

Dig

ital i

nput

sTe

mpe

ratu

re in

puts

Cur

rent

in

puts

5V C

onst

ant

volta

geVo

ltage

inpu

tsS

enso

r sup

ply

volta

ge2

x 5V

/30

mA

Freq

uenc

y in

puts

Speed sensor(opt. IDR)

Speed sensor(opt. DSM)

Funnelfill-up sensor(opt.)

Proportional solenoidhydraulic pump discharge

Failure LED (blinking)/funnel active (ON)

Eco mode (opt.)

Switch pump/funnel (opt.)

Accelerate diesel engine (opt.)

Decelerate diesel engine (opt.)

Digital outputdecelerate diesel engine (opt.)



SPCD Connection diagram Option using HDD2 speed sensor at pump and/or DSM speed sensor at hydraulic motor (feed forward control)

120



2)

4)40

39

2526

52

245051 C

DBEAH

FG

1)

3 A

10)

3)1 A

9)

9)

10 A

1530

30

31

1

3

13

41

42

27

228

36

8)

5)

9)

9)

9)

9)

38/49

8

20

9

21

34

45

48

10

11

6)

6)37

1

3233

4344

17

7

18

22

494647

3835

+12V/+24V

RS 232 RxDTxD

PWM_A2 DIGP_A2




FRQI_A4 DIG_ FA4

T

T_A2 DIG_

T

T_A4 DIG_

T_A1 DIG_ A1

A2

T_A3 DIG_ A3

TA4

T

CAN L

CAN N

2

1

24V = min

OV = max

ANA_A2

ANA_A1

ANA_A2V

ANA_A1V

7)

7)

7)





1324

2)

0V

2.3 A

2.3 A

2.0 A

2.0 A

29

15

DIGL_A3PMI_A1

DIGL_A1PWM_A3

PWM_A4DIGL_A2

PWM_A1 DIGP_A1

15

EECU

EECU

1) Short, low-resistance connection from a case screw to the device ground or vehicle ground2) Separate ground connection from solenoid return line to battery (chassis possible)3) Separate fuses for switches and sensors necessary4) CAN bus: termination resistor 120 necessary5) Sensor supply voltage for potentiometers and active sensors6) Can be switched together between high/low active by means of software - pull-up or pull-down for these inputs7) Separate ground connection fpr the sensors to controller GND possible (p.e. pins 38/49)8) If 5V is applied to the input, all power outputs are off9) Can be used as switch inputs if externally switched to GND10) The terminals are labeled according to DIN 72552. This does not apply for the controller


Ground

ShutdownOutputs



PWM-output

PWM-output

Switchedoutputs



clamp




CAN-Businterface

Button discharge

Button charge

Termination

Dig

ital i

nput

sTe

mpe

ratu

re in

puts

Cur

rent

in

puts

5V C

onst

ant

volta

geVo

ltage

inpu

tsS

enso

r sup

ply

volta

ge2

x 5V

/30

mA

Freq

uenc

y in

puts

Speed sensor(opt. HDD2)





Eco mode (opt.)







SPCD Connection diagram Option using speed sensor DSM hydraulic motor (closed loop control)

120



2)

2)

4)40

39

2526

52

245051 C

DBEAH

FG

3

31

30

1)

3 A

10)

3)1 A

9)

9)

10 A

1530

30

31

1

3

13

41

42

27

228

36

8)

5)

9)

9)

9)

9)

38/49

8

20

9

21

34

45

48

10

11

6)

6)37

1

3233

4344

17

7

18

22

494647

3835

+12V/+24V

+L

+L

DIGL_A3PMI_A1

RS 232 RxDTxD

DIGL_A1PWM_A3

PWM_A4DIGL_A2

PWM_A1 DIGP_A1

PWM_A2 DIGP_A2




FRQI_A4 DIG_ FA4

T

T_A2 DIG_

T

T_A4 DIG_

T_A1 DIG_ A1

A2

T_A3 DIG_ A3

TA4

T

CAN L

CAN N

2

1

24V = min

OV = max

ANA_A2

ANA_A1

ANA_A2V

ANA_A1V

7)

7)

7)





0V

2.3 A

2.3 A

2.0 A

2.0 A

15

1

29

15

EECU

EECU

1) Short, low-resistance connection from a case screw to the device ground or vehicle ground2) Separate ground connection from solenoid return line to battery (chassis possible)3) Separate fuses for switches and sensors necessary4) CAN bus: termination resistor 120 necessary5) Sensor supply voltage for potentiometers and active sensors6) Can be switched together between high/low active by means of software - pull-up or pull-down for these inputs7) Separate ground connection fpr the sensors to controller GND possible (p.e. pins 38/49)8) If 5V is applied to the input, all power outputs are off9) Can be used as switch inputs if externally switched to GND10) The terminals are labeled according to DIN 72552. This does not apply for the controller


Ground

ShutdownOutputs



PWM-output

PWM-output

Switchedoutputs



clamp




CAN-Businterface

Button discharge

Button charge

Termination

Dig

ital i

nput

sTe

mpe

ratu

re in

puts

Cur

rent

in

puts

5V C

onst

ant

volta

geVo

ltage

inpu

tsS

enso

r sup

ply

volta

ge2

x 5V

/30

mA

Freq

uenc

y in

puts

Park brake (opt.)





Eco mode (opt.)






Gear box neutral (opt.)


General instructions

The proposed circuits do not imply any technical liability for the system on the part of Bosch Rexroth.

Incorrect connections could cause unexpected signals at the outputs of the BODAS Controller RC with installed Soft- ware SPC.

Incorrect parameter settings on the Software SPC 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. Rexroth assumes no liability for dangers of this type.

The Software SPC must be installed and removed by Bosch Rexroth or by the authorized partner concerned in order to uphold the warranty.

To switch off the system in emergencies, the power supply to the electronics must be disconnected with a safety switch. The safety switch must be installed in an easily accessible position for the operator.

System developments, installations and commissioning of electronic systems for controlling hydraulic drives must only be car- ried out by trained and experienced specialists who are sufficiently familiar with both the components used and the complete system.

While commissioning and maintenance the Software SPC (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.

Notes on the installation point and position

Do not install the BODAS Controller RC with the Software SPC 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.

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 connection to vehicle ground.

Connect the RC controller to a PC with the BODAS service connection cable only. The BB-3 connection cable must not be used! Incorrect connection cables or wiring could cause the PC interface to be destroyed!

The control unit and the PC must be switched off when the BODAS service connection cable is connected or disconnected.

Safety instructions


Notes on wiring and circuitry

The electronics and the power outputs of a controller must be fed from the same power source.

Wires to the speed sensors are to 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 may only be wired when it is de-energized.

Cables to the electronics must not be routed close to other power-conducting wires in the machine or vehicle.

The wiring harness should be fixated mechanically in the area in which the BODAS Controller RC is installed (spacing < 150 mm). The wiring harness should be fixated so that in-phase excitation with the BODAS Controller RC occurs (e.g. at the RCs bolting point).

If possible, wires should be routed in the vehicle interior. If the wires are routed outside the vehicle, make sure that they are securely fixed.

Wires must not be kinked or twisted, must not rub against edges and must not be routed through sharp-edged ducts without protection.

Wires are to be routed with sufficient spacing to hot or moving vehicle parts.

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 BODAS Controller RC control unit/analog amplifier 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 RC must be connected to spark-suppression diodes.

Intended use

The BODAS Controller RC with installed Software SPC is designed for use in mobile working machines provided no limitations / restrictions are made to certain application areas in this data sheet.

Operation of the BODAS Controller RC with installed Software SPC 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.

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 complete system.

Improper use

Any use of the BODAS Controller RC with installed Software SPC other than that described in chapter "Intended use" is consi- dered to be improper.

The Software SPC is not suitable for use in functions relevant to safety.

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.

Use in functions relevant to safety

The suitability of the software must be validated by the customer by means of risk analysis on the complete machine. If necessary, suitable measures must be employed outside the travel drive control to enable the machine to be restored to a safe condition at any time.

The customer is responsible for performing risk analysis on the mobile working equipment and for defining possible safety- related functions.

The customer is responsible for taking suitable measures in safety-related applications (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.

Safety instructions


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 reprodu-ced 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 de-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 products are subject to a natural process of wear and aging.

Subject to change.

Bosch Rexroth AGMobile ElectronicsGlockeraustrae 289275 Elchingen, GermanyPhone +49 (0) 73 08 82-0Fax +49 (0) 73 08 72 [email protected] www.boschrexroth.com/mobile-electronics

More detailed information

Observe the operating instructions for Software SPC.

The safety measures are to be observed.

In addition, the application-specific documents (connection diagrams, software descriptions, etc.) are to be observed.

More detailed information on BODAS Controllers RCs Software SPC may be found at www.boschrexroth.com/mobile-electronics.

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

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

Safety instructions

Application SoftwareOpen and Closed LoopSpeed Control SPCOrdering codeVariant SPCCSPCC Connection diagramVariant SPCDSPCD Connection diagramSafety instructions

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