Re95300 2011-08

Linear Motion and
Assembly Technologies Service Pneumatics Hydraulics

Electric Drives
and Controls
Contents
Ordering code 2
Variant SPCC 2
SPCC Connection Diagram 7
Variant SPCD 9
SPCD Connection Diagram 13
Safety instructions 16
Data sheet
Application Software
Open and Closed Loop
Speed Control SPC
RE 95300/08.11 1/18
Replaces: 12.07
Electronic open and closed loop speed control
for hydraulic drives
Features
Hydraulic 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
Note
Variant C is described on page 2
Variant 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 SPCC
The 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 electropro-
portional 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 (me-
chanically 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.
Type
01 Application software AS
Software
02 Open and closed loop speed control SPC
Variants
03
Speed control C
Speed control for concrete mixer vehicles D
Version
04 Variants C and D 20
AS / SPC 20
01 02 03 04
Ordering code
For 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 description
In 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-
design
BODAS-
service
I/O
CAN
RS-232
RC2-2/21
PLC
(opt)
Potentiometer
Other electronic
control Direction 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-
design
BODAS-
service
I/O
CAN
RS-232
RC2-2/21
PLC
(opt)
Potentiometer
Other electronic
control Direction Release
Special function
CAN bus J1939
- setpoint
CAN bus J1939
- DM1/2 messages
- setpoint
i.e. A4VG..EP or
A10VG..EP
Hydraulic motor
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.)
Hydraulic
pump speed
(opt.)
Pressure
sensor
(opt.)
Hydraulic
motor speed
(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 specification
Type 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 behavior
The 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 function
SPCC 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
Volumetric
efficiency curve
Control
specification
Pump pressure
Proportional control
Open loop control
Closed loop control
Pilot control
Engine / hydraulic pump speed
Hydraulic motor speed
Parameter value
CAN J1939 message
PLC (0..5V / 0..10 V)
Potentiometer
(single / redundant)
Release input
Setpoint
specification
Curve Time ramps
time
proportional
open loop
open loop
closed loop
closed loop
Correction calculation pump control
Direction of
rotation
hydraulic
pump
E
m
e
r
g
e
n
c
y

s
w
i
t
c
h
Security functions
Various 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 features
A 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 pro-
portional control on or off.
Progressive curves for set-point handling can be used.
The acceleration and deceleration times can be set separate-
ly 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 mea-
sures 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 parameters
Hydraulic motor, diesel engine or hydraulic pump data (actu-
al 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 Diagnostics
The 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 Components
The 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
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 speci-
fication
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) or
A11VO..EP (RE92500) or
A7VO..EP (RE92202) or
A17VO..EP (RE92260)
Fixed motors
A2FM (RE 91001) or
A2FE (RE 91008) or
A4FM (RE 91120) or
A10FM (RE 91172) or
MCR (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 diagram
Version 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 ground
2)
Separate ground connection from solenoid return line to battery (chassis possible)
3)
Separate fuses for switches and sensors necessary
4)
CAN bus: termination resistor 120

necessary
5)
Sensor supply voltage for potentiometers and active sensors
6)
Can be switched together between high/low active by means of software - pull-up or pull-down for these inputs
7)
If 5V is applied to the input, all power outputs are off
8)
Can be used as switch inputs if externally switched to GND
9)
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
25
26
52
24
50
51
C
D
B
E
A
H
F
G
3
31
30
1)
3 A
9)
3)
1 A
8)
8)
10 A
15 30
30
31
4
1
2
3
13
41
42
27
2
28
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
p
U
4
37
1
32
33
43
44
17
7
18
22
49
46
47
38
35
15
+12V/
+24V
+L
+L
DIGL_A3
PMI_A1
RS 232
RxD
TxD
DIGL_A1
PWM_A3
PWM_A4
DIGL_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
Shutdown
Outputs
Switch-on signal
Electronic supply
Supply voltage of
the output stages
PWM-
output
PWM-
output
Switched
outputs
Proportional solenoid
hydraulic pump forward
hydraulic pump backward
special function
start release
Battery supply
error lamp
Low-side
measure-
ment input
Diagnostics connector
for BODAS-service
CAN-Bus
interface
Output drive direction backward
Output drive direction forward
Prop. drive on/off
Diesel engine clamp W+ (opt.)
Release (opt.)
Termination
D
i
g
i
t
a
l

i
n
p
u
t
s
T
e
m
p
e
r
a
t
u
r
e

i
n
p
u
t
s
C
u
r
r
e
n
t

i
n
p
u
t
s
5
V

C
o
n
s
t
a
n
t

v
o
l
t
a
g
e
V
o
l
t
a
g
e
i
n
p
u
t
s
S
e
n
s
o
r

s
u
p
p
l
y
v
o
l
t
a
g
e
2

x

5
V
/
3
0

m
A
F
r
e
q
u
e
n
c
y

i
n
p
u
t
s
n, hydraulic motor
(opt. HDD, DSA sensor)
n, diesel engine/hydraulic pump
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)
2)
3)
4)

necessary
5)
6)
7)
8)
9)
SPCC Connection diagram
Version with IDR sensor (diesel engine) + angle sensor at drive pedal
2)
1
2)
2
2)
1
29

2)
4) 40
39
25
26
52
24
50
51
C
D
B
E
A
H
F
G
3
31
30
1)
3 A
9)
3)
1 A
8)
8)
10 A
15 30
30
31
4
1
2
3
13
41
42
27
2
28
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
32
33
43
44
17
7
18
22
49
46
47
38
35
15
+12V/
+24V
+L
+L
DIGL_A3
PMI_A1
RS 232
RxD
TxD
DIGL_A1
PWM_A3
PWM_A4
DIGL_A2
PWM_A1 DIGP_A1
PWM_A2 DIGP_A2
FRQI_A4 DIG_ FA4
T
T_A2 DIG_
T
T_A4 DIG_
ANA_A2
ANA_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_A1
ANA_A1V
0V
2,3 A
2,3 A

2,0 A
2.0 A
2)
2 2.0 A
Ignition switch
Safety switch
Ground
Shutdown
Outputs
Switch-on signal
Electronic supply
Supply voltage of
the output stages
PWM-
output
PWM-
output
Switched
outputs
hydraulic pump forward
hydraulic pump backward
special function
start release
Battery supply
error lamp
Low-side
measure-
ment input
for BODAS-service
CAN-Bus
interface
Output drive direction backward
Output drive direction forward
Prop. drive on/off
Diesel engine clamp W+ (opt.)
Release
Termination
D
i
g
i
t
a
l

i
n
p
u
t
s
T
e
m
p
e
r
a
t
u
r
e

i
n
p
u
t
s
C
u
r
r
e
n
t

i
n
p
u
t
s
5
V

C
o
n
s
t
a
n
t

v
o
l
t
a
g
e
V
o
l
t
a
g
e
i
n
p
u
t
s
S
e
n
s
o
r

s
u
p
p
l
y
v
o
l
t
a
g
e
2

x

5
V
/
3
0

m
A
F
r
e
q
u
e
n
c
y

i
n
p
u
t
s
n, hydraulic motor
n, diesel engine
(opt. IDR)
n, hydraulic motor
(opt. DSM sensor)
n, diesel engine/ hydraulic pump
(opt. DSM sensor)
Angle sensor
drive pedal
only DSM
only DSM
Diagnostics
(KWP 2000) +
CAN communication
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 electropro-
portional 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 (me-
chanically 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 Description
In 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 control
The 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-
design
BODAS-
service
I/O
CAN
RS-232
RC2-2/21
Charge/
discharge
Funnel fill-up
sensor
(opt.)
Pump/
funnel
(opt.)
Gear box
in
neutral
(opt.)
Accelerate/
deaccelerate
diesel engine
(opt.)
CAN bus J1939
- DM1/2 messages
i.e. A4VG..EP or
A10VG..EP
Hydraulic motor
i.e. A2FM or
A2FE or
A4FM or
A10FM or
MCR
Park brake
(opt.)
Electronic engine
control unit
(EECU)
Diagnostics and
parametrization
Accelerate /
diesel engine
(opt.)
Deaccelerate /
diesel engine
(opt.)
GND relay
Diesel engine
speed (opt.)
Hydraulic
pump speed
(opt.)
Pressure-
sensor
(opt.)
Hydraulic
motor speed
(opt.)
Figure 6: Operation principle of speed control SPCD
Setpoint specification
Two 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 behavior
The 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 function
If 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 functions
The SPCD open and closed loop speed control offers the
following additional functions:
Memory function
If 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 diesel
engine speed
management
Error monitoring
Push button charge / mix
Eco mode
Funnel function
Fill level sensor 1
Fill level sensor 2
Engine / hydraulic pump speed
Hydraulic motor speed
Diesel engine acceleration
Setpoint
specification
(ramps, funnel,
memory and eco
mode)
Funnel control
open loop
1)
Limiter 20 %
closed loop
Correction calculation
pump control
Accelerate
diesel engine
Hydraulic pump
E
m
e
r
g
e
n
c
y

s
w
i
t
c
h
Decelerate
diesel engine
Eco function
Push button discharge
Diesel engine deceleration
Park 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 function
The 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-clock-
wise 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 dischar-
ging 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 management
The 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 V
g
= 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 mode
The 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 functions
Various options are available for monitoring working behavior:
Start condition
The 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 speed
The 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 outputs
The 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 features
Two 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 parameters
Hydraulic 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 Diagnostics
The 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 Components
The 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
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
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:
A10VGEP (RE 92750)
Fixed motor
A2FM (RE 91001)
or optionally:
A2FE (RE 91008) or
A4FM (RE 91120) or
A10FM (RD 91172) or
MCR (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
25
26
52
24
50
51
C
D
B
E
A
H
F
G
3
31
30
1)
3 A
10)
3)
1 A
9)
9)
10 A
15 30
30
31
1
3
13
41
42
27
2
28
36
8)
5)
9)
9)
9)
9)
38/49
8
20
9
21
34
45
48
10
11
6)
6)
37
1
32
33
43
44
17
7
18
22
49
46
47
38
35
15
+12V/
+24V
+L
+L
DIGL_A3
PMI_A1
RS 232
RxD
TxD
DIGL_A1
PWM_A3
PWM_A4
DIGL_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)
2)
3)
4)

necessary
5)
6)
7)
Separate ground connection fpr the sensors to controller GND possible (p. e. pins 38/49)
8)
9)
10)
Ignition switch
Safety switch
Ground
Shutdown
Outputs
Switch-on signal
Electronic supply
Supply voltage of
the output stages
PWM-
output
PWM-
output
Switched
outputs
hydraulic pump charge
Digital output
accelerate diesel engine (opt.)
clamp 15
Digital output
GND relay
Low-side
measure-
ment input
for BODAS-service
CAN-Bus
interface
Button discharge
Button charge
Termination
D
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C
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i
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5
V

C
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s
t
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v
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5
V
/
3
0

m
A
F
r
e
q
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n
c
y

i
n
p
u
t
s
Speed sensor
(opt. IDR)
Speed sensor
(opt. DSM)
Funnel
fill-up sensor
(opt.)
hydraulic pump discharge
Failure LED (blinking)/
funnel active (ON)
Eco mode (opt.)
Switch pump/funnel (opt.)
Accelerate diesel engine (opt.)
Decelerate diesel engine (opt.)
Digital output
decelerate diesel engine (opt.)
Diagnostics
(KWP 2000) +
CAN communication
Option using HDD2 speed sensor at pump and/or DSM speed sensor at hydraulic motor (feed forward control)
120
2)
4) 40
39
25
26
52
24
50
51
C
D
B
E
A
H
F
G
1)
3 A
10)
3)
1 A
9)
9)
10 A
15 30
30
31
1
3
13
41
42
27
2
28
36
8)
5)
9)
9)
9)
9)
38/49
8
20
9
21
34
45
48
10
11
6)
6)
37
1
32
33
43
44
17
7
18
22
49
46
47
38
35
+12V/
+24V
RS 232
RxD
TxD
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)
1
3
2
4
2)
0V
2.3 A
2.3 A

2.0 A
2.0 A
29
15
DIGL_A3
PMI_A1
DIGL_A1
PWM_A3
PWM_A4
DIGL_A2
PWM_A1 DIGP_A1
15
EECU
EECU
1)
2)
3)
4)

necessary
5)
6)
7)
Separate ground connection fpr the sensors to controller GND possible (p.e. pins 38/49)
8)
9)
10)
Ignition switch
Safety switch
Ground
Shutdown
Outputs
Switch-on signal
Electronic supply
Supply voltage of
the output stages
PWM-
output
PWM-
output
Switched
outputs
Digital output
clamp
Digital output
GND relay
Low-side
measure-
ment input
for BODAS-service
CAN-Bus
interface
Button discharge
Button charge
Termination
D
i
g
i
t
a
l

i
n
p
u
t
s
T
e
m
p
e
r
a
t
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e

i
n
p
u
t
s
C
u
r
r
e
n
t

i
n
p
u
t
s
5
V

C
o
n
s
t
a
n
t

v
o
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t
a
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e
V
o
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t
a
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p
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S
e
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s
o
r

s
u
p
p
l
y
v
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t
a
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e
2

x

5
V
/
3
0

m
A
F
r
e
q
u
e
n
c
y

i
n
p
u
t
s
Speed sensor
(opt. HDD2)
Speed sensor
(opt. DSM)
Funnel
fill-up sensor
(opt.)
funnel active (ON)
Eco mode (opt.)
Digital output
Diagnostics
(KWP 2000) +
CAN communication
Option using speed sensor DSM hydraulic motor (closed loop control)
120
2)
2)
4) 40
39
25
26
52
24
50
51
C
D
B
E
A
H
F
G
3
31
30
1)
3 A
10)
3)
1 A
9)
9)
10 A
15 30
30
31
1
3
13
41
42
27
2
28
36
8)
5)
9)
9)
9)
9)
38/49
8
20
9
21
34
45
48
10
11
6)
6)
37
1
32
33
43
44
17
7
18
22
49
46
47
38
35
+12V/
+24V
+L
+L
DIGL_A3
PMI_A1
RS 232
RxD
TxD
DIGL_A1
PWM_A3
PWM_A4
DIGL_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)
2)
3)
4)

necessary
5)
6)
7)
Separate ground connection fpr the sensors to controller GND possible (p.e. pins 38/49)
8)
9)
10)
Ignition switch
Safety switch
Ground
Shutdown
Outputs
Switch-on signal
Electronic supply
Supply voltage of
the output stages
PWM-
output
PWM-
output
Switched
outputs
Digital output
clamp
Digital output
GND relay
Low-side
measure-
ment input
for BODAS-service
CAN-Bus
interface
Button discharge
Button charge
Termination
D
i
g
i
t
a
l

i
n
p
u
t
s
T
e
m
p
e
r
a
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e

i
n
p
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t
s
C
u
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r
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t

i
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p
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s
5
V

C
o
n
s
t
a
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t

v
o
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t
a
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e
V
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t
a
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e
i
n
p
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s
S
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s
o
r

s
u
p
p
l
y
v
o
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t
a
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e
2

x

5
V
/
3
0

m
A
F
r
e
q
u
e
n
c
y

i
n
p
u
t
s
Park brake (opt.)
Speed sensor
(opt. DSM)
Funnel
fill-up sensor
(opt.)
funnel active (ON)
Eco mode (opt.)
Digital output
Diagnostics
(KWP 2000) +
CAN communication
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 con-
nection 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 machi-
ne 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 spe-
cified 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 necessa-
ry, 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 AG
Mobile Electronics
Glockeraustrae 2
89275 Elchingen, Germany
Phone +49 (0) 73 08 82-0
Fax +49 (0) 73 08 72 74
info.brm-ak@boschrexroth.de
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

Re95300 2011-08

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Re95300 2011-08

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Linear Motion and

Assembly Technologies Service Pneumatics Hydraulics

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