BODAS controller

RC4-5 series 30
RE 95205
Edition: 06.2018
Replaces: 11.2013

▶▶ For the closed and open loop control of hydraulic

components

Features Contents
▶▶ High performance thanks to 32-bit TriCore processor Ordering code 2
with 80 MHz clock frequency Optional accessories 2
▶▶ Component of BODAS system for mobile applications Description 3
▶▶ Robust and compact design meeting specifications for Block circuit diagram 4
mobile applications Technical data 5
▶▶ High Electromagnetic Compatibility (EMC) Connection diagram 8
▶▶ Inputs and outputs with fault detection Overview of the functions 10
▶▶ Central output deactivation Dimensions 15
▶▶ Pulse-Width-Modulated (PWM) solenoid currents for Installation position 16
minimum hysteresis Mating connector 17
▶▶ Closed-loop control of solenoid currents, i.e. not Safety instructions 19
dependent on supply voltage and temperature

Main components
▶▶ Nine power outputs, 4 of which current-controlled
▶▶ Program sequence monitoring with watchdog
▶▶ CPU-internal flash memory with ECC fault detection
▶▶ Four independent sensor voltage supplies
▶▶ Two independent CAN bus interfaces

 RE 95205/06.2018, Bosch Rexroth AG

2 RC4-5 series 30 | BODAS controller
Ordering code

Ordering code Optional accessories

01 02 03 ▶▶ BODAS-service software
RC 4-5 / 30 The windows-based PC software BODAS-service (see
Type data sheet 95086) is used for displaying functions,
01 BODAS controller RC errors, and system variables as well as for setting
parameters via a PC. It is also used for flashing pro-
Version
grams from a PC to the control unit.
02 1. Position: Number of
proportional power outputs
4-5
2. Position: Number of ▶▶ C-programming interface C-API
power switching outputs The programming interface C-API (see data sheet
Series 95115) is used for programming the BODAS controllers
03 Series 3, index 0 30 RC in the programming language C. All required
functions that are needed for the configuration and the
Notes:
reading of the inputs, the control of the outputs, the use
▶▶ The BODAS controllers are not functional without
of the communication interfaces and the creation of the
software.
diagnostic information for BODAS-service are available
▶▶ In order to use the BODAS controllers, you also need:
to the user in the form of a software library.
–– BODAS standard software or
Additionally, the user needs a C-compiler, with which
–– application-specific software
the created program is translated into a machine code
▶▶ If there is a sample label on the name plate, it is a
that is readable for the BODAS controller.
prototype or sample, i.e. components not released for
series production. Possible sample labels are:
▶▶ BODAS measuring adapter MA7
–– SC: A
The BODAS measuring adapter MA7 (see data sheet
–– SC: B
95090) is used for measuring all electrical signals at the
–– SC: C
inputs, outputs and interfaces of the BODAS controller.
–– SC: S (prototype software)
For testing purposes, it is connected in series between
the controller and the vehicle or device wiring.

▶▶ BODAS testbox TB3

The BODAS testbox TB3 is used to simulate vehicle and
device functions for development and test purposes
with BODAS controllers. The BODAS testbox TB3 is
connected to the control unit via an adapter cable TAK7.
A stencil provides specific channel designations for this
control unit. See data sheet 95092 for more details.

All products mentioned here are available from Bosch

Rexroth.
Further information can be found on the Internet at:
www.boschrexroth.com/mobile-electronics

Bosch Rexroth AG, RE 95205/06.2018

 BODAS controller | RC4-5 series 30 3
 Description

Description

The BODAS controller RC4-5/30 is a universal controller for The inputs are protected against overvoltage and electrical
mobile working machines. interference. The voltage inputs can be monitored to detect
State-of-the-art 32-bit TriCore technology, a clock frequency cable breaks or short circuits.
of 80 MHz and numerous I/O functions give the controller a CAN bus interfaces are available with all BODAS controllers
high power density in a very compact housing. RC for exchanging data with other bus users or electronic
The controller is used for the programmable control of systems (e.g. controller RC, joystick, engine control unit,
proportional and switching solenoids and of additional display).
electrical switching functions. Typical applications are Two independent CAN bus interfaces, each of which can
electrohydraulically actuated work functions, travel drives be operated with various protocols, are available in the
and transmission controls. RC4-5/30 BODAS controller. Communication with a service
Internally the BODAS controller RC4-5/30 contains a pow- tool is also conducted via one of the two CAN interfaces.
erful 32‑bit TriCore microprocessor TC1724, all input and The RC4-5/30 controller is supported as standard by the
output circuitry, and a power supply unit for operation in Rexroth tool BODAS-service.
mobile machines with 12 or 24 volt nominal supply volt- An application interface in the form of a C-API is available
ages. for programming the controller. This allows the software
With 9 power outputs, 6 small signal outputs, a total of developer to concentrate on the important functions of his
30 input channels, 4 constant voltage sources and two machine without having to become immersed in the details
CAN buses for communication in the vehicle, the RC4-5/30 of the TriCore technology and the hardware of the control-
controllers form a powerful platform for controlling mobile ler.
working machines. With the BODAS-service software, the programs can be
The four current-controlled, pulse-width-modulated (PWM) quickly and simply downloaded to the controller via the
outputs are used in particular for controlling proportional Flash module. Extensive service functions, such as
solenoids. The current control keeps the setpoint current diagnostics, parameter setting or display of process
constant without hysteresis even if the supply voltage or variables are available via the graphical Windows interface
temperature of the solenoid changes. The PWM outputs of BODAS-service. This enables simple parameter setting
match the electrical proportional control of Rexroth axial and diagnosis in order to place the machine in service
piston units and valves. quickly and safely.
Five switching outputs can be used for switching solenoids, The BODAS controllers RC were developed specifically for
relays or other electrical consumers. use in mobile working machines and satisfy corresponding
Of the input channels, five are used to measure frequency protection requirements regarding ambient temperatures,
signals. Two of these inputs are configured for active water and dust ingression, shock and vibration as well as
frequency sensors. Two other frequency inputs are specified Electromagnetic Compatibility (EMC). BODAS controllers
for the intelligent Rexroth DSM1-10 speed sensors with RC and corresponding software in combination with
integrated diagnosis function. An inductive speed sensor pumps, motors, valves, sensors, input devices and actua-
can be connected at the fifth frequency input. tors from Rexroth make for complete system solutions.
Four resistance inputs are used, for example, to directly
connect temperature sensors.
The other inputs can be used for measuring analog voltages
or as switching inputs.

 RE 95205/06.2018, Bosch Rexroth AG

4 RC4-5 series 30 | BODAS controller
Block circuit diagram

Block circuit diagram

Hardware Inhibit1)
Primary
activation input1) Central deactivation
(including processor
Power supply Voltage
voltage monitoring)
Terminal 30 supply with
Terminal 31 intelligent
watchdog

TriCoreTM TC1724
Switch-on Microcontroller, 32 bit
Ignition switch Power outputs
(terminal 15) pulse
μC DSP Risc μC
Switching out-
PFlash 1...5 High-side
DFlash RAM put stage switching output stage
Secondary 1.5
1 SW-INH 64 kbyte 120 kbyte 2.3 A/3.5 A
activation input2) Mbyte PWM output
1...4 Low-side proportional
stage solenoid outputs
Frequency 2.3 A/3.5 A
1...2
DSM

Frequency Frequency Digital input Control unit Voltage

inputs 1...2 1 Analog
active for outputs up to 5 V voltage output

Frequency
1
inductive 2 separate Current
1...4 Low-side
AD convert- up to 13 mA switching outputs
Voltage Interface
1...2 ers, 12 bit 13 mA
Voltage inputs 0 to 32 V controller
Current
Voltage 1 Low-side
1...13 up to 50 mA switching output
0 to 5 V 50 mA

Temperature Temperature
1...4
inputs (resistance) Interface driver 1...2 CAN bus
interfaces

Voltage 5 V 1...3 Sensor supply

5 V
150 mA each

Voltage 8.5 V 1 Sensor supply

8.5 V
50 mA

Abbreviations
µC Microcontroller
DSP Digital signal processor
RISC Reduced instruction set computer
PFlash Program flash
DFlash Data flash (e.g. for parameter storage)
RAM Random Access Memory

1) Input that is independent of the microcontroller, for the central

enabling/deactivation of the power outputs.
2) Input for the central activation/deactivation of the power outputs.

Bosch Rexroth AG, RE 95205/06.2018

 BODAS controller | RC4-5 series 30 5
 Technical data

Technical data

Nominal voltage RC4-5 series 30

Nominal battery voltage 12 V or 24 V
Supply voltage, permissible range 8 V to 29 V
temporarily up to 32 V
Current consumption
in the 12 V vehicle electrical system, without load 150 mA
in the 24 V vehicle electrical system, without load 90 mA
Fuses
internal none
External in supply path max. 15 A
Constant voltage source
150 mA 5 V ±4 % 3
50 mA 8.5 V ±10 % 1
Analog voltage inputs, total (can be used as a switching input, partly as alternative function) 28
0 to 5 V 18
0 to 32 V 10
Digital switching inputs 1
Resistance inputs
10 Ω to 20 kΩ 4
Frequency inputs total 5
Active sensors from 0 to 20 kHz, 2
DSM from 0 to 20 kHz 2
Inductive sensors from 500 Hz to 10 kHz 1
Analog voltage output
0.05 V to 5 V 1
Proportional solenoid output, total 4
Current-controlled low-side PWM output stage 0 to 2.3 A, PWM to 1 kHz 2
0 to 3.5 A, PWM to 1 kHz 2
Digital output stages total 5
Non-current-controlled high-side PWM output stage max. 2.3 A, PWM to 250 Hz 1
max. 3.5 A, PWM to 250 Hz 4
Low-side driver output 5
Low-side driver output, current-limited up to 13 mA 4
up to 50 mA 1
Interfaces
CAN 2.0 B, ISO 11898, max. 500 kBaud 2
Fault detection in the event of cable break and short circuit
Inputs *
Outputs *
CAN *
Protection against short circuits to supply voltage and ground
1)

(Requirement: controller is powered and switch-on signal at terminal 15 is on High is active)

Inputs *
Outputs, except OUT_141) *
CAN1) to ground only

1) The output OUT_14 and the CAN interfaces are not permanently
protected against short circuit to battery voltage.

 RE 95205/06.2018, Bosch Rexroth AG

6 RC4-5 series 30 | BODAS controller
Technical data

Reverse polarity protection RC4-5 series 30

Power supply / battery1) –
Microcontroller
SAK-TC1724
Clock frequency
MHz 80
Internal memory capacity in microcontroller
RAM kB 120 kByte
DFlash kB 64 kByte
PFlash kB 1.5 MByte
Software installation
Download in PFlash ✓
Electromagnetic compatibility
Spurious interference (ISO 11452-2) 200 MHz to 2 GHz: 140 V/m *
Spurious interference (ISO 11452-4) BCI 20 MHz to 400 MHz: 100 mA *
Load dump with 12 V battery voltage *
Load dump with 24 V battery voltage Us = +123 V *
(ISO 7637-2: 2004)
Electrostatic Discharge ESD (DIN EN 60068-2-30Db; version 2)
Out of service, class C Contact and air 8 kV
In service, class C Contact / air 6 kV / 8 kV
Maximum power dissipation
Electronics approx. 3 W
Outout stages approx. 15 W
Permissible operating temperature, housing
With mounting point on cooling surface <= +60 °C (+140 °F) –40 to +85 °C
(–40 to +185 °F)
Storage temperature, housing
Maximum permissible housing temperature –40 to +105 °C
momentary, passive: (–40 to +221 °F)
Vibration resistance, broadband noise oscillations (ISO 16750-3: 2007)
57.9 m/s2, 10 bis 2000 Hz,
32 h per axis
10 Hz: 18 (m/s2) 2/Hz
20 Hz: 36 (m/s2) 2/Hz *
30 Hz: 36 (m/s ) /Hz
2 2

180 Hz: 1 (m/s2) 2/Hz

2000 Hz: 1 (m/s2) 2/Hz
Shock resistance
Transport shock (IEC 60068-2-27: 2010)
a = 30 g; t = 11 ms
per spatial axis x, y, z *
and in each direction (pos./neg.)
Moisture resistance (DIN EN 60068-2-30Db; version 2)
90–96 % (+25 °C to +55 °C) *

1) Reverse polarity protection can be realized by the external fuse

Bosch Rexroth AG, RE 95205/06.2018

 BODAS controller | RC4-5 series 30 7
 Technical data

Combined salt spray and moisture test

RC4-5 series 30
(DIN EN 60068-2-52Kb)
Salt spray 4x 2 h, 5 % NaCl
Followed by 22 h storage at 40 °C and 93% humidity *
72 h storage at room temperature
Type of protection (ISO 20653)
with installed mating connector1) IP65, IP66 with protected pressure equalizing element *
Housing material
Cover Aluminium sheet AlMg3 *
Base Aluminium sheet AlMg3 *
Weight approx. 0.2 kg
Outer dimensions
Without mating connector, with multipoint connector Length (in mm) 140
Width (in mm) 123
Height (in mm) 43
Mating connector 56-pin 12)

1) While following the installation instructions

2) Second connector chamber not used

 RE 95205/06.2018, Bosch Rexroth AG

8 RC4-5 series 30 | BODAS controller
Connection diagram

Connection diagram

RC4-5/30
VP_1

Switching output
55 Switching solenoids
3) Out_1
15 A 7) 11) 50 VB Voltage supply for 1 3.5 A
electronics and power 2)
49 VB
outputs Switching output
56
Out_2
2 3.5 A
Ignition switch
2)
1A 7 VCTRL Switching output
Switch-on signal 53
+12 V/ 30 15 Out_3
3 3.5 A
+24 V 30
2)
Switching output
0V 54
Out_4
31 4 3.5 A
Ground 51 GND 2)
Switching output
52 GND 14) Constant voltage 1
Out_5
8.5 V 5 2.3 A
2)

24 IN_20
1
Active
28 IN_21
Frequency inputs

2
Active
19 IN_22
3
Proportional output Proportional solenoids6)
DSM 1 3.5 A
37
23 IN_23 Out_6
4
DSM
34 IN_24
5 Proportional output
Ind 25 2 3.5 A
Out_7
4 GND
Sensor ground14)
Switch to VSS_1, VSS_2 or VSS_3 if used Proportional output
as switching input 14 3 2.3 A
Out_8

1 45 IN_1
Proportional output
OV/3.3V 13 4 2.3 A
2 38 IN_2 Out_9
OV/3.3V
3 48 IN_3
OV/3.3V VSS_x
4 35 IN_4
Voltage inputs 0 to 5 V or switching inputs

OV/3.3V Switching output

5 36 IN_5 resilient to 13 mA10)
OV/3.3V 1
6 47
44 IN_6 Out_10

7 OV/3.3V
39 IN_7
Switching output
8 OV/3.3V resilient to 13 mA10)
32 IN_8 2
46
OV/3.3V Out_11
9 30 IN_9
OV/3.3V
10 33 IN_10 Switching output
resilient to 13 mA10)
11 OV/3.3V 3
31 IN_11 26
Out_12
OV/3.3V
12 27 IN_12
Switching output
OV/3.3V
resilient to 13 mA10)
4
Contact voltage 5 V
29
Out_13

13 22 IN_13

5)
43 VSS_1 Constant voltage source
5 V / 150 mA

5)
42 VSS_2 Constant voltage source
5 V / 150 mA Analog
voltage output
5)
2 VSS_3 Constant voltage source Out_14
40
0.05 V to 5 V
5 V / 150 mA

5)
41 VSS_4 Constant voltage source 8)
8.5 V / 50 mA Switching output VSS_x
resilient to 50 mA10)
Active sensors/
15 IN_14
1 8
Voltage inputs Out_15
potentiometers
21 IN_15 0 – 32 V
0–32 V 2
Switch
12 CAN bus4)
CAN H1
VB (KL30) Stop switch CAN L1 11 Interface
fuse-protected VB VP_1
20 HW-INH12) 9
CAN H2 CAN bus4)
CAN L2 10 Interface

5V constant voltage

13)
5 IN_25
Switching input
or SW-INH
(EMCY)
5V constant voltage
Temperature inputs
PTC 1000
18 IN_16

1
9)
6 IN_17
Temperature inputs

2
9)
17 IN_18

3
9)
16 IN_19

4
9)
3 GND
Sensor ground14)

1)
 For footnotes, see page 9

Bosch Rexroth AG, RE 95205/06.2018

 BODAS controller | RC4-5 series 30 9
 Connection diagram

1) Short, low-resistance connection from a case screw to the vehicle Note

ground. ▶▶ To switch off the system in emergencies, the power
2) Own ground connection to battery (chassis possible).

3) Separate fuse protection for sensors supplied from UBat, and

supply to the controller must be disconnected by an
solenoids switched to ground. Fuse configuration specific to emergency-stop switch.
application (in particular current needed and line cross section). The emergency-stop switch must be installed in an
4) CAN bus: 120 Ω termination resistor and twisted line necessary.
easily accessible position for the operator.
5) Constant voltage sources can be used as sensor supply or

switching voltage for switches/push-buttons.

Safe braking must be ensured when the emergency stop
6) The power line to consumers switched to ground must be fused, function is activated.
see 3. ▶▶ All GND pins are connected together on the printed
7) Can be adjusted to the actual current consumption of the
circuit board. Maximum permissible currents depend on
consumers and must be adjusted to the permissible rating of
the lines and pins.
the contacts used (pins 51 and 52: MQS 1.5 CB; pins 3
8) Independent ground connection of the current source to the and 4: BCB 0.6) and on the lines used.
battery, controller ground possible. ▶▶ Lines to the controller must not be routed close to other
9) Can be used as switching inputs.
power-conducting lines in the device.
10) Alternatively, can be used as input.

11) If deactivated during operation, data will not be saved in the

▶▶ The proportional solenoids must not be wired with
non-volatile memory and there will be no after run. spark-suppression diodes.
12) First deactivation channel: Switching solenoids at the outputs of the controller do
In deactivation state, the main switch for the power supply to the not need to be connected to spark-suppression diodes.
high-side output stages is opened by the hardware and the
low-side output stages are deactivated.
Other switched inductive consumers in the
13) Second deactivation channel: system must be equipped with spark-suppression
If used as SW-INH, main switch opened and low-side output diodes.
stages deactivated by the software. ▶▶ For information about mating connectors and contacts,
14) Terminal 31 (ground supply) and sensor ground are joined at a star

point in the controller and are connected to the housing.

please refer to Bosch offer drawing 1 928 A00 443.
▶▶ The illustrated fuses act as line protection.

 RE 95205/06.2018, Bosch Rexroth AG

10 RC4-5 series 30 | BODAS controller
Overview of the functions

Overview of the functions

Pin1) Description Main function Alternative function

49, 50 Voltage supply Power supply for electronics and
VB (terminal 30) output stages
Nominal battery voltage
12 V DC or 24 V
Operating range 8 V to 29 V,
temporarily permissible 32 V
51, 52 Vehicle ground Supply ground
GND (terminal 31) (internally connected to pins 3 and 4)
3, 4 Internal sensor Sensor ground
ground (internally connected to pins 51
GND and 52)
20 Hardware Inhibit Primärer activation input
5 V HW-INH Hardware deactivation function for all
power output stages
Disable VP_1 Activation level > 7.9 V
PIN and PWM Deactivation level < 2.8 V
LowSide outputs
CPU Port

GND

5 Software Inhibit Secondary activation input Digital switching input

5 V SW-INH Activation with low level High level > 2.0 V
or switching input Deactivation with high level Low level < 0.5 V
10 kΩ

IN_25
Pull-up 10 kΩ to 5 V
To
PIN CPU Port

GND

7 Ignition switch Digital input

To VCTRL Switch on controller with level > 8 V
PIN Logic
(terminal 15) up to supply voltage VB
10.5 kΩ

Pull-down 10.5 kΩ

GND

24, 28 Active Frequency input for active sensors Analog input

frequency input Measuring range: 0 to 32 V
8.5 V IN_20, IN_21 Cut-off frequency filter 22 kHz Resolution: 12 bit
Frequency measurement up to 20 kHz
Digital input
5 kΩ

Level low < 1.5 V Level configurable in

CPU
PIN Level high > 4 V, ≦ VB software up to 32 V
Port
ADC
Pull-up 5 kΩ Pulse counter input
to 8.5 V Pulse width measurement
GND GND Pull-down 40 kΩ Measurement of pulse/
pause ratio

1) Pin numbers in bold type are for MQS 1.5-CB contacts; others are
for BCB 0.6 contacts

Bosch Rexroth AG, RE 95205/06.2018

 BODAS controller | RC4-5 series 30 11
 Overview of the functions

Pin1) Description Main function Alternative function

19, 23 DSM frequency input Frequency input Frequency input
ADC
IN_22, IN_23 for Rexroth DSM sensors for active sensors that
Cut-off frequency filter 26 kHz switch to High
Frequency measurement up to 20 kHz (type PNP)
GND GND Evaluation of additional information such as
PIN
CPU direction of rotation and fault monitoring Level Low < 1.7 V
Port possible Level High > 2.2
Pull-down 10 kΩ
200 Ω
20 kΩ

Switching thresholds 7 mA / 14 mA

From
CPU Analog input
Internal resistance 200 Ω to ground Measuring range:
0 to 32 V
VSS_4 can be used as power supply for DSM Resolution: 12 bit
frequency sensors.
Digital input
Level configurable in
software up to 32 V
Pulse counter input
Pulse width measure-
ment
Measurement of pulse/
pause ratio
34 Induktive ­frequency input Frequency input Pulse counter input
IN_24 for inductive frequency sensors Pulse width
3.3 V
Frequency measurement measurement
from 500 Hz to 10 kHz to 1 VRMS AC Measurement of pulse/
20 kΩ CPU pause ratio
PIN
Port

GND

18, 6, 17, 16 Resistance input Temperature measurement via Analog input

5 V IN_16, IN_17, IN_18, IN_19 resistance measurement of connected NTC/ Measuring range: 0 to 5 V
PTC temperature sensors Resolution: 12 Bit
2.15 kΩ

from 10 Ω to 20 kΩ

Support from Rexroth Digital input
To
PIN
ADC
Temperature sensors TSF and TSA Level configurable in
software up to 5 V
Pull-up 2.15 kΩ to 5 V
GND GND Pull-down 120 kΩ

Frequency limit 230 Hz

15, 21 Analog input Analog input Digital input
IN_14, IN_15 Measuring range: 0 to 32 V Level configurable in
To
PIN
ADC
Resolution: 12 bit software up to 32 V

Pull-down 50 kΩ
GND GND
Frequency limit 500 Hz

1) Pin numbers in bold type are for MQS 1.5-CB contacts; others are
for BCB 0.6 contacts

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12 RC4-5 series 30 | BODAS controller
Overview of the functions

Pin1) Description Main funktion Alternative function

45, 38, 48, 35, 36, 44 Analog Input Analog Input Digital input
IN_1 bis IN_6 Measuring range: 0 to 5 V Level configurable in
μC Pin
Resolution: 12 bit software up to 5 V
46 kΩ

If μC pin is switched to 3.3 V:

To Pull-up 46 kΩ
PIN
ADC
Pull-down 129 kΩ

GND GND If μC pin is switched to ground:

Pull-down 33 kΩ

Frequency limit 230 Hz

39, 32, 30, 33, 31, 27 Analog Input Analog Input Digital input
IN_7 bis IN_12 Measuring range: 0 to 5 V Level configurable in
μC Pin
Resolution: 12 bit software up to 5 V
46 kΩ

If μC pin is switched to 3.3 V:

To Pull-up 46 kΩ
PIN
ADC
Pull-down 250 kΩ

GND GND If μC pin is switched to ground:

Pull-down 39 kΩ

Frequency limit 120 Hz

22 Analog Input Analog Input Digital input
5 V IN_13 Measuring range: 0 to 5 V Level configurable in
Resolution: 12 bit software up to 5 V
242 Ω

Pull-up 242 Ω via diode to 5 V

To
PIN
ADC Pull-down 230 kΩ

Frequency limit 200 Hz

GND GND

37, 25 PWM output Closed-loop current controlled

Battery voltage stage Low side
Free
OUT_6, OUT_7 PWM output stage
wheeling
LS switch
diode
PIN Pulse frequency configurable in software
R068
GND in defined steps from 50 Hz to 1 kHz
From CPU PWR_ON
Inhibit &
current Duty cycle 0 % to 100 %
measurement
to ADC
State to CPU Max. current 3.5 A

Can only be operated if the main switch

GND GND
VP_1 is activated
14, 13 PWM output Closed-loop current controlled
Battery voltage stage Low side
Free
OUT_8, OUT_9 PWM output stage
wheeling
LS switch
diode
PIN Pulse frequency configurable in software
R068
GND in defined steps from 50 Hz to 1 kHz
From CPU PWR_ON
Inhibit &
current Duty cycle 0 % to 100 %
measurement
to ADC
State to CPU Max. current 2.3 A

Can only be operated if the main switch

GND GND VP_1 is activated

1) Pin numbers in bold type are for MQS 1.5-CB contacts; others are
for BCB 0.6 contacts
Bosch Rexroth AG, RE 95205/06.2018
 BODAS controller | RC4-5 series 30 13
 Overview of the functions

Pin1) Description Main function Alternative function

55, 56, 53, 54 Switching output High-side switching output stage Open-loop controlled
stage with current sensing PWM output stage
From main switch From main switch
OUT_1, OUT_2, with current sensing
(battery voltage) (battery voltage)
OUT_3, OUT_4 max. 3.5 A
HS switch 20 kΩ Duty cycle 0 % to 100 %
current Central power supply via VP_1
PIN
Sense
to ADC Free Pulse frequency
wheeling configurable in software
PWR_ON
From CPU diode
in defined steps up to
GND
State 250 Hz
to CPU

max. 3.5 A
GND GND
Central power supply via
VP_1
1 Switching output High-side switching output stage Open-loop controlled
stage with current sensing PWM output stage
From main switch From main switch
OUT_5 with current sensing
(battery voltage) (battery voltage)
max. 2.3 A
HS switch 20 kΩ Duty cycle 0 % to 100 %
current Central power supply via VP_1
PIN
Sense
to ADC Free Pulse frequency
wheeling configurable in software
PWR_ON
From CPU diode
in defined steps up to
GND
State 250 Hz
to CPU

max. 2.3 A
GND GND
Central power supply via
VP_1
47, 46, 26, 29 Small signal- Low-side driver output Analog input
switching output (when driver output is
From
PIN OUT_10, OUT_11, Limited to 13 mA deactivated)
CPU OUT_12, OUT_13 (current limitation in case of overload)
Measuring range:
voltage
e.g. for LED with external resistor 0 to 30 V
measurement
to ADC Resolution: 12 Bit

GND GND Pull-down 31 kΩ

Frequency limit 860 Hz

8 Small signal- Low-side driver output
switching output
PIN TX From CPU
OUT_15 Limited to 50 mA
RX To CPU
(current limitation in case of overload)

e.g. for LED with external resistor

40 Analog output Analog voltage output Analog input
5 V
OUT_14 (when driver output is
Output signal 0.05 V to 5 V deactivated)
Minimum 5 kΩ external ohmic resis-
From tance required Measuring range:
CPU 32.2 Ω (<= 1 mA) 0 to 5 V
voltage PIN
Resolution: 12 Bit
measurement
to ADC
Pull-down ~20 kΩ
GND GND
Frequency limit 550 Hz

1) Pin numbers in bold type are for MQS 1.5-CB contacts; others are
for BCB 0.6 contacts
 RE 95205/06.2018, Bosch Rexroth AG
14 RC4-5 series 30 | BODAS controller
Overview of the functions

Pin1) Description Main function Alternative function

43, 42, 2 Sensor supply Power supply for external sensors
VSS_1, VSS_2, Output voltage 5 V
VSS_3 Accuracy ±4 %
Load capacity 150 mA

The sensor supplies must not be

operated or bridged in parallel.

41 Sensor supply Power supply for external sensors

VSS_4 Output voltage 8.5 V at supply voltage
of at minimum 9.5 V
Accuracy ±10 %
Load capacity 50 mA

In particular used as power supply for

DSM frequency sensors

12, 11 CAN interface CAN interface

CAN1_H, CAN1_L CAN 2.0 B, up to 500 kBaud

PIN External termination resistor

1.21 kΩ 1.21 kΩ

120 Ω in the CAN bus required

From
TxD
CPU
RxD To Standard diagnosis interface with
GND CPU 250 kBaud factory setting

PIN

9, 10 CAN interface CAN interface

CAN2_H, CAN2_L CAN 2.0 B, up to 500 kBaud
PIN
1.21 kΩ 1.21 kΩ

External termination resistor

From
TxD
CPU
120 Ω in the CAN bus required
RxD To
GND CPU

PIN

1) Pin numbers in bold type are for MQS 1.5-CB contacts; others are
for BCB 0.6 contacts

Bosch Rexroth AG, RE 95205/06.2018

Dimensions [mm]
 BODAS controller | RC4-5 series 30 15
 Dimensions

Dimensions

Mounting
View from below
▶▶ The BODAS controller must be fastened at
(174.4)
4 points (a, b, c and d).
17
▶▶ The 4 mounting points must have an evenness of
(54.9) 18 Screw (4x)
0.5 mm.
▶▶ The upper limit for surface pressure on the screwing
areas of the controller is 140 N/mm2.
(63.2)

▶▶ Recommended screws M4 with head diameter ≥ 7 mm

30
▶▶ Tightening torque with washer 3.0 Nm, without washer

3
2.5 Nm
Wiring harness ▶▶ The BODAS controller must be mounted in the vehicle
connector in such a way that it does not bounce against other
plugged Bottom
vehicle parts and additional fastening elements of the
controller.
Long-side side view
▶▶ A distance of at least 1 mm over the entire surface
must be maintained between the bottom of the con-
(49.1)
(43.1)

35.5 ±2

troller and the mounting surface. The distance should

be less than 10 mm. If the control unit is not mounted
with a bracket, it should be mounted with four dis-
Side view of connector side with pulled connector tance bolts that guarantee this distance and prevent

Pin 56
the bottom plate from bending in the area of the screw
holes.
▶▶ It must be ensured that the screw fitting cannot come
loose unexpectedly.
▶▶ The wiring harness should be fixated mechanically in
Pin 1 the area in which the controller is installed
Pin 12
(spacing < 100 mm).
Plan view ▶▶ The wiring harness should be fixated so
(187) that in-phase excitation with the controller occurs.
20.3±0.5 119.5±2 ▶▶ The wiring harness connector is not included in the
Wiring
harness connector 44.1±4 43.2±0.3 scope of supply.
a b Cover
unplugged
▶▶ Bosch Rexroth’s consent is required if fixing is differ-
ent from above.
3 ±4
114 ±0.3

123 ±2
(41)

(67.5)
d c
DAE
4.5+0.3 (4x)

Illustration not to scale

[mm]

 RE 95205/06.2018, Bosch Rexroth AG

16 RC4-5 series 30 | BODAS controller
Installation position

Installation position

The installation position must be chosen such that no

standing or continuously flowing water can occur in the
area of the pressure equalization element (DAE) and the
sealings.
The pressure equalization element (DAE) and the sealing
area must not be immersed in water.
The controller must not bounce when mounted in the
vehicle.

Pressure equalization element (DAE)

Sealing area (cover-base-male multipoint connector)

Bosch Rexroth AG, RE 95205/06.2018

 BODAS controller | RC4-5 series 30 17
 Mating connector

Mating connector

A 56-pin module from Bosch is used as wiring harness

connector. The 1928xxx numbers stated below are Bosch
designations. Technical details about these document and
part numbers are available at www.bosch-connectors.com.
Installation specification 1928 A01 41M
Technical customer documentation 1928 A01 40T
Offer drawing (assembly) 1928 A00 443

The following parts are required for assembling a wiring

harness connector:

Designation Version Part number Manufacturer Number

Contact carrier, code 13 Wire outlet left 1928 405 161 Bosch 1
Wire outlet right 1928 405 217 Bosch
Cover Outlet up 1928 405 164 Bosch 1
Outlet straight 1928 405 163 Bosch
Secondary lock 1928 405 165 Bosch 1
Holding plate 1928 405 162 Bosch 1
Wire tie 1928 401 713 Bosch 1
Contact BCB 0.6 Line cross section in mm
2
1928 492 555 Bosch up to 481)
0.35 mm2 – 0.5 mm2
Insulation diameter in mm
1.2 – 1.6 (FLR-B)
Line cross section in mm2 1928 492 556 Bosch
0.75
Insulation diameter in mm
1.7 – 1.9 (FLR-B)
Contact MQS 1.5-CB Line cross section in mm2 1241608-1 TE connectivity up to 81)
0.75 – 1.5 (www.te.com)
Insulation diameter in mm
1.7 – 2.4 (FLR)
Dummy contact 1928 405 239 Bosch 1)

BCB 0.6 blue

Dummy contact 1928 405 240 Bosch 1)

MQS 1.5-CB green

For part numbers of tools (crimping tongs, contact removal

tools, etc.), see Bosch offer drawing.

1) Free contact chambers are to be sealed with dummy contacts to

ensure water-tightness.

 RE 95205/06.2018, Bosch Rexroth AG

18 RC4-5 series 30 | BODAS controller
Mating connector

Mating connector sets with the following content are

available under Rexroth part number R917008789 for the
manual assembly of wiring harness connectors for laboratory
or small-series requirements:

Designation Version Part number Manufacturer Number

Contact carrier, code 13 Wire outlet right 1928 405 217 Bosch 1
Cover Outlet straight 1928 405 163 Bosch 1
Secondary lock 1928 405 165 Bosch 1
Holding plate 1928 405 162 Bosch 1
Contact BCB 0.6 Line cross section in mm
2
1928 492 555 Bosch 48
0.35 – 0.5
Insulation diameter in mm
1.2 – 1.6 (FLR-B)
Contact MQS 1.5-CB Line cross section in mm2 1241608-1 TE connectivity 8
0.75 – 1.5 (www.te.com)
Insulation diameter in mm
1.7 – 2.4 (FLR)
Dummy contact 1928 405 239 Bosch 30
BCB 0.6 blue
Dummy contact 1928 405 240 Bosch 4
MQS 1.5-CB green

Delivered loose in a PE bag. Not suitable for processing by

a machine.

Bosch Rexroth AG, RE 95205/06.2018

 BODAS controller | RC4-5 series 30 19
 Safety instructions

Safety instructions

General instructions ▶▶ Make sure that nobody is in the machine‘s danger zone.
▶▶ External measures in the vehicle are required to implement ▶▶ No defective or incorrectly functioning components may
commonly used safety standards for mobile working be used. If the components should fail or demonstrate
machines with the RC4-5/30 controller. If necessary, faulty operation, repairs must be performed immediately.
please contact Bosch Rexroth in this regard. ▶▶ Controllers used to develop software may only be
▶▶ Reliable operation cannot be guaranteed if samples or installed in series production machines if it can be
prototypes are used in series production machines. guaranteed that these controller have not been flash-
▶▶ The proposed circuits do not imply any technical liability programmed with new software more than 500 times.
for the system on the part of Bosch Rexroth. Controllers that have been programmed more than 1000
▶▶ Incorrect connections could cause unexpected signals at times are not to be installed in series production
the outputs of the controller. machines.
▶▶ Incorrect programming or parameter settings on the
controller may create potential dangers while the Notes on the installation location and position
machine is in operation. It is the responsibility of the ▶▶ Do not install the controller close to parts that generate
machine manufacturer to determine dangers of this type considerable heat (e.g. exhaust).
in a danger analysis and to bring them to the attention ▶▶ Radio equipment and mobile telephones must not be
of the end user. Bosch Rexroth shall assume no liability used in the driver‘s cab without a suitable antenna or
for dangers of this kind. near the control electronics.
▶▶ The component firmware/software must be installed ▶▶ A sufficiently large distance to radio systems must be
and removed by Bosch Rexroth or by the authorized maintained.
partner concerned in order to uphold the warranty. ▶▶ All connectors must be unplugged from the electronics
▶▶ It is not permissible to open the controller or to modify during electrical welding and painting operations.
or repair the controller. Modification or repairs to the ▶▶ Cables/wires must be sealed individually to prevent
wiring could result in dangerous malfunctions. Repairs water from entering the device.
to the controller may only be performed by Bosch ▶▶ The controller must not be electrostatically charged,
Rexroth or by an authorized partner. e.g. during painting operations.
▶▶ A stop switch can be used for deactivation of the con- ▶▶ The controller will heat up beyond normal ambient
troller (refer to the connection diagram). temperature during operation. To avoid danger caused
▶▶ When the electronics is not energized no pins must be by high temperatures, it should be protected against
connected to a voltage source. Thus, when the current contact.
supply is switched off, the supply for the electronics, the ▶▶ Install the controller in such a way that the connector is
output stages and the external sensor supply have to be not pointing upwards. This ensures that any condensa-
switched off together. tion water that may form can flow out.
▶▶ Make sure that the controller´s configuration does not ▶▶ Standing or permanently running water is not permitted
lead to safety-critical malfunctions of the complete anywhere near the circumferential sealing (cover/base/
system in the event of failure or malfunction. This type connector) or the pressure equalizing element (DAE).
of system behavior may lead to danger to life and/or ▶▶ The housing must be wired to vehicle ground in order to
cause much damage to property. comply with EMC guidelines. Metallic screws must be
▶▶ System developments, installations and commissioning used to create a connection to vehicle ground.
of electronic systems for controlling hydraulic drives
must only be carried out by trained and experienced
specialists who are sufficiently familiar with both the
components used and the complete system.
▶▶ While commissioning and maintenance the controller
(with BODAS Tools) the machine may pose unforeseen
dangers. Before commissioning the system, you must
therefore ensure that the vehicle and the hydraulic
system are in a safe condition.

 RE 95205/06.2018, Bosch Rexroth AG

20 RC4-5 series 30 | BODAS controller
Safety instructions

Notes on transport and storage ▶▶ PWM outputs (OUT_6 to OUT_9) must not be connected
▶▶ If it is dropped, the controller must not be used any to each other or bridged. No light bulbs are to be oper-
longer as invisible damage could have a negative impact ated at these outputs.
on reliability. ▶▶ None of the sensor supplies VSS_x is to be connected to
▶▶ Controllers must be stored at a temperature between one or more sensor supply VSS_x.
–40 °C and +40 °C. Up to 1000 hrs are permissible ▶▶ The sensor supplies VSS_x can be "pulled up" by external
between +40 °C and +85 °C. Up to 200 hrs are connection, e.g. the application of a higher voltage,
permissible between +85 °C and +105 °C. Air humidity because they operate only as a voltage source but not as
up to 96% at 55 °C. a voltage sink. Pulling up a sensor supply may result in
▶▶ After a storage time of more than 5 years, the controller unexpected malfunctions and damage of the controller
must be examined by the manufacturer. in lasting operation.
▶▶ The "high side" (OUT_1 to OUT_5) outputs must not be
Notes on wiring and circuitry externally connected to battery.
▶▶ The electronics and the power outputs of a controller
must be fed from the same power source. Note on proportional and switching solenoids and other
▶▶ Lines to the speed sensors must be designed as short wired inductive consumers
as possible and be shielded. The shielding must be ▶▶ The proportional solenoids must not be wired with
connected on one side to the electronics or to the spark-suppression diodes.
machine or vehicle ground via a low-resistance connec- ▶▶ Switching solenoids at the outputs of the controller do
tion. not need to be connected to spark-suppression diodes.
▶▶ The controller may only be wired when it is de-ener- ▶▶ The electronics may only be tested with the proportional
gized. solenoids connected.
▶▶ Lines to the electronics must not be routed close to ▶▶ Other switched inductive loads that are in the system
other power-conducting lines in the machine or vehicle. but not connected to the controller must be connected
▶▶ The wiring harness should be fixated mechanically in the to spark-suppression diodes. The same applies to relays
area in which the controller is installed (spacing if these have the same power supply as the controller.
< 100 mm). The wiring harness should be fixated so
that in-phase excitation with the controller occurs Intended use
(e.g. at the controller mounting points). ▶▶ The controller is designed for use in mobile working
▶▶ If possible, lines should be routed in the vehicle interior. machines provided no limitations / restrictions are made
If the lines are routed outside the vehicle, make sure to certain application areas in this data sheet.
that they are securely fixed. ▶▶ Operation of the controller must generally occur within
▶▶ Lines must not be kinked or twisted, must not rub the operating ranges specified and released in this data
against edges and must not be routed through sheet, particularly with regard to voltage, current, tem-
sharp-edged ducts without protection. perature, vibration, shock and other described environ-
▶▶ Lines are to be routed with sufficient distance from hot mental influences.
or moving vehicle parts. ▶▶ Use outside of the specified and released boundary
conditions may result in danger to life and/or cause
damage to components which could result in
consequential damage to the mobile working machine.

Bosch Rexroth AG, RE 95205/06.2018

 BODAS controller | RC4-5 series 30 21
 Safety instructions

Improper use Safety features in the BODAS controller

▶▶ Any use of the controller other than that described in ▶▶ Faults in the voltage supply are detected by internal
chapter "Intended use" is considered to be improper. monitoring.
▶▶ Use in explosive areas is not permissible. ▶▶ All output signals can be monitored by the microcontroller
▶▶ ‌Damages which result from improper use and/or from with the appropriate software.
unauthorized, interference in the component not ▶▶ For service purposes, the controllers can be operated
described in this data sheet render all warranty and with all power outputs de-energized.
liability claims with respect to the manufacturer void. ▶▶ The internal watchdog module centrally switches off the
power supply of all proportional and switching outputs
Use in safety-related functions in the event of disturbances to the program execution.
▶▶ The customer is responsible for performing a risk analy-
sis of the mobile working machine and determining the Further information
possible safety-related functions. ▶▶ In addition, the application-specific documents
▶▶ In safety-related applications, the customer is respon- (connection diagrams, software descriptions, etc.)
sible for taking suitable measures for ensuring safety are to be observed.
(sensor redundancy, plausibility check, emergency ▶▶ Further information about the BODAS controllers can be
switch, etc.). found at www.boschrexroth.com/mobile-electronics
For example, a suitable assignment of input values (e.g.
by connecting the acceleration pedal signal to two
independent analog inputs) can be used to detect faults
and to activate specially programmed reactions.
Special measures may be initiated if the plausibility
check shows deviations between the setpoint values and
the values read back by the microcontroller.
▶▶ Please consult Bosch Rexroth if you require product
data for a safety assessment of the machine.
–– Notes about all controllers in the API description
(manual) must be observed.

 RE 95205/06.2018, Bosch Rexroth AG

22 RC4-5 series 30 | BODAS controller

Bosch Rexroth AG © Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal,
Glockeraustraße 4 exploitation, reproduction, editing, distribution, as well as in the event of
89275 Elchingen, Germany applications for industrial property rights. The data specified within only
Tel. +49 9352 40 50 60 serves to describe the product. No statements concerning a certain condi-
info.bodas@boschrexroth.de tion or suitability for a certain application can be derived from our informa-
www.boschrexroth.com tion. 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.

Bosch Rexroth AG, RE 95205/06.2018