REXROTH BODAS PR4280GB05/10 Montageanleitung

RE 95156/02.2017, Bosch Rexroth AG

BODAS Pressure sensor

PR4

RE 95156

Edition: 02.2017

Replaces: 12.2015

Features

▶ Tightening torque 45 Nm

▶ Shock and vibration resistant

▶ High resistance to pressure spikes

▶ Very good resistance to temperature shock

▶ High accuracy over the complete measuring range

▶ Compact dimensions for all pressure ranges

▶ Thin-ﬁlm measurement principle

▶ Measurement range

0 ... 280 bar

0 ... 420 bar and

0 ... 600 bar

▶ Ratiometric output signal 0.5 ... 4.5V

at 5V supply voltage

▶ Type of protection IP67 and IP69K

Inhalt

Ordering code 2

Description 2

Technical data 3

Characteristics 4

Dimensions 4

Connector Bosch Compact 5

Manufacturer conﬁrmation of PR4 MTTFd-values 6

Installation instructions 7

Wiring and error diagnostic of the sensor 8

Error diagnosis 9

Safety instructions 11

Bosch Rexroth AG, RE 95156/02.2017

2PR4 | BODAS Pressure sensor

Ordering code

01 02 03 04 05 06

BODAS PR4 / 10

Type

01 Pressure sensor PR4

Measurement range

02 0 ... 280 bar 280

0 ... 420bar 420

0 ... 600bar 600

Mechanical connection 280 420 600

03 G1/4A according to DIN EN ISO 1179-2 ● ● – G

M14x1.5 according to ISO6149-2 – – ● M

Electrical connection

04 Bosch Compact B

Supply Output signal

05 5 ±0.25V 0.5 ... 4.5V ratiometric (at 5 V supply) 05

Series

06 10

●= Available –= Not available

Available variants

Type Material number

Bulk pack (136 pieces) Single pack

PR4 280 G B 05 / 10 R917C05562 R917A05562

PR4 420 G B 05 / 10 R917C09842 R917A09842

PR4 600 M B 05 / 10 R917C10105 R917A10105

Description

This sensor is used for measuring pressure in hydraulic

circuits. Due to its outstanding characteristics, it is also

ideally suited for use in mobile hydraulics: shock and

vibration resistance, type of protection, resistance

topressure spikes, resistance to temperature shock,

EMCcharacteristics better than 150 V/m. The measurement

principle uses a hermetically welded thin-ﬁlm measurement

cell, which ensures long-term leak resistance. The sensor

signal can be directly evaluated by a BODAS controller RC.

RE 95156/02.2017, Bosch Rexroth AG

BODAS Pressure sensor | PR4

Technical data

Type PR4 280

GB05

420

GB05

600

MB05

Measurement range 0 ... 280 bar 0 ... 420 bar 0 ... 600 bar

Overload limit1) 400 bar 560 bar 800 bar

Bursting pressure2)4) 2500 bar 3750 bar 5250 bar

Output signal 0.5V ... 4.5V, ratiometric (at 5 V supply)

Supply voltage Us5V ±0.25V

Maximum supply voltage 18V (maximum 1h)

Short circuit signal output to GND or supply voltage US,short = 0 … 18 V, (max. 8 h) in case of simultaneous supply of USwith US, short

Sensor output impedance Rdiﬀerntial at

0.1Us<Uout<0.9Us

typical: 5 Ω

maximum: 10 Ω

Current consumption

Typical at 5V supply voltage 12 mA

Maximum without load ≤15mA

Maximum at reverse connection 260 mA

Connector Bosch Compact 1.1a

Parts contacting measuring materials X5CrNiCuNb16-4

Housing material PBT-GF30/CrNi steel

Response time (10 ... 90 %) ≤1.0 ms

Overall accuracy ≤1.5%, refer to table "tolerance over temperature, pressure and life time"

Medium temperature range3) –40 °C ... +140°C

Ambient temperature range –40°C ... +100°C

Storage temperature range –30°C ... +60°C at 0 ... 80% relative humidity and 5 years

Transportation conditions, Conditions deviating from the storage conditions are allowed for the transport:

Duration, max. 48 h temperature –40 °C ... +80 °C

Relative humidity 0 % ... 80 %

Service life 10000 operating hours or 15 years

Diﬀerent values, depending on operational conditions on request

Pressure cycles over service life 10 million cycles

Shock resistance 50g (DIN EN 60068-2-27, 11ms), 500g (DIN EN 60068-2-27, 1ms)

Vibration resistance

Amplitude of the deﬂection s = 0.25 mm in the range 70 Hz ... 147 Hz

Amplitude of the acceleration a = 210 m/s2in the range 147 Hz ... 1350 Hz

a = 175 m/s2in the range 1350 Hz ... 2000 Hz

Frequency change 0.5 octave/min

Duration of excitation 100 h in each spatial direction with the same test specimen

Drop test

Controlled drop from 1 m height onto concrete in accordance with ISO 16750-3. One

drop event per axial direction. The component must then be fully functional or visually

damaged

CE conformity According to EMC directive 2014/30/EU (EN ISO 14982 and EN 13309)

E1 Type approval UN ECE 10 Rev4

Electromagnetic compatibility EMC ISO 11452-2, -4, -5 as well as according to IEC61000

BCI up ... 200 mA open and closed loop according ISO 11452-4 up ... 400 MHz.

Antenna > 150 V/m according ISO 11452-2 from 200 MHz - 3.2 GHz

Electrical protection Protection from voltage reversal, short circuits and undervoltage;

protection from overvoltage in the deﬁned supply voltage range

Type of protection with installed mating connector IP67 and IPX9K according to ISO 20653 (2006-08-15)

Weight approx. G 1/4: 48g, M14: 52 g

1) maximum 15 minutes at Pnto Pmax

2) maximum 15 minutes at Pnto Pberst

3) 150°C: 250h over live time

4) The speciﬁeld bursting pressure is valid for the device only.

This value does not include the mechanical interface - the thread between the sen-

sor and the hydraulic component

Bosch Rexroth AG, RE 95156/02.2017

4PR4 | BODAS Pressure sensor

Dimensions and labeling

ø18.75±0.2

12.55±2

4±0.5

11±0.3

19.9±0.7

M14×1.56g

ø18.75±0.2

12±0.3

19.9±0.7

G1/4 A

Date of production and

serial number not encoded

Customer wordmark

ACC: ZN 02110-A7/2

Data matrix code

according typ ECC200

according ISO/IEC 16022

CE-marking

Nominal pressure

Materialnumber

R9170XXXXX

Sensor with mechanical connection M14 × 1.5

according DIN EN ISO 6149-2

Sensor with mechanical connection G 1/4

according DIN EN ISO 1179-2

Wrench size 27

Data matrix code content

Content Digits Count

Start digit 1 1

Customer content material number R917010105 2-11 10

Year of production 12-13 2

Day of the year 14-16 3

Serial number 17-21 5

Number of production-line 22 1

Content Digits Count

Bosch plant number 23-25 3

Last 4 digits from Bosch part-number 26-30 5

Bosch change index 31-32 2

Bosch drawing index 33-35 3

Empty place for CD-free sensor 36 1

Connector Bosch Compact

Pin assignment Assembly example

321

1 Ground GND

2 Output

3 Supply voltage Us

1 Compact 1.1a

2 End clip

3 Cap straight

Mating connector 1)

Mating connector sets with the following content are

available under Rexroth part number R917009890 for the

manual assembly of wiring harness connectors for laboratory

or small-series requirements:

Designation Number Material number

Bosch Compact 1.1a Connector 1 1928403966

BDK Terminal Gold for 18-20 AWG,

0.5-1.0 mm2

3 1928498054

Bosch compact cap straight 1 1928300527

Single seal, BDK, blue, ROHS 3 1928300599

End clip 1 1928403423

1) The mating connectors are not included in the scope of supply.

These are available from Bosch Rexroth under the corresponding

material numbers.

RE 95156/02.2017, Bosch Rexroth AG

BODAS Pressure sensor | PR4

Wiring and error diagnostic of the sensor

Instruction for cable guide

≥10

≥R50

≤150

– 45°

135°

Required tooling2)

Designation Number Material number

Bosch crimping tool

for BDK 2.8 terminal

0.5, 0.75, 1.0 sq mm wire

1 1928498161

Bosch terminal extraction tool

for BDK 2.8 terminals

1 1928498167

Notes regarding assembly

In the assembly of the connectors, respect the assembly

instructions for plug connections (Y 928 P00 222) and

BDK2.8 contacts (1 928 F00 025).

These assembly instructions are available on request from

Rexroth.

Caution:

In the installation of the connector in the vehicle, observe

the following:

The ﬁxation of the cable harness must be done at a dis-

tance ≤ 150 mm after the outgoing cable unit at the same

vibration level of the sensor.

Electrical connection

▶ The device may only be installed by a trained electrician.

▶ The national and international speciﬁcations regarding

the installation of electro-technical systems must be

followed.

▶ Voltage supply according to SELV, PELV.

▶ De-energize the system.

Wiring and error diagnostic of the sensor

Recommended wiring of the sensor

The sensor is to be connected to the ECU according to the

following wiring diagram and provided with a supply volt-

age of 5 V.

▼ Sensor wiring in the ECU

Pin 3

Pin 2

Pin 1

Pressure sensor ECU

Signal

(UOUT)

+5 V (US)

A/D

converter

and μC

Pull up

resistance

GND

Supply voltage

Ground

The assignment of the connector pins of the high-pressure

sensor is depicted on previous page.

The pressure sensor delivers an analog output signal that

has a ratiometric relationship with the supply voltage.

Speciﬁcation of the pull-up resistor:

Quantity Symbol Value Unit

min typ max

Pull-up resistor

as per US

RPull-up 4.41 4.64 4.87 kΩ

In addition to this, a low-pass ﬁlter with a time constant of

maximum 0.7 ms is to be provided in the signal path.

The electrical output of the sensor is designed such that

malfunctions through cable breaks or short-circuits can be

detected with the wiring shown in the representation with

a pull-up resistor of 4.64 kΩ ±5 % against supply voltage.

2) The tools may be purchased from Bosch dealers or Bosch Service

(www.bosch-service.com)

Drawings and further information about Bosch connectors and

tools can be found on the internet: www.bosch-connectors.com

Bosch Rexroth AG, RE 95156/02.2017

6PR4 | BODAS Pressure sensor

Error diagnosis

Diagnostic ranges outside the operating range are provided

for the error diagnosis (also see characteristic on page 8).

Since the sensor characteristic of the upper operating

range is limited, overpressure conditions can be distin-

guished from errors.

The coding of the response to an error in the following

table is as follows:

0 = no error band and no reset

-1 = lower error band and no reset

-2 = lower error band and reset is triggered

Response of the sensor in case of error

Error description Debounce characteristics Error mode

Initialization, P and T not yet available ‒1

Indicates that OTP Bit for ﬁnal programming at Bosch of OTP Master is not set

(lock-bit not set)

error is set immediately,

no Reset is triggered

‒1

1) Power-on

complete RAM check (Read/Write)

beginning of continuous ROM check

2) Online

continuous ROM check

continuous RAM check

RAM/ROM checks DSP by Parity during each Access

HW-Check of SignalProcessor (Question/Answer)

signature monitoring of program counter

error is set immediately,

Reset is triggered

‒2

1) OTP CRC check of boot loading failed 4 times (consecutive)

2) Sum-check on trim data. Test carried out during boot loading and continuous cycle

1) error is set immediately,

Reset is triggered

2) error is set immediately,

Reset is triggered

‒2

Test on Aquisition Chain Pressure by injection of test signal before ADC on power-up

Thresholds are deﬁned during EoL programming at Bosch for each sensor individually

error is set immediately,

Reset is triggered

‒2

Decimation interval error (Only possible in case of severe hardware malfunction) no Reset, debouncing next frame ‒1

Pressure Sensor element failure (Wiring Detection) ‒2

1) Power-On

Common Mode at Power-On

2) Online

Common Mode

Current Modulation

1) error is set immeadiately,

Reset is triggered

2) Reset, debouncing next frame

Signal Input ADC too high, also for Sensor Element Error no Reset, debouncing next frame ‒1

Signal Input ADC too low, also for Sensor Element Error no Reset, debouncing next frame ‒1

Reference temperature input too high or low no Reset ‒1

Failure of internal temperatur sensor --> HW Defects of ADC_T or PTAT itself no Reset ‒1

Low Voltage Supply detection, programmable threshold no Reset, debouncing next frame ‒1

High Voltage Supply detection, programmable threshold no Reset, debouncing next frame ‒1

RE 95156/02.2017, Bosch Rexroth AG

BODAS Pressure sensor | PR4

Error diagnosis

Behavior after reset and initialization

In case of certain errors, a reset is triggered in the sensor.

These are then generated every 400 ms. After a reset, and

during the subsequent initialization of the sensor, the

output is pulled to ground. If the error is still present, the

output signal remains in the lower error band. In case, the

error is no longer present, the output signal controls its

value into the applicable operating range. The course of

the output signal and the related typical time at room

temperature, after the reset, are shown in diagram below.

▼ Representation of the time after reset and initialization

0 t1 t2 t3 t

Reset

Operating range

Power-

up Lower

error band

Typicals [ms] t1 t2 t3

CRC OK 0.03 0.9 1.1

CRC NOK 0.03 2.1 2.3

Behavior after undervoltage and overvoltage

In case of undervoltage < 4.75 V or overvoltage > 5.25 V

detection, the output is pulled to ground.

Bosch Rexroth AG, RE 95156/02.2017

8PR4 | BODAS Pressure sensor

Characteristics

Output voltage as function of the pressure

The signal output voltage is (up to the nominal pressure)

calculated from the actual pressure as follows:

UOUT = (c1×p+c0)×US

where

UOUT = Signal output voltage

US= Supply voltage (typ. 5 V)

p= Pressure [MPa]

c0= 0.1

c1= 0.8 : pn

pn= Nominal pressure [MPa]

0pn

0.96 US(4.8 V)

0.90 US(4.5 V)

0.10 US(0.5 V)

0.04 US(0.2 V)

Upper range for signal range check (SRC)

Lower range for signal range check (SRC)

Values for

US= 5 V

in brackets

Pressure p

Tolerance over temperature, pressure and life time

new condition / after life time

pnenn

pnenn/2

Temperature

−40 °C

1.10

% / 1.50

0.90

% / 1.30

0.70

% / 1.10

−0 °C

0.70

% / 1.20

0.60

% / 1.10

0.50

% / 1.00

100 °C

0.70

% / 1.20

0.60

% / 1.10

0.50

% / 1.00

140 °C

1.10

% / 1.50

0.90

% / 1.30

0.70

% / 1.10

Pressure

The tolerance for the pressure measurement is given in

%FS= "full scale". FS denotes the sensor nominal pressure

pnenn or the usable range. The relative tolerance is depen-

dent on the pressure and temperature, and increases over

the service lifetime. Here, the service lifetime encompasses

the entire lifetime. The tolerances for new parts are statisti-

cally observed with 3s per manufacturing batch. Delivery of

100 % sorted products is permitted. After lifetime the toler-

ance for new parts can broaden to the values given in the

diagram. Here the given tolerances also represent the 3s

limit.

RE 95156/02.2017, Bosch Rexroth AG

BODAS Pressure sensor | PR4

Installation instructions

Mounting

Mounting process of sensor must be ensured by customer

by adequate validation.

Rexroth recommends to wet the surface of thread and

tightening plane of pressure sensor completely with Oil or

Molykote WI5 prior to mounting.

To prevent accumulation of lubricant in the pressure port

application of lubricant by spraying while pressure port

facing downwards is recommended.

Recommended position α = ±0 ... 90° in all direction from

vertical position.

Tightening only permitted with hexagonal socket wrench or

with box wrench α >90°.

Vector of gravity

Mechanical connection

▶ Before installing and removing the device, make certain

that the system is not pressurized.

Tightening torque

Before mounting the PR4 pressure sensor, check the speci-

ﬁeld tightening torque of the hydraulic pump, motor or valve

block.

If the torque for mounting the sensor in the respective

hydraulic component is not speciﬁeld use a torque of

35±5Nm.

Do not exceed the maximum tightening torque of: 45 Nm.

Operating conditions - temperatures

The sensor is designed for use in hydraulic components

(direct motor attachment) and the corresponding ambient

temperatures with a typical temperature distribution:

Temperature

‒40 °C 6 %

23 °C 20 %

85 °C 65 %

135 °C 8 %

140 °C 1 %

Storage conditions

The pressure sensor is to be stored under the following

conditions:

Temperature range ‒30 °C ... +60 °C

Rel. humidity 0 ... 80 % r. h.

Maximum storage duration after the delivery

by the Bosch production plant

5 years

The sensor has to be kept under dry and dust-free storage

conditions. It is important to ensure that there is no con-

tamination due to liquid or solid media in the connector

area or on the threaded ﬁtting. Sulfurous atmospheres have

to be avoided for silver-plated connector pins.

These storage conditions do not lead to any change in the

properties and the functioning of the high-pressure sensor.

After the maximum storage duration is exceeded, the sen-

sors must be sent back to Bosch Rexroth AG for inspection

or testing.

Transportation conditions

Conditions deviating from the storage conditions are

allowed for the transport:

Duration max. 48 h

Temperature ‒40 °C ... +80 °C

Relative humidity 0 % ... 80 %

Bosch Rexroth AG, RE 95156/02.2017

10 PR4 | BODAS Pressure sensor

Manufacturer conﬁrmation of PR4 MTTFd-values

The MTTFd-values were determined in accordance with ISO 13849-1:2008-12, Appendix D, Parts Count Method, and the

speciﬁed temperature proﬁles below.

Ambient temperature

Control unit [°C]

Self-heating

[°C]

Temperature proﬁle, Operating time share [%]

1234567

10 10 100 0 0 0 0 0 0

20 10 0 100 0 0 0 0 0

30 10 0 0 100 0 0 0 0

40 10 0 0 0 100 0 0 0

50 10 0 0 0 0 100 0 0

60 10 0 0 0 0 0 100 0

70 10 0 0 0 0 0 0 100

80 10 0000000

90 10 0000000

100 10 0 0 0 0 0 0 0

110 10 0 0 0 0 0 0 0

120 10 0 0 0 0 0 0 0

130 10 0 0 0 0 0 0 0

140 10 0 0 0 0 0 0 0

MTTFd-value [years] with 4h use per day 594 592 589 585 578 569 556

8h use per day 371 370 368 365 361 356 347

16h use per day 212 212 211 209 207 203 199

24h use per day 149 148 147 146 145 142 139

MTTFd-value of the printed circuit board 15712 11362 8117 5738 4010 2767 1881

Ambient temperature

Control unit [°C]

Self-heating

[°C]

Temperature proﬁle, Operating time share [%]

8 9 10 11 12 13 14 15

-40 10 00000006

10 10 00000000

20 10 00000000

23 10 000000020

30 10 00000000

40 10 00000000

50 10 00000000

60 10 00000000

70 10 00000000

80 10 100 0 0 0 0 0 0 0

85 10 000000065

90 10 0 100 0 0 0 0 0 0

100 10 0 0 100 0 0 0 0 0

110 10 0 0 0 100 0 0 0 0

120 10 0 0 0 0 100 0 0 0

130 10 0 0 0 0 0 100 0 0

135 10 00000008

140 10 0 0 0 0 0 0 100 1

MTTFd-value [years] with 4h use per day 536 508 468 416 351 280 209 486

8h use per day 335 317 293 260 220 175 131 304

16h use per day 192 182 167 149 126 100 75 174

24h use per day 134 127 117 104 88 70 52 122

MTTFd-value of the printed circuit board 1258 826 534 339 212 131 80 641

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