Electric Drives

and Controls

Hydraulics

Linear Motion and

Assembly Technologies

Pneumatics

LLC Load Limiting Control

Application Software

Service

RE 95 310/01.09
replaces: 03.06

Data sheet

Version 10 (LLCB) and Version 30 (LLCA)

Electronic load limiting control for
power management in hydraulic systems
Features

Inhalt
Type code

Variant LLCA
Parameterization and diagnostics
Required components
LLCA connection diagram (without CAN bus)
LLCA connection diagram (with CAN bus)

2
6
6
7
8

Variant LLCB
Functional description
Parameterization and diagnostics
LLCB connection diagram
Required components

9
9
10
11
12

Safety instructions

12

The electronic load limiting control LLC is an easy-to-customize software system for managing power in hydraulic systems.
The load limiting control LLC always matches the power input
of an adjustable axial piston pump with the available power
from the internal combustion engine.
It prevents overloading of the internal combustion engine.
The axial piston pump converts the maximum available power
at all times.
Two variants of the load limiting control LLC are available: Variant A "Universal software" and variant B "Slew drive mode" for
controlling a slew drive irrespective of the diesel engine speed.
The load limiting control LLC is designed for axial piston pump
from Rexroth.
Adjustable parameters enable the user to easily customize the
software for different configurations of pumps, internal combustion engines, sensors and machines.
The load limiting control LLC is suitable for diesel engines with
or without a CAN-bus interface, protocol SAE J1939.
Diagnostics and parameterization are performed with the
BODAS service PC software.

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Bosch Rexroth AG

LLC Load Limiting Control

RE 95310/01.09

Type code
AS/

LLC

01

02

10
03

04

Type
01 Application software

AS/

Software
02 Load Limiting Control

LLC

Variante A
Load limiting control for two pumps
03
Option: CAN bus, Option: Constant speed control

Variante B
Load limiting control for one pump, Option: Slew drive
03
Option: Power mode (switchable diesel power and speed drop)

04

Version
LLCB

10

LLCA

30

Ordering information
The AS/LLC application software must only be used with the RC2-2/20 controller (variant B) or RC2-2/21 controller (variant A)
and other add-on components (see page 11). When placing an order, the hardware and software type codes should be linked with
a "+".
Example: RC2-2/21+AS/LLCA30

Variant LLCA

With positive ID, the hydraulic system includes one or two

A10VO variable displacement pumps with an FHD pump
controller.

With the LLCA electronic load limiting control, it is possible to

design the size of the diesel engine in the hydraulic system for
the average power requirement and to reduce the power input
of the individual consumers (pumps) in the event of an overload. Thus, the load limiting control ensures optimum use of
power from the diesel engine with varying loads.

The total installed pump powers exceeds the diesel engine

power.

The electronic load limiting control supports different hydraulic

concepts and different diesel engine configurations. These
concepts can be used in any combination.

A third, uncontrolled pump can be used with both hydraulic

concepts. This pump has priority in the system. As a result, it
receives the power it requires with no reduction. Whatever power remains available is then divided between pumps 1 and 2.

The electronic load limiting control is designed for controlling

variable displacement pumps in an open hydraulic circuit.
A distinction is made between the following hydraulic concepts
for the purpose of control:
With negative ID, the hydraulic system includes one or two
A11VO variable displacement pumps or variable double
pumps A8VO or A20VO, each with hydraulic power and load
limiting controllers (LG1, LE, LA1).
Each pump is set to 100 % of the available diesel power.
The controller controls the pump controller (LE) and/or the
pressure reduction valves (DRE) directly; the latter turn
down the setting on the pump power controller (LG1, LA1)
by means of an increased pilot pressure.

The controller controls the pressure reduction valves (DRE)

which in turn override the pilot pressures of the pumps,
thereby reducing the flow rate.

Two different diesel engine configurations can be used:

In the case of diesel engines without a CAN-bus interface, the controller receives the diesel engine's specified
speed from an angle sensor (accelerator pedal position as
specified speed) or from a fixed speed value set in the controller. The actual speed is measured using a speed sensor
on the starter gear rim.
In the case of diesel engines with a CAN-bus interface,
the controller receives the necessary data for the load limiting control (specified and actual speed and/or torque and
engine temperature) directly via the CAN bus.
It is also possible to use a combination of analog sensors
and CAN-bus data.

RE 95310/01.09

Bosch Rexroth AG

LLC Load Limiting Control

Variant LLCA
RC2-2/21 controller
with LLCA software
Error
lamp
BODAS service
PC software

Speed sensor

Angle
sensor
Diesel engine without
CAN interface

Pumps
A8VOLA1 or
A11VOLG1 / LE or
A20VOLG1 / LE or
A10VOFHD

Optional
third pump

Figure 1: Typical configuration for LLCA without CAN-bus interface

CAN-bus interface
RC2-2/21 controller
with LLCA software

Error
lamp

Optional
third pump on
power take-off

Diesel engine with

CAN interface

Pumps
A8VOLA1 or
A11VOLG1 / LE or
A20VOLG1 / LE or
A10VOFHD

Figure 2: Typical configuration for LLCA with CAN-bus interface

BODAS service
PC software

3/12

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Bosch Rexroth AG

LLC Load Limiting Control

RE 95310/01.09

Variant LLCA
Safety switch
Actual speed

Specified
speed

Calculation
Speed drop

Evaluation
Speed drop

Load limiting
controller

Pump
power
sharing

Pump 1
Pump 2

Power
mode 2/3
Temperature
Ext. power
limiting
Power
sharing 1
Power
sharing 2
Limp home mode
activated

Figure 3: How the LLCA load limiting control works

Functional description
Figure 3 illustrates how the load limiting control works:
The load limiting control calculates the current speed drop
of the diesel engine from the speed setting and the diesel
characteristic depending on the set power mode.
The power modes are used to switch between three different
permissible hydraulic powers. The switch is performed using
switches which are connected to the controller.
In the case of diesel engines with a CAN interface, torque
can alternatively be used for control purposes.
The load limiting control compares the current speed drop
with the parameterizable limit values. Different limit values
can be parameterized for different specified speeds.
In case of diesel engines with a CAN interface, the
temperature of the diesel engine can also be taken into
account in this evaluation. As soon as the temperature value
passes out of a parameterizable range, the limit value for the
drop in engine speed is further reduced.
By externally specifying the reduction in power, the maximum
power can be further limited. This is specified by means of a
limit potentiometer connected to the controller.

As long as the total of the hydraulic powers does not exceed

the installed diesel power, the speed drop will not exceed
the parameterized limit values. The load limiting control will
not intervene.
If, however, the diesel engine speed drop exceeds the limit
value, the load limiting control will intervene and reduce the
pump power.
The controller will calculate the available pump power as a
control value.
The pump power distributor shares the pump power determined by the controller among the connected pumps.
The percentages used for sharing the available power
between the connected pumps can be parameterized.
A switch on the controller also allows the operator to switch
between two different distribution patterns.
Instead of pump 2, a valve can also be connected and
parameterized for limp home mode or for precision mode.

RE 95310/01.09

Bosch Rexroth AG

LLC Load Limiting Control

5/12

Variant LLCA
Important features

Important parameters

The ratio in which the power reduction is distributed between pump 1 and pump 2 in the event of a limit load can be
set as a parameter. Depending on the parameter setting, the
power reduction may be distributed evenly between the two
pumps, or the division may be asymmetrical.

For a diesel engine with a CAN-bus interface:

A second distribution value of the power reduction can be

set as an optional additional parameter. An external switch
can then be used to switch between the two methods
(power sharing mode switch).
The total maximum permitted pump power can be reduced
using an external potentiometer.
An additional temperature mode is possible if a diesel engine
with a CAN-bus interface is used. If the temperature passes
above or below the limits set as parameters, power is reduced to a user-definable level.
Power modes: Switches between three different permissible
hydraulic powers. These arise from the permissible speed
drops that are specified differently for each power mode.
Precision mode: A valve is controlled depending on the position of a dial potentiometer. The drop in LS pressure caused
by the valve can be used to slow operating functions, e.g. for
precision work.
Automatic speed reduction: If no operating function is
requested for a longer period of time, the diesel engine
switches to idle mode to reduce fuel consumption. For this
purpose, a pressure switch (normally closed contact) must
be installed in an appropriate location. At low LS pressure,
the pressure switch closes, signaling to the controller that
automatic speed reduction is requested.
If a diesel engine with a CAN-bus interface is used, the present output currents from pump 1 and pump 2 are sent via the
CAN bus every 100 ms. This includes the power sharing set
externally with a potentiometer and, if relevant, error messages.
The second proportional solenoid output can be used for
limp home mode or for controlling a valve for the fine mode
(parameterizable). Under normal circumstances this output
produces a constant 100 %; this value falls to 0 % in the
event of an error. Thus, the pumps can be switched by an
external valve to an operating mode that enables the device
to be run with no electronics.
The inputs and outputs of the controller are monitored (for
cable break, short-circuit). In the event of an error or if the
safety switch is actuated, the drive is stopped immediately.
All of the above errors as well as errors in the CAN communication with the diesel engine and excessively high or low
engine temperature can be indicated by a flashing code on a
connected error lamp.
All errors that occur are stored in the controller and can also
be read later in plain text form using BODAS service.

Diesel engine data (specified speed and actual speed via

CAN bus, specified torque and actual torque via CAN bus,
dynamic behavior, permissible speed drop)
CAN bus (baud rate, controller addresses, signal priorities)
Configuration (number of pumps and limp home mode,
power sharing, hydraulic concept, specified-speed source)
Minimum and maximum magnetic current for pumps 1 and 2
Load limiting control (dynamic controller data)
Function (minimum/maximum temperatures, power reduction)
For a diesel engine without a CAN-bus interface:
Diesel engine data (actual speed from sensor, number of
teeth on flywheel, dynamic behavior, permissible speed drop)
Potentiometer for specified speed and power sharing
Configuration (number of pumps and limp home mode,
power sharing, hydraulic concept, specified speed source)
Minimum and maximum magnetic current for pumps 1 and 2
Load limiting control (dynamic controller data)

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Bosch Rexroth AG

LLC Load Limiting Control

RE 95310/01.09

Variant LLCA
LLCA connection diagram (without CAN bus)
1 A 3)
13

42
6)

31

Speed sensor
(optional)
LS pressure
(optional)

27
1

Power supply for the

power outputs

2
28
33
32
44
43
18
17
22
7

Sensor supply5)
2 x 5 V/30 mA

Voltage
inputs

36
35
38
47
46
49

34

45

Current
inputs

External specification
of power reduction or
specification for
precision mode
(optional)
Angle position
sensor on
accelerator pedal
or injection linkage
(optional)

Switched outputs

10 A
+12 V/+24 V 30
+

Voltage supply for

the electronics

Teaching set speeds (optional)

37

Power sharing mode (optional)

48

Power mode 2 (optional)

10

Power mode 2 (optional)

11

2)

29
2)
15
2)

Temperature inputs

Main pump 2,
valve control for
limp home mode
or valve control for
precision mode
(optional)

Error
lamp
Signal lamp for
automatic speed
reduction

Diagnostics connector
for BODAS service
C
D
B
E
A
H

Reserved 52

Switch inputs

21

30

51
TxD
50
RS-232
24
RxD

Main pump 1
2)

5V
constant voltage

20

31

Proportional outputs

41

Low-side
measurement
input

3A
30 15

Frequency inputs

Ignition lock7)

1)Short,

Ground
connection,
case
1)

low-resistance connection from a case screw to the device ground or vehicle ground
ground connection from solenoid return line to battery (chassis possible)
3)Separate fuses recommended for switches, sensors and electronics
5)Sensor supply voltage for potentiometers and active sensors
6)Observe maximum current consumption where proportional solenoids and switched outputs are controlled simultaneously
7)Can be used as switch inputs if connected externally to GND
2)Separate

Figure 4: Inputs and outputs on the controller (variant LLCA, configuration without CAN-bus interface)

RE 95310/01.09

Bosch Rexroth AG

LLC Load Limiting Control

Variant LLCA
LLCA connection diagram (with CAN bus)
1 A 3)
13
41

30 15

42
10 A

6)

+12 V/+24 V 30
+
-

31

Speed sensor
(optional)
LS pressure
(optional)

27
1

Voltage supply for

the electronics
Power supply for the
power outputs

2
28
33
32
44
43
18
17

31

Proportional outputs

3A

Frequency inputs

Ignition lock7)

Main pump 1
2)

30
2)

34

45

5V
constant voltage

21

Temperature inputs

48

Power mode 2 (optional)

10

Power mode 2 (optional)

11

Switch inputs

37

Power sharing mode (optional)

15
2)

1)Short,

Error
lamp
Signal lamp for
automatic speed
reduction

Diagnostics connector
for BODAS service
C
D
B
E
A
H
G
F

Reserved 52
CAN H
40
26
120 Ohm 25 4 )
39
CAN L

Teaching set speeds (optional)

2)

51
TxD
50
RS-232
24
RxD

20

29

Low-side
measurement
input

36
35
38
47
46
49

Voltage
inputs

Sensor supply5)
2 x 5 V/30 mA

Current
inputs

External specification
of power reduction or
specification for
precision mode
(optional)
Angle position
sensor on
accelerator pedal
or injection linkage
(optional)

Switched outputs

22
7

Main pump 2,
valve control for
limp home mode
or valve control for
precision mode
(optional)

Ground
connection,
case
1)

low-resistance connection from a case screw to the device ground or vehicle ground
ground connection from solenoid return line to battery (chassis possible)
3)Separate fuses recommended for switches, sensors and electronics
4)CAN bus: 120 termination resistor recommended
5)Sensor supply voltage for potentiometers and active sensors
6)Observe maximum current consumption where proportional solenoids and switched outputs are controlled simultaneously
7)Can be used as switch inputs if connected externally to GND
2)Separate

Figure 5: Inputs and outputs on the controller (variant LLCA, configuration with CAN-bus interface)

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Bosch Rexroth AG

LLC Load Limiting Control

RE 95310/01.09

Variant LLCB
The LLCB electronic load limiting control functions in basically
the same way as the LLCA variant, but is designed to control
only one pump instead of two.
In addition, the valve for the slew drive is controlled in such a
way that the flow rate for the slew drive motor is maintained
irrespective of the diesel engine speed. As a result, the slew
drive always turns at the same speed regardless of the speed
at which the diesel engine is running.

Functional description
The diagram below illustrates how the load limiting control
works:
From the specified speed value and the diesel characteristic,
the load limiting control calculates the current speed drop of
the diesel engine.
The load limiting control compares the current speed drop
with the parameterizable limit values. Different limit values
can be parameterized for different specified speeds.

The electronic load limiting control is designed for controlling

variable displacement pumps in an open hydraulic circuit.
The following hydraulic concept can be used for control purposes:
The hydraulic system consists of the axial piston pumps
A8VO or A11VO with a hydraulic or electrohydraulic power
controller and load limiting controller (LA1, LG1, LE) together
with a control block (e.g. M7) with a pressure reduction valve
(DRE) on the slew drive spool.
The RC2-2/20 controller controls the pump controller and
the pressure reduction valve in the control block.

As long as the total of the hydraulic powers does not exceed

the installed diesel power, the speed drop will not exceed
the parameterized limit values. The load limiting control will
not intervene.
If, however, the diesel engine speed drop exceeds the limit
value, the load limiting controller will intervene and reduce
the pump power.
The maximum permissible speed drop of the diesel engine
can be adjusted in three steps using the "power mode"
switches.

The following diesel engine configuration can be used:

Diesel engine with or without CAN-bus interface
The controller receives the specified speed for the diesel
engine from an angle sensor (accelerator pedal position as
specified speed). The actual speed is measured using a
speed sensor on the starter gear rim.
The LLCB variant does not evaluate the CAN bus.

RC2-20 controller
with LLCA software
Error
lamp
BODAS service
PC software

Speed sensor

Slew drive
shaft in
control block
M7
Slew drive
GFB

Angle
sensor
Diesel engine with
or without CAN-bus
interface

Figure 6: Configuration for LLCB

Pumps
A8VO... LA1..F.4 or
A11VO...LE / LG1

RE 95310/01.09

Bosch Rexroth AG

LLC Load Limiting Control

9/12

Variant LLCB
Safety switch

Teach

Specified
speed

Diesel
characteristic

Calculation
Speed drop

Power mode 2/3

Actual speed
Maximum
power

Figure 7: How the LLCB load limiting control works

Important features
The maximum flow rate of the slew drive motor can be
set using a characteristic irrespective of the diesel engine
speed.
Power modes: Switches between three different permissible
hydraulic powers. These arise from the permissible speed
drops that are specified differently for each power mode.
Maximum power mode: A switched input, "Maximum Power",
can be used to switch between reduced hydraulic handling
power and maximum working power.
The definition of the ratio of specified speed to actual speed
can be executed in "Teach Mode" without BODAS service.
All errors that occur are stored in the controller and can also
be read later in plain text form using BODAS service.

Important parameters
Diesel engine data (number of teeth on the starter gear rim,
dynamic behavior, permissible speed drop)
Potentiometer for specified speed
Minimum and maximum magnetic current for working hydraulic pump and slew drive valve
Load limiting control (dynamic controller data)

Characteristic
Slew drive

Slew drive
shaft in
control block

Load limiting
control

Working
pump

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Bosch Rexroth AG

LLC Load Limiting Control

RE 95310/01.09

Variant LLCB
LLCB connection diagram

Ignition lock
with starter
non-repeat
unit

1 A 3)

Power supply

41
42

8A
12V/
24 V
0V

1
27

Supply of the power

outputs

2
28

Speed sensor

33
32
31
30

2)

Angle position
sensor on
accelerator pedal or
injection linkage

47

+5 V / 15 mA

46
49

Error detection for

potentiometers 1K-5K

2)

+L

Working pump

Control block slew drive shaft

29

Error lamp
2)

Diagnostics connector
for BODAS serivce
TxD 51
RS232 RxD 50
17

Teach
Maximum power

37

Power mode 2
Power mode 3

10

C
D
B
E
A
G
F
H

52

48

11

1)

1) Short,

low-resistance connection from the plug connector and one housing screw to the device ground

2) Separate

ground connection from the solenoid return line to the battery (chassis also possible)

3) Separate

fuses for switches and sensors

Figure 8: Inputs and outputs on the controller (variant LLCB)

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Bosch Rexroth AG

Required components
The following electronic components are required:
BODAS RC2-2/21 controller with 52-pin mating connector
(RE95201) and AS/LLCA software, Version 30
BODAS RC2-2/20 controller with 52-pin mating connector
(RE95200) and AS/LLCB software, Version 10

LLC Load Limiting Control

RE 95310/01.09

Parameterization and
diagnostics
The parameters that need to be assigned for commissioning
the LLC load limiting control can be set easily using the
BODAS service PC software.

Speed sensor IDR (RE95130) with mating connector for

diesel engine without a CAN bus
Angle sensor WS1 (RE95140) with mating connector for
diesel engine without a CAN bus
The following hydraulic components are required:
Variable displacement pump with appropriate controller
A8VOLA1 (RE 93010) or
A11VOLG1 or LE (RE 92500) or
A20VOLG1 or LE (RE 93100) or
A10VOFHD (RE 92701)
Possibly a mating connector, depending on the connector
variant selected for the pump
For A11VOLG1, A20VOLG1 and A10VOFHD separate DRE4K pressure control valves (RE29181) with mating
connector and control oil pump
Possibly an additional valve and mating connector for limp
home mode (e.g. DRE4K...)
The following items are required for commissioning and service:
BODAS service PC software (RE95086)
BODAS service connecting cable (RE95086)
Diagnostics socket (RE95086)

You can configure BODAS serivce to display the most important process data and the error messages for diagnostics and
troubleshooting purposes.

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Bosch Rexroth AG

LLC Load Limiting Control

RE 95 310/03.06

Safety instructions
The suggested circuits do not imply any technical liability for
the system on the part of Rexroth.
Lines to speed sensors must be shielded. The shielding is
to be connected to the electronics on one side or to the
machine or vehicle ground via a low-resistance connection.
Lines to the electronics must not be routed close to other
power conducting lines in the machine or vehicle.
Sufficient distance from radio systems must be maintained.
All connectors must be unplugged from the electronics during electrical welding operations.
The electronics may only be tested with the proportional
solenoids connected.
The proportional solenoids must not be connected to spark
suppression diodes.
On/off solenoids at the outputs of the controller RC do not
need to be connected to spark suppression diodes.
Other inductive loads that are in the system but not connected to the controller RC must be connected to spark
suppression diodes.
In order to preserve the warranty, any installation or replacement of the RC software (flash EPROM) must be performed
by Rexroth staff.
Observe operating instructions RE 95310-01-B for the LLCA
variant and RE 95311-B for the LLCB variant.

Bosch Rexroth AG
Hydraulics
Mobile Electronics
Glockeraustrae 4
89275 Elchingen, Germany
Phone +49 (0) 73 08 82-0
Fax
+49 (0) 73 08 72 74
info.brm-me@boschrexroth.de
www.boschrexroth.com/mobile-electronics

This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth AG. Without their consent
it may not be reproduced or given to third parties.
The data specified above only serve to describe the product. No statements
concerning a certain condition or suitability for a certain application can be
derived from our information. The given information does not release the user
from the obligation of own judgement and verification. It must be remembered
that our products are subject to a natural process of wear and aging.
Subject to change.