Catalogue

Aplicações industriais Aplicaciones industriales Industrial applications

Motores Elétricos Motores Eléctricos Electric Motors

2010 | 2011

pt

es

en

Motores Elétricos Bosch - A melhor escolha.

Motores Eléctricos Bosch - La mejor elección.

Electric Motors Bosch – The best choice.

A Bosch, líder mundial em desenvolvimento de auto peças, é sinônimo de produtos Elétricos, por exemplo, sua versatilidade industriais, permite que ela se adapte ! de motores de corrente contínua, ventiladores "# $ %! & $ " ' !(

) $ !'

Bosch, líder mundial en desarrollo y es uno de

* de auto partes, es sinónimo de productos # Eléctricos, por ejemplo, su versatilidad como proveedora de las más diversas divisiones industriales permite que ella se adapte + & - - total a la aplicación de motores de corriente

- .# $ % $ "' /( de aplicaciones y adaptabilidad superior a los * - * 0)* '

-

Bosch, worldwide leader in development, -- 1# 2

-

3 - -43 - and total support to direct current motors, 3 % # 3 35- '

3 (- 3

- - % - ' -

pt

es

Conteúdo

en

Contenido

Content

Informações / Informaciones / Information

A5

Garantia de qualidade mundial Bosch #' ! 6

A11

Explicación de los parámetros

A17

Parameter explanation

A23

+

* #' industriais

A4

A83

Garantía de calidad mundial Bosch

Bosch worldwide quality warranty

+

Ejemplos de aplicaciones industriales

73 #' applications

Características técnicas dos motores / Características técnicas de los motores / Engines technical features B24

)89(:9;

B28

9! corpos estranhos kzIH

9!

>

9! *

[S

9 poeira

9!

>S

9! * !

|S

Lacrado contra poeira

9!

5

9! 0 *

6

9! 0 *

|S

9! 0 * !

7

9!

!*

]

9!

! !

_S

9!

!(

) %

9! contato com

FHIH J FHII

#' ! 6 | A7

Classes de funcionamento

T . #+ 9 elétricos Bosch nunca precisam levar o & +#

3. Instruções EMC # * $ # também se aplicam a componentes complexos tais como motores elétricos, mas somente se eles estiverem livremente disponíveis ? " $

* ! '

: 0 ? ! !

FHIH J FHII

#' ! 6 | A9

Motores com sensor Hall

Efeito Hall Circuito.

Características das curvas.

B +

+

1kΩ

+

Induction B

Efeito Hall. d Espessura do chip

+ + + +

d

-

UV

-

t

0

t

-

0

UH

R UA

Output voltage UA

-

IS

2 I2 passa através de um chip, !7

UH$ ! " ! $ $ % (perpendicular a corrente I2U I2) !7

UH$ !^

UH = RHY

I2YB

27

1+ Hall sensor IC

d

"RH é a constante de Hall

! 7

& o circuito para o processamento do sinal é

#$ 7

M1+T U A saída é um transistor com coletor aberto, ! !$ + '

* $ $ 7

'

M" & T U !T U

FHIH J FHII

) %

A10 | #' ! 6

Aplicação do efeito hall em motores de corrente continua (CC)

Ajuste básico em motor com ímãs de anel de 2 pólos.

Sinais de saída, 1 rotação do induzido.

) $ ! & $& ? !

UA1

H1

N

+ ' 7

6 D entre eles, pode se

α

$ !

UA2

S

H2 0

Ajuste básico em motor com ímãs de anel de 8 pólos.

α

Sinais de saída, 1 rotação do induzido.

1

S

360

3

4

UA1

H1

N

2

1

2

3

4

α UA2

H2 0 α

Ajuste Básico no Motor

Sinais de Saída

HI, HF 2 D

U)I

27

9/ 9/ 2 sensores Hall

U)F D M

) %

360 360 + α

|-_ ZU + #0 ^19I|S% protección contra la penetración de ' N/ * - [H / / protección contra el contacto con los

Explicación del código IP Iº? y letra suplementaria S

Protección de equipos contra penetración de ' N

Personal

Fº? y letra suplementaria S

Protección del equipo contra penetración de

Letra T U

Protección del Letra personal contra T U el contacto con

H

H

A

I

Protección contra ' N kz[H

Protección contra I toque con el dorso dela mano

F

Protección contra ' N kzIF[

Protección contra F toque con los dedos

3

Protección contra ' N kzF[

Protección contra 3 toques com herramientas

Protección B verticalmente Protección + inclinación de I[f Protección D contra spray de

Protección contra contacto con el dorso de la mano Protección 2 contra contacto con los dedos Protección contra contacto con herramientas

>

Protección contra ' N kzIH

Protección contra > toques por alambres

Protección N

[S

9 polvo

Protección contra >S toques por alambres

Protección 0 presión

|S

2

polvo

Protección contra 5 toques por alambres

Protección contra chorros

6

Protección contra chorros

|S

Protección contra chorros presión Protección contra inmersión rápida

7

) %

]

Protección contra inmersión /

_S

Protección /( vapor

8 de partes Parada de partes

Protección contra contacto con herramientas

FHIH J FHII

Explicación de los parámetros | A13

Clases de fucionamiento Servicio continuo S 1 " / /

$ Medidas para las curvas PI potencia de entrada PV potencia de pérdida temperatura temperatura máxima max tB tr / T 0U t2 t2

/

T / 0 Los puntos de intersección de esta línea recta con las otras curvas se obtendrán como resultado los datos de operación: velocidad nominal n, corriente nominal I, potencia de salida PF- K La curva de rendimiento K orienta la aplicación de los motores cuya aplicación / - condiciones de ventilación limitadas, en estos casos, se recomienda el uso de motores de 0 / Para el caso de motores de dos velocidades, las curvas de líneas continuas representan la primera velocidad y las entrecortadas / características )9 9 M 5 n Velocidad PF Potencia de salida I + K # Ejemplo: Dato:

M>

n>] PFIX Encontrado: I = 3 A KF>

Símbolo

y declaración del fabricante con respecto a las instrucciones EC

8 #+ & +# N máquinas, dispositivos y sistemas eléctricos - Q /# . #+ - individuales relevantes para usuarios de

2. Instrucciones para bajo voltaje Estas instrucciones deben aplicarse a todos los motores eléctricos de voltaje nominal límite de [ ' 5 3 the other curves results in the operation data: the nominal speed n, nominal current I, output power PF -K Yield curve K

3 demands load duration and limited ventilation @3 - 1 FM

C curves: )9 XC M 5 n 2 PF "3 I + K # - Example: Given: M> n>] PFIX :^ I = 3 A KF>

symbol and manufacturer’s declaration as per EC directive 1 3 #+ +# symbol must be attached to all electrically driven machinery, devices, and systems 3 # Q 5#+

3

2. Low-voltage directive 5

[

Desenho dimensional 8 N 8 3

5

U

5! 5 /

P

9K Potencia nominal 3

n

= ! = /

I

+ 1

MA

5 Par de arranque % C 3 -

I F

3

>

5 6

8 ! !^ 8 T=U # T.U 2 ^ Rot. 8T=U 1 T.U 8 ^ .T.U= T=U

S

+ + 5--

IP

; ! Grado de protección 8

kg

Peso X Peso ? = Part number

FHIH J FHII

7

6

+ & + & +

7

Esquema elétrico Esquema eléctrico #

) %() %(%) ) C

B24 | Bosch

ADP 18 V 23 W

P2 W

U

I]
HZH_[

1 2 3

S

6 5 4

60

27, 2

4,6

VMC U

24 V 0,26 W

P2 W

F>
H

C

HIFHC

20

0

0

0

0 132 801 143

0

25

29 4

19,25

6

3

4

5

6

45,2

2

S 2 +(+Î_F]>HZH_[

FHIH J FHII

65,5

4,6

36

33,5

11

72

1

75

63,5 47

1,5

M

50 N.cm

14,4

1 2 3 6 5 4

S

27, 2

60

4,6

) %() %(%) ) C

VMC

B30 | Bosch

VMC 12 V 0,16 W

U

IF
[

1

I[H)

160 200

4

Z[

120 150

3

=

.(= 80 100

2

2

2I

19

19[H

40

50

1

C

HH_HC 0

0

0

n

Up = 12 V

P2

I

0 132 801 346

0

30

60 N.cm

90

120

47

27 6,6

11 R

10 ,

72 46,25 R 12 ,5

54,5

62

36

5

90

7,4

4,6

14,5

+5-(+5-ÎZ[[H]FMI

25

27,5

56

6

57

VMC U

IF
[

1

I[H)

160 200

4

Z[

120 150

3

=

.(= 80 100

2

2

2I

19

19[H

40

50

1

C

HH_HC

I n mA rpm

0

0

0

n

Up = 12 V

P2

I

0 132 801 351

0

30

60 N.cm

27 11

90

120

47 6,6

R

10 ,

72 46,25 R 12 ,5

54,5

36

5

62

VMC

12 V 0,16 W

90

7,4 14,5 +5-(+5-ÎZ[[H]FMI

123

56

) %() %(%) ) C

27,5

4,6

25

6

57

FHIH J FHII

Bosch | B31

MH 24 V 1,6 kW

U

F>
U

n

F|[H

1

IFH)

n rpm 3000

M lbft 60

P HP 6

S2 min 15

S3 % 30

U V 30

Eff % 75

2400

48

4.8

12

24

24

60

1800

36

3.6

9

18

18

U S3

=

45

P M

L 2F

2Z

2

>[

I>]

19

19>>

1200

24

2.4

6

12

12

600

12

1.2

3

6

6

30

n

15

S2 0

0

0

0

0

0 0

F 000 MM0 003

80

160

240

320

400

480

560

640

I A 0 720

181,9 ± 1 152,4 42,9

16

5/16"-24 UNF-2A

M

Ø 24,8 max.

Ø 114 + 1,5

87 ± 1

39,66

A

A

Rolamento 6202-ZZ Rodamiento 6202-ZZ

5/16"

Rolling Bearing 6202-ZZ

4 (3x)

B

B

5 (3x)

Furo de dreno Orificio de dreno

89,4

Drain hole

MH 12 V 1,3 kW

U

IF
U

n

FF|H

S3 % 28.0

S2 min 14.0

P HP 5.6

M n rpm lbft 28.0 5600

U V 14

24.0

12.0

4.8

24.0 4800

12

20.0

10.0

4.0

20.0 4000

10

16.0

8.0

3.2

16.0 3200

8

12.0

6.0

2.4

12.0 2400

6

8.0

4.0

1.6

8.0 1600

4

4.0

2.0

0.8

4.0

800

2

0

0

0

0

0

MH U M P

1

FHH)

=

L

2 19

2F

2Z

>

IZ

S3

19>>

n

S2 0 0

F 000 MM0 005

80

160

240

320

I A 400

480

560

640

720

181,9 ± 1 152,4 42,9

5/16 "-24 UNF-2A THD

A

Ø 24,8 max.

M

Ø 114 + 1,5

87 ± 1

39,66

A

Rolamento 6202-ZZ Rodamiento 6202-ZZ Rolling Bearing 6202-ZZ

4 (3x)

B 5 (3x)

FHIH J FHII

B


89,4

Drain hole

) %() %(%) ) C

B32 | Bosch

MH 12 V 1,2 kW

U

IF
U

n

FIHH

1

FHH)

=

n M rpm lbft 6000 30

P S2 S3 HP min % 3 15 30

U V 15

Eff % 75

4800

24

2.4

12

24

12

60

3600

18

1.8

9

18

9

2400

12

1.2

6

12

6

1200

6

0.6

3

6

3

P 45

M

=

U

2F

2Z

2

5,5 min

I|Z

19

19>>

30

S3

15

n S2

0

9 130 450 043

0

0

0

0

0 0

I A0 160 240 320 400 480 560 640 720

80

174,7 ± 0,6 152,4 33,27

53,85

31,75 5/16"-24 UNF-2A THD SW 1/2 5/16"-24 UNF-2B

Ø 114 + 1,5

Ø 24,8 max.

M

89,4

MH 24 V 1,8 kW

U

F>
U

n

ZIHH

1

IIH)

n rpm 6000

M lbft 60

P HP 3

S2 min 15

S3 % 30

U V 30

4800

48

2.4

12

24

24

3600

36

1.8

9

18

18

Eff % 75 P 60

U 45 M

=

= 2F

2Z

2

6,3 min

I|[

19

19>>

2400

24

1.2

6

12

12

30

1200

12

0.6

3

6

6

15

0

0

0

0

0

0 0

S3 S2

9 130 450 044

80

160

240

320

n 400

480

560

640

I A 0 720

174,7 ± 0,6 152,4 33,27

53,85

31,75 5/16"-24 UNF-2A THD

M

Ø 114 + 1,5

SW 1/2 5/16"-24 UNF-2B

Ø 24,8 max.

MH

89,4

) %() %(%) ) C

FHIH J FHII

Bosch | B33

MH 24 V 1,6 kW

U

F>
U

n

F|[H

1

IFH)

n rpm 3000

M lbft 60

P HP 6

S2 min 15

S3 % 30

U V 30

Eff % 75

2400

48

4.8

12

24

24

60

1800

36

3.6

9

18

18

U S3

=

45

P M

= 2F

2Z

2

>[

I>]

19

19>>

1200

24

2.4

6

12

12

600

12

1.2

3

6

6

30

n

15

S2 0

0

0

0

0 0

0

9 130 450 051

80

160

240

320

400

480

560

640

I A 0 720

181,9 ± 1 152,4 42,9

5/16" - 24 UNF-2A THD

16

A

A

Ø 24,8 max.

M

Ø 114 + 1,5

87

39,66

Rolamento 6202-ZZ Rodamiento 6202-ZZ Rolling Bearing 6202-ZZ

4 (3x)

B

B 5 (3x)


89,4

Drain hole

MH 12 V 1,4 kW

U

IF
CXT [>U

n

F>_H

1

FIZ)

=

=

2 19

S3 % 37.5

2F

2Z

3 min

IF

S2 P min HP 15 3.75

M n lbft rpm 15.0 7500

U V 15

MH

P

30.0

12

3.0

12.0 6000

12

22.5

9

2.25

9.0 4500

9

15.0

6

1.50

6.0 3000

6

7.5

3

0.75

3.0 1500

3

0

0

0

U

M

n

19>>

9 130 450 099

0

S3 S2

0 0

0

100

200

300

I A

400

500

600

172 ± 1,0 93º

152,4 39,66

A

SW 1/2" 5/16" - 24 UNF-2B

º

9,4 0'

Ø8

46 º3

112º

Ø 24,8 max.

4

70º

1/4 - 20 UNC - 2A THD

Ø

Ø 114 + 1,5

25

x)

(2

+1

6,3 –0,5 20

A

FHIH J FHII

Furo de dreno / Orificio de dreno / Drain hole

) %() %(%) ) C

B34 | Bosch

MR 12 V

1,2 kW

U

IF
U

n

FIHH

1

FHH)

=

n M rpm lbft 6000 30

P S2 S3 HP min % 3 15 30

U V 15

Eff % 75

4800

24

2.4

12

24

12

60

3600

18

1.8

9

18

9

2400

12

1.2

6

12

6

1200

6

0.6

3

6

3

P 45

M

.(=

U

2F

2Z

2

5,5 min

I|Z

19

19>>

30

S3

15

n S2

0

F 000 MM0 622

0

0

0

I A0 80 160 240 320 400 480 560 640 720

0 0

0

232,3 1 163,2

15º

109

15º

4,8 0,25

20,3

1,5 (

21,4 1,5

SW 13 (3x)

2x)

M8 x 1,25 (3x)

Ø 3,17 – 0,07

42,2

Ø 16,975 0,005

A M

F2

=

40 Ø 114 + 1,5

F1

=

M8 x 1,25

Ø 25,4 1

MR U

IF
CXT [>U

n

Z[HH

1

ZHH)

=

.(=

n M P S2 S3 rpm lbft HP min % 15000 30 6.0 15 30

U V 15

12000

24

4.8

12

24

12

9000

18

3.6

9

18

9

6000

12

2.4

6

12

6

2Z

2

FF

_F

19

19>>

S3 3000

6

0

0

F 000 MM0 629

209.2±1

0

3

0 0

M8x1.25

±0.25

S2

100

200

C

C C

4.8

400

500

600

I A 700 800

C

19° C

C

C

C

C

C

Ø 114

40

+1.5

Ø 16.975±0.005

C

C

Ø 43.8 (Dia 1.724)

300

n

C

C

F2

A 29 slot armature

0

6

19°

C

Ø 3.17-0.07

79±1

C

M

0

3

C

C

C C

1.2

C

159±1

C

F1

P M

2F

64.8

U

81 ±1

1,4 kW

C

12 V

C

MR

C

C

12.5 90.5

M8x1.25 Ø 25.4 "X"

) %() %(%) ) C

FHIH J FHII

Bosch | B35

MR 12 V

1,0 kW

U

IF
U

n

ZF[H

1

I|H)

S3 % 30

S2 min 15

P HP 3.0

M n lbft rpm 15.0 7500

U V 15

24

12

2.4

12.0 6000

12

18

9

1.8

9.0 4500

9

average curve minimum curve

U P

=

.(= 2F

2Z

2

IZ

|

19

19>>

12

6

1.2

6.0 3000

6 M

6

3

0.6

3.0 1500

3

n S3

F 000 MM0 804

0

0

0

0

0 0

0

I A

S2 100

200

300

400

500

114,8 5/16" - 24 UNF - 2A (2x) 9,8 (mín.) M5 (2x)

R 0,9 (máx.)

133

M

74,2 + 0,12

78,2

+ 0,3 – 0,2

Ø 32 + 0,5

+

+

– 0,75 ± 0,25

-

5

3 + 0,2

15

67 ± 0,2

MR U

IF
U

n

ZFHH

1

I|H)

=

.(=

n I rpm A 7500 450

2F

2Z

2

IZ

|

19

19>>

P S2 S3 KW min % 3.0 12 30

U V 15

6000 360

2.4

9.6

24

12

4500 270

1.8

7.2

18

9

3000 180

1.2

4.8

12

6

1500

90

0.6

2.4

6

3

0

0

0

0

0

0 0

F 000 MM0 805 12±05 (.472±.0197)

FHIH J FHII

0.5 (.0197+.00787) Ø 74.2+0.12 (Ø 2.92+.0047) Ø 78.5 max. (Ø 3.09 max.)

25.7 (1.012 ref.)

0.2+0.2 (.00787+.00787) 7 (.2755) 6.0 min. (.236 min.) 108±0.5 ±.0197 (4.25 )

23.24±0.3 (.915±.0118)

U

P n

S3 S2 2

4

6

8

M 10

1/4-20 UNC -2A (2x)

C

3+0,2 (.118±.0078)

+0.2

C

3.0 min. (.118 min.)

Ø 32+0,5 (Ø 1.26+.0197)

M5 (2x)

MR I

2

1

67±0.2 (2.638±.00787)

9.525-.0762 (.375-.003)

Ø 13.208-0.0127 (Ø .52-.0005)

R 0.6 (.0236)

13 max. (.5118 max.

1,0 kW

C

12 V

0.635±0.127 (.025±.005)

8.636±0.127 (.340±.005)

1.7 max. (.06692 max.)

) %() %(%) ) C

B36 | Bosch

MR 24 V 1,0 kW

U

F>
U

n

ZHHH

1

]H)

=

.(=

n M P S2 S3 rpm lbft HP min % 7500 15 3.0 4.5 15

U V 30

12

24

6000

12

3.6

2.4

U 4500

9

1.8

2.7

9

18

3000

6

1.2

1.8

6

12

1500

3

0.6

0.9

3

6

S3

2F

2Z

2

IZ

[]

19

19>>

M

P

S2 0

0

0

0

0 0

0

F 000 MM0 814

12 .47

150

200

6 min. .24 min. 2.5 min. .098 min. 11 .43 108±0.5 4.25±.02

3+0,5 (.12±.02)

Ø 13 max. Ø .512 max.

0.6±0.15 x45º 0.0236±.0059 x45º

9.525 0-0.076 .375 0-.003

1

Ø 13.208 0-0.0127 Ø .52 0-.0005

M5 (2x) (SW7)

Ø 74.2+0,12 Ø 2.921+.005 Ø 78.5 max. Ø 3.09 max.

1

Ø 32+0,5 (Ø 1.26+.02)

M

100

1/4"-20 UNC-2A (2x)

2

2

I A 250

n 50

1.7 max. .067 max.

25.9 1.02

8.64±0.12 .34±.005

67±0.2 2.638±.008

23.3 .92

CPB CPB

12 V 107 W

U

IF
[HH

1

I[)

A

H]|

=

=

2

2I

19

19IH

C

IIHHC

I A

30

n rpm

'p Pa

Up = 13 V

6000 750 n

20

4000 500

10

2000 250

I

'p

0

0 130 063 804

) %() %(%) ) C

0

0

0

200

400

m³/h

V

FHIH J FHII

Bosch | B37

CPB 24 V 66 W

U

F>

_HC

I (A) n (%)

200,0 n (rpm) x10 P (W)

24 V 36 W

60,0 40,0

50,0

I 20,0

0,0 0,0

9 130 451 236

25,0 50,0

0,0 75,0 100,0 125,0 150,0 175,0 200,0 M (N.cm)

Terminais AMP 180 908 Terminales AMP 180 908 (+) 59,4

Vermelho

19,5

1,9 5,6 29,3

10

5

Rojo

Marrom

Red

Marrón Brown

0°

12

7 M6

12

0°

5

12

Ø 20

Ø 16

Ø3 Ø 68

Ø 8 0.005 0.014

18

M

Terminal AMP 180 908

0

25

0

21°

Ø 75,8

(–)

13

28

14,5

147 max.

DPG 400,0

P

I|_X

350,0

140,0

n

FZHH

300,0

120,0

1

F>)

250,0

100,0

A

I]F

=

=

2

2I

19

19FZ

C

IF|HC

n (rpm) x100 P (W)

IF
HHC

16,0

50,0 0,0 0,0

0,3

0,6

0,9

F 006 B10 351

1,2

1,8

R7 7 R 7 .45 0.9

14 9

.2

0.4

91

16

24°

12.5°

61

.5°

24°

12.5°

132.5 125.5

6° 12.5° 1

57.45

12.5° 16°

.5°

53

+

M

0,0

2,1

65° 33

R8

R

3.6

Ø

1,5

M (N.m)

6

Ø -

112,0

I

P

I (A) n (%)

U

n (rpm) x100 P (W)

12 V 212 W

63

90.3 45°

KKP 1620.3

25° 65° Ø 143

GBM IF
HHC

I

250,0

500,0 200,0 400,0

n

I (A) n (%)

n

400,0

700,0

n (rpm) x10 P (W)

12 V 480 W

150,0 300,0 200,0

100,0

n

50,0

100,0 0,0 0,0

F 006 B10 268

163 max 140.3

100

200

300

400 500 M (N.cm)

600

700

0,0 800

M6

8 11

150

Ø 12g7

Ø 108

M

SW10

M12

Ø 12

5.5

0°

120°

Ø 100

11

11

12

0°

0°

22,3 10

Terminal DIN 46 340 - A6,3-6-MS-Bd

GPA U

IF
]

=

L

2

2I

200,0

19

19IH

100,0

C

Z>HHC

400,0

200,0

300,0

150,0

0,0 0,0

F 006 B10 269

I (A) n (%)

n (rpm) x10 P (W)

P

100,0

n

50,0

100

200

300 400 M (N.cm)

500

600

0,0 700

0° 11

M6 9

0°

° 120

4

11

12 0°

10

M8x1 9h12 Ø 12g7

Ø 108

Ø 100

M

140.3 188.5 max.

22.3

150

GPA

12 V 515 W


) %() %(%) ) C

FHIH J FHII

Bosch | B55

GPA U

12 V 510 W

1000,0

IF
HHC

I 300,0

700,0

250,0

600,0 500,0 400,0

200,0 n 150,0

300,0 200,0

100,0

n

50,0

100,0

0,0 0,0 0,0 100 200 300 400 500 600 700 800 900 M (N.cm)

F 006 B10 270

0° 11

M12

Ø 12g7

SW8

8

Ø 108

M6

Ø 10

Ø 12

12 0°

°

13

0° 11

120

8 min.

M6

10

18 10 5

Ø 100

I (A) n (%)

ZFHH n (rpm) x10 P (W)

n

11

M 22.3

150

140.3 185 max.


GPA IF
[X

700,0

n

ZHHH

600,0

1

|])

500,0

A

|Z]

=

L

2

2I

19

19IH

C

Z>HHC

400,0

300,0 250,0 I

400,0 n

200,0

300,0

150,0

200,0

100,0

n

100,0 0,0 0,0

F 006 B10 271

50,0 0,0 100

M12

11

Ø 12q7 Ø 108

600

0°

0°

Ø 12

500

0°

12

300 400 M (N.cm)

11

°

120

6.5

200

M6

10

Ø 100

GPA

350,0

P

I (A) n (%)

U

n (rpm) x10 P (W)

12 V 475 W

SW10

8 11

M

150

5.1 max. 140.3 185 max.

22.3


FHIH J FHII

) %() %(%) ) C

B56 | Bosch

GPA 600,0

U

F>
HHC

100,0

n I

100,0

50,0 0,0 0,0

F 006 B10 272

0,0 100

200

300

400 500 M (N.cm)

600

700

800

Ø 8g7

11

0°

12

120° Ø 108

Ø 100

18 22

0° 11

M6

0°

10

SW10

7.2

M

150

140.3 176 max.

29.3


GPA 1200,0

F>
HHC

F 006 B10 273

Ø 100

200,0

500,0

=

C

300,0

800,0 I (A) n (%)

[[HX

n (rpm) x10 P (W)

P

12

19

M

150

GPA

U

24 V 550 W

140.3 188.5 max.

35


) %() %(%) ) C

FHIH J FHII

Bosch | B57

GPA U

24 V 550 W

1200,0

F>
HHC

0,0

F 006 B10 274

0,0 0 100 200 300 400 500 600 700 800 900 1000 1100 M (N.cm)

188.5 max. 35 10

Ø 108

11 0° Ø 12g7

Ø 11.5

120°

Ø 100

6.5 7.5

150

M

SW10

0° 11

12

0°

M6

140.3

Terminal DIN 46 340 - A6, 3-6-MS-Bd

GPA 24 V 555 W

U

F>
[

=

=

2

2I

19

19IH

250,0

900,0 800,0

I

700,0 600,0

200,0

I (A) n (%)

1

ZZHH n (rpm) x10 P (W)

n

150,0

500,0

C

400,0 n 300,0

100,0

n

200,0

50,0

100,0

Z>HHC

0,0 0

F 006 B10 275

200

400

600 800 M (N.cm)

1000

1200

0,0 1400

35

19

M

150

° 11 0

Ø 12g7

Ø 108

0.5x45

2.5 4N9

2.5 Ø 31 Ø 12

17

0°

120°

Ø 100

11

12 5

M12-LH

12 0°

M6

10

140.3 188.5 max.

35


FHIH J FHII

) %() %(%) ) C

B58 | Bosch

GPB P

400,0

500,0

F>

200,0

n

180,0

P

160,0

=

2

2I

19

19HZ

C

I[_[C

120,0

200,0

100,0

I

n

I (A) n (%)

n (rpm) x10 P (W)

=

140,0

80,0

150,0

60,0 100,0 40,0 50,0

20,0

0,0 0,0

F 006 KM0 611

0,0 50,0 100,0 150,0 200,0 250,0 300,0 350,0 M (N.cm)

Ø 110,8

ró

8 13

Ø 368

ro

(A–)

Ø 390 Ø 154

(C+)

B M

Ø 4,35 (3x)

12 0º

M

ar

o

14,9

Ø

m

5

/N eg

15

/M

ro

ar

Ø

et

n

/B la

/B

ck

ro

w

n

23

Pr

GPB

12 V 218 W

20

(–) Marrom / Marrón / Brown 21,5 (+) Preto / Negro / Black

Vista "B" / View "B"

) %() %(%) ) C

20,2 87,6

FHIH J FHII

Bosch | B59

GPC 12 V 125 W

200,0

U

IF
H

=

=

300,0 n

180,0 P 160,0

120,0

150,0 80,0 n 100,0

2

2I

19

19HZ

C

I[ZHC

60,0 40,0

50,0 20,0 0,0 0,0

9 130 451 125

0,0 50,0 100,0 150,0 200,0 250,0 300,0 350,0 M (N.cm)

33

0°

(+)

20,5 9

12

0°

0°

22

Ø 366

~~6

10

M6

12

(–)

100,0

I

(–) Marrom / Marrón / Brown

~Ø 20 Ø 86 Ø 101

Ø 132

138

M

I (A) n (%)

n (rpm) x10 P (W)

140,0

X XX XX XX XX XX XX

X XX XX XX XX XX XX

25

26

XX XX XX XX XX XX XX XX

"Y"

158

0

°

(+) Preto / Negro / Black

26,3 60

Vista "Y" / View "Y"

32,5

GPC U

F>
_

=

=

2

2I

19

19HZ

C

I[ZHC

GPC 120,0

n 250,0 200,0

80,0 I

150,0

60,0

100,0

40,0

50,0

20,0

0,0

9 130 451 127

100,0 I (A) n (%)

n

n (rpm) x10 P (W)

24 V 150 W

0,0

0,0 50,0 100,0 150,0 200,0 250,0 300,0 350,0 M (N.cm)

"X" 25°

Ø 20

-

,5

+

Ø 101

(+)

50 5 28,

(–)

23

5

Ø 86

24,

M

(–)

(+)

Vista "X" / View "X"

FHIH J FHII

99 113,5

) %() %(%) ) C

B60 | Bosch

GPC 300,0

IF

13

Vista "X" View "X" 8,5-0.15

+ + + +++++

L1 C1

++ ++++ +

Marrom/Marrón/Brown (+) (–) Verde/Green CCW Verde/Green (+) (–) Marrom/Marrón/Brown CW

15,0

36,0

9,0

"X"

I (A) n (%)

U

n (rpm) P (W)

24 V 26 W

33±0,8

Ø 61 max.

CHP Z

42,0

>Z)

Z>)

II[)

I>)

Z

I[

IH[

[

35,0

[[Î L

16,0

n2 n2 I2

n1

14,0

I1 n1

12,0 10,0

28,0

8,0

21,0

6,0

14,0

4,0 P2

2I

I (A) n (%)

56,0

[>>| 20 $ # ! 20 # / 20 3 5

23165_1076En_001 14.03.2002 7:34 Uhr Seite 1

Relays Tractive electromagnets

Explanatory notes on parameters 2 Degrees of protection and operating modes 4

Relays Micro-relays Mini-relays Accessories Power relays

6 8 12 14

Tractive electromagnets Pulling electromagnets Pushing electromagnets

24 28

Industrial-sales contact addresses Special-requirements data sheet

32 33

Bosch – Excellence comes as standard

23165_1076En_002-005 14.03.2002 7:35 Uhr Seite 2

2

A

Relays

B

Explanatory notes on parameters

Overview Relay applications This catalog contains the technical information which a design engineer requires in order to select a relay for his particular requirements. Bosch DC relays were originally designed for automotive applications. We recommend prior technical clarification for all other applications, especially where requirements, loading or ambient conditions differ from those applying to automotive applications.

Micro-relay 1 Cap, 2 Magnet bracket and term. 3, 3 Coil, 4 Bobbin, 5 Armature, 6 Baseplate, 7 Damping resistor or diode, 8 Connecting wire, 9 Core, 10 Term. 1/2, 11 Contact, 12 Spring, 13 Term. 4, 14 Term. 5.

1

8

2

9

3 4 5

10

6

Bosch DC relays are able to withstand exposure to extreme conditions and must comply with the following requirements: They must – switch high powers – function efficiently and reliably in a broad temperature range – be extremely resistant to vibration – have a long service life, and – be highly climate-proof. Bosch DC relays are used to switch electrical devices featuring high power levels or which are sensitive to voltage loss. Relays relieve the load on control switches and make for small voltage drops with economical conductor crosssections. And relays make simple interlock circuits possible.

7

11 12

13 14

Mini-relay 1 Baseplate, 2 Term. 86, 3 Term. 87, 4 Term. 87a, 5 Term. 85, 6 Clamping piece, 7 Coil connection bracket, 8 Term. 30, 9 Magnet bracket, 10 Cap, 11 Coil, 12 Bobbin, 13 Core, 14 Armature, 15 Spring, 16 Contact. 6

1

7

2 3

8

4 5

Mini-relays and micro-relays are ideal for use where the available space is restricted. Multiple connectors, together with pre-tested wiring harnesses, ensure simple assembly and the lowest possible error rate. This applies in particular to OEM, but also to customer service. The following versions of mini-relays and microrelays are available: – Relays without mounting bracket. Easily plugged into buttable socket housings for screwing on – Relays with mounting bracket. Connected using a 5-pole socket housing Power relays can switch a nominal current of 50 A and more, and are suitable for switching motors, starting motors and other devices.

9

14

10 11

12 13

15 16

23165_1076En_002-005 14.03.2002 7:35 Uhr Seite 3

B

A

Relays

3

Parameters and definition of terms Definition of terms (to DIN 41 215, where standardized) The various parameters with their specific characteristic values permit the selection of the correct relay for a particular job. During its service life, every type of relay must fulfill defined tasks at the specified characteristic values. The response voltage is the value of the smallest excitation voltage which makes a relay respond, taking into account the ambient temperature and self-heating factors. The response time is the time that elapses between the closing of the exciter circuit to the first closing of an NO contact or the first opening of an NC contact. The operating voltage is the value of the excitation voltage at which the relay shows the characteristic data required for operation. The excitation voltage is the electrical voltage which permits the electric current to flow through the excitation winding and produce the excitation. The connection is made via terminals 1 and 2 or 85 and 86. The nominal value is the value of a variable (e.g. voltage, current, resistance) for which a relay, its parts and properties are designed or after which they are named. Correction factor The specifications for the energizing side apply at an ambient temperature of +20 °C. If the ambient temperature deviates from this figure, the correction factor K can be applied to convert the winding resistances, response voltages and release voltages. K = [1 + α(tu – 20 °C)] tu = actual ambient temperature or coil temperature α = 0.004 K–1 (mean temperature coefficient for copper).

The bounce time is the time that elapses between the first and last closing of a relay contact when the relay changes to another switching position. The release voltage is the value of the maximum excitation voltage at which the relay drops out, taking into account ambient temperature and self-heating factors. The release (dropout) time is the time that elapses between the opening of the exciter circuit and the first opening of an NO contact or the first closing of an NC contact. The switching voltage is the voltage which is present between the contacts when the electric circuit is open, once transient processes have settled. The voltage drop is the voltage at the relay terminals of a closed relay contact measured at a defined current. The overall resistance of the exciter circuit is the electrical resistance between the terminals 1 and 2 or 85 and 86.

23165_1076En_002-005 14.03.2002 7:35 Uhr Seite 4

4

A

Relays

B

Degrees of protection and operating modes Switching operations Response is the operation by which a relay is switched from its normal position to its operated position. Opening is an operation which results in the electrical contact being opened. Release (dropout) is the operation by which a relay is switched from its operated position to its normal position. A switching cycle comprises the single response and release of a relay. The number of switching operations comprises the total number of switching cycles. Closing is an operation which results in contact closure. With inductive loads and motors, a suppresser circuit, which can be set up parallel to the load with a free-wheeling diode, is required (see circuit).

Typical load characteristics 1 Excitation voltage for relay coil 2 Current characteristic for resistive load 3 Current characteristic for lamp load 4 Current characteristic for motor load 5 Current characteristic for inductive load 6 Voltage characteristic for inductive load

Service life

1U

The contact service life is defined as the number of switching cycles, with electrical loading of the contacts, during which the relay remains operational.

t

2

I

t

3

I

Switching contacts

t

4

I

–

L

R

5

I

t

t

U+

L Inductive Load, D Free-wheeling diode, R Relay, U Supply voltage.

The NO (Normally Open) contact is a relay contact which is open in the relay’s normal position and closes as the relay changes to its operated position.

t

6U D

The mechanical service life is defined as the number of switching cycles, without electrical loading of the contacts, during which the relay remains operational.

The NC (Normally Closed) contact is a relay contact which is closed in the relay’s normal position and opens as the relay changes to its operated position. The changeover contact is a contact assembly with three electrically isolated connections consisting of an NO contact an NC contact and a common contact spring. When the switch position changes, the closed contacts open first, followed by the closing of the other contacts (which up to that point were open).

23165_1076En_002-005 14.03.2002 7:35 Uhr Seite 5

B

A

Relays

5

Degrees of protection and operating modes Degrees of protection In accordance with DIN 40 050, the degree of protection is designated by a code which is always made up of the letters IP (Internal Protection) followed by two numbers signifying the actual level of protection. The first number indicates the

degree of protection against accidental contact and against the ingress of solid foreign bodies, the second number indicates the degree of protection against the ingress of water. If the degree of protection of one of a device’s

operational parts (e.g. terminals) differs from that of the main part of the device, then its code will be stated separately. The lower degree of protection is given first. Example: Terminals IP 20 – Housing IP 5K4.

Degrees of protection (DIN 40 050, extract from page 9) Overview of elements of IP code First classiProtection against contact fication number by persons 0 No protection 1 Back of hand 2 With a finger 3 Tools 4 Thin wire 5K Thin wire 6K Thin wire

Protection against ingress of solid foreign bodies No protection Object with Ø ≥ 50 mm Object with Ø ≥ 12.5 mm Object with Ø ≥ 2.5 mm Object with Ø ≥ 1 mm Protection against dust Dust-proof

Second classification number 0 1 2 3 4 4K 5 6 6K 7 8 9K

Protection against ingress of water No protection Vertical drops Drops at 15° inclination Water spray Splashing water Splashing water at increased pressure Water jets Heavy water jets Water jets at increased pressure Temporary immersion Lasting submersion High-pressure/ steam cleaning

Application Bosch relays were originally designed for use in automotive applications. The great range of different versions are used for the most varied applications, such as for – wiper motors – fan motors – starting motors – cooling fans – rear defrosters – brake lamps – electric power-window mechanisms – central locking – electric seat adjustment – electric seat heating – electric wing mirrors – fuel pumps – horns – headlamps

– security systems and many more.

pneumatic tube conveyor systems) – garage-door drives In addition to these purely auto- – battery chargers motive applications, Bosch re- – emergency generators lays are ideal for switching 12- – agricultural machinery or 24-V components. This is – furniture adjustment true for both mobile and statio- – cleaning devices nary applications where, for – robot controls example, electric motors are – control cabinets actuated. With these relays, – toys a multiplicity of drive assign– vending machines ments can be implemented. and many more. Bosch relays are employed in – automatic sliding doors – devices for the disabled – boat electrics – electric lawn mowers – materials-handling technology (e.g. conveyor belts,

23165_1076En_006-013 14.03.2002 7:36 Uhr Seite 6

6

A

Micro-relays

B

Micro-relays

Parameters Nominal voltage (load and excitation circuit) Permissible operating voltage Permissible ambient temperature 1) Response voltage (at 20 °C) Release voltage (at 20 °C) Response time Release time Contact material Voltage drop at NO contact when new Voltage drop at NO contact after specified number of switching operations Voltage drop at NC contact when new Voltage drop at NC contact after specified number of switching operations Degree of protection for housing and terminals in general (see page 5) Degree of protection for socket housing with blade terminals pointing downwards (s. p. 5) 1) Up to 125 °C on request. 2) ≤ 15 ms for part numbers 0 332 207 304 and 0 332 207 402. 3) Hard silver for changeover relay part number 0 332 207 304.

12 V 8...16 V – 40...100 °C ≤8V ≥ 1.5 V ≤ 10 ms ≤ 10 ms 2) Silver tin oxide 3) ≤ 50 mV at 10 A ≤ 100 mV at 10 A ≤ 50 mV at 10 A ≤ 200 mV at 10 A IP 20 IP 5K4

24 V 17...27 V – 40...100 °C ≤ 17 V ≥3V ≤ 10 ms ≤ 10 ms 2) Silver tin oxide ≤ 40 mV at 5 A ≤ 75 mV at 5 A ≤ 40 mV at 5 A ≤ 150 mV at 5 A IP 20 IP 5K4

Product overview Resistive load 4) Switching current/ no. of operations 9) NO contact NC contact A/Thousand A/Thousand

Motor load 5) Making/continuous current/ no. of operations 9) NO contact A/A/Thousand

Lamp load 6) Switching current/ no. of operations 9) NO contact NC contact A/Thousand A/Thousand

NO relays 12 V 20/≥ 300 – 20/≥ 300 – 30/≥ 100 – 22/≥ 200 7) –

30/15/≥ 200 30/15/≥ 200 65/17/≥ 200 8) –

20/≥ 150 20/≥ 150 17/≥ 150 10/≥ 200

35/20/≥ 100

–

30/15/≥ 200 30/15/≥ 200 65/17/≥ 200 8) 30/7/≥ 200 8)

20/≥ 150 20/≥ 150 17/≥ 150 10/≥ 200

Changeover relays 12 V 20/≥ 100 10/≥ 125 16/≥ 200 25/≥ 250 10/≥ 500 20/≥ 300 10/≥ 150 20/≥ 300 10/≥ 150 30/≥ 100 10/≥ 100 22/≥ 200 7) 25/≥ 200

– – – –

10/≥ 75 10/≥ 75 10/≥ 150 3,5/≥ 200

Exciter cir- Illustr. Circuit Terminal Part number cuit total re- and diagram diagram sistance 10) dimens. drawing Ω 78 ±6 78 ±6 75 ±6

1 2 3

S1 S1 S1

A1 A1 A1

0 332 017 300 0 332 017 302 0 332 011 007

88 ±6

1

S3

A2

0 332 207 304

78 ±6 78 ±6 75 ±6

1 2 3

S2 S2 S2

A2 A2 A2

0 332 207 307 0 332 207 310 0 332 201 107

Changeover relays 24 V 10/≥ 250 5/≥ 250 – – – 410 ±20 1 S3 A2 10/≥ 250 5/≥ 250 – – – 335 ±20 2 S2 A2 Switching rhythm: 4) 2 s on, 2 s off. 5) 5 s on, 5 s off. 6) 1 s on, 9 s off. 7) 1 s on, 2 s off. 8) 2 s on, 6 s off. 9) At a test voltage of 13.5 V (12-V relay) or 27 V (24-V relay); test temperature of 23 ±5 °C. 10) At 20 °C.

Blade terminal connection Refer to page 12 for corresponding connectors and socket housings.

0 332 207 402 0 332 207 404

23165_1076En_006-013 14.03.2002 7:36 Uhr Seite 7

B

A

Micro-relays

7

Illustrations and dimension drawings

1

1

15,5-0,5

23-0,5

26-1

3

11 0,5

5

2

4

1

Blade terminal size to DIN 46 244, similar to ISO 8092: Terms. 1 and 2 (4): 4.8 x 0.8 mm; terms. 3 and 5: 6.3 x 0.8 mm

2

23-0,5

2+0,2

15,5-0,5

1,5+0,2

12,8+0,2

3

5

11 0,5

26-1

5,3+0,15

13 0,2

6+0,2

2

2

4

1

Blade terminal size to DIN 46 244, similar to ISO 8092: Terms. 1 and 2 (4): 4.8 x 0.8 mm; terms. 3 and 5: 6.3 x 0.8 mm

3

3

15,5-0,5

23-0,5

26-1

3

11 0,5

5

2

4

1

Blade terminal size to DIN 46 244, similar to ISO 8092; Terms. 1 and 2 (4): 4.8 x 0.8 mm; terms. 3 and 5: 6.3 x 0.8 mm

Terminal diagrams

Circuit diagrams

A1

S1

A2

2

1

NO contact

Changeover contact

S2

5

2

1

3

5

4

S3

2

5

1 +

3

Cross-reference of terminal designations Micro-relay Mini-relay Polarity 1 2 3 4

86 85 30 87a

+ – +

4

3

23165_1076En_006-013 14.03.2002 7:36 Uhr Seite 8

8

A

Mini-relays

B

Mini-relays

Parameters Nominal voltage (exciter and switching voltage) Permissible operating voltage Permissible operating temperature 1) Response voltage (at 20 °C) Release voltage (at 20 °C) NO contact: Voltage drop in load circuit at 10 A when new after specified number of switching operations NC contact: Voltage drop in load circuit at 10 A when new after specified number of switching operations Changeover contact: Voltage drop in load circuit at 10 A 2) NO contact when new NO contact after specified number of switching operations NC contact when new NC contact after specified number of switching operations Resistive, motor and lamp load

1)

Up to 125 °C on request

12 V 8...16 V – 40...+100 °C ≤8V 1.2...5.0 V 2)

24 V 16...32 V – 40...+ 85 °C ≤ 16 V 2.4...10.0 V

≤ 50 mV ≤ 80 mV

≤ 50 mV ≤ 100 mV

≤ 175 mV ≤ 250 mV

≤ 50 mV ≤ 50 mV 3) ≤ 100 mV ≤ 80 mV 4) ≤ 50 mV ≤ 70 mV 3) ≤ 120 mV 4) ≤ 150 mV The number of switching cycles was The number of switching cycles was determined at a test voltage of determined at a test voltage of 27 V. 13.5 V. When hard silver is the con- Temperature cycling program tact material, the test temperature 48 h at 85 °C, 24 h at 20 °C and was 23 ±5 °C, in the case of silver 24 h at –40 °C. tin oxide it was 85 °C. 2) 0.5...5.0 V with 0 332 109 011 3) ≤ 30 mV with 0 332 209 158 4) ≤ 60 mV with 0 332 209 158

Product overview NO relays 12 V Resistive load NO contact Switching current/ no. of operations 5)

Motor load NO contact Making current/ continuous current/ no. of operations 6) A/A/Thousand 90/40/≥ 75 75/30/≥ 125 50/20/≥ 250 72/16/≥ 50

A/Thousand 50/≥ 75 40/≥ 125 30/≥ 250 50/≥ 50 40/≥ 75 30/≥ 100 50/≥ 75 90/40/≥ 75 40/≥ 125 75/30/≥ 125 30/≥ 250 50/20/≥ 250 30/≥ 250 50/25/≥ 100 20/≥ 300 10/≥ 500 30/≥ 250 50/25/≥ 100 20/≥ 300 10/≥ 500 30/≥ 100 40/20/≥ 100 20/≥ 200 10/≥ 350 5) Switching rhythm: 2 s on – 2 s off 6) Switching rhythm: 5 s on – 5 s off 7) Switching rhythm: 1 s on – 9 s off for silver tin oxide 2 s on – 2 s off for hard silver 8) Switching rhythm: 2 s on – 2 s off (8 mH) 9) a = silver tin oxide, b = hard silver

10)

Lamp load NO contact Switching current/ no. of operations 7)

Inductive load NO contact Switching current/ no. of operations 8)

Contact material 9)

Part number

A/Thousand 30/≥ 75 20/≥ 125 10/≥ 250 30/≥ 75 20/≥ 125 10/≥ 250 30/≥ 75 20/≥ 125 10/≥ 250 30/≥ 100 20/≥ 200 10/≥ 500 30/≥ 100 20/≥ 200 10/≥ 500 20/≥ 100 10/≥ 350

A/Thousand –

a

0 332 019 103

–

a

0 332 019 109

–

a

0 332 019 110

24/≥ 100

b

0 332 019 150

24/≥ 100

b

0 332 019 151

15/≥ 50

b

0 332 019 155

When a socket housing is used and when installed with blade terminals 12) pointing downwards. In a different installation position, the housing degree of protection is IP 20. 11) Switching rhythm: 2 s on – 6 s off

23165_1076En_006-013 14.03.2002 7:36 Uhr Seite 9

B

A

Mini-relays

9

Product overview (continued) NO relays 12 V continued Overall resistance Response of excitation circuit time at 20 °C Ω ms 75 ±5 ≤ 10 85 ±5 ≤ 10 75 ±5 ≤ 10 85 ±5 ≤ 10 85 ±5 ≤ 10 85 ±5 ≤ 10 NC relay 12 V Resistive load NC contact Switching current/ no. of operations 5) A/Thousand 10/≥ 100 20/≥ 50

A/Thousand 50/≥ 50 20/≥ 50 40/≥ 75 30/≥ 100 50/≥ 75 20/≥ 100 40/≥ 150 15/≥ 150 30/≥ 300 10/≥ 300 50/≥ 75 20/≥ 100 40/≥ 150 15/≥ 150 30/≥ 300 10/≥ 300 30/≥ 250 5/≥ 250 20/≥ 300 10/≥ 500 30/≥ 250 20/≥ 250 20/≥ 300 10/≥ 250 10/≥ 500 5/≥ 250 30/≥ 250 20/≥ 250 20/≥ 300 10/≥ 250 10/≥ 500 5/≥ 250 30/≥ 150 20/≥ 150 20/≥ 500 10/≥ 250 10/≥ 750 5/≥ 500 30/≥ 250 20/≥ 250 20/≥ 300 10/≥ 250 10/≥ 500 5/≥ 250 * see page 11

ms ≤ 10 ≤ 15 ≤ 10 ≤ 10 ≤ 10 ≤ 15

Motor load NC contact Making current/ continuous current/ no. of operations 11) A/A/Thousand 100/18/≥ 200

NC relays 12 V continued Overall resistance Response of excitation circuit time at 20 °C Ω ms 75 ±5 ≤ 10 Changeover relays 12 V Resistive load NO contact NC contact Switching current/ no. of operations 5)

Release time

Release time ms ≤ 10

Degree of protection 10) Illustration Terminals Housing Dimension drawing *

Circuit diagram *

Terminal diagram *

Part number

IP 20 IP 20 IP 20 IP 20 IP 20 IP 20

S7 S2 S7 S1 S1 S2

A3 A1 A3 A1 A1 A1

0 332 019 103 0 332 019 109 0 332 019 110 0 332 019 150 0 332 019 151 0 332 019 155

Contact material 9)

Part number

a

0 332 109 011

50/25/≥ 100 – 40/20/≥ 100 – 50/25/≥ 100 –

1 1 2 2 1 2

Lamp load NC contact Switching current/ no. of operations 7)

Inductive load NC contact Switching current/ no. of operations 8)

A/Thousand 12/≥ 100

A/Thousand –

Degree of protection 10) Illustration Terminals Housing Dimension drawing *

Circuit diagram *

Terminal diagram *

Part number

IP 20

S9

A4

0 332 109 011

Motor load NO contact NC contact Making current/ continuous current/ no. of operations 6) A/A/Thousand 90/40/≥ 75 – 75/30/≥ 150 50/20/≥ 300 90/40/≥ 75 35/15/≥ 50 75/30/≥ 150 25/10/≥ 150 50/20/≥ 300 15/5/≥ 300 90/40/≥ 75 35/15/≥ 50 75/30/≥ 150 25/10/≥ 150 50/20/≥ 300 15/5/≥ 300 50/25/≥ 100 – 50/25/≥ 100 –

IP 5 K4 IP 34 IP 5 K4 IP 34 IP 34 IP 34

IP 34

1

Lamp load NO contact NC contact Switching current/ no. of operations 7)

Inductive load Contact NO contact NC contact material 9) Switching current/ no. of operations 8)

Part number

A/Thousand 30/≥ 75 20/≥ 150 10/≥ 300 30/≥ 75 20/≥ 150 10/≥ 300 30/≥ 75 20/≥ 150 10/≥ 300 30/≥ 100 20/≥ 200 10/≥ 500 30/≥ 100 20/≥ 200 10/≥ 500 30/≥ 100 20/≥ 200 10/≥ 500 30/≥ 150 20/≥ 250 10/≥ 750 30/≥ 100 20/≥ 200 10/≥ 500

5/≥ 150

A/Thousand – –

a

0 332 209 135

5/≥ 300

–

–

a

0 332 209 137

5/≥ 300

–

–

a

0 332 209 138

10/≥ 100 5/≥ 150

15/≥ 100

15/≥ 100

b

0 332 209 150

10/≥ 100 5/≥ 150

15/≥ 100

15/≥ 100

b

0 332 209 151

10/≥ 100 5/≥ 150

15/≥ 100

15/≥ 100

b

0 332 209 152

10/≥ 150 5/≥ 250

15/≥ 100

15/≥ 100

b

0 332 209 158

10/≥ 100 5/≥ 150

15/≥ 100

15/≥ 100

b

0 332 209 159 continued on next page

23165_1076En_006-013 14.03.2002 7:36 Uhr Seite 10

10

A

Mini-relays

B

Mini-relays (continued)

Product overview (continued) Changeover relays 12 V continued Overall resistance Response of excitation circuit time at 20 °C Ω ms 85 ±5 ≤ 10 75 ±5 ≤ 10 75 ±5 ≤ 10 85 ±5 ≤ 10 85 ±5 ≤ 10 85 ±5 ≤ 10 85 ±5 ≤ 10 75 ±5 ≤ 10 NO relays 24 V Resistive load NO contact Switching current/ no. of operations 5) A/Thousand 20/≥ 250 20/≥ 250 20/≥ 250

Release time ms ≤ 15 ≤ 10 ≤ 10 ≤ 10 ≤ 10 ≤ 15 ≤ 15 ≤ 10

Motor load NO contact Making current/ continuous current/ no. of operations 6) A/A/Thousand 40/16/≥ 250 40/16/≥ 250 40/16/≥ 250

NO relays 24 V continued Overall resistance Response of excitation circuit time at 20 °C Ω ms 255 ±15 ≤ 15 216 ±15 ≤ 15 255 ±15 ≤ 15

Release time ms ≤ 15 ≤ 15 ≤ 15

Changeover relays 24 V Resistive load Motor load NO contact NC contact NO contact NC contact Switching current/ Making current/ continuous current/ no. of operations 5) no. of operations 6) A/Thousand A/A/Thousand 20/≥ 250 10/≥ 250 40/16/≥ 250 – 20/≥ 250

10/≥ 250

40/16/≥ 250 –

20/≥ 250

10/≥ 250

40/16/≥ 250 –

20/≥ 250

10/≥ 250

40/16/≥ 250 –

20/≥ 250

10/≥ 250

40/16/≥ 250 –

Degree of protection 10) Illustration Terminals Housing Dimension drawing

Circuit diagram

Terminal diagram

Part number

IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 IP 20

S6 S5 S5 S4 S4 S6 S6 S5

A2 A2 A2 A2 A2 A2 A2 A2

0 332 209 135 0 332 209 137 0 332 209 138 0 332 209 150 0 332 209 151 0 332 209 152 0 332 209 158 0 332 209 159

Contact material 9)

Part number

a a a

0 332 019 203 0 332 019 204 0 332 019 213

IP 5K4 IP 5K4 IP 5K4 IP 34 IP 34 IP 34 IP 34 IP 34

1 1 2 2 1 1 2 1

Lamp load NO contact Switching current/ no. of operations 7)

Inductive load NO contact Switching current/ no. of operations 8)

A/Thousand 16/≥ 250 16/≥ 250 16/≥ 250

A/Thousand – – –

Degree of protection 10) Illustration Terminals Housing Dimension drawing

Circuit diagram

Terminal diagram

Part number

IP 20 IP 20 IP 20

S1 S8 S1

A1 A1 A1

0 332 019 203 0 332 019 204 0 332 019 213

IP 5K4 IP 5K4 IP 5K4

2 1 1

Lamp load NO contact NC contact Switching current/ no. of operations 7)

Inductive load Contact NO contact NC contact material 9) Switching current/ no. of operations 8)

A/Thousand 16/≥ 250 8/≥ 50 5/≥ 150 16/≥ 250 8/≥ 50 5/≥ 150 16/≥ 250 8/≥ 50 5/≥ 150 16/≥ 250 8/≥ 50 5/≥ 150 16/≥ 250 8/≥ 50 5/≥ 150

A/Thousand – –

a

0 332 209 203

–

–

a

0 332 209 204

–

–

a

0 332 209 206

–

–

a

0 332 209 207

–

–

a

0 332 209 211

Circuit diagram

Terminal diagram

Part number

Changeover relays 24 V continued Overall resistance Response Release Degree of protection 10) Illustration of excitation circuit time time Terminals Housing Dimension at 20 °C drawing Ω ms ms 255 ±15 ≤ 15 ≤ 15 IP 20 IP 5K4 2 255 ±15 ≤ 15 ≤ 25 IP 20 IP 5K4 1 216 ±15 ≤ 15 ≤ 15 IP 20 IP 5K4 1 216 ±15 ≤ 15 ≤ 15 IP 20 IP 5K4 2 255 ±15 ≤ 15 ≤ 15 IP 20 IP 5K4 1 5) Switching rhythm: 2 s on – 2 s off 18) Switching rhythm: 2 s on – 2 s off (8 mH) 6) Switching rhythm: 5 s on – 5 s off 19) a = silver tin oxide, b = hard silver 7) Switching rhythm: 1 s on – 9 s off for silver 10) When a socket housing is used and tin oxide; 2 s on – 2 s off for hard silver when installed with blade terminals

Part number

S4 A2 0 332 209 203 S6 A2 0 332 209 204 S5 A2 0 332 209 206 S5 A2 0 332 209 207 S4 A2 0 332 209 211 12) pointing downwards. In a different installation position, the housing degree of protection is IP 20 (see page 5).

23165_1076En_006-013 14.03.2002 7:36 Uhr Seite 11

A

B

Mini-relays

11


1

2

12 1,7 0,1 Ø 5,4 0,1

86

11,5-1 26-0,8

Blade terminal size: 6.3 x 0.8 mm to DIN 46 244 (similar to ISO 8092)

Terminal diagrams

A1

S1

A2 87

86 87 85

86 87a 85

A3 86

30

86

87 87

85

S4

87

Terminal configuration

S2

86

87

30

86

87a

87

87

S5

85

30

86

87a

S3

86

87

*3 85

87

30

S6

86

87a

87

85 30

A4

85

S7

86

85

30

S8

87

86

30

85

S9

87

86

30

87a

87

87a 86

87 87a 30 85

Circuit diagrams

87

30

28,5-1

4 0,3

28,5-1

10 0,3

6 0,3

22 0,5

85 30

85

30

Recommended polarity Term. 86 + Term. 30 +

85

30

85

30

* S3 available on request

23165_1076En_006-013 14.03.2002 7:36 Uhr Seite 12

12

A

Accessories

B

Accessories

Socket housings for micro-relays 15,6 6,8

8

6

12

Individual and multiple mounting possible, for screwing on, 5-pole. Receptacles 6.3 mm or 4.8 mm with locking lance for engagement in housing. Pack of 5 3 334 485 045

9

24,4

2,7

Socket housing without bracket 5-pole. Receptacles 6.3 mm or 4.8 mm with locking lance for engagement in housing. Pack of 5 3 334 485 046

14

3 5,2

1 12,4

housing 1 Socket with bracket

7,8

32,2

2

18,5

2

2

housing 3 Socket for soldering into PC boards

4,5 0,07

4,5 0,07

5

4,5 0,1

14,5

4,5 0,1

Leiterplatte

2,5

8 0,1

22,6 0,3

14 0,1

3

15,2 0,3

14 0,1

0,3 0,1

8 0,1

3

3 0,2

Micro-relays with blade terminals can be attached to PC boards using a solder-in socket housing. The resulting ease of replacement makes for rapid and reasonably priced service work. Pack of 5 3 334 485 049

7,6

Socket housing for mini-relays 27,7

2

A

7,3

A 13,85

12

Individual and multiple mounting possible, for screwing on, 5-pole. Receptacles 6.3 mm with locking lance for engagement in housing. Pack of 5 3 334 485 008

5,3

4

12

24,4

6

housing 4 Socket with bracket

2,7

13,85

21

36 30,5

36

housing 5 Socket without bracket 10

1,2

7,5 13 0,1

1,8 0,1

13 0,1 17,4 0,1

B

18,2 0,1

8,7 0,1

8 0,1

7,5 0,05 6,5 0,05

Ø 2-0,1

14,5

8,7 0,1

A

3,2

Ø ca. 2,5

24

7

11,9

10 +0,3

26,5

6

23

Ø 2,1+0,1

A Two locating lugs B Holes for locating lugs

2

2,4 26,5

7,5 0,05 6,5 0,05

Mini-relays with blade terminals can be attached to PC boards using a solder-in socket housing. The resulting ease of replacement makes for rapid and cost-effective service work. Receptacles in socket housing. Pack of 1 3 334 485 041

10

housing 6 Socket for soldering into PC boards

7

7,5

5 24

5-pole. Receptacles 6.3 mm with locking lance for engagement in housing. Pack of 5 3 334 485 007

23165_1076En_006-013 14.03.2002 7:36 Uhr Seite 13

B

A

Accessories

Assembly parts

7 Plastic extractor tool For extracting micro-relays from the socket housing. Pack of 1 3 331 329 049 receptacles 8 Bronze with locking lance for engagement in socket housing. Plug size 4.8 x 0.8 mm for micro-relays (similar to DIN 46 340). Tin-plated surface, attachable conductor cross-section 1...2.5 mm2. Pack of 25 1 904 492 016 Plug size 6.3 x 0.8 mm for micro- and mini-relays (to DIN 46 340) Tin-plated surface, attachable conductor cross-section 1...2.5 mm2. Pack of 25 1 901 355 895

receptacles 9 Brass with insulated sleeve (to DIN 46 245)

7

Plug size 6.3 x 0.8 mm for power relay types 1 and 2 Tin-plated surface, attachable conductor cross-section 0.5...1 mm2. Identification color: red Pack of 100 1 901 355 880 Attachable conductor cross-section 1...2.5 mm2. Identification color: blue Pack of 100 1 901 355 881 Plug size 9.5 x 1.2 mm for power relay type 1 Tin-plated surface, attachable conductor cross-section 4...6 mm2. Identification color: yellow Pack of 50 8 781 355 811

8

9

Further accessories such as connectors, protection sleeves, crimping pliers, leads, etc. are contained in our “Accessories” catalog 1 987 721 074.

Recommended assembly method: The socket housing should be soldered to the PC board with the relay inserted, as then the receptacles are automatically centered and the PC board is not put under strain by plugging in the relay. If the relay is plugged in after the socket housing has been soldered in place, take care to care to ensure that the receptacle locking lance is up against the socket-housing stop, so that the soldered connection is not subject to pressure.

1 2 3 4 A L R

Relay with blade terminal Socket housing Receptacle PC board Stop Soldered connection Locking lance

1

3 2

R A 4 L

13

23165_1076En_014-019 14.03.2002 7:37 Uhr Seite 14

14

A

Power relays

B

Power relays

Parameters Nominal voltage (switching and excitation circuit) 12 V (type 1) 24 V (type 1) 12 V (type 2) 24 V (type 2) Permissible operating voltage 8...14.5 V 16...27 V 15 V 30 V Permissible ambient temperature – 40...+100 °C 1) – 40...+100 °C 1) – 40...+65 °C 2) – 40...+65 °C 2) Voltage drop at test current when new ≤ 200 mV/50 A ≤ 150 mV/20 A ≤ 100 mV 3)/75 A ≤ 100 mV 3)/75 A Voltage drop after specified no. of operations ≤ 225 mV/50 A – ≤ 200 mV 4)/75 A ≤ 200 mV 4)/75 A Degree of protection of housing/terminals (see p. 5) IP 20 5)/IP 20 IP 20 5)/IP 20 IP 54/IP 00 IP 54/IP 00 1) Up to 125 °C on request. 2) +100 °C for short-time operation with 25 % duty cycle, based on 2-minute cycle. 3) ≤ 50 mV/75 A with double-contact relay 0 332 002 150. 4) ≤ 100 mV/75 A with double-contact relay 0 332 002 150. 5) Degree of protection of housing IP 5K4 when using a socket housing installed with blade terminals pointing downwards.

Product overview Resistive load 6) Switching current/ Short-time no. of operations 10) load ≤ 1 s

Motor load 7) Making current/ continuous current/ no. of operations 10) A/A/Thousand

Response/ release voltage 8)

Response/ release time

V/V

ms/ms

NO relays 12 V type 1 50/≥ 100 120

86/55/≥ 130

≤ 6.0/1.0...5.0

≤ 10/≤ 10

E

plugged in

NO relays 24 V type 1 30/≥ 50 70

70/20/≥ 120

≤ 16.0/3.0...8.0 ≤ 15/≤ 15

V

none 11)

NO relays 12 V type 2 75/≥ 125 400 75/≥ 100 250 100/≥ 125 12) 400

– – –

≤ 8.0/1.5...4.0 ≤ 8.5/1.0...4.0 ≤ 5.5/0.5...4.0

D E E

fixed fixed fixed

A/Thousand

A

NO relays 24 V type 2 50/≥ 100 200 – 50/≥ 50 150 – 50/≥ 50 – – 16) Switching rhythm 2 s on, 2 s off. 17) Switching rhythm 4 s on, 26 s off. 18) of the excitation circuit at 20 °C. 19) E = single, D = twin, V = leading contact.

≤ 10/≤ 15 ≤ 10/≤ 15 ≤ 10/≤ 10

Con- Bracket tact type 9)

Overall Circuit Part number resistance 8) diagram Ω

45 ±5

S4

0 332 002 192

200 ±10

S1

0 332 002 270

46 ±5 46 ±5 20 ±3

S5 S2 S4

0 332 002 150 0 332 002 156 0 332 002 161

≤ 18.0/1.0...8.0 ≤ 10/≤ 10 V fixed 130 ±10 S1 0 332 002 250 ≤ 17.0/≥ 4.0 ≤ 10/≤ 15 E fixed 130 ±10 S2 0 332 002 256 ≤ 18.0/1.0...8.0 ≤ 10/≤ 10 E fixed 130 ±10 S3 0 332 002 257 10) The number of switching cycles was determined at a test voltage of 13.5 V for the 12-V relay and at 27 V for the 24-V relay. Type 1: temperature cycling program 6 h at 23 °C, 6 h at – 40 °C, 12 h at 125 °C; type 2 at 23 ± 5 °C. 11) Bracket can be obtained under part number 3 331 335 063. 12) Switching rhythm 1.5 s on, 13.5 s off.

Notes Compact design. High degree of corrosion protection due to use of glass-fiber-reinforced polyamide for baseplate and cap. High degree of protection against splash water thanks to drip rim between cap and baseplate. Leakage-current barriers in baseplate. Designed-in ventilation by means of “labyrinth”. Option of “heavy duty” version with tungsten leading contact.

Automotive applications: Load-reducing relay for switches. Operating relay for starting motors. Switch-on relay for hydraulic assemblies, blowers and heaters for the passenger compartment, engine-cooling fans. Pre-heating device for diesel starting systems. Motor relay for antilock braking system (ABS). Battery cutoff relay.

Accessories See page 12

23165_1076En_014-019 22.03.2002 7:33 Uhr Seite 15

B

A

Power relays

15


18 0,5

16,8 0,2

34,5 0,5

86

85 30

Blade terminals: Energizing side terms. 85 and 86: 6.3 x 0.8 mm Contact side terms. 30 and 87: 9.5 x 1.2 mm.

2

4,5

62

31,5

44

13

max. 9,5

6,4

20

39

17

2 Typ 2

21 75

Accessories: Twin socket housing for energizing side (terms. 85 and 86). Order with AMP number 180 907 from: AMP Deutschland GmbH, Amperestraße 7-11, D-63225 Langen, Germany, tel. +49 61 03 70 90.

Method of operation of leading contact 1

Circuit diagrams 2

1. Closure of leading contact Coil energized; current flows in leading contact for a fraction of a second. 2. Closure of main contact Coil energized; current flows in main contact. The characteristics of the tungsten leading contact make it ideal for the considerable loads resulting from the separation arc when contacts are opening (inductive loads). The main contact ensures efficient current flow with minimum voltage losses. The tungsten leading contact (late-opening when the contacts open) ensures that the main contacts are not subject to separation arcs.

S1 S1

86

87

85

30

S3 S3

S5 S5

S2 S2

85

86

87

85

30

86

87

85

30

Polarity: Terms. 86 and 30 to +

86

S4 S4

87

30

86

87

85

30

17,9 0,2

87

11,5 0,5

15 0,5 28,5 0,5

1,2 0,1

6,2 0,2

3,2 0,5

8,4 0,2

32,5 0,5

6,4 0,2

1

12,5 0,5 9 0,5

1 Typ 1

23165_1076En_014-019 14.03.2002 7:37 Uhr Seite 16

16

A

Power relays

B

Power relays (continued) for industrial trucks, hydraulic systems, etc. Series 200, 201 – single-pole

Parameters Designation Nominal voltages *) Construction Operating mode Version Voltage limits (permissible) Switching times at nominal voltage Utilization category Creepage distances and clearances Coil output Coil connection Main current contacts Nominal value of operating current Continuous thermal current Contact material Connection stud Auxiliary contact Continuous current of auxiliary contact Connection of auxiliary contact Blowout magnet Degree of protection (see page 5) Operating temperature range Note

230 A hinged-armature relay 24 V, 36 V, 48 V, 80 V Open Continuous duty up to 1 h Available on request with auxiliary relay and blowout magnet 0.7 x nominal voltage to nominal voltage Response time ≤ 50 ms; release time ≤ 30 ms Starting, switching off while running DC4-VDE 0660 To insulation group C-VDE 0110 32 W Blade terminal 0.8 x 6.3 mm NO contact – series 0 333 200 ..; changeover contact – series 0 333 201 .. 375 A 230 A Sintered silver cadmium oxide (AgCdO) M 8; permissible tightening torque 6...8 Nm Changeover contact 2.5 A with inductive load, 6 A with resistive load Blade terminal 0.8 x 6.3 mm As an option for 36 V, 48 V and 80 V. IP 00 – 40...+100 °C Ensure correct polarity of main current connections. Connect to fixed contact.

Product overview Relay function

NO relays

Nominal Nominal Switching current voltage *) value of excitation Contin. Load current duty current 1s V A A A

Service life of contact MechaElecnical trical

Thousand Thousand A

mm

24 24 36 80 24

1250 1250 1250 1250 1250

135x70x100 135x70x100 135x70x100 135x70x100 135x70x100

1.3 1.3 0.9 0.4 1.3

230 230 230 230 230

1500 1500 1500 1500 1500

250 250 250 250 250

Interrupting current with inductive load

375 375 375 375 375

Dimensions

Circuit Weight Part number diagram

LxWxH kg

S1 S1 S1 S1 S2

1.2 1.2 1.2 1.2 1.2

0 333 200 010 0 333 200 012 2) 0 333 200 015 0 333 200 013 3) 0 333 200 011

NO relays with aux. relay 1) Changeover 24 1.3 230 1500 1250 100 375 135x70x128 S3 1.3 0 333 201 010 relays 80 0.4 230 1500 1250 100 375 135x70x128 S3 1.3 0 333 201 012 3) Changeover 24 1.3 230 1500 1250 100 375 135x70x128 S4 1.3 0 333 201 011 relays with 80 0.4 230 1500 1250 100 375 135x70x128 S4 1.3 0 333 201 013 3) aux. relay 1) *) Excitation and switching voltage. 1) With additional auxiliary relay (changeover contact), e.g. for indicator lamps, max. 6 A (resistive load); 2.5 A (inductive load); contact P switches from 1 to 2. 2) Installation position: long edge of baseplate vertical, max. inclination 10°. 3) With blowout magnet.

23165_1076En_014-019 14.03.2002 7:37 Uhr Seite 17

A

B

Power relays

Illustrations

Circuit diagrams

S1

31

50

S2

31

1

2

50

S3

P

31

50

S4

31

1

2

50

P

Dimension drawings Series 0 333 200 ..

Series 0 333 201 ..

7

+2 8 - 0,5

M8 +1,5 -1

B

7

+1,5 -1

100

10 1,5

88

M8

128

M8

M8

B

21 1

10 1,5 9 0,5

21 1

9 0,5

88

M8

135 1 115 0,3

135 1

Ø 6,4 H14 (+0,36)

42 1

10 1

70 1

56 0,3

42 1

10 1

70 1

56 0,3

115 0,3

A Ø 6,4 H14 (+0,36)

A Version with one auxiliary relay, B Blowout magnet

A

A Version with one auxiliary relay, B Blowout magnet

17

23165_1076En_014-019 14.03.2002 7:37 Uhr Seite 18

18

A

Power relays

B

Power relays (continued) Series 006 – single-pole

Parameters Designation Nominal voltages *) Construction Operating mode Voltage limits (permissible) Switching times at nominal voltage Utilization category Creepage distances and clearances Coil output Coil connection Main current contacts Contact material Connection stud Degree of protection (see page 5) Operating temperature range Note

80 A solenoid plunger circuit 6 V, 12 V, 24 V Closed Continuous duty up to 1 h 0.75 x nominal voltage, after 1 h continuous duty up to nominal voltage Response time ≤ 50 ms; release time ≤ 30 ms Starting, switching off while running DC4-VDE 0660 To insulation group C-VDE 0110 13 W Screw terminals, for conductor cross-section 3 mm NO contact, NC contact Copper M 8; permissible tightening torque 10…15 Nm Terminals IP 00; housing IP 54 –40…+100 °C Ensure adequate ventilation (cooling) during continuous operation.

Product overview Nominal Nominal Nominal voltage*) excitation load current current Contin. Load current duty up to 1 s V A A A

Service life of contact

Interrupting Dimensions current with inductive Mechanical Electrical load LxWxH Thousand Thousand A mm

Illustration, Circuit Weight Part number dimens. diagram drawing kg

NO relays 6 2.5 12 1.1 24 0.6 6/0.25 1) 0.8 6/0.25 1)

80 80 80 200 75 2) 100

800 800 800 800 150 2) 500

500 500 500 500 150 500

100 100 100 100 100 100

80 80 80 – – –

110 x 55 x 60 110 x 55 x 60 110 x 55 x 60 95 x 50 x 52 130 x 58 x 70 95 x 50 x 52

1 1 1 2 3 2

S1 S1 S1 S5 S3 S6

0.79 0.78 0.77 0.27 0.89 0.27

0 333 006 003 0 333 006 004 0 333 006 006 0 333 006 010 0 333 006 014 0 333 006 017 4)

NC relays 12 2.3 24 0.9

100 100

500 500

500 500

100 100

100 100

110 x 55 x 60 1 110 x 55 x 60 1

S4 S4

0.8 0.8

0 333 006 007 0 333 006 008

NO relays with auxiliary relay 3) 12 1.5 80 800 500 100 80 140 x 55 x 56 1 S2 0.77 0 333 006 015 5) 24 0.6 80 800 500 100 80 140 x 55 x 56 1 S2 0.7 0 333 006 018 *) Excitation and switching voltage. 1) Pull-in current 6 A, continuous current 0.25 A. 2) Referred to terminals 88 – 88a; terminals 87 – 87a must not be subjected to inductive loads of more than 3 A. 3) With additional auxiliary relay (changeover contact), e.g. for indicator lamps, max. 6 A (resistive load); 2.5 A (inductive load); contact P switches from 1 to 2. Method of functioning: When switching on, auxiliary contact switches before main contact; When switching off, main contact breaks before auxiliary contact switches. 4) Response time ≤ 14 ms, release time ≤ 58 ms. 5) Degree of protection for housing: IP 33 (see page 5).

23165_1076En_014-019 14.03.2002 7:37 Uhr Seite 19

B

A

Power relays

19


1

58 2

110

30 1

66 1,5

M

1

8

2

17 1

+ -1 2

A

8, 5

40 +1 -0,5

Ø 30 -1

55 +1,5 -1

Ø 48 0,5

50

56 +1,5 -1

V 31

M4

SW 13

5,3 0,2

A Auxiliary relay only with 0 333 006 015 and 0 333 006 018. Parts supplied loose with 0 333 006 006.

2

max. MA = 15 Nm

SW Width across flats

22 0,5 5,5

M8

26,5 0,5

M5

46 1

35 0,2

49,5 0,5

2

25 1

1,5 25

67,5

26,5 0,5

3

40 1

30,5 0,5

127 3

56 1

3

70

5,3+0,2

M8

Circuit diagrams S1

S2

S3 S3

50

30

50

31

30

31

1

2

P

S4 S4

S5

86

88a 87a

50

30

EW HW

85

88

31

30

+3

87

S6 1

-4 2

EW HW

+3

1

-4 2

EW Excitation winding, HW Hold-in winding

23165_1076En_020-023 14.03.2002 7:38 Uhr Seite 20

20

A

Power relays

B

Power relays (continued) Series 007

Parameters Nominal voltage *) Designation Construction Operating mode Voltage limits (permissible) Switching times at nominal voltage Utilization category Creepage distances and clearances Coil output Coil connection Main current contacts Contact material Connection bars Degree of protection (see page 5) Operating temperature range *) Excitation and switching voltage

24 V 150 A solenoid plunger circuit Open Continuous duty up to 1 h 0.7 x nominal voltage to nominal voltage Response time ≤ 30 ms; release time ≤ 30 ms Starting, switching off while running DC4-VDE 0660 To insulation group C-VDE 0110 20 W Blade terminals 0.8 x 6.3 mm 2 NO contacts (2-pole double break or 1-pole four-fold break) Sintered silver cadmium oxide (AgCdO) Hole Ø 6.4 mm for M 6 steel screws IP 00 –40…+100 °C

Product overview Relay Nominal Nominal function excitation load current current Contin. Load duty current NO 1s contact A A A

Service life of contact MechaElecnical trical

Interrupting Dimensions current with inductive load LxWxH

Thousand Thousand A

Illustra- Circuit Dim. Weight Part number tion diagram drwg.

mm

Single 2.3 – 250 1) 100 – – 87 x 62 x 102 1 Double 1 3) 2 x 150 2 x 1000 > 300 > 150 375 98 x 57 x 89 2 1) For max. 3 minutes. 2) Contact material: copper. 3) A maximum peak current of 13 A occurs at the pull-in moment. 4) Installation position: long edge of baseplate vertical, max. inclination 10°.

kg

S1 S2

1 2

0.8 0.8

0 333 007 002 2) 0 333 007 004 4)

Circuit diagram

S1 S1

S2

HW

EW

HW Hold-in winding EW Pull-in winding

The pull-in and hold-in windings are connected in parallel before response and the resulting high making current (approx. 13 A max.) guarantees rapid, reliable response. After the relay has operated, the electric circuit of the pull-in winding is interrupted and the hold-in winding holds the relay in its operated position at a current of approx. 1 A.

23165_1076En_020-023 14.03.2002 7:38 Uhr Seite 21

B

A

Power relays

Illustration

Dimension drawing

1

1

21

70,5 87 60

5

68 46 90

2 18

2

3 0,2

A

89 3

3,5 0,3

A

A

68 3 98 3

A Blade terminal 6.3 x 0.8 DIN 46 244

57 2

2 1,5

8,4 H 12 (+ 0,150)

A

6,4 H 13 (+ 0,220)

2

5

3,5

2

8

58

13

M5

4

52,5

170

32,5

38

2

97

M5

23165_1076En_020-023 14.03.2002 7:38 Uhr Seite 22

22

A

Power relays

B

Series 009 – one-pole

Parameters Designation Construction Operating mode Nominal voltages *) Voltage limits (permissible) Switching times at nominal voltage Utilization category Creepage distances and clearances Coil output Coil connection Main current contacts Contact material Connection bars Degree of protection (see page 5) Operating temperature range Note *) Excitation and switching voltage

150 A solenoid plunger circuit Closed Continuous duty up to 1 h 12 V, 24 V 0.75 x nominal voltage to nominal voltage Response time ≤ 50 ms; relaease time ≤ 40 ms Starting, switching off while running DC4-VDE 0660 To insulation group C-VDE 0110 20 W Blade terminals 0.8 x 6.3 mm, M 4 cable lug NO contact (double break) Silver nickel alloy (AgNi) M 8; permissible tightening torque 5.5 Nm Terminals: IP 00; housing: IP 54 –40…+100 °C Ensure adequate ventilation (cooling) during continuous operation

Product overview Nominal excitation current A

Nominal load current Contin. Load duty current 5 s A A

Service life of contact Mecha- Elecnical trical Thousand Thousand

Interrupting Dimensions current with inductive load LxWxH A mm

Illustration

Circuit diagram

Weight

Part number

kg

NO relays 12 V 1) 3.9 – 1.5 150 1.5 150 1.5 150

500 800 800 800

2000 2000 2000 2000

100 200 200 200

150 150 150 150

114 x 55 x 56 105 x 56 x 56 104 x 56 x 57 104 x 56 x 57

1 1 1 1

S1 S1 S1 S1

0.70 0.75 0.75 0.75

0 333 009 003 0 333 009 004 0 333 009 010 2) 0 333 009 014

NO relays 24 V 1) 0.83 150 0.83 150 0.83 150 0.83 150 1.20 –

800 800 800 800 800

2000 2000 2000 2000 2000

200 200 200 200 200

150 150 150 150 150

104 x 56 x 57 104 x 56 x 57 104 x 56 x 56 106 x 56 x 57 114 x 56 x 88

1 1 1 1 2

S1 S1 S1 S1 S1

0.75 0.75 0.75 0.75 0.80

0 333 009 002 0 333 009 005 0 333 009 009 2) 0 333 009 011 0 333 009 017 5)

NO relays 24 V 1) with auxiliary relay 4) 0.83 150 800 2000 200 150 127 x 50 x 67 1 S2 0.75 0 333 009 008 3) 4) 1) Nominal value of voltage (excitation and switching voltage). 2) With electric lead. 3) Degree of protection of housing IP 30 (see page 5). 4) With additional auxiliary relay (changeover contact), e.g. for indicator lamps, max. 6 A resistive load or 2.5 A inductive load. Contact P switches from 1 to 2. 5) Degree of protection of housing IP 6K9K (see page 5).

23165_1076En_020-023 14.03.2002 7:38 Uhr Seite 23

B

A

Power relays

Illustration

Circuit diagram

S1

50

30

31

S2

30 31

1

50

2

P

Dimension drawing

1 43

25 M8

56

40

50,6

M4

6

5,3

56

25,5 105

2

43

M8

25

88

60

40

50,6

15,7

3 30 56,2

11

5,3 9 30 114

23

23165_1076En_024-029 14.03.2002 7:39 Uhr Seite 24

24

A

Tractive electromagnets


B

Besides positioning applications, tractive electromagnets may also be used in the following: Ticket stamping/punching machines, guiding, locking, triggering, metering, ventilating, pushing, clamping, riveting, blocking, etc.

Pulling electromagnets 12 V for electromagnetic operation

Product overview Nominal Working Nominal voltage stroke wattage 1)

Operating mode 2)

Forces Working With armature Return spring stroke 3) pulled in 3) V mm W N N N 12 1.3 max. 21 Contin. duty ≥8 ≥ 11 2.3 ±0.5 15.3 960/12.5 4) Contin. duty ≥ 110 ≥ 270 – 4 69 Short-time duty ≥ 14 ≥ 70 4 ±1 6 211 Short-time duty ≥ 80 ≥ 250 – 15.3 277 Short-time duty ≥ 95 ≥ 200 4.5 ±0.5 1.3 14 Contin. duty 13 15 2.3 ±0.5 1) With armature pulled in. 2) Short-time duty, after 45 sec. of operation there should be a break of 4.5 min. 3) At nominal voltage and winding temperature 23 ±5 °C. 4) Pull-in winding/hold-in winding

Illustr./ Circuit Weight dimens. diagram drawing kg 1 S1 0.074 2 S2 1.1 3 S1 0.11 4 S3 0.65 5 S4 1.11 6 S1 0.103

Part number

0 330 001 040 0 330 003 007 0 330 001 004 0 330 002 004 0 330 003 002 0 330 001 020

Circuit diagrams S1

S2

S3 50

H

S4

31i

50

50

31i

31i

E

E Pull-in winding H Hold-in winding


1

40 14,7 10 6,3

H Stroke SW Width across flats

9,5

14

2

37 Ø5

97 7

M5

Ø5

5,6

120°

19

M6

H Stroke

M6

6 H 15,3 0,3

Ø 62

2

5,95

H 1,3 4,4

SW 24

8 7

16 23

26

M 24x1 22,8 20,2 14

M5

X

X 2:1 7

Ø 54,5

1

28,5 46

23165_1076En_024-029 14.03.2002 7:39 Uhr Seite 25

B

A


25

Illustrations and dimension drawings max. 48

28 0,5 7,5 0,5

38 0,1

2 0,3

28

5,3+0,2

-0,032 Ø 16-0,130 +0,061 Ø 10+0,025

2 0,3

48 0,5

3

Ø 28 0,3

3

0,5

H4

H Stroke

4

4

6,4+0,15 3,8 +0,15

26+0,3

57

60 0,1 H

6 0,2

72 0,5

M 4x8

Ø 19 0,1

Ø 47+0,5

M6

6,5 0,1

14,3- 0,2

57

7,1

5 20 13

5

5,5

H Stroke

70 0,1

Ø 62

44

57+1

7

Ø 28,5

Ø5

H 15,3 M6

43,5

6,4

58

100

H Stroke

6

14

Ø7 6

Ø 1,2

6

Ø 1,2

Ø7

Ø8

Ø 9,7

Ø 26,5

Ø 9,7

7 M5

M 27x1

SW 27

H 0,7…1,7


6

Ø 7,8

46,2 18

Ø 29 0,2

6

23165_1076En_024-029 14.03.2002 7:39 Uhr Seite 26

26

A


Tractive electromagnets (continued) Pulling electromagnets 24 V for electromagnetic operation

B


Product overview Nominal Working Nominal voltage stroke wattage 1)

Operating mode 2)

Forces Working stroke 3) N Contin. duty ≥ 16 Contin. duty ≥8 Contin. duty 13 Contin. duty ≥8 Short-time duty ≥ 14 Short-time duty ≥ 24 Short-time duty ≥ 95 Contin. duty ≥ 55

V 24

With armature pulled in 3) N ≥ 26 ≥ 11 15 ≥ 11 ≥ 70 ≥ 80 ≥ 250 ≥ 350

Return spring N 7.8 ±1 2.3 ±0.5 2.3 ±0.5 2.2 4 ±1 4 ±1 4.5 ±0.5 5 ±1

mm W 1.8 14 1.3 max. 21 1.3 14 1.3 max. 21 4 75 6 50 15.3 274 15.3 695/18 4) 1) With armature pulled in. 2) Short-time duty, after 45 sec. of operation there should be a break of 4.5 min. 3) At nominal voltage and winding temperature 23 ±5 °C. 4) Pull-in winding/hold-in winding

Illustr./ Circuit Weight dimens. diagram drawing kg 1 S1 0.32 2 S2 0.076 * S2 0.103 3 S4 0.094 4 S5 0.11 5 S5 0.44 6 S5 1.11 6 S3 1.18 * see figure 6, page 25

Part number

0 330 005 002 0 330 001 047 0 330 001 021 0 330 001 048 0 330 001 003 0 330 004 005 0 330 003 001 0 330 003 003

Circuit diagrams

S1

S2

+

S3

50

H

S4

E Pull-in winding

31i

E

S5

H Hold-in winding


1

32 61,3 0,5

30 3 0,1

54 0,5 H 1,8

H Stroke

46

22

Ø37,5 0,5

11

M 27x1

11

Ø4

1

8 0,1

23165_1076En_024-029 14.03.2002 7:39 Uhr Seite 27

B

2

A


2

40 14,7 6,3 10

7

X 2:1 M5 Ø 16 Ø 23 Ø 9,5 Ø8 Ø7

Ø 26

M 24x1 Ø 22,8 Ø 20,2 Ø 14

X

H 1,3 SW 24

27

6

4,4 14


3

3

37,3 33 14

14,7 10

X

510

6,3

20 X 2:1 9,5 8 7

26

M 24x1 22,8 20,2 14

7

H 1,3 4,4

SW 24

6

2 x 0,5mm 2

H Stroke SW Width across flats max. 48

28 0,5 7,5 0,5

5

5,3+0,2

-0,032 Ø 16-0,130 +0,061 Ø 10+0,025

28

0,5

H4

H Stroke

5

38 0,1

2 0,3

Ø 28 0,3

2 0,3

45°

45°

5,3+0,2

69

M4

Ø 32 0,5

M6

45+0,8

Ø 15,5 c10

H6

5,2 0,5

2 0,2

45+0,8

12 0,3

17+1

50 0,1

H Stroke

6

Ø5

44

Ø 62

7

Z

Ø 28,5

70 0,1

57+1

H 15,3 6,4

Y

H Stroke X 0 330 003 001 = 43.5 mm 0 330 003 003 = 70 mm Y 0 330 003 003 = U-fork offset by 90°

X

100 Z

7,1

5,5

58 M6

20 13

6

48 0,5

4

Ø 41-0,5

4

23165_1076En_024-029 14.03.2002 7:39 Uhr Seite 28

28

A


Tractive electromagnets (continued) Pushing electromagnets 12 V / 24 V for electromagnetic operation

B


Programmübersicht Nominal Working Nominal voltage stroke wattage 1) V 12

mm W 1 32 2.6 42.5 3 42.5 6.5 137 7 137 24 1 26 1 26 3 48 4.8 26.7 7 152 1) With armature pulled in.

Operating mode 2)

Forces Illustr./ Circuit Weight Working With armature Return dimens. diagram spring drawing stroke 3) pulled in 3) N N N kg Short-time duty ≥ 12 ≥ 12 – 2 S1 0.088 Short-time duty ≥ 20 ≥ 30 – 1 S1 0.19 Short-time duty ≥ 12 ≥ 60 0.9 ±0.2 4 S2 0.14 Short-time duty ≥ 50 ≥ 120 – 5 S3 0.4 Short-time duty ≥ 50 ≥ 120 – 6 S1 0.4 Short-time duty ≥ 11 ≥ 11 – 2 S1 0.088 Short-time duty ≥ 11 ≥ 11 – 3 S4 0.094 Short-time duty ≥ 12 ≥ 60 0.9 ±0.2 4 S2 0.14 Short-time duty ≥ 32 ≥ 100 – 5 S3 0.6 Short-time duty ≥ 50 ≥ 120 – 5 S3 0.4 2) Short-time duty, after 45 sec. of operation there should be a break of 4.5 min. 3) At nominal voltage and winding temperature 23 ±5 °C.

Part number

0 330 106 010 0 330 106 006 0 330 106 001 0 330 101 022 0 330 101 012 0 330 106 012 0 330 106 017 0 330 106 003 0 330 100 022 0 330 101 026

Circuit diagrams

S1

S2

S3

S4


Ø 30

52 6,4

16,5

M4

31,5 73,5

H Stroke

28

15,3

42

34,5

18

Ø 4,5

H 2,6 0,3

1

14

1

23165_1076En_024-029 14.03.2002 7:39 Uhr Seite 29

2

A


2

29

42,5 10

8,5

X 9,2 8 7,1

M5

M 24 x1

26

23,2

X 2:1

5,2 7,5 8,8

H1

SW 24

9,75

B

14


3 X

14

39,8 12,5 8,5 10

300 20 X 2:1 9,2 8 7,1

26

M 24x1 20,2

7

9,75

3

5,2 7,5 8,8

2 x 0,5mm 2

SW 24 H1

35,5


4

Ø3

Ø 28

38

Ø 8,6

5,3

48 0,5

4

M4

5

H 3

28,5

H Stroke

48,5

15,2

5 45°

45° 5,3

M4

10,3

Ø32 Ø41

45+0,8

Ø5

H 6,5 +0,7

45+0,8 50

53 70

H Stroke 50 5,3

50

H Stroke

H 7

20

53 70

Ø 41

Ø 32

M4

45

Ø 7,8

6

33 22

6

23165_1076En_030-031 14.03.2002 7:40 Uhr Seite 30

30

A

B

23165_1076En_030-031 14.03.2002 7:40 Uhr Seite 31

B

A

31

23165_1076En_032 14.03.2002 7:41 Uhr Seite 32

A

32

B

Industry sales Contacts

Austria

Germany

Norway

Robert Bosch AG Abteilung VAA Geiereckstraße 6 A-1110 Wien

Robert Bosch GmbH Abteilung AA/PKN Postfach 41 09 60 D-76227 Karlsruhe

Robert Bosch AS Postboks 629 N-1411 Kolbotn

Phone +43 [0]1 / 7 97 22-0 Fax +43 [0]1 / 7 97 22-10 96

Phone +49 [0]7 21 / 9 42-26 21 Fax +49 [0]7 21 / 9 42-25 20

Phone +47-66 81 71 58 Fax +47-66 81 71 86

e-m@il: [email protected]



Belgium

Great Britain

Spain

Robert Bosch NV SA Afdeling EA/Département EA Rue Henri Genessestraat 1 B-1070 BRUSSEL/BRUXELLES

Robert Bosch Ltd. Department RBGB/SAA/PKN P.O. Box 98 Uxbridge, UB9 5HN

Robert Bosch España, S.A. RBSP/VAC2 – Juan Benayas Hnos. García Noblejas, 19 E-28037 Madrid

Phone +32 [0]2 / 5 25-53 60 Fax +32 [0]2 / 5 25-52 62

Phone +44 [0]18 95 83 – 83 71 Fax +44 [0]18 95 83 – 83 32

Phone +34 91 3 27 96 59 Fax +34 91 3 27 98 58




Denmark Robert Bosch A/S Telegrafvej 1 DK-2750 Ballerup Phone +45 44 89 83 20 Fax +45 44 89 86 80 e-m@il: [email protected]

Israel Ledico Ltd. Automation Technology Mr. Adi Tasman P.O. Box 1746 IL-58117 Holon Phone 9 72-3-6 50 40 00 Fax 9 72-3-6 50 40 55 e-m@il: [email protected] Internet: www.ledico.com

Finland

Italy

Sweden Robert Bosch Aktiebolag Industriförsäljning Box 1154 SE-164 26 Kista Phone +46 [0]8 7 50 15 00 Fax +46 [0]8 7 50 15 60 e-m@il: [email protected] Internet: www.bosch.se

Switzerland

Robert Bosch Oy Ensiasennustuotteet PL44 (Tekniikantie 4 A) FIN-02151 Espoo

Robert Bosch S.p.A. RBIT/CRV-Ricambi per Veicoli Via M. A. Colonna 35 I-20149 Milano

Robert Bosch AG Abteilung EA Industriestr. 31 CH-8112 Otelfingen

Phone +358 [0]9-43 59 92 78 Fax +358 [0]9-43 59 92 70

Phone +39 02 36 96-3 60 Fax +39 02 36 96-4 23

Phone +41 [0]1 8 47-15 30 Fax +41 [0]1 8 47-15 29




France

Netherlands

Robert Bosch (France) S.A. Sales Pièces de Rechange – Ventes Industrielles (AA/SPR4-So) 32, Av. Michelet – BP 170 F – 93404 Saint-Ouen Cedex (France)

Robert Bosch B.V. Afdeling EA Postbus 502 NL-2130 AM Hoofddorp

Phone +33 [0]1 / 40 10-76 90 Fax +33 [0]1 / 40 10-73 08

Phone +31 [0] 23-56 56 8 75 Fax +31 [0] 23-56 56 8 70



23165_1076En_U3 14.03.2002 7:41 Uhr Seite U3

B

A

Relay

Special-requirements data sheet

If you have any requirements beyond the scope of the relays offered in this catalog, please enter these in the data sheet below. In the event of modifications, please enter the known product here. Bosch part number:

Please make a photocopy of this data sheet and return the completed copy to us.

Address:

Sender (customer):

Robert Bosch GmbH Abt. AA/PKN Postfach 41 09 60 D-76225 Karlsruhe Fax: 07 21/9 42-25 20 Your reference/letter of

Our dept./contact partner

Telephone (direct line)

Date

Project, application:

Basic sketch:

Technical data Nominal voltage

6V

Nominal current

A

Type

NO contact

Type of load

Resistive load

Termination

Blade-type terminal

Service life

Switching cycles

Switching rhythm

seconds on / ___ seconds off

Ambient temperature Additional requirements Excitation coil damping

min. ___ °C / max. ___ °C

Inductive load

None

Installation conditions

12 V

24 V

Changeover contact

NC contact

Motor load

Lamp load

Screw-on version

Soldered version

Resistance

Diode

Quantity required

Brief description:

Once only

Qty.

Desired delivery date Following quantities on given dates Date Qty. Yearly Specifications available

yes

no

Qty.

Monthly

Qty.

I would like more information 2002/2003

Original-Equipment Information

Lambda Sensor

HC HC

NOx

NOx

CO

CO

CO

HC

HC

US

0,9

0,95

Application Together with the 3-way catalytic converter, the Lambda oxygen sensor and the Lambda closed-loop control represent today's most effective exhaust-emissions control system for the spark-ignition (SI) engine. At present, there is no alternative available which even approaches the low exhaust-emission figures obtained with this system. Since 1976, Bosch has been producing the Lambda sensor for exhaust-emission control systems in the USA and Europe. The Bosch Lambda sensor was the world's first oxygen sensor to go into operation, and played a decisive role in the breakthrough of exhaust-emissions control using the closed-loop-controlled 3-way catalytic converter. In the meantime, this sensor has proved itself in millions of vehicles.

1,0

1,05

The Lambda sensor is screwed into the exhaust system. It is a detecting element for measuring the residual oxygen in the exhaust gas which, since it provides a precise indication of whether combustion is complete or not, is highly suitable as the measured quantity for closed-loop control of the A/F ratio. The Lambda-sensor output signal not only provides an indication of instantaneous A/F mixture composition, but it also follows any A/F mixture changes. The mixture-formation system controls the supply of fuel to the engine in accordance with the signal from the Lambda sensor so that a stoichiometric A/F ratio "Lamda" of λ = 1 is maintained.

λ

1,1

Lambda is the dimension used to define the mixture's A/F ratio.

λ=

instantaneous A/F ratio stoichiometric A/F ratio

Referred to the stoichiometric ratio λ = 1, a lean mixture (λ > 1) contains more air, and a rich mixture (λ < 1) contains less air. Heated or unheated Lambda sensors are used depending upon exhaust-system design and operating conditions. The extensive Bosch Lambda sensor program covers a wide variety of variants. The Lamda sensor is also used outside the automotive sector. For instance, for the closed-loop control of gas engines or of gas/oil burners.

A

Lambda Sensor

Design (Fig. 1) The Lambda sensor operates according to the principle of a galvanic oxygen concentration cell with solid electrolyte (Nernst principle). The solid-state electrolyte comprises a gas-impermeable ceramic element of circonium dioxide which is stabilized with yttrium oxide and closed at one end. The ceramic element's inside and outside surfaces are provided with electrodes composed of a thin, gas-permeable, porous layer of platinum which on the one side has an influence on the sensor characteristic due to its catalytic effects, and on the other serves for electrical contacting. On the outside surface of the sensor ceramic which protrudes into the exhaustgas stream, the platinum layer is itself coated with a highly porous ceramic layer. This robust layer prevents the catalytic platinum layer being attacked by the corrosive and erosive effects of the deposits in the exhaust gas, and thus ensures long-term sensor stability.

Fig 1: Arrangement of the Lambda sensor in the exhaust pipe (schematic) 1 Sensor ceramic, 2 Electrodes, 3 Contact, 4 Housing contact, 5 Exhaust pipe, 6 Ceramic protective layer (porous), 7 Exhaust gas, 8 Air.

¥¥ @@@ AA BBB CC ÀÀÀ ÁÁ ÂÂÂ ÃÃ ,,, QQQ RR SSS TT ¢¢¢ ££ ¤¤¤ @@@ AA BBB CC ÀÀÀ ÁÁ ÂÂÂ ÃÃ ,,, QQQ RR SSS TT ¢¢¢ ££ ¤¤¤ ¥¥ @@@ AA BBB CC ÀÀÀ ÁÁ ÂÂÂ ÃÃ ,,, QQQ RR SSS TT ¢¢¢ ££ ¤¤¤ ¥¥ @@@ AA BBB CC ÀÀÀ ÁÁ ÂÂÂ ÃÃ ,,, QQQ RR SSS TT ¢¢¢ ££ ¤¤¤ ¥¥ @@@ AA BBB CC ÀÀÀ ÁÁ ÂÂÂ ÃÃ ,,, QQQ RR SSS TT ¢¢¢ ££ ¤¤¤ ¥¥ 5

1

7

6

4

B

Fig. 2: Voltage characteristic of the Lambda sensor at 600°C working temperature a Rich mixture (air deficiency) b Lean mixture (air surplus) mV

8

3

a

b

1000

Sensor voltage US US Sondenspannung

2

800

600

400

200

2

0 0,8

0,9

1,1

1

1,2

Excess-air factor Luftzahl λ λ

Fig. 3: Engine with exhaust-gas system 1 Exhaust-gas system with catalytic converter, 2 Lambda sensor(s)

Operation (Fig. 2) The Lambda sensor is installed in the engine's exhaust-gas system at a point which throughout the engine's complete operating range provides the temperature which is necessary for efficient sensor functioning. The sensor protrudes into the exhaust gas, design being such that one electrode surface is surrounded by the exhaust gas and the other is connected to the atmosphere. Even under excess-fuel conditions, there is always residual oxygen in the SI engine's exhaust gas (at λ = 0.95, approx. 0.1 ... 0.3% by volume). The use of porous platinum electrodes means that at the electrode surface, catalytic conversion of this residual oxygen can take place with the carbon monoxide (CO), hydrocarbons (HC), and the hydrogen present in the exhaust gas. The residual oxygen remaining after complete conversion is a function of the exhaustgas Lambda value, and is measured by the Lambda (oxygen) sensor. During transition from a lean mixture (high residualoxygen content) to a rich mixture (very low residual-oxygen content), the residual-oxygen content reduces abruptly by several powers of 10 in the stoichiometric region λ = 1 of air-fuel mixture. This results in the sudden jump of sensor voltage output at λ = 1. The sensor voltage and its

1 2

2

internal resistance depend upon temperature. Reliable closed-loop control takes place at temperatures above 350°C (for the unheated sensor) and above 150°C (for the heated sensor).

Installation (Fig. 3) The Lambda sensor is installed in the exhaust system at a point which, besides featuring exhaust-gas composition which is representative for all cylinders, must also be hot enough (at least 350°C for the unheated sensor and 150° for the heated sensor). A sensor life corresponding to more than 160,000 km as driven by the vehicle can be achieved if the specifications for sensor loading are complied with.

The Lambda closed-loop (feedback) control The control loop comprises the engine (controlled system), the Lambda sensor (measuring element), the controller in the ECU, and the injectors (actuators). The controlled variable is the residual oxygen in the exhaust gas. The object of the closed-loop control is to generate an optimal A/F mixture by adjusting the quantity of fuel (manipulated variable) injected by the injectors (actuators). The Lambda closed-loop control automatically takes into account special modes such as start, acceleration, and full load.

B

A

Lambda Sensor

Unheated Lambda sensor LS (Fig. 4)

Fig. 4: Unheated Lambda sensor LS 1 Connection cable, 2 Disc spring, 3 Ceramic support tube, 4 Protective sleeve, 5 Contact element, 6 Sensor housing, 7 Active sensor ceramic, 8 Protective tube.

,, ,,

,,,

, ,,,,,,, ,,, ,,,

,,, ,,,,,,, ,,,,,,,, , , , ,,,,,,, ,,,,, ,,,,

The sensor's active ceramic body is held in position and sealed in the housing by means of a "finger-shaped" ceramic support tube and a disc spring. A contact element between the support tube and the active ceramic body is used to provide contacting from the inner electrode to the connection cable. The outer electrode is connected to the sensor housing by the metal seal ring. The sensor's internal elements are fastened and aligned by a protective metal sleeve which, apart from serving as a support for the disc spring, also protects the interior of the sensor against contamination. The cable is crimped to the end of the contact element which protrudes from the sensor, and is sealed off against dampness and mechanical damage by means of a temperature-resistant PTFE cap. In order to keep the exhaust-gas combustion deposits away from the sensor ceramic, the end of the housing which protrudes into the exhaust-gas flow is protected by a specially shaped tube having slots designed to provide highly effective protection against the effects of excessive thermal and chemical stresses.

3

1

2

3

4

5

6

8

,,,,, ,,,,, ,,,,, ,,,,, ,,,,, ,,,,, ,,,,, ,,,,, ,,,,, ,,,,, ,,,,, ,,,,,

,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,,

7

Fig. 5: Heated Lambda sensor LSH 1 Connection cable, 2 Disc spring, 3 Ceramic support tube, 4 Protective sleeve, 5 Clamp connection for the heating element, 6 Heating element, 7 Contact element, 8 Sensor housing, 9 Active sensor ceramic, 10 Protective tube.

, , 2

3

4

5

6

7

8

9

10

,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,,

,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,,,,, ,,, ,,,,, ,,, ,,,,, ,,, ,,,,, ,,, ,,,,, ,,, ,,,,, ,,

Heated Lambda sensor LSH (Fig.5)

Design Basically, the heated Lambda sensor is identical to the unheated version. The active sensor ceramic is heated from the inside by a ceramic heating element so that it remains above the 350°C function limit independent of the exhaust-gas temperature. The ceramic heating element has a PTC characteristic so that it heats up quickly and needs only very little power when the exhaust gas has heated up. The heating-element connections are fully decoupled from the sensor signal line (R ≥ 30 MΩ). In contrast to the unheated version, the heated sensor is equipped with a protective tube with small slots for exhaust-gas passage. This increases the protection against contamination and prevents the sensor ceramic cooling down excessively when the exhaust gas is still "cold".

,,,,, ,,,,, ,,,,, ,,,,, ,,,,, ,,

, ,, , ,, , , , ,, , , , ,, , , , , , , ,,,,, ,,,,,,,,, ,,,,,, ,,,,,

,,,,,,, ,,,,, , ,,,,,,,, , , , ,

1

Versions

Advantages

Bosch has a number of versions of its heated Lambda sensor available: – 3-pole version, – 3-pole version with additional grounding by cable, – 3-pole version with additional grounding by cable for lean-burn applications (LSM11), and – 4-pole version, isolated ground.

– Efficient closed-loop control even at low exhaust-gas temperatures (e.g. at idle), – Flexibility of installation, considerable latitude regarding mounting method, – Efficient functioning depends less on exhaust-gas temperature, – Lambda control comes into effect more quickly after engine start, – Improved exhaust-gas figures due to improved sensor dynamics, – Reduced danger of contamination leads to longer service life.

4

A

Lambda Sensor

Planar Lambda sensor (LSF) (Fig. 6)

Fig. 6: Planar Lambda sensor LSF 1 Connection cable , 2 Protective sleeve, 3 Planar sensor element, 4 Ceramic support tube, 5 Sensor housing, 6 Ceramic seal packing, 7 Protective tube.

1

2

3

,,

4

5

6

7

Special characteristics: – Short start-up times for the Lambda closed-loop control, – Stable control characteristics, – Lower heater rating, – Small size, – Low weight, and – Isolated-ground design.

,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,,

,,,, ,,,,, ,, ,, ,,,,, ,,,,, ,,,,, ,,,,,

trol electronics for the pump and sensor cells as required for generation of the sensor signal, but also the control electronics for controlling the sensor's temperature. As a result, novel applications become possible: – Control also possible at λ > 1 and λ < 1, – Continuous Lambda control at λ = 1, – Diesel-engine control, – Lean-burn concept for SI engines, – Gas-engine control.

The broadband Lambda sensor is a planar dual-cell limit-current sensor. Its modular construction, combined with planar techniques, makes it possible to integrate a number of additional functions. The fact that the LSU sensor is a combination of a Nernst concentration cell (sensor cell) and a pump cell for oxygenion transport, means that it can also measure accurately in lean and rich regions, not only at λ = 1 (Fig. 9). Each sensor is individually calibrated. Special control electronics are required for the LSU sensor (evaluation circuit) This contains not only the internal con-

,,,,,,, ,,,,,,, ,,,,,,, ,,,,,,, ,,,,,,, 1

Fig. 7: Planar Lambda sensor LSF (functional layers). 1 Porous protective layer, 2 External electrode, 3 Sensor foil, 4 Inner electrode, 5 Reference-air passage foil, 6 Insulation layer, 7 Heater, 8 Heater foil, 9 Connection contact.

Us

,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,, 2

1

Planar broadband Lambda sensor LSU

Fig. 8: Planar Lambda sensor LSF (layer build-up) 1 Exhaust gas, 2 Reference-air passage, 3 Heater. US Sensor voltage.

3

Fig. 9: Planar broadband Lambda sensor LSU (layer build-up and curve) 1 Exhaust gas, 2 Pump cell, 3 Diffusion gap, 4 Sensor cell, 5 Reference-air passage, 6 Heater, 7 Sensor signal, 8 Controller. Ip Pump current.

,, ,,, ,,,,, ,, ,,, ,,,,, ,,,,, 1

2

2

3

3

4

,,,,,,,,,,,

5

4 6

5

7 Ip

8

mA

6 7 6 8

3,0

Pump current Ip IP Pumpstrom

From the construction viewpoint, the major differences between the LSF sensor and the LSH sensor are as follows: – The LSF sensor element is fixed in the sensor housing by means of a ceramic seal packing. – The double-wall protective tube was specially designed for the planar sensor and provides the sensor element with highly effective protection against excessive thermal and mechanical stresses.

,,,,,, ,,,,,,

, , ,, , , , , ,, , , , ,,,,, , , ,,,,,,,, , , , ,,,,, ,,,,,,,, ,,,

The planar Lambda sensor has been developed from the proven tube-type ("finger-version") sensor. Functionally, with its voltage curve jump at λ = 1, it corresponds to the heated finger version, while at the same time providing the basic technology for further ceramic-type sensors. In contrast to the finger sensor though, the planar sensor uses ceramic foils as the solid-state electrolyte. Screen-printing techniques are employed for producing the individual functional layers (electrodes, protective layers, etc.). The printed foils are laminated one on top of the other, and this principle enables a heater to be integrated in the sensor element (Figs. 7 and 8).

B

2,0 1,0 0,0

–1,0

– 2,0

9

Robert Bosch GmbH, Automotive Equipment Business Sector, Division K3, Product Group Lambda Sensor (K3-LS/VKA), Postfach 30 02 20, D-70442 Stuttgart.

1,0

1,6 2,2 Excess-air factor Luftzahl λ λ

2,5

K3-LS/VKA-D323E01 (08.95) En

22223_1021En_A001

12.07.2001

9:44 Uhr

Seite 1

Sensors Techniques and applications CAN-Bus

2 4

Angular-position sensors Steering-wheel-angle sensors ±780° Throttle-valve angular-position sensors 88° Yaw-rate sensors

6 8 10

Rotational-speed sensors Rotational speeds and angle Rotational speeds

12 14

Acceleration sensors Pyroelectric sensors up to ±5 g Piezoelectric sensors up to 35 g Surface-type micromechanical sensors ±10 g to ±50 g Piezoelectric vibration sensors Vibration sensors for signal evaluation

16 18 20 22 24

Pressure sensors Pressure measurement In gases from –100 kPa to 5 kPa In gases and liquid mediums from –2.5 kPa to +3.75 kPa In atmosphere from 60 kPa to 115 kPa In gases up to 250 kPa In gases up to 400 kPa In gases and liquid mediums up to 600 kPa Pressure sensors up to 1800 bar (180 MPa)

26 28 30 32 34 40 45

Temperature sensors Air temperatures from –40 °C to 130 °C Liquid temperatures from –40 °C to 130 °C

50 52

Air-mass meters Air-mass flow rates up to 1080 kg/h Air-mass flow rates up to 1000 kg/h

54 56

Lambda oxygen sensors

58

Enquiry data sheet

61

We reserve the right to make technical changes.

22223_1021En_002-003

12.07.2001

9:45 Uhr

Seite 2

A

2 Sensors

B

Techniques and applications

This catalog features the most important technical data required for selecting a given sensor. To date, the sensors listed have all been used in automotive applications, but their universal and highly versatile characteristics also make them ideally suitable for industrial applications. For instance in:

● Manufacturing engineering ● Mechanical engineering ● Automation ● Materials handling and conveying ● Heating and air-conditioning ● Chemical and process engineering ● Environmental and conservation technology ● Installation and plant engineering

Brief descriptions and examples of application are to be found in the Table below. For the applications listed below, prior clarification of the technical suitability is imperative. This Catalog only lists those products which are available from series manufacture. If your problem cannot be solved with this range of products, please inform of us of your requirements using the Enquiry Data Sheet.

Sensors

Automotive application

Examples of non-automotive applications

Angular position sensors measure simple angular settings and changes in angle.

Throttle-valve-angle measurement for engine management on gasoline (SI) engines.

Door/window opening angle, setting-lever angles in monitoring and control installations.

Rotational-speed sensors measure rotational speeds, positions and angles in excess of 360°.

Wheel-speed measurement for ABS/TCS, engine speeds, positioning angle for engine management, measurement of steeringwheel angle, distance covered, and curves/bends for vehicle navigation systems.

Proximity or non-contact measurement of rotational speed, displacement and angular measurement, definition of end and limit settings for industrial machines, robots, and installations of all types.

Spring-mass acceleration sensors measure changes in speed, such as are common in road traffic.

Registration of vehicular acceleration and deceleration. Used for the Antilock Braking System (ABS) and the Traction Control System (TCS).

Acceleration and deceleration measurement for safety, control, protective systems in lifts, cable railways, fork-lift trucks, conveyor belts, machines, wind power stations.

Bending-beam acceleration sensors register shocks and vibration which are caused by impacts on rough/unpaved road surfaces or contact with kerbstones.

For engine management, detection of vibration on rough/unpaved road surfaces.

Forced switch-off for machines, industrial robots, manufacturing plant, and gaming machines in case of sudden acceleration or deceleration caused by shock or impact.

Piezoelectric acceleration sensors measure shocks and vibration which occur when vehicles and bodies impact against an obstacle.

Impact detection used for triggering airbags and belt tighteners.

Detection of impact in monitoring/surveillance installations, detection of foreign bodies in combine harvesters, filling machines, and sorting plants. Registration of score during rifleman competitions.

Yaw sensors measure skidding movements, such as occur in vehicles under road traffic conditions.

Used on the vehicle dynamics control (Electronic Stability Program, ESP) for measuring yaw rate and lateral acceleration, and for vehicle navigation sensors.

Stabilization of model vehicles and airplanes, safety circuits in carousels and other entertainment devices on fairgrounds etc.

Piezoelectric vibration sensors measure structure-borne vibrations which occur at engines, machines, and pivot bearings.

Engine-knock detection for anti-knock control in engine-management systems.

Machine-tool safety, cavitation detection, pivotbearing monitoring, structure-borne-noise detection in measurement systems.

Absolute-pressure sensors measure the pressure ranges from about 50% to 500% of the earth’s atmospheric pressure.

Manifold vacuum measurement for engine management. Charge-air-pressure measurement for charge-air pressure control, altitudepressure-dependent fuel injection for diesel engines.

Pressure control in electronic vacuum cleaners, monitoring of pneumatic production lines, meters for air-pressure, altitude, blood pressure, manometers, storm-warning devices.

Differential-pressure sensors measure differential gas pressures, e.g. for pressurecompensation purposes.

Pressure measurement in the fuel tank, evaporative-emissions control systems.

Monitoring of over and underpressure. Pressure limiters, filled-level measurement.

Temperature sensors measure the temperature of gaseous materials and, inside a suitable housing, the temperatures of liquids in the temparature range of the earth’s atmosphere and of water.

Display of outside and inside temperature, control of air conditioners and inside temperature, control of radiators and thermostats, measurement of lube-oil, coolant, and engine temperatures.

Thermometers, thermostats, thermal protection, frost detectors, air-conditioner control, temperature and central heating, refrigerant-temperature monitoring, regulation of hot-water and heat pumps.

Lambda oxygen sensors determine the residual oxygen content in the exhaust gas.

Control of A/F mixture for minimization of pollutant emissions on gasoline and gas engines.

Pollutants reduction during combustion, smoke measurement, gas analysis.

Air-mass meters measure the flow rate of gases.

Measurement of the mass of the air drawn in by the engine.

Flow-rate measurement for gases on test benches and in combustion plant.

22223_1021En_002-003

B

12.07.2001

9:45 Uhr

Seite 3

A

Sensors 3

IP degrees of protection Valid for the electrical equipment of road vehicles as per DIN 40 050 (Part 9). ● Protection of the electrical equipment inside the enclosure against the effects of solid foreign objects including dust. ● Protection of the electrical equipment inside the enclosure against the ingress of water. ● Protection of persons against contact with dangerous parts, and rotating parts, inside the enclosure.

Structure of the IP code IP

2

1)

2)

3

C

M

Code letters First characteristic numeral 0...6 or letter X Second characteristic numeral 0...9 or letter X Additional letter (optional) A, B, C, D Supplementary letter (optional) M, S K1) If a characteristic numeral is not given, it must be superseded by the letter “X” (i.e. “XX” if both characteristic numerals are not given). The supplementary and/or additional letters can be omitted at will, and need not be superseded by other letters. 1) The supplementary letter “K” is located either directly after the first characteristic numerals 5 and 6, or directly after the second characteristic numerals 4, 6 and 9. 2) During the water test. Example: IP16KB protection against the ingress of solid foreign bodies with diameter ≥ 50 mm, protection against high-pressure hose water, protection against access with a finger.

Comments on IP code 1st characteristic numeral and supplementary letter K 0

Protection of electrical equipment against ingress of solid foreign objects Non-protected

Persons

1

Protection against foreign bodies Ø ≥ 50 mm

2

Protection against foreign bodies Ø ≥ 12.5 mm

Protection 1 against contact with back of hand Protection 2 against contact with finger

3

5K

Protection against foreign bodies Ø ≥ 2.5 mm Protection against foreign bodies Ø ≥ 1.0 mm Dust-protected

Protection 3 against contact with tool Protection 4 against contact with wire Protection 4K against contact with wire

6K

Dust-proof

Protection 5 against contact with wire 6

4

Non-protected

2nd characteristic numeral and supplementary letter K 0

6K 7 8 9K

Protection of electrical equipment against the ingress of water Non-protected

Additional Protection of letter persons against (optional) contact with hazardous parts A

Protection M against contact with back of hand

Protection against vertically dripping water

B

Protection against contact with finger

S

Protection C against dripping water (at an angle of 15°) Protection D against splash water Protection against spray water Protection against highpressure spray water Protection against jets of water Protection against powerful jets of water Protection against high-pressure jets of water Protection against temporary immersion Protection against continuous immersion Protection against highpressure/steamjet cleaners

Protection against contact with tool

K

Protection against contact with wire

Additional letter (optional) Movable parts of the equipment are in motion2) Movable parts of the equipment are stationary2) For the electrical equipment of road vehicles

22223_1021En_004-005

4

12.07.2001

9:48 Uhr

Seite 4

A

Sensors

B

CAN-Bus Controller Area Network

Present-day motor vehicles are equipped with a large number of electronic control units (ECUs) which have to exchange large volumes of data with one another in order to perform their various functions. The conventional method of

doing so by using dedicated data lines for each link is now reaching the limits of its capabilities. On the one hand, it makes the wiring harnesses so complex that they become unmanageable, and on the other the finite number of pins

on the connectors becomes the limiting factor for ECU development. The solution is to be found in the use of specialized, vehicle-compatible serial bus systems among which the CAN has established itself as the standard.

Applications There are four areas of application for CAN in the motor vehicle, each with its own individual requirements:

Bus configuration CAN operates according to the multimaster principle, in which a linear bus structure connects several ECUs of equal priority rating (Fig. 1). The advantage of this type of structure lies in the fact that a malfunction at one node does not impair bus-system access for the remaining devices. Thus the probability of a total system failure is substantially lower than with other logical architectures (such as ring or active star structures). When a ring or active star structure is employed, failure at a single node or at the CPU is sufficient to cause a total failure.

they then repeat the transmission attempt as soon as the bus is free again.

Real-time applications Real-time applications, in which electrical systems such as Motronic, transmissionshift control, electronic stability-control systems are networked with one another, are used to control vehicle dynamics. Typical data transmission rates range from 125 kbit/s to 1 Mbit/s (high-speed CAN) in order to be able to guarantee the real-time characteristics demanded. Multiplex applications Multiplex applications are suitable for situations requiring control and regulation of body-component and luxury/convenience systems such as air conditioning, central locking and seat adjustment. Typical data transmission rates are between 10 kbits and 125 kbit/s (low-speed CAN). Mobile-communications applications Mobile-communications applications connect components such as the navigation system, cellular phone or audio system with central displays and controls. The basic aim is to standardize control operations and to condense status information so as to minimize driver distraction. Data transmission rates are generally below 125 kbit/s; whereby direct transmission of audio or video data is not possible. Diagnostic applications Diagnostic applications for CAN aim to make use of existing networking for the diagnosis of the ECUs incorporated in the network. The use of the “K” line (ISO 9141), which is currently the normal practice, is then no longer necessary. The data rate envisaged is 500 kbit/s.

Content-based addressing Addressing is message-based when using CAN. This involves assigning a fixed identifier to each message. The identifier classifies the content of the message (e.g., engine speed). Each station processes only those messages whose identifiers are stored in its acceptance list (message filtering, Fig. 2). Thus CAN requires no station addresses for data transmission, and the nodes are not involved in administering system configuration. This facilitates adaptation to variations in equipment levels. Logical bus states The CAN protocol is based on two logical states: The bits are either “recessive” (logical 1) or “dominant” (logical 0). When at least one station transmits a dominant bit, then the recessive bits simultaneously sent from other stations are overwritten. Priority assignments The identifier labels both the data content and the priority of the message being sent. Identifiers corresponding to low binary numbers enjoy a high priority and vice versa. Bus access Each station can begin transmitting its most important data as soon as the bus is unoccupied. When several stations start to transmit simultaneously, the system responds by employing “Wired-AND” arbitration to sort out the resulting contentions over bus access. The message with the highest priority is assigned first access, without any bit loss or delay. Transmitters respond to failure to gain bus access by automatically switching to receive mode;

Message format CAN supports two different data-frame formats, with the sole distinction being in the length of the identifier (ID). The standardformat ID is 11 bits, while the extended version consists of 29 bits. Thus the transmission data frame contains a maximum of 130 bits in standard format, or 150 bits in the extended format. This ensures miminal waiting time until the subsequent transmission (which could be urgent). The data frame consists of seven consecutive bit fields (Fig. 3 ): “Start of frame” indicates the beginning of a message and synchronizes all stations. “Arbitration field” consists of the message’s identifier and an additional control bit. While this field is being transmitted, the transmitter accompanies the transmission of each bit with a check to ensure that no higher-priority message is being transmitted (which would cancel the access authorization). The control bit determines whether the message is classified under “data frame” or “remote frame”. “Control field” contains the code indicating the number of data bytes in the data field. “Data field’s” information content comprises between 0 and 8 bytes. A message of data length 0 can be used to synchronize distributed processes. “CRC field” (Cyclic Redundancy Check) contains the check word for detecting possible transmission interference. “Ack field” contains the acknowledgement signals with which all receivers indicate receipt of non-corrupted messages. “End of frame” marks the end of the message.

22223_1021En_004-005 01.02.2002 10:45 Uhr Seite 5

B

A

Sensors

1 Linear bus structure. Transmission shift control Station 1

2 Message filtering.

3 Message format.

Engine management Station 2 CAN Station 1

CAN Station 2

Accept

Make ready

Selection

Send message

CAN

Reception

5

CAN Station 3

Start of Frame Arbitration Field Control Field Data Field CRC Field ACK Field End of Frame Inter Frame Space

CAN Station 4

Accept

Selection

Selection

Reception

Reception

1 IDLE 1* 12* 6* 0...64* 16*

2* 7* 3* IDLE

0 Data Frame ABS/TCS/ESP Station 3

Instrument cluster Station 4

Transmitter initiative The transmitter will usually initiate a data transfer by sending a data frame. However, the receiver can also request data from the transmitter. This involves the receiver sending out a “remote frame”. The “data frame” and the corresponding “remote frame” have the same identifier. They are distinguished from one another by means of the bit that follows the identifier. Error detection CAN incorporates a number of monitoring features for detecting errors. These include: – 15 Bit CRC (Cyclic Redundancy Check): Each receiver compares the CRC sequence which it receives with the calculated sequence. – Monitoring: Each transmitter compares transmitted and scanned bit. – Bit stuffing: Between “start of frame” and the end of the “CRC field”, each “data frame” or “remote frame” may contain a maximum of 5 consecutive bits of the same polarity. The transmitter follows up a sequence of 5 bits of the same polarity by inserting a bit of the opposite polarity in the bit stream; the receivers eliminate these bits as the messages arrive. – Frame check: The CAN protocol contains several bit fields with a fixed format for verification by all stations. Error handling When a CAN controller detects an error, it aborts the current transmission by sending an “error flag”. An error flag consists of 6 dominant bits; it functions by deliberately violating the conventions governing stuffing and/or formats.

Bus

Fault confinement with local failure Defective stations can severely impair the ability to process bus traffic. Therefore, the CAN controllers incorporate mechanisms which can distinguish between intermittent and permanent errors and local station failures. This process is based on statistical evaluation of error conditions. Implementations In order to provide the proper CPU support for a wide range of different requirements, the semiconductor manufacturers have introduced implementations representing a broad range of performance levels. The various implementations differ neither in the message they produce, nor in their arrangements for responding to errors. The difference lies solely in the type of CPU support required for message administration. As the demands placed on the ECU’s processing capacity are extensive, the interface controller should be able to ad-

Message Frame

minister a large number of messages and expedite data communications with, as far as possible, no demands on the CPU’s computational resources. Powerful CAN controllers are generally used in this type of application. The demands placed on the controllers by multiplex systems and present-day mobile communications are more modest. For that reason, more basic and less expensive chips are preferred for such uses. Standardization CANs for data exchange in automotive applications have been standardized both by the ISO and the SAE – in ISO 11519-2 for low-speed applications ≤ 125 kbit/s and in ISO 11898 and SAE J 22584 (cars) and SAE J 1939 (trucks and busses) for high-speed applications >125 kbit/s. There is also an ISO standard for diagnosis via CAN (ISO 15765 – Draft) in the course of preparation.

Source: Texts and illustrations on the subject of CAN-Bus are taken from the Bosch Automotive Handbook, 5th Edition, 2000. The Automotive Handbook contains a very wide variety of information covering the whole range of modern-day automotive engineering. Further information on sensors in the vehicle can be taken from the Bosch Yellow Jacket publication “Automotive Sensors” which is scheduled to appear in the Autumn.

22223_1021En_006-007

6

12.07.2001

10:13 Uhr

Seite 6

A

Steering-wheel-angle sensors

B

Steering-wheel-angle sensor Measurement of angles from –780° to +780° φ CAN P “True-Power-On” function. P Multiple-rotation function. P CAN interface.

Application The steering-wheel-angle sensor was developed for use with vehicle dynamics systems (ESP*). Due to integral plausibility tests, and special self-diagnosis functions, this steeringwheel-angle sensor is highly suitable for application in safety systems. Design and function When the steering wheel is turned it rotates a gearwheel which in turn drives two other special measuring gears which incorporate magnets. AMR elements which change their resistance as a function of the direction of magnetic field register the angular position of the magnets. These analog measured values are then inputted to the microprocessor via an A/D converter. The number of teeth on one measuring gear differs to that on the other, which means that they therefore change their rotational position at different speeds. By combining both the actual angles of rotation, it is possible to calculate the total angle of rotation. After a number of rotations of the steering wheel, each of the measuring gears has returned to its initial position. Using this principle, it becomes possible to cover a measurement range of several steering-wheel rotations without the need to use a revolution counter. The steering-wheel angle is outputted in the form of an absolute angle across the total steering-column rotation range. One of this sensor’s special features is the fact that the (correct) angle-of-rotation is available immediately the ignition is switched on, without the steering wheel having been moved (“True-Power-On”). The steeringwheel angle and the steering-wheel speed are outputted via CAN. * ESP = Electronic Stability Program

Installation possibilities. A Steering-column switch, B Steering column

Design and function. 1 Steering column, 2 AMR sensor element, 3 Measuring gear with m teeth, 4 Evaluation electronics, 5 Magnets, 6 Measuring gear with n>m teeth, 7 Gearwheel with m+1 1 teeth

A

2

5 6

B 3 4

7

Technical data / Range Order No.

0 265 005 411 1)

Steering-wheel-angle sensor/Type Measuring range, angle Measuring range, acceleration Sensitivity and resolution throughout the measuring range, angle Sensitivity and resolution throughout the measuring range, acceleration Non-linearity throughout measuring range Hysteresis throughout measuring range Rate of steering-wheel-angle change, max. Rate of steering-wheel-angle change, displayed

LWS 3 –780°...+779.9° 0...1016°/s 0.1° 4°/s –2.5°...+2.5° 0°...5° –2000°...+2000°/s 0°...1016°/s

General data Operating temperature Storage temperature Supply voltage Supply-voltage range UV Current consumption at 12 V 1) Details of further designs upon request

–40...+85 °C –40...+50 °C 12 V nominal 8...16 V < 150 mA

B

12.07.2001

10:13 Uhr

Seite 7

A

Steering-wheel-angle sensors

Dimension drawings. A Distance hub to mount B Distance LWS (steering-wheel-angle sensor) to steering-column mounting flange H Mounting bracket M Mounting direction P Space for mating connector and wiring harness X Connector-pin assignment

Steering-column installation dimensions

Y

ø 32,7 ± 0,5 27

,5

m ax

.

30

26

,7

17,6 ± 0,2

P

+ - 0, 0, 2 1

22,7 ± 0,1

7

23 ± 0,2

22223_1021En_006-007

2,8 ± 0,3

30

8 ± 0,5 ø 32,7 ± 0,5

A 0,5

14,3 ± 0,5

60 ø 8,3 ± 0,1

0,8

0

6,7 ± 0,5

1,8

1

H Y 84 ± 0,5 79 ± 0,5

49,1 ± 0,5 35,1

79

B

M ø 34

1 2 4 5 6

3 7

X

Characteristic curve. Counterclockwise

Clockwise

Output signal

700°

Further application possibilities Using the standardized CAN-Bus, the steering-wheel angle information can be used for such systems as electronic stability program (ESP), navigation and electric power steering. Details of mechanical connection variants, as well as of the electrical interface are available on request.

Connector-pin assignment. Pin 1 Ground Pin 2 12 V Pin 3 CAN high Pin 4 CAN low Pin 5 – Pin 6 – Pin 7 –

0°

1

4

2

5

3

6

7

-780° 700°

0° Steering-wheel angle

-780°

Block diagram.

AMR element AMR element

A/D converter

Microprocessor

CANDriver

CAN-Bus

22223_1021En_008-009

8

12.07.2001

9:47 Uhr

Seite 8

A

Angular-position sensors

B

Throttle-valve angular-position sensor Measurement of angles up to 88° φ R P Potentiometic angularposition sensor with linear characteristic curve. P Sturdy construction for extreme loading. P Very compact.

Design The position sensor 0 280 122 001 has one linear characteristic curve. The position sensor 0 280 122 201 has two linear characteristic curves. This permits particularly good resolution in the angular range 0°...23°. Explanation of symbols UA Output voltage UV Supply voltage φ Angle of rotation UA2 Output voltage, characteristic curve 2 UA3 Output voltage, characteristic curve 3 Accessories for 0 280 122 001 Connector 1 237 000 039 Accessories for 0 280 122 201 Plug housing 1 284 485 118 Receptacles, 5 per pack, Qty. required: 4 1 284 477 121 Protective cap, 5 per pack, Qty. required: 1 1 280 703 023

1,00 0,94

1,00 0,9125 0,80

T

UA UV

N

Voltage ratio

Design and function The throttle-valve angular-position sensor is a potentiometric sensor with a linear characteristic curve. In electronic fuel injection (EFI) engines it generates a voltage ratio which is proportional to the throttle valve’s angle of rotation. The sensor’s rotor is attached to the throttle-valve shaft, and when the throttle valve moves, the sensor’s special wipers move over their resistance tracks so that the throttle’s angular position is transformed into a voltage ratio. The throttle-valve angular-position sensor’s are not provided with return springs.

Characteristic curves 2 and 3. A Internal stop, φW Electrically usable angular range.

Characteristic curve 1. A Internal stop, L Positional tolerance of the wiper when fitted, N Nominal characteristic curve, T Tolerance limit, φW Electrically usable angular range.

U Voltage ratio UA V

Application These sensors are used in automotive applications for measuring the angle of rotation of the throttle valve. Since these sensors are directly attached to the throttlevalve housing at the end of the throttleshaft extension, they are subject to extremely hostile underhood operating conditions. To remain fully operational, they must be resistant to fuels, oils, saline fog, and industrial climate.

0,05 0 L A

0 10

ϕw Angle of rotation ϕ

3

0,60 0,40 0,20 0,05 0

100° 96 A

2

88 0

23 30

ϕw

A

60

90° A

Angle of rotation ϕ

Technical data / Range Part number Diagram Useful electrical angular range Useful mechanical angular range Angle between the internal stops (must not be contacted when sensor installed) Direction of rotation Total resistance (Terms. 1–2) Wiper protective resistor (wiper in zero setting, Terms. 2–3) Operating voltage UV Electrical loading Permissible wiper current Voltage ratio from stop to stop Chara. curve 1 Voltage ratio in area 0...88 °C Chara. curve 2 Chara. curve 3 Slope of the nominal characteristic curve Operating temperature Guide value for permissible vibration acceleration Service life (operating cycles)

Degree Degree

Degree kΩ Ω V µA

0 280 122 001 1; 2 ≤ 86 ≤ 86

0 280 122 201 3 ≤ 88 ≤ 92

≥ 95 Optional 2 ±20 %

– Counterclockwise –

710...1380 5 Ohmic resistance ≤ 18

– 5 Ohmic resistance ≤ 20

0.04 ≤ UA/UV ≤ 0.96 –

deg–1 °C

– – 0.00927 –40...+130

0.05 ≤ UA2/UV ≤ 0.985 0.05 ≤ UA3/UV ≤ 0.970 – –40...+85

m · s–2 Mio

≤ 700 2

≤ 300 1.2

22223_1021En_008-009

12.07.2001

9:47 Uhr

Seite 9

A

B

Angular-position sensors

Dimension drawings. A Plug-in connection, B O-ring 14.65 x 2 mm, C Fixing dimensions for throttle-valve housing, D Clockwise rotation 1), E Counterclockwise rotation 1), Ö Direction of throttle-valve opening. 1) Throttle valve in idle setting.

F O-ring 16.5 x 2.5 mm, G 2 ribs, 2.5 mm thick, H Plug-in connection, I Blade terminal, K This mounting position is only permissible when the throttle-valve shaft is sealed against oil, gasoline, etc., Ö Direction of throttle-valve opening, L Fixing dimensions for throttle-valve potentiometer.

0 280 122 001

0 280 122 201

1 23

5 ± 0,1

7°±1° 14°+2° -1° 20 39

54

67

35

R

13

10,5

12 3 4

R4

4,5 ± 0,1

5 6,

F G

55 ± 0,2 68

4,8 + 0,3

16

7

K

4,6 ± 0,3

22

2 ± 0,2

59 ø20,5 ± 0,3

4 ± 0,05 1 ± 0,2 x45°

38

30,5 ± 0,1

L

1+0,2

,8° ±2

9,7

° 90

ø25 min.

D

70 ± 0,2

ø8 -0,05

2

M4

M4

E 7,5 8,5

X

°± 90

2

2°

Ö

176° ± 2°

Ö

Ö

Diagram 1.

Diagram 2.

3

I

+1

13,5 -0,3

+0,2

4,5 ± 0,3

30°

0,5 -0,1x 45°

11 ± 0,5

ø21 h10

min.ø21 13

55 ± 0,2

6 -0,1

H

2,5 -0,5

X 16

30,5 ± 0,1 24,5 ± 0,1

B

2,3

+0,02

M4

7,5

ø15,1-0,10

M4

ø15,1 D10 ø8 -0,05

C

ø21 D10

35

85 70 ± 0,2

A

2

1

(+)

(-)

Diagram 3. Throttle valve in idle setting. 3

2

1

(-)

(+)

( )

S2

( )

S1

4

3

2

1

9

22223_1021En_010-011

10

12.07.2001

9:46 Uhr

Seite 10

A

Yaw sensor

B

Yaw sensor (gyrometer) with micromechanical acceleration sensor Ω U P Compact system design with highly integrated electronics. P Insensitive to mechanical or electrical interference. P Simultaneous measurement of yaw rate and acceleration vertical to the rotary axis. P Extensive yaw-rate measuring range from 0.2...100 degrees per second (corresponds to 2...1,000 rotations per hour). P Capacitive measuring concept. Design The complete unit is comprised of a yaw sensor and an acceleration sensor, together with evaluation electronics. These components are all mounted on a hybrid and hermetically sealed in a metal housing. Application This sensor is used in automotive engineering for the vehicle dynamics control (Electronic Stability Program, ESP) and measures the vehicle’s rotation around its vertical axis, while at the same time measuring the acceleration at right angles to the driving direction. By electronically ervaluating the measured values, the sensor is able to differentiate between normal cornering and vehicle skidding movements. Operating principle Two oscillatory masses each have a conductor attached through which alternating current (AC) flows. Since both of the masses are located in a constant magnetic field, they are each subjected to an electrodynamic force which causes them to oscillate. If the masses are also subjected to a rotational movement, Coriolis forces are also generated. The resulting Coriolis acceleration is a measure for the yaw rate.The linear acceleration values are registered by a separate sensor element. Installation information – Installation near to the vehicle’s center of gravity – Max. reference-axis deviation transverse to the direction of movement ±3° – Refer to sketch on Page 9 – Tightening torque for fastening screws: 6 +2/–1 Nm. Explanation of symbols Ω Yaw rate g Acceleration due to gravity 9.8065 m · s–2 aq Linear (transverse) acceleration

Technical data / Range Part number

0 265 005 258

Yaw sensor Maximum yaw rate Ωmax. about the rotary axis (Z-axis) Minimum resolution ∆Ω Sensitivity Change of sensitivity Offset yaw rate Change of offset Non-linearity, max. deviation from best linear approximation Ready time Dynamic response Electrical noise (measured with 100 Hz bandwidth)

DRS-MM1.0R ±100°/s ±0.2°/s 18 mV/°/s ≤ 5% 2°/s 1) ≤ 4°/s ≤ 1% FSO ≤1s ≥ 30 Hz ≤ 5 mVrms

Linear acceleration sensor Maximum acceleration αqmax Sensitivity Change of sensitivity Offset Change of offset Non-linearity, max. deviation from best linear approximation Ready time Dynamic response Electrical noise (measured with 100 Hz bandwidth)

±1.8 g 1000 mV/g ≤ 5% 0 g 1) ≤ 0,06 g ≤ 3% FSO ≤ 1.0 s ≥ 30 Hz ≤ 5 mVrms

General data Operating-temperature range Storage-temperature range Supply voltage Supply-voltage range Current consumption at 12 V Reference voltage 1) Zero point is 2.5 V (reference).

–30...+85 °C –20...+50 °C 12 V nominal 8.2...16 V < 70 mA 2.5 V ±50 mV 1)

Accessories 2) Plug housing – Qty. required: 1 AMP-No: 1-967 616-1 Contact pins for 0.75 mm2 Qty. required: 6 AMP-No: 965 907-1 Gaskets for Ø 1.4...1.9 mm2 Qty. required: 6 AMP-No: 967 067-1 2) To be obtained from AMP Deutschland GmbH, D-63225 Langen, Tel. 0 61 03/7 09-0, Fax 0 61 03/7 09-12 23, E-Mail: [email protected]

22223_1021En_010-011

B

12.07.2001

9:46 Uhr

Seite 11

A

Yaw sensor

Dimension drawings. F Forward driving direction S 6-pole plug Ra Reference axis Rf Reference surface ac Acceleration direction

11

Operating principle. ➝ ac Coriolis acceleration ➝ V Speed of oscillation ➝ Ω Angular velocity ➝ ➝ ➝ ac = 2V x Ω F

A

➝ Deviation of Ω-axis to reference surface ±3°

42,6

S

Ω

12

35,1 33,1

A-A

ac A Rf

35

80,2 62 ±0,3

Ra

Ω

6,1

+0,2 -0,1

ac

33 79,6 83,6

ac

V Ω

Connector-pin assignment Pin 1 Reference Pin 2 BITE Pin 3 12 V Pin 4 Out: Yaw-rate sensor Pin 5 Out: Acceleration sensor Pin 6 Ground

4 5 6 1 2 3

Block diagram.

1. Coriolis acceleration

Oscilator Yaw sensor

GND

V

Characteristic curve.

2. Coriolis acceleration

VDD

V t1 m

V t2

Acceleration sensor

C U

+

C

Sens. adjust

Offset adjust

DRS-OUT

Output voltage UA

Test

ac

U Oscilator loop

C U

Sens. adjust

PLL

Low pass filter

REF-OUT

Offset adjust

Evaluation circuit

LIN-OUT 0.65 V -100

V 5.0 4.0

4.35 V

3.0 2.0 1.0 0.0 Yaw rate

+100

22223_1021En_012-013

12

12.07.2001

9:56 Uhr

Seite 12

A

Rotational-speed sensors

B

Inductive rotational-speed sensors Incremental* measurement of angles and rotational speeds n U P Non-contacting (proximity) and thus wear-free, rotationalspeed measurement. P Sturdy design for exacting demands. P Powerful output signal. P Measurement dependent on direction of rotation.

2

3

1

Application Inductive rotational-speed sensors of this type are suitable for numerous applications involving the registration of rotational speeds. Depending on design, they measure engine speeds and wheel speeds for ABS systems, and convert these speeds into electric signals. Design and function The soft-iron core of the sensor is surrounded by a winding, and located directly opposite a rotating toothed pulse ring with only a narrow air gap separating the two. The soft-iron core is connected to a permanent magnet, the magnetic field of which extends into the ferromagnetic pulse ring and is influenced by it. A tooth located directly opposite the sensor concentrates the magnetic field and amplifies the magnetic flux in the coil, whereas the magnetic flux is attenuated by a tooth space. These two conditions constantly follow on from one another due to the pulse ring rotating with the wheel. Changes in magnetic flux are generated at the transitions between the tooth space and tooth (leading tooth edge) and at the transitions between tooth and tooth space (trailing tooth edge). In line with Faraday’s Law, these changes in magnetic flux induce an AC voltage in the coil, the frequency of which is suitable for determining the rotational speed.

Range Cable length with plug 360 ± 15 553 ± 10 450 ± 15

Wheel-speed sensor (principle). 1 Shielded cable, 2 Permanent magnet, 3 Sensor housing, 4 Housing block, 5 Soft-iron core, 6 Coil, 7 Air gap, 8 Toothed pulse ring with reference mark. 1

2

3

Diagram. Connections: 1 Output voltage, 2 Ground, 3 Shield. 0 281 002 214, ..104

4

xxxxxxxxxx xxxxxx

1 N S

S

2

N

0 261 210 147 5

3

6 7 8

N S

Order No. 0 261 210 104 0 261 210 147 0 281 002 214

* A continuously changing variable is replaced by a frequency proportional to it.

1 2

Technical Data Fig./ Dimension drawing 1 2 3

3

Rotational-speed range n 1) min–1 < 20...7000 Permanent ambient temperature in the cable area For 0 261 210 104, 0 281 002 214 °C –40...+120 For 0 261 210 147 °C –40...+130 Permanent ambient temperature in the coil area °C –40...+150 Vibration stress max. m · s–2 1200 Number of turns 4300 ±10 Winding resistance at 20 °C 2) Ω 860 ±10 % Inductance at 1 kHz mH 370 ±15 % Degree of protection IP 67 Output voltage UA 1) V 0...200 1) Referred to the associated pulse ring. 2) Change factor k = 1+0.004 (ϑ –20 °C); ϑ winding temperature W W

9:56 Uhr

A


Dimension drawings.

45 ± 1 0,1 21 24+- 0,2 5

5 2, R1

0,15 18+- 0,2 27

ø 3,5

180 ± 5°

6,7 + 0,3

19 ± 0,2

0 261 210 104 R7

1

Seite 13

ø 17,95 -0,35

B

12.07.2001

ø 18 h9

22223_1021En_012-013

R11

8 14 10

12

X 1 2 3

X

2

45 ±1 +0,1 21 24 -0,2 5

0 261 210 147

26,5 19 ±0,1

R 90 12 570 ±10

13±0,5 7,6+0,6

° ±5

°

17,95-0,35 20,7-0,2 21,36+0,63

27

25

O 8 14

X 3

2

1

X

9,5 15,5

12

X

19 ±

X 3

2

1

450 ±15

Accessories For rot-speed sensor 0 261 210 104 0 261 210 147 0 261 002 214

From offer drawing A 928 000 019 A 928 000 012 A 928 000 453

Plug part number 1 928 402 412 1 928 402 579 Enquire at AMP 1 928 402 966

13

0,3

0,2

6,7 +

3

20

R7

,7

-0 ,

25

3,5

27

R1

5°

17,95-0,35 21,15+0,64

0° ±

11 R

59 ±1 +0,1 22,5 36,5 -0,2 5 O

30

18±0,2

0 281 002 214

2,5

3

The sensor generates one output pulse per tooth. The pulse amplitude is a function of the air gap, together with the toothed ring’s rotational speed, the shape of its teeth, and the materials used in its manufacture. Not only the output-signal amplitude increases with speed, but also its frequency. This means that a minimum rotational speed is required for reliable evaluation of even the smallest voltages. A reference mark on the pulse ring in the form of a large “tooth space” makes it possible not only to perform rotational-speed measurement, but also to determine the pulse ring’s position. Since the toothed pulse ring is an important component of the rotational-speed measuring system, exacting technical demands are made upon it to ensure that reliable, precise information is obtained. Pulse-ring specifications are available on request. Explanation of symbols UA Output voltage n Rotational speed s Air gap

R

7,

5

3,5

11

L = 360 ± 15

13

22223_1021En_014-015

14

12.07.2001

9:57 Uhr

Seite 14

A


B

Hall-effect rotational-speed sensors Digital measurement of rotational speeds n, φ, s U P Precise and reliable digital measurement of rotational speed, angle, and distance travelled. P Non-contacting (proximity) measurement. P Hall-IC in sensor with opencollector output. P Insensitive to dirt and contamination. P Resistant to mineral-oil products (fuel, engine lubricant).

Design Hall sensors comprise a semiconductor wafer with integrated driver circuits (e.g. Schmitt-Trigger) for signal conditioning, a transistor functioning as the output driver, and a permanent magnet. These are all hermetically sealed inside a plastic plugtype housing. Application Hall-effect rotational-speed sensors are used for the non-contacting (proximity), and therefore wear-free, measurement of rotational speeds, angles, and travelled distances. Compared to inductive-type sensors, they have an advantage in their output signal being independent of the rotational speed or relative speed of the rotating trigger-wheel vane. The position of the tooth is the decisive factor for the output signal. Adaptation to almost every conceivable application requirement is possible by appropriate tooth design. In automotive engineering, Hall-effect sensors are used for information on the momentary wheel speed and wheel position as needed for braking and drive systems (ABS/TCS), for measuring the steering-wheel angle as required for the vehicle dynamics control system (Electronic Stability Program, ESP), and for cylinder identification. Operating principle Measurement is based upon the Hall effect which states that when a current is passed through a semiconductor wafer the socalled Hall voltage is generated at right angles to the direction of current. The magnitude of this voltage is proportional to the magnetic field through the semiconductor. Protective circuits, signal conditioning circuits, and output drivers are assembled directly on this semiconductor. If a magnetically conductive tooth (e.g. of soft iron) is moved in front of the sensor, the magnetic field is influenced arbitrarily as a function of the trigger-wheel vane shape. In other words, the output signals are practically freely selectable.

Technical Data 1) / Range Part number 0 232 103 021 0 232 103 022 Minimum rotational speed of trigger wheel nmin 0 min–1 10 min–1 Maximum rotational-speed of trigger wheel nmax. 4000 min–1 4500 min–1 Minimum working air gap 0.1 mm 0.1 mm Maximum working air gap 1.8 mm 1.5 mm Supply voltage UN 5V 12 V Supply-voltage range UV 4.75...5.25 V 2) 4.5...24 V Supply current IV Typical 5.5 mA 10 mA Output current IA 0...20 mA 0...20 mA Output voltage UA 0... UV 0... UV Output saturation voltage US ≤ 0.5 V ≤ 0.5 V Switching time tf 3) at UA = UN, IA = 20 mA (ohmic load) ≤ 1 µs ≤ 1 µs Switching time tr 4) at UA = UN, IA = 20 mA (ohmic load) ≤ 15 µs ≤ 15 µs Sustained temperature in the sensor and transition region –40...+150 °C –30...+130 °C 5) Sustained temperature in the plug area –40...+130 °C –30...+120 °C 6) 1) At ambient temperature 23 ±5 °C. 2) Maximum supply voltage for 1 hour: 16.5 V 3) Time from HIGH to LOW, measured between the connections (0) and (–) from 90% to 10% 4) Time from LOW to HIGH, measured between the connections (0) and (–) from 10% to 90% 5) Short-time –40...+150 °C permissible. 6) Short-time –40...+130 °C permissible. Accessories for connector Plug housing Contact pins Individual gaskets For cable cross section 1 928 403 110 1 987 280 103 1 987 280 106 0.5...1 mm2 1 987 280 105 1 987 280 107 1.5...2.5 mm2 Note: For a 3-pin plug, 1 plug housing, 3 contact pins, and 3 individual gaskets are required. For automotive applications, original AMP crimping tools must be used.

Installation information – Standard installation conditions guarantee full sensor functioning. – Route the connecting cables in parallel in order to prevent incoming interference. – Protect the sensor against destruction by static discharge (CMOS components). – The information on the right of this page must be observed in the design of the trigger wheel. Symbol explanation nmin = 0: Static operation possible. nmin > 0: Only dynamic operation possible. US: Max. output voltage at LOW with IA: Output current = 20 mA. IV: Supply current for the Hall sensor. tf: Fall time (trailing signal edge). tr: Rise time (leading signal edge).

Trigger-wheel design 0 232 103 021 The trigger wheel must be designed as a 2-track wheel. The phase sensor must be installed dead center. Permissible center offset: ±0.5 mm. Segment shape: Mean diameter ≥ 45 mm Segment width ≥ 5 mm Segment length ≥ 10 mm Segment height ≥ 3.5 mm 0 232 103 022 The trigger wheel is scanned radially. Segment shape: Diameter ≥ 30 mm Tooth depth ≥ 4.5 mm Tooth width ≥ 10 mm Material thickness ≥ 3.5 mm

22223_1021En_014-015

12.07.2001

9:57 Uhr

Seite 15

A

B


Dimension drawings. S 3-pin plug-in connection Sez Sensor area Stz Plug area

Tz O

Installation stipulation 0 232 103 022. Dr Direction of rotation Ls Air gap S Sharp-edged Zh Tooth height

Temperature area O-ring

0 232 103 021

15

0 232 103 022 25 ±0,4

36,8

21 12

Stz 25 15,4 Sez 24 ±0,2 1,5 ±0,2

Tz 49 ±0,2 6,5 12 ±0,5

Sez 20 ±0,2

Ls

21 2

Stz 25

33 47,3

Tz

O

1,5

22 ±0,4

Z1

24

° 4,5

O

+0,5

L1 Dr

ø15 - 0,2 ø17,98 - 0,24 ø18,7 ±0,26

ø17,98 - 0,24 R8

2 ±0,

1

24° ±10´

Test wheel

4,

5

Z

h

S

3

1

±

,05

11,5 ±0,3

7,5

-0

2

R1

0,2

24,4 ±0,3 15 ±0,3

3

19

ø45

R2

7,1

19 S

S

UV UA

UV UA

8 +0,1

10 H8 (+0,022) 45 - 0,1

Output-signal shape. UA, O Output voltage UA, SAT Output saturation voltage α Angle of rotation αS Signal width

Block diagram.

Z3

L3

0 232 103 021 A IV

RL

L1

UA,O UA,Sat

L2

L3

Z2

Z3

Z2 S2

L4

αS Z1

L2 Dr

+

Installation stipulation 0 232 103 021. Dr Direction of rotation

Z4

L1

Z4

90° A

S1

270°

OSCI

360°

IA

α HIGH

UA,Sat

LOW

°

2 R2

R3 -0, 5 L3

Z2 L1

,5

° 66

L4

,1

±0

,5

,1

Z4

α

66

L2

-0 R3

αS

±0

Z1 24°

24°

24°

UA,O

2,5

1

° 66 Z3

R3

±0,

U0 V

7,5

0 232 103 022

HallSensor

180°

Test wheel

R2

0°

°

0

66

GND

L4

24°

UV V

Z1

180°

90 °

UV

22223_1021En_016-017

16

12.07.2001

9:55 Uhr

Seite 16

A

Acceleration sensors

B

Acceleration sensor Measurement of acceleration up to ±5 g a U P Ratiometric output signal. P Temperature-compensated. P Low pyroelectric sensitivity. P Hermetically sealed housing. P High-level EMC. P Overvoltage protection. P Short-circuit proof. P Protected against reverse polarity.

Design and function The sensor element comprises a “bending element” consisting of two anti-parallel polarized piezoelectric layers. If acceleration forces are applied to this bending element, mechanical tension is caused which in turn results in a charge of electricity at the bending-element surfaces. This charge is evaluated by a hybrid circuit. The sensor can measure in the horizontal and in the vertical measurement directions when mounted appropriately, whereby the measurement direction is usually vertical to the clamping surface. An output signal UA > U0 is generated for vertical upwards acceleration of the clamping surface, whereas the corresponding downward acceleration generates a signal UA < U0. The output voltage UA has a cosine relationship to the angle between the sensor measurement direction and the direction of acceleration. Taking an angle of 15°, this produces a (calculated) signal reduction of 3.4%.

Accessories Connector

1 237 000 039

UAR Open-circuit output voltage UA = U0 ± UD


Output-voltage excursion for measuring range UD = ±2 V Output voltage UA For acceleration > +5 g 4.5 V For acceleration < –5 g 0.5 V

4,5 V

Output voltage UA

Applications In automotive engineering, this sensor is used to rule out the chance of faulse diagnosis in the engine electronics. It registers the vehicle accelerations which are the direct result of fluctuations in crankshaft speed. In order to ascertain whether these crankshaft-speed fluctuations result from ignition misfire or a poor road surface, the latest engine-management systems also register the ignition misfires of the individual cylinders.

UAR

2,5 V

0,5 V -5g

0 Acceleration a

+5g

Technical Data / Range Part number Measuring range Limit of operating load Sustained operation in the sensor’s dynamic core-frequency range without damage Overload protection Peak amplitude: 20 times without damage Lateral sensitivity Nominal sensitivity at f = 15.8 Hz Operating temperature range Storage-temperature range Service life (ageing) In operating temperature range –40...+105 °C Weight Electrical specifications for Uv = 5 V ±3 % Input current Iv Output-voltage zero point Uo Sensitivity Dynamic output resistance RAO in the range 0...100 Hz Load resistance RL (pullup above +5 V) Load capacity CL Lower critical frequency fu (–3 dB) Upper critical frequency fo (–3 dB)

0 273 101 021 ±5 g

±10 g 100 g < 10 % 2V/5g –40...+105 °C –40...+95 °C

4000 h 75 g

< 20 mA Uv / 2 = 2.5 V ±100 mV 400 mV / g ±12 % < 300 > 7.5 kΩ < 15 nF 0 Hz < fu < 5 Hz 50 Hz < fo < 100 Hz

22223_1021En_016-017

B

12.07.2001

9:55 Uhr

Seite 17

A


Dimension drawings. M Direction of measurement.

Installation instructions The sensor must be securely screwed to the base. We recommend two M6 screws with collar or washer. Screw tightening torque: 2.5 N · m.

11

36

M

2

Explanation of symbols UA Output voltage U0 Output-voltage zero point (ratiometric to UV) UD Dynamic portion of the output signal UV Supply voltage g Acceleration due to gravity = 9.81 m · s–2

1

65 53 ± 0,2 37

3

Pin assignment Pin 1 +5 V (UV) Pin 2 Ground Pin 3 OUT

6,6± 0,2 55

Sensor principle. a Without effect of acceleration b With effect of acceleration 1 Piezo-ceramic bending element “measuring beam” 2 Opposed-polarity layers

Pin assignment.

Pin 3 a

a=0 2

1 b

a

0

Block diagram. P Piezo-ceramic element

2

3

P

1

17

Pin 2

Pin 1

22223_1021En_018-019

18

12.07.2001

9:53 Uhr

Seite 18

A


B

Piezoelectric acceleration sensors Measurement of acceleration up to 35 g a U P Acceleration measurement using piezoelectric bending elements (bimorphous strips). P Micromechanical acceleration sensor (please enquire). P Low temperaturedependence. P High sensitivity. P Wide measuring range.

Range Dual-channel sensor With two identical, but independent, piezo-ceramic bending strips. These are connected so that the output voltages of each channel are phase-opposed. Suitable for pcb mounting. 0 273 101 141 With two sensing directions offset to each other by 90°. Suitable for pcb mounting. 0 273 101 150 With one sensing direction only. In this direction, acceleration leads to a 180° phase shift of channel A, whereas the channel B phase shift is 0°. Suitable for pcb mounting. 0 273 101 131 Applications Used in automotive occupant-protection systems for triggering the airbag, the seatbelt tightener, the roll-over bar, or the seatbelt locking systems. Used for instance as the impact sensor for monitoring impact loads during transportation. Since the lower frequency limit is 0.9 Hz, this sensor can only be used to register acceleration changes. Design and function The heart of this acceleration sensor is a piezo-ceramic strip of polycrystalline sintered material. When electrically polarized, this material displays a piezoelectrical effect: That is, when pressure is applied, the mechanical loading results in charge separation, or a voltage which can then be picked-off by electrodes. The piezo bending element comprises a bonded structure containing two inversely polarized piezo strips, the so-called bimorphous strips. These have electrodes, and are bonded to a center electrode. This configuration has the advantage that the pyroelectrical signals caused by temperature fluctuations compensate each other.

Technical data / Range Part number Block diagram Measuring range at UV = 5 V Frequency range (–3dB) Supply voltage UV Supply current IV Open-circuit voltage at zero acceleration Calibrated sensitivity at room temperature Calibrated sensitivity at operating temperature Operating-temperature range

0 273 101 141 X min. typ. max.

0 273 101 150 – min. typ. max.

0 273 101 131 – min. typ. max.

Hz V mA

–35 0.9 4.75 –

– – 5.00 –

+35 250 5.25 12

–35 0.9 4.0 –

–35 0.9 4.0 –

mV

–45

–

+45

mV · g–1 57.5

60

62.5

57.5

60

62.5

57.5

60

62.5

% °C

– –

4 +95

– –45

– –

– +95

– –45

– –

– +95

– –

– –

– –

– –

– –

– –

g 1)

– –45

Electrical output Current-carrying capacity mA 0.9 – – Capacitive loadability pF 1200 – – Pin assignment Pin 1 UV = +5 V Pin 2 Output B Pin 3 UV = +5 V Pin 4 Test input Pin 5 Ground Pin 6 Output A Pin 7 Housing, ground 1) Acceleration due to gravity g = 9.81 m · s–2.

When subjected to acceleration, the piezoceramic bends by as much as 10–7 m. For signal processing, the sensor is provided with a hybrid circuit which is comprised of an impedance converter, a filter, and an amplifier. These serve to define the sensitivity and effective frequency range. The filter removes the HF signal components. The lower frequency limit of 0.6 Hz is defined by the piezo element itself. Using a supplementary test input, the sensor’s electronic functions can be monitored as well as piezo-strip integrity.

– – 5.0 –

+35 340 5.25 15

UV /2 ±60 mV

– – 5.0 –

+35 340 5.25 15

UV /2 ±60 mV

Output B

Output B

UV = +5 V

UV = +5 V

Data Test input Output A Housing, ground –

Data Test input Output A Housing, ground –

Test signal A fully operational sensor generates a positive output pulse when +5V are briefly applied across its test input. If there is an open-circuit in the signal path, this output pulse will be missing, and if the bimorphous strip is broken the signal will exceed +5V. For the versions with two bimorphous strips, the output pulse must appear at each output.

22223_1021En_018-019

B

12.07.2001

9:53 Uhr

Seite 19

A


19

Block diagram of dual-channel sensor.

Dimension drawings.

0 273 101 141

3,81

13,6

30

X

2,8 0,05 4,35+- 0,15

43,82 ± 0,2

0,7 3,5+- 0,5

0,6- 0,1 4,1± 0,2

0,65 + 0,1

9

20,85 ± 0,3

R4

123456 7

2,54

4,9± 0,2

++ –

++

15,24 4,4 ± 0,2

X

–

0 273 101 131/150

18,8 ++ 0,2 0,1

1,4± 0,4

X

8 ± 0,3

0,7+ 0,2

6

0,2 20++ 0,1 ± 3,8 0,4

1 2 3 4 5 6

6

1± 0,4

1 2 3 4 5 6

X

Installation instructions The acceleration sensors must be installed so that the baseplate is either vertical or horizontal referred to the direction of acceleration or deceleration. Installation position. A, B, M Directions of measurement Baseplate vertical referred to direction of measurement. 0 273 101 141 Deceleration in direction of measurement Channel A output voltage

UAA

UV 2

Baseplate parallel to direction of measurement. 0 273 101 150 Acceleration in A direction Channel A output voltage

UV

UAA >

. 2 Acceleration in B direction Channel B output voltage

.

UAB >

UV 2

0 273 101 131 Acceleration in A direction Channel A output voltage

UV

UAA
.

UV 2

A M

B

A

.

22223_1021En_020-021

20

12.07.2001

9:53 Uhr

Seite 20

A


B

Surface-type micromechanical acceleration sensors Measurement of accelerations of ±35 g or ±50 g

a U

P Complete measuring range of ±35 g or ±50 g. P Low number of external components required. P Integrated self-diagnosis. P Integrated offset calibration. P Integrated 2nd-order Bessel filter. P Ratiometric output signal. P Standard SMD PLCC28 housing. P Temperature range suitable for commercial-vehicle applications. Applications This acceleration sensor is used in vehicles as one of the components for the front airbag. Depending upon installation position in the passenger compartment, it can be used to measure longitudinal or transverse acceleration (referred to the vehicle’s direction of travel). Design and function These acceleration sensors rely on a capacitive measuring principle. Lateral sensing direction (in the component level). Acceleration causes the seismic mass to deflect in the x-direction. This seismic mass is suspended on wave-shaped bending springs. One electrode set is connected to the seismic mass (comb-like structure) and moves along with the particular acceleration. These movable electrodes are designed as capacitor plates and are also provided with immovable counter-electrodes which are separated from each other by a narrow air gap. The application of a capacitive differential circuit with two capacitors results in a reduction of the non-linearity of the signal evaluation. Overload stops are provided as a protection against over-acceleration. These prevent direct contact between the electrodes (combs). Mechanical sensitivity is defined by the geometrical shape of the springs. Changes in C1 and C2 are registered and changed to a corresponding voltage by a capacity/voltage converter.

Range Acceleration 1)

Sensing axis

Sensor type

Order No.

± 35 g

X SMB 050 0 273 101 138 X/Y SMB 060 0 273 101 143 X/-X SMB 065 0 273 101 144 ± 50 g X SMB 052 0 273 101 155 X/Y SMB 062 0 273 101 154 X/-X SMB 067 0 273 101 157 1) Measuring range for full-load deflection is guaranteed after setting the offset to VDD/2. Sensing direction.

U (X Out) +a VDD X VDD/2

Y -a +a

-a GND

Design and function. VDD C/V converter

SC filter

Out X

Offset adjust

X Axis

Off X

Oscillator Offset Adjust

Y axis

C/V converter

SC filter

Off Y

Out Y Test

Sensor element

Evaluation ASIC

GND

22223_1021En_020-021

B

12.07.2001

9:53 Uhr

Seite 21

A


Technical Data Limit values Parameter Supply voltage UV Storage temperature Mechanical impact 1) Not energized Energized ESD (each pin) Temperature gradient Operating conditions Parameter Supply voltage UV Supply current IV Single-channel unit Two-channel unit Operating temperature

Connector-pin assignment.

V °C g g kV K/min

V mA mA °C

min. –0.3 –55

normal

max. 6 +105 2000 1000

1.5 20 min. 4.75

–40

normal 5

max. 5.25

6 10

7 14 +85

Measuring and function characteristics Parameter min. normal max. Sensitivity mV/g 55 mV/g 38.5 Sensitivity tolerance 2) % 5 9 Non-linearity of the sensitivity % 0.8 2 Transverse-axis sensitivity 3) % 5 Zero-acceleration output VDD/2 Offset at zero acceleration After offset adjustment mV ±150 Without offset adjustment V ±Vdd/4 Offset-adjustment time s 1.65 Offset/Test-voltage input (X/Y) Low V 0.25 x VDD High V 0.75 x VDD Self-test ±35g g type at 5 V mV 250 385 866 ±50g g type at 5 V mV 200 336 610 Output-voltage range UA IOut = ±50 µA V 0.25 VDD –0.25 Output current IA µA ±50 Capacitive output load pF 1000 3 dB corner frequency 2nd order Bessel filter Hz 320 400 480 Output noise 4) 10 to 1000 Hz mg/ÎãHz 2.5 4.5 1) The effects of excessive shock can permanently damage the unit. Maloperation of the sensor due to mechanical impact, and excessive g figures, are detected by on-chip self-test. 2) In percentage of nominal sensitivity, as a function of service life and temperature range. 3) Output signal resulting from acceleration in any axis vertical to the sensing axis. 4) Output noise with the offset adjustment out of operation. With offset adjustment in operation, the output noise is approx. double the figure.

M marking pin 1 Pin Order No. 1 273 101... .. 138 .. 143 .. 155 .. 154 1-11 N.C. (*) N.C. (*) 12 Offset X Offset X 13 Out X Out X 14 Test Test 15 GND GND 16 VDD VDD 17 N.C. Offset Y 18 N.C. Out Y 19-28 N.C. N.C. * Pin has no bond connection

4

3

VDD VDD + (Voff + S · a) · 2 5V

1

.. 144 .. 157 N.C. (*) Offset X Out X Test GND VDD Offset X Out X N.C.

28 27 26

25

M

24

6

23

7 SMB05x/SMB06x

8

22

(PLCC28)

9

21

10

20

11

19

12

13

14

15

16 17

18

Operating principle. 1 Horizontal sprung seismic mass with springs, 2 Spring, 3 Fixed electrodes with capacitance C1, 4 Al conductor, 5 Bond pad, 6 Fixed electrodes with capacity C2, 7 Silicon oxide, 8 Torsion spring, 9 Vertical sprung seismic mass with electrodes. A Acceleration in sensing direction, CM measuring capacity. a~

C1 – C2 C1 + C2 1

2

3

a

C2 4

Explanation of symbols a Acceleration (gn = 9.81 m/s2) Vout Output voltage VDD Supply voltage Voff Offset voltage S Sensitivity

2

5

C1

Vout =

21

5

Installation information A deviation in the installation by ±1° from the horizontal results in a measuring error of 0.02 g. The sensor is protected against polarity reversal.

CM 6 8

C1

CM

C2

7 9

22223_1021En_022-023

22

12.07.2001

9:54 Uhr

Seite 22

A


B

Piezoelectric vibration sensors Measurement of structure-borne noise/acceleration a U P Reliable detection of structure-borne noise for protecting machines and engines. P Piezo-ceramic with high degree of measurement sensitivity. P Sturdy compact design.

Applications Vibration sensors of this type are suitable for the detection of structure-borne acoustic oscillations as can occur for example in case of irregular combustion in engines and on machines. Thanks to their ruggedness, these vibration sensors can be used even under the most severe operating conditions. Areas of application – Knock control for internal-combustion engines – Protection of machine tools – Detection of cavitation – Monitoring of bearings – Theft-deterrent systems Design and function On account of its inertia, a mass exerts compressive forces on a ring-shaped piezo-ceramic element in time with the oscillation which generates the excitation. Within the ceramic element, these forces result in charge transfer within the ceramic and a voltage is generated between the top and bottom of the ceramic element. This voltage is picked-off using contact discs – in many cases it is filtered and integrated – and made available as a measuring signal. In order to route the vibration directly into the sensor, vibration sensors are securely bolted to the object on which measurements take place. Measurement sensitivity Every vibration sensor has its own individual response characteristic which is closely linked to its measurement sensitivity. The measurement sensitivity is defined as the output voltage per unit of acceleration due to gravity (see characteristic curve). The production-related sensitivity scatter is acceptable for applications where the primary task is to record that vibration is occurring, and not so much to measure its severity. The low voltages generated by the sensor can be evaluated using a high-impedance AC amplifier.

Technical data Frequency range Measuring range Sensitivity at 5 kHz Linearity between 5...15 kHz at resonances Dominant resonant frequency Self-impedance Capacitance range Temperature dependence of the sensitivity Operating-temperature range: Type 0 261 231 118 Type 0 261 231 148 Type 0 261 231 153 Permissible oscillations Sustained Short-term

1...20 kHz ≈ 0.1...400 g 1) 26 ±8 mV/g +20/–10 % of 5 kHz-value (15...41 mV/g) > 25 kHz > 1 MΩ 800...1400 pF ≤ 0.06 mV/(g · °C) –40...+150 °C –40...+150 °C –40...+130 °C ≤ 80 g ≤ 400 g

Installation Fastening screw

Grey cast iron M 8 x 25; quality 8.8 Aluminum M 8 x 30; quality 8.8 Tightening torque (oiled permitted) 20 ±5 N · m Mounting position Arbitrary 1) Acceleration due to gravity g = 9.81 m · s–2. Resistant to saline fog and industrial climate.

Range Vibration sensor 2-pole without cable 2-pole, with cable, length 480 mm, up to +130 °C 3-pole, with cable, length 410 mm, up to +150 °C

0 261 231 148 0 261 231 153 0 261 231 118

Accessories Sensor

Plug housing

Contact pins

Individual gasket For cable cross section 0 261 231 148 1 928 403 137 1 987 280 103 1 987 280 106 0.5...1.0 mm2 1 987 280 105 1 987 280 107 1.5...2.5 mm2 0 261 231 153 1 928 403 826 1 928 498 060 1 928 300 599 0.5...1.0 mm2 1 928 498 061 1 928 300 600 1.5...2.5 mm2 0 261 231 118 1 928 403 110 1 987 280 103 1 987 280 106 0.5...1.0 mm2 1 987 280 105 1 987 280 107 1.5...2.5 mm2 Note: A 3-pole plug requires 1 plug housing, 3 contact pins, and 3 individual gaskets. In automotive applications, original AMP crimping tools must be used.

22223_1021En_022-023

12.07.2001

9:54 Uhr

Seite 23

A

B


Vibration sensor (design). 1 Seismic mass with compressive forces F, 2 Housing, 3 Piezo-ceramic, 4 Screw, 5 Contact, 6 Electrical connection, 7 Machine block, V Vibration.

Response characteristic as a function of frequency.

Mounting hole.

mV. g-1 0,05 0,05 A

30 2

3

4

5

6

22 RZ16

20

10 V 0 F

F

5

7

11,65

±1,5

24

+0,3 - 0,1

ø13

a

8,4 ±0,15

27

ø22

52,2 ±2

11,65

+0,3 -0,1

Part number

L mm

.. 118

410 ±10

.. 153

430 ±10

Connector-pin assignments Pin 1, 2 Measuring signal Pin 3 Shield, dummy

ø20

28

13

Pin 2

8,4 ±0,2

Pin 1 L 41,1 ±1

18

ø5

±0,2

32,1 ±1

a

ø20

L

8,4 ±0,2

27

13

Pin 2

Pin 1

Installation instructions The sensor’s metal surfaces must make direct contact. No washers of any type are to be used when fastening the sensors. The mounting-hole contact surface should be of high quality to ensure low-resonance sensor coupling at the measuring point. The sensor cable is to be laid such that there is no possibility of sympathetic oscillations being generated. The sensor must not come into contact with liquids for longer periods.

18

0,4 ±0,2

a

ø4,55

Pin 3

0 261 231 153

A

Explanation of symbols E Sensitivity f Frequency g Acceleration due to gravity

32 ±1 ±0,2

0 261 231 118

kHz

Evaluation The sensor’s signals can be evaluated using an electronic module. This is described on Pages 26/27.

20°

0 261 231 148

15

18

Dimension drawings. a Contact surface.

10 Frequency f

M8

,, ,, ,, ,, ,, ,

Sensitivity E

1

23

22223_1021En_024-025

24

12.07.2001

9:58 Uhr

Seite 24

A

Vibration sensors

B

Piezoelectric vibration sensors Signal-evaluation module a U P Choice of 4 selectable sensor inputs or 2 symmetrical inputs. P Programmable amplification. P Programmable bandpass filter. P External calibration unnecessary. P Integral programmable frequency divider. P Analog stage with signal test. P Suitable for a wide variety of microcomputers. P PLCC28 housing. Technical data / Range Applications Evaluation of the analog signals from piezoelectric sensors (vibration sensors). Design and function The analog signals are evaluated by a circuit integrated in the module. The circuit contains a programmable amplifier, a bandpass filter, a rectifier, an integrator, and control logic circuitry. The use of “SC” circuit engineering ensures that operation remains insensitive to interference, and that there is no necessity for external calibration. It is an easy matter to use this fully programmable circuit for a variety of applications. The start and end of the integration are controlled through the “measuring window” input. For a variety of different pulse frequencies applied from outside (8 steps of 1...16 MHz), a frequency divider which is programmed through 3 inputs, generates the system clock for the analog stage, and the test frequencies (9 mid-frequencies from 5...16 kHz) depending upon the setting of the filter. The internal pulse frequency can be changed from nominal 100 kHz to values between 50 kHz and 150 kHz by changing the quartz frequency. At the same time, a shift of the band-filter mid-frequencies, the test frequencies, and the integration time constants also takes place. Note Due to its having MOS inputs, this module is to be handled very carefully. It is not to be touched directly and a MOS workstation is to be used. Operating-voltage switch-on is only to take place with a voltage gradient < 1 V · µs–1.

Part number

UV Supply voltage IV Supply current Input voltage, UKE Analog Input current, IKE Analog V Signal amplification Signal amplification, dV Tolerance fx Clock frequency fKE Input-signal frequency Bandpass-filter mid-frequency fM Q Filter quality dQ Filter quality, tolerance Integrator voltage excursion, dVKU effective Integrator offset Integrator time constant Integrator output impedance Operating temperature

tI ZKL

ϑ

V mA

Condition – UV/2

0 272 230 424 min. max. 4.75 5.25 – 30

V

–

0

2

µA

UKE = 2 V –

– 2

10 128

– – – – – –

–3 0,5 – 5 3 –0.5

+3 27 30 16 – +0.3

–

3.8

+4.5

–300 –400 148 – –40

+300 +400 152 2 +125

% MHz kHz kHz

V

tMF = 10 ms mV mV µs kΩ °C

> 0 °C ≤ 0 °C – – –

V

–

min. –0.5

typ. –

max. 6.7

µs

–

–

1

–

mA

–

–2.5

–

+2.5

kV °C

– –

–2 –55

– –

2 +135

°C

–

–40

–

+125

Limit values Max. supply voltage Max. rate of rise of the supply voltage Max. current in all inputs and outputs Protection of the inputs and outputs against destruction due to electrostatic charge Storage temperature Ambient temperature during operation

22223_1021En_024-025

12.07.2001

9:58 Uhr

Seite 25

A

B

Vibration sensors

Dimension drawings. M Marking for pin 1

M

1,27 ± 0,06

TP0 TP2 MF KTI/ADT TP1 KI UREF 1 28 27 26 25

T1

6

24

T0

BF3

7

23

T2

BF2

8

22

UV

G0

9

21

X1

G2

10

20

n.c.

G1

19 11 12 13 14 15 16 17 18

VSS

BF1

5

BF0

11,4 ± 0,2

4

2

3

CC195

KSA1 KE2 KE4 KSA3 KSA2 KE1 KE3

12,56 ± 0,2

1,86 ± 0,06

0,5 min.

1,14

± 0,02

3,81 ± 0,05

10,7 ± 0,35 0,5 ± 0,05

1,14

± 0,02

Design and function. F Frequency divider, G Rectifier, L Filter, I Integrator, O Oscillator, P Multiplexer, R Reference signals, S Sensor inputs, T Test-pulse divider, V Amplifier, OUT Output. R

F

O

N 1

T M 1

S

1 . . 4

Σ

P

I

G

L

V

OUT

Application circuit (Example). K Signal-integral output, P From microcomputer port driver, S Sensors, T Quartz clock, C1/C2 Capacitors as near as possible to housing pins. 4 C0

R0

3

P

3

BF0-3 KSA G0-2 1-3 KE1

MF T0-2

3

T

KE2 KE3

S

UV

KE4 V SS

R0

U REF X1 Clock input C1

10nF

K

5V C2 4,7nF

25

Connector-pin assignment. UREF Reference voltage UV/2 (Output loadable with ±0.5 mA) UV Supply voltage 5 V VSS Ground BF0/BF1/BF2/BF3*) Setting of the bandpass mid-frequency G0/G1/G2*) Setting of the amplification factor KE1/2/3/4 Sensor inputs KI Signal-integral output KSA1/2/3*) Sensor selection KTI/ADT Controlled input/test output MF*) Measuring window N.C. Not connected T0/T1/T2 Clock-frequency selection TP0/TP1/TP2 For test purposes X1 Clock input *) TTL-compatible inputs from the microcomputer port driver

22223_1021En_026-027

26

12.07.2001

9:58 Uhr

Seite 26

A

Pressure sensors

B

Micromechanical differential-pressure sensors Hybrid design Measurement of pressure in gases from –100 kPa to 5 kPa

p U

P High accuracy. P EMC protection better than 100 V m–1. P Temperature-compensated.

Applications On internal-combustion engines, this sensor is used to measure the differential pressure between the intake-manifold pressure of the drawn-in air and a reference pressure which is inputted through a hose. Design and function The piezoresistive pressure-sensor element and suitable electronic circuitry for signal amplification and temperature compensation are mounted on a silicon chip. The measured pressure is applied to the rear side of the silicon diaphragm. The reference pressure is applied from above to the diaphragm’s active surface. Thanks to a special coating, both sides of the diaphragm are insensitive to the gases and liquids which are present in the intake manifold. Installation information The sensor is designed for mounting on a horizontal surface of the vehicle’s intake manifold. The pressure fitting extends into the manifold and is sealed-off to atmosphere by an O-ring. Care must be taken, by ensuring appropriate mounting, that condensate does not form in the pressure cell or in the reference opening. Generally speaking, installation is to be such that liquids cannot accumulate in either the sensor or the pressure hose. Water in the sensor leads to malfunctions when it freezes.

Range Pressure range kPa (p1...p2) Order No. –80...5 B 261 260 314 1) –100...0 B 261 260 318 1) 1) Provisional draft number, order number available upon enquiry. Deliverable as from about the end of 2001.

Technical data Pressure-measuring range Operating temperature Supply voltage Current consumption at UV = 5 V Load current at output Load resistance to UV or ground Response time Voltage limitation at UV = 5 V Lower limit Upper limit Limit data Supply voltage Pressure Storage temperature

pe ϑB UV IV IL Rpull-up Rpull-down t10/90

kPa °C V mA mA kΩ kΩ ms

min. –100 –40 4.5 6.0 –1.0 5 50.0 –

typ. – – 5.0 9.0 – 680 100 1.0

max. 0 +130 5.5 12.5 0.1 – – –

UA min UA max

V V

0.25 4.75

0.3 4.8

0.35 4.85

UV max pe ϑL

V kPa °C

– –500 –40

– – –

+16 +500 +130

Accessories Plug housing Contact pins Individual gaskets

Qty. required: 1 Qty. required: 3 Qty. required: 3

1 928 403 966 1 928 498 060 1 928 300 599

22223_1021En_026-027

12.07.2001

9:58 Uhr

Seite 27

A

B

Pressure sensors


Characteristic-curve tolerance.

27

Tolerance-extension factor.

5

2.5

in V

4.5 2

0

p1

Factor

Tolerance

Output voltage

UA

1.5

p2

1.5 1

-1.5 0.5

0.5 0

p1 Pressure

p

p2

0 -50 -40

kPa Absolute pressure p

Section drawing (overall system). 1 Sensor cell, 2 Measured pressure, 3 Reference pressure

10

85

130 C

Temperature

Dimension drawings. Pin assignment Pin 1 +5 V Pin 2 Ground Pin 3 Output signal 75

1

13

15

19

3

12

5

2 A 1 2

Signal evaluation: Recommendation. D Pressure signal, R Reference UH

5.5 to 16 V

US

ADC

680 k

P

VCC

R

22 k

OUT

D 10 nF

100 nF

U 10 nF

GND

Pressure sensor

5V

ECU

12

23

A

3

Signal evaluation: Recommendation The pressure sensor’s electrical output is so designed that malfunctions caused by cable open-circuits or short circuits can be detected by a suitable circuit in the following electronic circuitry. The diagnosis areas situated outside the characteristiccurve limits are provided for fault diagnosis. The circuit diagram shows an example for detection of all malfunctions via signal outside the characteristic-curve limitation.

22223_1021En_028-029

28

12.07.2001

9:59 Uhr

Seite 28

A

Pressure sensors

B

Differential-pressure sensors Measurement of pressures in gases and liquid mediums from –2.5 kPa to +3.75 kPa p U P Resistant to the monitored medium. P Piezoresistive sensor element. P Integrated protection against humidity.

Application In automotive applications, this type of pressure sensor is used for measuring fueltank pressure. In the process, a differential pressure is established referred to the ambient pressure. Design and function A micromechanical pressure element with diaphragm and connector fitting is the most important component in this differentialpressure sensor. The diaphragm is resistant to the effects of the monitored medium. The measurement is carried out by routing the monitored medium through the pressure connector and applying the prevailing pressure to the piezoresistive sensor element. This sensor element is integrated on a silicon chip together with electronic circuitry for signal amplification and temperature compensation. The silicon chip is surrounded by a TO-type housing which forms the inner sensor cell. The surrounding pressure is applied to the active surface through an opening in the cap and a reference fitting. The active surface is protected against moisture by Silicagel. The pressure sensor generates an analog signal which is ratiometric referred to the supply voltage. Installation instructions The sensor is designed for horizontal mounting on a horizontal surface. In case of non-horizontal mounting, each case must be considered individually. Generally speaking, installation is to be such that liquids cannot accumulate in the sensor or in the pressure hose. Water in the sensor leads to malfunctions when it freezes.

Range Pressure range kPa (p1...p2) –2.50...2.50 –2.50...2.50 –3.75...1.25

Characteristics

Dimension drawing

Part No.

– with protective cover –

1 2 1

0 261 230 015 0 261 230 026 B 261 260 317 1)

Technical data pe ϑB UV IV IL RL t10/90

kPa °C V mA mA kΩ ms

min –2.5 –40 4.75 – –0.1 50 –

typ – – 5.0 9.0 – – 0.2

max +2.5 +80 5.25 12.5 +0.1 – –

UA min UA max

V V

0.25 4.75

0.3 4.8

0.35 4.85

Recommendation for signal evaluation Load resistance to UH = 5.5...16 V

RL.H

kΩ

–

680

–

Limit data Supply voltage (1 min) Pressure measurement Storage temperature

UVmax Pe, max ϑL

V KPa °C

– –30 –40

– – –

16 +30 +80

Pressure-measuring range Operating temperature Supply voltage UV Input current at UV = 5 V Load current at output Load resistance to ground or UV Response time Voltage limitation at UV = 5 V Lower limit Upper limit

Accessories Plug housing Qty. required: 1 AMP-Nummer 1 928 403 110 Contact pins Qty. required: 3 3) AMP-Nummer 929 939-3 2) Contact pins Qty. required: 3 4) AMP-Nummer 2-929 939-1 2) Individual gaskets Qty. required: 3 AMP-Nummer 828 904 2) 1) Provisional draft number, Order No. available upon request. Available as from the end of 2001. 2) To be obtained from AMP Deutschland GmbH, Amperestr. 7–11, D-63225 Langen, Tel. 0 61 03/7 09-0, Fax 0 61 03/7 09 12 23, E-Mail: [email protected] 3) Contacts for 0 261 230 026 4) Contacts for 0 261 230 015, B 261 260 317

22223_1021En_028-029

12.07.2001

9:59 Uhr

Seite 29

A

B

29

Pressure sensors

Characteristic-curve.


Temperature-error multiplier. D After endurance test N In as-new state 3.0

5 4.5

2.5 2.0 0

p1

Factor k

Tolerance [% FS]

Output voltage UA in V

8

p2

D

1.5

N

1.0 -8 0.5

0.5 0

p1

0 -50 -40

p2

Differential pressure pe

Differential pressure pe

0 Temperature

80 °C

2 0 261 230 026

Dimension drawings. S 3-pole plug 10

56 S 2

1

7,35 ± 0,1

21,5

12 ± 0,5

18,5

3 ± 0,2

± 0,25

3

27

12,3

ø 5,1± 0,1

56

1 0 261 230 015 B 261 260 317

ø11,85 ± 0,1 8 ø 11,8 - 0,2

27

X

ø

23,6

6 ± 0,1

20,5

Sectional drawing of pressure sensor (overall system). 1 Sensor cell, 2 Applied pressure, 3 Reference pressure.

X

Sectional drawing of sensor cell. 1 Silicagel, 2 Applied pressure, 3 Reference pressure, 4 Sensor chip, 5 Glass base.

3

3

4 1

Connector-pin assignment Pin 1 +5 V (UV) Pin 2 Ground Pin 3 Output signal

1 5

2 0

10

20 mm

Explanation of symbols Differential pressure pe Output voltage (signal voltage) UA Supply voltage UV k Tolerance multiplier D Following endurance test N As-new state

2

22223_1021En_030-031

30

12.07.2001

10:00 Uhr

Seite 30

A

Pressure sensors

B

Absolute-pressure sensor for measuring atmospheric pressure Measurement of temperatures from 60 kPa to 115 kPa

p U

P SMD assembly. P Low-profile micromechanics. P Temperature-compensation. P Integral signal amplification.

Design and function This sensor comprises a temperaturecompensated measuring element for determining the barometric absolute pressure. In this monolithic integrated silicon pressure sensor, the sensor element, and the respective evaluation circuitry with calibration elements are all united on a single silicon chip. The silicon chip is glued onto a hybrid substrate to facilitate automatic SMD assembly.

Characteristic curves. ∆pabs kPa

UA V 4.5

+4 –

4

3 2.5

+2 –

Explanation of symbols UV Supply voltage UA Output voltage (signal voltage) k Temperature-error multiplier ϑ Temperature pabs Absolute pressure D Following endurance test N Nominal status

UA

3.5 +3 –

Block diagram. E sensitivity, O Offset, K Compensation circuit, S Sensor bridge, V Amplifier.

2 D

1.5 +1 –

N

1

∆pabs S

0.5

V

0 60

80 100 115 kPa Absolute pressure pabs

k

2 E, K, O

1 -40

0

40

80

Temperature

125 °C

22223_1021En_030-031

12.07.2001

10:00 Uhr

Seite 31

A

B

Pressure sensors

31

Technical data / Range Part number Pressure-measuring range Operating temperature range Supply voltage Supply current at UV = 5 V

Load current at output Signal voltage Voltage limitation at UV = 5 V Lower limit Upper limit Response time Load capacity Signal evaluation: Recommendation Load resistance to UV or ground Limit data Supply voltage, 1 min Pressure Storage temperature

0 273 300 030 min. typ. 60 – –40 – 4.75 5.0 6.0 9.0 –1.0 – 2.37 –

pabs ϑB UV IV IL UA

kPa °C V mA mA V

UA min UA max t10/90 CL

V V ms nF

0.25 4.75 – –

0.3 4.8 – –

Rpull-up kΩ Rpull-down kΩ

5 10.0

680 100

– – –40

– – –

V kPa °C

UV max pmax ϑL

Dimension drawings. M Pin marking

1,33

1,65

4,15 3,5

9,4

M 7,4 -0,1

0,75

3,2

3,2

M

M

12,7 ±0,2 3,55

0,69

3

Pin 1

Pin 2

1

Pin 3

3 1 3,6

10,06 ±0,2

3,6

0,4

5,6

1

1 1 4,35 ±0,2

6,35 ±0,2 8,35 ±0,2

max. 115 +125 5.25 12.5 0.5 4.54 0.35 4.85 1 12

16 160 130 Connector-pin assignment For operation, only the following pins are needed: Pin 1 OUT output signal Pin 2 GND (ground) Pin 3 UV supply voltage

22223_1021En_032-033

32

12.07.2001

10:02 Uhr

Seite 32

A

Pressure sensors

B

Piezoresistive absolute-pressure sensors in thick-film technology Measurement of pressures in gases up to 250 kPa

p U

P Thick-film pressuremeasuring element ensures a high degree of measurement sensitivity. P Thick-film sensor element and IC on the same substrate guarantee problem-free signal transmission. P Integrated evaluation circuit for signal amplification, temperature compensation, and characteristic-curve adjustment P Sensor enclosed by robust housing. Design and function The heart of this sensor is the “sensor bubble” (pressure-measuring element) produced using 100% thick-film techniques. It is hermetically sealed on a ceramic substrate and contains a given volume of air at a reference pressure of approx. 20 kPa. Piezo-resistive thick-film strain gauges are printed onto the bubble and protected with glass against aggressive media. The strain gauges are characterized by high measurement sensitivity (gauge factor approx. 12), as well as by linear and hysteresis-free behavior. When pressure is applied, they convert mechanical strain into an electric signal. A full-wave bridge circuit provides a measurement signal which is proportional to the applied pressure, and this is amplified by a hybrid circuit on the same substrate. It is therefore impossible for interference to have any effect through the leads to the ECU. DC amplification and individual temperature compensation in the –40 °C...+125 °C range, produce an analog, ratiometric (i.e. proportional to the supply voltage UV) output voltage UA. The pressure sensors are resistant to gauge pressures up to 600 kPa. Outside the temperature range 10 °C...85 °C the permissible tolerance increases by the tolerance multiplier. To protect the sensors, the stipulated maximum values for supply voltage, operatingtemperature, and maximum pressure are not to be exceeded. Explanation of symbols UV Supply voltage UA Output voltage ∆p Permissible accuracy in the range 10 °C...85 °C k Tolerance multiplier ϑ Temperature pabs Absolute pressure

Characteristic curves 1 (UV = 5 V).

(

Characteristic curves 2 (UV = 5 V).

)

pabs UA = UV · 0,01 –0,12 kPa

UA = UV ·

p · +0,0061) ( 0,85 230 kPa

∆p UA kPa V _ 2.0 5 +

∆p UA kPa V _ + 2.0 5

4

4

_ 1.5 +

3

_ 1.0 +

_ + 1.0 2

0

∆p

_ + 1.5

∆p 3

_ 0.5 +

abs

2

UA _ + 0.5

1 0

0

0

20

40

60

80 100

UA

1 0 0

kPa

100

200 kPa

Absolute pressure pabs

Absolute pressure pabs k

k

2

2

1

1

3

3

0 -40

0

40 80 Temperature

120 °C

0 -40

0

40 80 Temperature

120 °C

Technical data / Range Part number Characteristic curve Measuring range Max. pressure (1 s, 30 °C) Pressure-change time Supply voltage UV Max. supply voltage Input current IV Load impedance RL Operating temperature range Degree of protection

kPa kPa ms V V mA kΩ °C


1 237 000 039

0 261 230 004 1 20…105 600 ≤ 10 4.75…5.25 16 < 10 > 50 –40…+125 IP 54 A

0 281 002 119 2 20…250 500 ≤ 10 4.75…5.25 16 < 10 > 50 –40…+120 –

22223_1021En_032-033

B

12.07.2001

10:02 Uhr

Seite 33

A

Pressure sensors

Block diagram. A Strain-gauge pressure-measuring cell, B Amplifier, C Temperature-compensation circuit

A

Design. 1 Strain-gauge pressure-measuring cell, 2 Plastic housing, 3 Thick-film hybrid (sensor and evaluation circuit), 4 Operational amplifier, 5 Housing cover, 6 Thick-film sensor element (sensor bubble), 7 Aluminum base plate. UV

B

1

2

3

4

5

UA

6

7

Dimension drawings.

8

6.5

6.9

Point attachment. The housing must not make contact outside this contact area. Torsion resistance must be provided.

Pin 2

Pin 1 38.9 13.6 23.3

1

16 10.5

0.5±0.2

Pin 3

Installation instructions A hose forms the connection between the sensor and the gas pressure to be measured. Upon installation, the sensor pressure connection should point downwards to prevent the ingress of moisture. The angular position referred to the vertical must be +20°...–85°, preferably 0°. Suggested fastening: M6 screw with spring washer. Connector-pin assignment Terminal 1 +UV Terminal 2 Ground Terminal 3 UA

C

Groove 1.2 deep

5.5

Blind hole 4 deep

33

22223_1021En_034-037

34

12.07.2001

10:17 Uhr

Seite 34

A

Pressure sensors

B

Absolute-pressure sensors in micromechanical hybrid design Measurement of pressures in gases up to 400 kPa

p U

P High accuracy. P EMC protection better than 100 V m–1. P Temperature-compensated. P Version with additional integral temperature sensor.

Applications This sensor is used to measure the absolute intake-manifold pressure. On the version with integral temperature sensor, the temperature of the drawn-in air flow is also measured. Design and function The piezoresistive pressure-sensor element and suitable electronic circuitry for signalamplification and temperature compensation are mounted on a silicon chip. The measured pressure is applied from above to the diaphragm’s active surface. A reference vacuum is enclosed between the rear side and the glass base. Thanks to a special coating, both pressure sensor and temperature sensor are insensitive to the gases and liquids which are present in the intake manifold. Installation information The sensor is designed for mounting on a horizontal surface of the vehicle’s intake manifold. The pressure fitting together with the temperature sensor extend into the manifold and are sealed-off to atmosphere by O-rings. By correct mounting in the vehicle (pressure-monitoring point on the top at the intake manifold, pressure fitting pointing downwards etc.) it is to be ensured that condensate does not collect in the pressure cell.

Range Pressure Character- Features Dimension Order No. range istic drawing 2) kPa (p1...p2) curve1) 10...115 1 1 B 261 260 136 3) 10...115 1 2 0 261 230 052 20...250 1 1 0 281 002 487 10...115 1 Integral temperature sensor 3 0 261 230 030 20...250 1 Integral temperature sensor 3 0 261 230 042 20...300 1 Integral temperature sensor 3 0 281 002 437 50...350 2 Integral temperature sensor 3 0 281 002 456 50...400 2 Integral temperature sensor 3 B 261 260 508 3) 1) The characteristic-curve tolerance and the tolerance expansion factor apply for all versions, see Page 36 2) See Page 37 3) Provisional draft number, order number available upon enquiry. Available as from about the end of 2001

Accessories Plug housing Qty. required: 1 4) 1 928 403 966 Plug housing Qty. required: 1 5) 1 928 403 736 Contact pin Qty. required: 3 or 4 6) 1 928 498 060 Individual gasket Qty. required: 3 or 4 6) 1 928 300 599 4) Plug housing for sensors without integral temperature sensor 5) Plug housing for sensors with integral temperature sensor 6) Sensors without temperature sensor each need 3 contacts and gaskets. Sensors with integral temperature sensor each need 4 contacts and gaskets

22223_1021En_034-037

12.07.2001

B

10:17 Uhr

Seite 35

A

Pressure sensors

35

Technical data Operating temperature Supply voltage Current consumption at UV = 5 V Load current at output Load resistance to UV or ground Response time Voltage limitation at UV = 5 V Lower limit Upper limit Limit data Supply voltage Storage temperature

ϑB UV IV IL Rpull-up Rpull-down t10/90

°C V mA mA kΩ kΩ ms

min. –40 4.5 6.0 –1.0 5 10.0 –

typ. – 5.0 9.0 – 680 100 1.0

max. +130 5.5 12.5 0.5 – – –

UA min UA max

V V

0.25 4.75

0.3 4.8

0.35 4.85

UV max ϑL

V °C

– –40

– –

+16 +130

°C mA kΩ s

–40 – – –

– – 2.5±5% –

+130 11) – 10 2)

Temperature sensor Measuring range ϑM Measured current IM Nominal resistance at +20 °C Thermal time constant t63 1) Operation at 5 V with 1 kΩ series resistor 2) In air with a flow rate of 6 m · s–1

Sectional view. Section through the sensor cell

Section through the sensor cell. 1 Protective gel, 2 Pressure, 3 Sensor chip, 4 Bonded connection, 5 Ceramic substrate, 6 Glass base.

Section through the DS-S2 pressure sensor

1

2

2

3

4 5 1 3

Section through the pressure sensor. 1 Bonded connection, 2 Cover, 3 Sensor chip, 4 Ceramic substrate, 5 Housing with pressure-sensor fitting, 6 Gasket, 7 NTC element.

6

6 4 7 5

Signal evaluation: Recommendation. R Reference D Pressure signal T Temperature signal UH

5,5 bis 16 V

US

ADC

680 k OUT

R

68 k

D T VCC

P

1,5 nF

33 nF

U NTC

NTC

GND

Pressure sensor

5V

1,5 nF

1,5 nF

2,61 k 10 k

38,3 k

ECU

33 nF

Signal evaluation: Recommendation. The pressure sensor’s electrical output is so designed that malfunctions caused by cable open-circuits or short circuits can be detected by a suitable circuit in the following electronic circuitry. The diagnosis areas situated outside the characteristiccurve limits are provided for fault diagnosis. The circuit diagram shows an example for detection of all malfunctions via signal outside the characteristic-curve limitation.

22223_1021En_034-037

36

12.07.2001

10:17 Uhr

Seite 36

A

Pressure sensors

B

Absolute-pressure sensors in micromechanical hybrid design (contd.) Measurement of pressures in gases up to 400 kPa

Characteristic curve 1 (UV = 5.0 V).


Temperature-sensor characteristic curve. Ω

V

105

5 4,65 Tolerance (% FS)

Output voltage UA

3 2

0 p1

p2

Resistance R

1.5

4

104

R=f( ) 103

- 1.5

1 0,40 0

102

P1

Pressure p

P2

kPa

40

Absolute pressure p

Characteristic curve (UV = 5.0 V).

V 5 1.5

1 Factor

Output voltage UA

4 3 2

0.5

1 0,50 0

0

P1

Pressure p

P2

kPa

-40

110 130 °C

10 Temperature

40 80 Temperature

Explanation of symbols. UA Output voltage UV Supply voltage k Tolerance multiplier D After continuous operation N As-new state

Tolerance-expansion factor.

4,50

0

120 °C

22223_1021En_034-037

12.07.2001

10:17 Uhr

Seite 37

A

B

Pressure sensors

37

Dimensions drawings.

1

2

3

Connector-pin assignment Pin 1 +5 V Pin 2 Ground Pin 3 Output signal

Connector-pin assignment Pin 1 +5 V Pin 2 Ground Pin 3 Output signal

Connector-pin assignment Pin 1 Ground Pin 2 NTC resistor Pin 3 +5 V Pin 4 Output signal

B

12 12

22

15

20 13

13

15

19

33

60

12

56

C 48

38

23

A

72

C

B

A 3

2

1

3

2

1

4

3

2

1

22223_1021En_038-039

38

12.07.2001

10:01 Uhr

Seite 38

A

Pressure sensors

B

Piezoresistive absolute-pressure sensor with moulded cable Measurement of pressures in gases up to 400 kPa

p U

P Pressure-measuring element with silicon diaphragm ensures extremely high accuracy and long-term stability. P Integrated evaluation circuit for signal amplification and characteristic-curve adjustment. P Very robust construction.

Applications This type of absolute-pressure sensor is highly suitable for measuring the boost pressure in the intake manifold of turbocharged diesel engines. They are needed in such engine assemblies for boostpressure control and smoke limitation. Design and function The sensors are provided with a pressureconnection fitting with O-ring so that they can be fitted directly at the measurement point without the complication and costs of installing special hoses. They are extremely robust and insensitive to aggressive media such as oils, fuels, brake fluids, saline fog, and industrial climate. In the measuring process, pressure is applied to a silicon diaphragm to which are attached piezoresistive resistors. Using their integrated electronic circuitry, the sensors provide an output signal the voltage of which is proportional to the applied pressure. Installation information The metal bushings at the fastening holes are designed for tightening torques of maximum 10 N · m. When installed, the pressure fitting must point downwards. The pressure fitting’s angle referred to the vertical must not exceed 60°. Tolerances In the basic temperature range, the maximum pressure-measuring error ∆p (referred to the excursion: 400 kPa–50 kPa = 350 kPa) is as follows: Pressure range 70...360 kPa As-new state ±1.0 % After endurance test ±1.2 % Pressure range < 70 and > 360 kPa (linear increase) As-new state ±1.8 % After endurance test ±2.0 %

Technical data / Range Part number Measuring range Basic measuring range with enhanced accuracy Resistance to overpressure Ambient temperature range/sustained temperature range Basic range with enhanced accuracy Limit-temperature range, short-time Supply voltage UV Current input IV Polarity-reversal strength at IV ≤ 100 mA Short-circuit strength, output Permissible loading Pull down Response time t10/90 Vibration loading max. Protection against water Strong hose water at increased pressure High-pressure and steam-jet cleaning Protection against dust

Throughout the complete temperature range, the permissible temperature error results from multiplying the maximum permissible pressure measuring error by the temperature-error multiplier corresponding to the temperature in question. Basic temperature +20...+110 °C 1.0 1) range +20... – 40 °C 3.0 1) +110...+120 °C 1.6 1) +120...+140 °C 2.0 1) 1) In each case, increasing linearly to the given value.


1 237 000 039

0 281 002 257 50...400 kPa 70...360 kPa 600 kPa –40...+120 °C +20...+110 °C ≤ 140 °C 5 V ±10 % ≤ 12 mA –UV To ground and UV ≥ 100 kΩ ≤ 100 nF ≤ 5 ms 20 g IPX6K IPX9K IP6KX

22223_1021En_038-039

12.07.2001

10:01 Uhr

Seite 39

A

B

Pressure sensors

Maximum permissible pressure-measuring error.

Characteristic curve (UV = 5 V). UA V 4

UA = U V

(

p abs - 1 437.5 kPa 70

Error % of stroke, mV

)

39

Temperature-error multiplier.

k

3

±2.0%, 80

3

±1.8%, 72

2

±1.2%, 48

2 1.6

D N

±1.0%, 40

1

1

50 100

200

50

300 kPa 400

X

3 2 1

S

400 kPa

-40

+20

110 120

Temperature

Connector-pin assignment Pin 1 UA Pin 2 +5 V Pin 3 Ground

150 ±10

ø6 ±0,3

22,5 6,5 ±0,2

- 0,2

ø15,9

25

55,1

ø15,8 - 0,2 ø11,9 ±0,15

O

6,6 ±0,2 48,4 ±0,15 62,4

360

Explanation of symbols UV Supply voltage UA Output voltage (signal voltage) k Temperature-error multiplier pabs Absolute pressure g Acceleration due to gravity 9.81 m · s–2 D After endurance test N As-new state

Dimension drawings. S 3-pole plug O1 O-ring dia. 11.5x2.5 mm HNBR-75-ShA

X

70

Absolute pressure p abs

Absolute pressure pabs

1,2 x 45° 3,6 ±0,3 7 ±0,3 9,3 ±0,3 27,8 29,6

140 °C

22223_1021En_040-041

40

12.07.2001

10:20 Uhr

Seite 40

A

Pressure sensors

B

Medium-resistant absolute-pressure sensors Micromechanical type Measurement of pressure in gases and liquid mediums up to 600 kPa

p U

P Delivery possible either without housing or inside rugged housing. P EMC protection up to 100 V · m–1. P Temperature-compensated. P Ratiometric output signal. P All sensors and sensor cells are resistive to fuels (incl. diesel), and oils such as engine lube oils.

14

2

3 Applications These monolithic integrated silicon pressure sensors are high-precision measuring elements for measuring the absolute pressure. They are particularly suitable for operations in hostile environments, for instance for measuring the absolute manifold pressure in internal-combustion engines. Design and function The sensor contains a silicon chip with etched pressure diaphragm. When a change in pressure takes place, the diaphragm is stretched and the resulting change in resistance is registered by an evaluation circuit. This evaluation circuit is integrated on the silicon chip together with the electronic calibration elements. During production of the silicon chip, a silicon wafer on which there are a number of sensor elements, is bonded to a glass plate. After sawing the plate into chips, the individual chips are soldered onto a metal base complete with pressure connection fitting. When pressure is applied, this is directed through the fitting and the base to the rear side of the pressure diaphragm. There is a reference vacuum trapped underneath the cap welded to the base. This permits the absolute pressure to be measured as well as protecting the front side of the pressure diaphragm. The programming logic integrated on the chip performs a calibration whereby the calibration parameters are permanently stored by means of thyristors (Zener-Zapping) and etched conductive paths. The calibrated and tested sensors are mounted in a special housing for attachment to the intake manifold.

56

Signal evaluation The pressure sensor delivers an analog output signal which is ratiometric referred to the supply voltage. In the input stage of the downstream electronics, we recommend the use of an RC low-pass filter with, for instance, t = 2 ms, in order to suppress any disturbance harmonics which may occur. In the version with integrated temperature sensor, the sensor is in the form of an NTC resistor (to be operated with series resistor) for measuring the ambient temperature. Installation information When installed, the pressure connection fitting must point downwards in order that condensate cannot form in the pressure cell.

7

Construction Sensors with housing: This version is equipped with a robust housing. In the version with temperature sensor, the sensor is incorporated in the housing. Sensors without housing: Casing similar to TO case, pressure is applied through a central pressure fitting. Of the available soldering pins the following are needed: Pin 6 Output voltage UA, Pin 7 Ground, Pin 8 +5 V.

22223_1021En_040-041

B

12.07.2001

10:20 Uhr

Seite 41

A

Pressure sensors

Accessories

Range Pressure sensor integrated in rugged, media-resistant housing Pressure range Chara. Features Dimension kPa (p1...p2) curve 1) drawing 2) 20...115 1 – 4 1 20...250 1 – 4 1 10...115 1 Integrated temperature sensor 2 2 20...115 1 Integrated temperature sensor 2 2 20...250 1 Integrated temperature sensor 2 2 50...350 2 Integrated temperature sensor 5 (5) 3) 50...400 2 Integrated temperature sensor – – 50...600 2 Integrated temperature sensor 6 6 10...115 1 Hose connection 1 (1) 3) 15...380 2 Clip-type module with 3 3 connection cable

Part number 0 261 230 020 0 281 002 137 0 261 230 022 0 261 230 013 0 281 002 205 0 281 002 244 0 281 002 316 0 281 002 420 0 261 230 009 1 267 030 835

Pressure-sensor cells in casings similar to transistors Suitable for installation inside devices Pressure range Chara. Features Dimension Part number kPa (p1...p2) curve 1) drawing 2) 10...115 1 – 7 7 0 273 300 006 15...380 2 – 7 7 0 273 300 017 15...380 2 – 8 (7) 3) 0 261 230 036 20...105 1 – 7 7 0 273 300 001 20...115 1 – 7 7 0 273 300 002 20...250 1 – 7 7 0 273 300 004 50...350 2 – 7 7 0 273 300 010 50...400 2 – 7 7 0 273 300 019 50...400 2 – 8 (7) 3) 0 261 230 033 50...600 2 – 7 7 0 273 300 012 1) The characteristic-curve tolerance and the tolerance extension factor apply to all versions, refer to Page 42. 2) See Page 43/44 3) For similar drawing, see dimension drawing on Pages 43/44 4) To be obtained from AMP Deutschland GmbH, Amperestr. 7–11, D-63225 Langen, Tel. 0 61 03/7 09-0, Fax 0 61 03/7 09 12 23, E-Mail: [email protected]

For 0 261 230 009, .. 020; 0 281 002 137 Plug housing 1 928 403 870 Contact pin 2-929 939-1 4) Individual gasket 1 987 280 106 For 0 261 230 013, .. 022; 0 281 002 205, ..420 Plug housing 1 928 403 913 Contact pin 2-929 939-1 4) Individual gasket 1 987 280 106 For 0 281 002 244 Plug housing Contact pin Individual gasket

1 928 403 913 2-929 939-6 4) 1 987 280 106

For 0 281 002 420 Plug housing Contact pin Individual gasket

1 928 403 736 1 928 498 060 1 928 300 599

Note Each 3-pole plug requires 1 plug housing, 3 contact pins, and 3 individual gaskets. 4-pole plugs require 1 plug housing, 4 contact pins, and 4 individual gaskets.

Technical data Supply voltage UV Current input IV at UV = 5 V Load current at output Load resistance to ground or UV Lower limit at UV = 5 V Upper limit at UV = 5 V Output resistance to ground UV open Output resistance to UV, ground open Response time t10/90 Operating temperature

V mA mA kΩ V V kΩ kΩ ms °C

min. 4.5 6 –0.1 50 0.25 4.75 2.4 3.4 – –40

typical 5 9 – – 0.30 4.80 4.7 5.3 0.2 –

max. 5.5 12.5 0.1 – 0.35 4.85 8.2 8.2 – +125

Limit data Supply voltage UV Operating temperature

V °C

– –40

– –

16 +130

Recommendation for signal evaluation Load resistance to UH = 5.5...16 V Load resistance to ground Low-pass resistance Low-pass capacitance

kΩ kΩ kΩ nF

– – – –

680 100 21.5 100

– – – –

°C mA kΩ s

–40 – – –

– – 2,5 ±5 % –

+125 1 5) – 45

Temperature sensor Measuring range Nominal voltage Measured current at +20 °C Temperature time constant t63 6) 5) Operation with series resistor 1 kΩ. 6) In air with airflow speed 6 m · s–1.

41

22223_1021En_042-044

42

12.07.2001

10:08 Uhr

Seite 42

A

Pressure sensors

B

Micromechanical TO-design absolute-pressure sensors (contd.) Measurement of pressures in gases and liquid media up to 600 kPa


Characteristic-curve tolerance. ∆p % p 3

5 4,65 4

2

3

1

2

0

Ω 105

P1 0

P2 0,2

0,4

0,6

0,8

1,0

Resistance R

V

Output voltage UA

Temperature-sensor characteristic curve.

104

R=f( )

1 -1 0,40 0

P1

P2

Pressure p

kPa

103

-2

102

-3


40

Pressure p kPa

V

k

Output voltage UA

4,50 4

3

3

2

120 °C

40 80 Temperature

Explanation of symbols UA Output voltage UV Supply voltage k Tolerance multiplication factor D Following endurance test N As-new state

Tolerance extension factor.

5

0

D 2

N

1

1 -40

0,50 0

0

40

80

120 °C

Temperature ϑ P1

P2

Pressure p

Block diagram. E Characteristic curve: Sensitivity, K Compensation circuit O Characteristic curve: Offset, S Sensor bridge, V Amplifier

kPa

Sectional views. Pressure sensor in housing. 1 Pressure sensor, 2 pcb, 3 Pressure fitting, 4 Housing, 5 Temperature sensor, 6 Electrical bushing, 7 Glass insulation, 8 Reference vacuum, 9 Aluminum connection (bonding wire), 10 Sensor chip, 11 Glass base, 12 Welded connection, 13 Soldered connection.

8

S

V

1

2

10

11

3

13

12

7

6

Section through the installed pressure sensor.

9

Installed pressure sensor. Version with temperature sensor. 2

1

E, K, O

3

4

5

22223_1021En_042-044

B

12.07.2001

10:08 Uhr

Seite 43

A

Pressure sensors

43

Dimension drawings. P Space required by plug and cable.

1 0 261 230 009

2 0 261 230 013, 0 261 230 022, 0 281 002 205

Connector-pin assignment Pin 1 +5 V Pin 2 Ground Pin 3 Output signal 11,7 ± 0,15

3,5 min. 1

Connector-pin assignment Pin 1 Ground Pin 2 NTC resistor Pin 3 +5 V Pin 4 Output signal 58 39

R 10

P

8,85

5 min. 1

8

ø 17,6

4

15,1

28,2

70

27

15

P

X

P

6,8

12

min. 4

4

15,5

3

2

4 3

X 1

min. 35

°

20

0°

16,2

6,6 20

+6

-60

0°

49 36

2 1

1 2 3 4

11,7 ± 0,15

4 0 261 230 020, 0 281 002 137

3 1 267 030 835

Connector-pin assignment Pin 1 +5 V R 10 Pin 2 Ground Pin 3 Output signal 5,6 +- 0,05 0,15 2,6 ± 0,45

12

7 1,5 +- 0,05 0,15 (3x)

7,8 ± 0,15 20

26,7

70

60° (3x)

4 ± 0,5

2,3 ± 0,3

12 ± 0,5

4

15,1

20 +- 0,25 0,05

16 +- 0,25 0,05

ø11,85 ± 0,1

30

70 ± 5

17

X 3

12,5 +- 0,3 0,5 20 16,2

19,5

P

X

28,2

17 +- 0,05 0,25

1± 0,15 (3x)

25 +- 0,25 0,05 ø3,8 ± 0,1 ø1,5 ± 0,05

3,6 - 0,1 (3x)

Connector-pin assignment Pin 1 Ground Pin 2 +5 V Pin 3 Vacant Pin 4 Output signal

2

1

57

18

min. 4

± 0,15

15°

26,7 7,8

22223_1021En_042-044

44

12.07.2001

10:08 Uhr

Seite 44

A

Pressure sensors

B

Micromechanical TO-design absolute-pressure sensors (contd.) Measurement of pressures in gases and liquid media up to 600 kPa

Dimension drawings A Space required by plug and cable B Space required when plugging in/unplugging

5 0 281 002 244

7 0 273 300 ..

Connector-pin assignment Pin 1 Ground Pin 2 NTC resistor Pin 3 +5 V Pin 4 Output signal

Sensor without housing D Pressure-connection fitting Pin 6 Output signal Pin 7 Soldered

A

5

min.3

B

6 min.1 1 min.2 ,5 4 min.1

58

12,7 +- 0,5 0,1

1,5 ±0,1 7,62 2,54

9,3

58

4

2,54

15°

2,5

18

ø16,6

10

39

8,5

30

min.1

PIN 8 7,62

D 15,5

PIN 7

ø17,7 ± 0,2 18

12,5 1,7 max.

73

AIR

4 3 2 1

9,5

36 ± 0,3

54

18

PIN 6

0,8 +- 0,15 0,05

7,6

ø1,5

8 0 261 230 036 .. D Pressure connection L In the area of the measuring surface

6 0 281 002 246 Connector-pin assignment Pin 1 Ground Pin 2 NTC resistor Pin 3 +5 V Pin 4 Output signal

A

B

5

min.3 6 . min 1

1 min.2 ,5 4 min.1

58 39 ø16,6

2,1

15,5

ø17,7 ± 0,2 18

5

min.1

8,5 ± 0,25

27

8,5

ø6,3 2,1

6,4± 0,3

L 8,8 ± 0,4

10

55

4 12

15°

2,5

18

12,7 11,4 ± 0,2

1,5 ± 0,1

18

1,5 (3x) 6,7 6,9

13,6 ± 0,25

73

OIL

7,6

4 3 2 1

9,5

36 ± 0,3

54

D

5,2

13,9

22223_1021En_045-049

B

12.07.2001

10:04 Uhr

Seite 45

A

Pressure sensors

45

Pressure sensors For pressures up to 1800 bar (180 Mpa)

P Ratiometric signal evaluation (referred to supply voltage). P Self-monitoring of offset and sensitivity. P Protection against polarity reversal, overvoltage, and short circuit of output to supply voltage or ground. P High level of compatibility with media since this only comes into contact with stainless steel. P Resistant to brake fluids, mineral oils, water, and air. Application Pressure sensors of this type are used to measure the pressures in automotive braking systems, or in the fuel-distributor rail of a gasoline direct-injection engine, or in a diesel engine with Common Rail injection.

Only for 0 265 005 303 This sensor differs from conventional sensors due to the following diagnostic functions: – Offset errors – Amplification errors can be detected by comparing two signal paths in the sensor. Storage conditions Temperature range –30...+60 °C Relative air humidity 0...80 % Maximum storage period 5 years Through compliance with the above storage conditions, it is ensured that the sensor functions remain unchanged. If the maximum storage conditions are exceeded, the sensors should no longer be used. Explanation of symbols Output voltage UA Supply voltage UV bar Pressure

Characteristic curve. UA = (0.8 · p / pNom. + 0.1)UV

V 4.5 4 Output voltage UA

Design and function Pressure measurement results from the bending of a steel diaphragm on which are located polysilicon strain-gauge elements. These are connected in the form of a Wheatstone bridge. This permits high signal utilisation and good temperature compensation. The measurement signal is amplified in an evaluation IC and corrected with respect to offset and sensitivity. At this point, temperature compensation again takes place so that the calibrated unit comprising measuring cell and ASIC only has a very low temperature-dependence level. Part of the evaluation IC is applied for a diagnostic function which can detect the following potential defects: – Fracture of a bonding wire to the measuring cell. – Fracture anywhere on any of the signal lines. – Fracture of the bridge supply and ground.

3

2

1

0.5 0

35

0

70

0

50

100

0

250

500

750

0

300

600

900

105 150

200

140 250

1000 1250 1500

1200 1500 1800 bar Pressure p

22223_1021En_045-049

46

12.07.2001

10:04 Uhr

Seite 46

A

Pressure sensors

B

Pressure sensors (contd.) For pressures up to 1800 bar (180 MPa)

Diagnostic function during self-test (following switch-on). Only for 0 265 005 303. – Correctness of the calibration values – Function of the sensor signal path from the sensor to the A/D converter of the evaluation unit – Check of the supply lines. Diagram: Characteristic of the output voltage following switch-on – Function of the signal and alarm paths – Detection of offset errors – Detection of short circuits in wiring harness – Detection of overvoltage and undervoltage – If an error is detected during the sensor’s self-test, the signal output is switched to the voltage range > 96%UV.

Self-monitoring. Offset and sensitivity. Only for 0 265 005 303. UA UV 96 %

Error band Limitation, working signal

90 % Measuring range

100 %

Error range Offset error Sensitivity error 12 % 4%

Error range Error band Pressure p

Measuring circuit. Pressure sensor

Diagnostic function during normal operation. Only for 0 265 005 303. – Detection of offset errors – Detection of sensitivity errors (with pressure applied) – Wiring-harness function, detection of wiring-harness short circuits – Detection of overvoltage and undervoltage – If an error is detected during the sensor’s self-test, the signal output is switched to the voltage range >96%UV.

ECU 3

+ 5 V (UV)

Pull up resistor Signal (UA) 2 A/Dconverter and C 1

GND

Range Pressure range bar (MPa) 140 (14) 250 (25) 1500 (150)

Sensor Type KV2 BDE – RDS2 RDS3

1800 (180)

RDS2 RDS3

Thread

Connector

Pin

M 10x1 M 10x1 M 12x1.5 M 12x1.5 M 12x1.5 M 12x1.5 M 12x1.5 M 18x1.5 M 18x1.5 M 18x1.5

Compact 1.1 PSA Working circuit Compact 1.1 Working circuit Compact 1.1 Compact 1.1 Compact 1.1 Compact 1.1 Working circuit

Gold-plated – Silber-plated Gold-plated Silber-plated Gold-plated Gold-plated Gold-plated Gold-plated Silber-plated

Dimens. drawing 1 2 3 4 5 6 4 7 8 9

Page

Part number

47 48 48 48 48 49 48 49 49 49

0 261 545 006 0 265 005 303 0 281 002 238 0 281 002 405 0 281 002 498 0 281 002 522 0 281 002 398 0 281 002 472 0 281 002 534 0 281 002 504

Accessories For 0 265 005 303 Plug housing – Quantity required: 1 AMP No. Contact pins for 0.75 mm2 Quantity required:3 AMP No. Gaskets for 1.4...1.9 mm2 Quantity required: 3 AMP No. 1) To be obtained from AMP Deutschland GmbH, Amperestr. 7–11, D-63225 Langen, Tel. 0 61 03/7 09-0, Fax 0 61 03/7 09 12 23, E-Mail: [email protected]

2-967 642-1 1) 2-965 907-1 1) 2-967 067-1 1)

22223_1021En_045-049

B

12.07.2001

10:04 Uhr

Seite 47

A

Pressure sensors

47

Technical data Pressure sensor Pressure-sensor type Application/Medium Pressure range

bar (MPa) UV

Offset accuracy Sensitivity accuracy at 5 V In range 0...35 bar

FS 2) of measured value

In range 35...140 bar In range 35...250 bar In range 35...1500 bar

In range 35...1800 bar Input voltage, max. Us V Power-supply voltage UV V Power-supply current IV mA Output current IA µA...mA Load capacity to ground nF Temperature range °C Overpressure max. pmax bar Burst pressure pburst bar Tightening torque Ma Nm Response time T10/90 ms Note: All data are typical values 1) RME = Rapeseed methyl ester 2) FS = Full Scale 3) Of measured value 4) Output current with pull-up resistor 5) +140 °C for max. 250 h

0 261 545 006 0 265 005 303 0 281 002 238 0 281 002 405 KV2 BDE – RDS2 Unlead. fuel Brake fluid Diesel fuel or RME 1) 140 250 1500 (14) (25) (150) 0.7 % FS 2.0 % 1.0 % FS 1.5 % FS –

≤ 0.7 %

1.5 % – –

– ≤ 5.0 % 3) –

– 16 5 ±0.25 9...15 – 13 –40...+130 180 > 300 22 ±2 2

– – 5 ±0.25 ≤ 20 –100...3 – –40...+120 350 > 500 20 ±2 –

1.0 % FS 1.5 % FS – – 2.0 % FS 2.5 % FS – 16 5 ±0.25 9...15 2.5 mA 4) 10 –40...+120 5) 1800 3000 35 ±5 5

Dimension drawings Space required by plug, approx. 25 mm Space required when plugging/unplugging, approx. 50 mm SW = A/F size

0 281 002 498 0 281 002 522 RDS3 Diesel fuel or RME 1) 1500 (150) 0.7 % FS



0.7 % FS

1.0 % FS

0.7 % FS

– – 1.5 % FS

– – –

– – –

– 16 5 ±0.25 9...15 – 13 –40...+130 2200 4000 35 ±5 2

2.3 % FS 16 5 ±0.25 9...15 2.5 mA 4) 10 –40...+120 5) 2100 3500 70 ±2 5

1.5 % FS 16 5 ±0.25 9...15 – 13 –40...+130 2200 4000 70 ±2 2

Connector-pin assignment Pin 1 Ground Pin 2 Output voltage UA Pin 3 Supply voltage UV 59,8

1

24,4

3,8 Pin 2 S 2

90°

3

30

M 10x1-6g

13

ø 25

27

SW

2 1

21,5

ø 8,5 ± 0,3 ø 2,8 ± 0,1

0 261 545 006 140 bar

5,3 ± 2

1

6 16,5 ± 3

F

Pin 1

3

Pin 3

22223_1021En_045-049

48

12.07.2001

10:04 Uhr

Seite 48

A

Pressure sensors

B

Pressure sensors (contd.) For pressures up to 1800 bar (180 MPa)

D F S


41 B 24,3 A

2 10 ± 0,1

53,3 38 ± 0,6 20,9 ± 0,5 17,1± 0,2 3 2,8 - 0,5

Pin 2

ø8,5 - 0,1 ø2,8 ± 0,1

90°

M10x1

ø25 - 0,1

SW 24

0 281 002 238 1500 bar

Connector-pin assignment Pin 1 Ground Pin 2 Output voltage UA Pin 3 Supply voltage UV

ø22,1

0 265 005 303 250 bar

Gasket Date of manufacture 3-pin plug

1

2

3

5,3 ± 0,2 Pin 1

15,3 ± 0,1

Pin 3

29 ± 2

3

7

R

Pin 2

S

ø 25

27

SW

1,5

2

30

0 281 002 405 1500 bar 0 281 002 398 1800 bar

2

D

3

1

M 12 x1,5

1

0,6 - 0,1 12,5

Pin 3

69 ± 2

29 ± 2 7

R 27 SW

Pin 2

S

D

3

1

M 12x1,5

1

1,5

2

2

13

ø 25

Pin 1

F

16

4

24,4

0 281 002 498 1500 bar

3

30

3

0,6 - 0,1 12,5

Pin 1

F

Pin 3

16 68 ± 2

5 21,5 ± 2 6 ± 0,5

± 0,1

7

2 SW

2 1

2

D

3

30

1

M 12x1,5

ø 24,8

Pin 2

S

3

2,15 ± 0,15 12,5

F

16,6 ± 0,7 60,5 ± 2

Pin 1

Pin 3

22223_1021En_045-049

12.07.2001

10:04 Uhr

Seite 49

A

B

Pressure sensors


0 281 002 522 1500 bar

D F S

Gasket Date of manufacture 3-pin plug

Connector-pin assignment Pin 1 Ground Pin 2 Output voltage UA Pin 3 Supply voltage UV

6 21,5 ± 2 6 SW

R

Pin 2

S

1

24,4

0 281 002 472 1800 bar

D

3

1

30

3

0,6 - 0,1

M 12x1,5- 6g

13

ø 25

27 2

2 1

12,5 ± 2

Pin 1

F

Pin 3

16 59,3 ± 2

7

29 ± 2 3,8 - 2 7 3

Pin 2

ø12,6

ø15,5

3

M 18x1,5-6g

60°

13

ø 25

27

SW

2 1

S 2 1

Pin 1

F 24,4

30

3

Pin 3

17,1 69 ± 2

0 281 002 534 1800 bar

8

21,5 ± 2

17,1 15 °

Pin 2

ø12,6

ø15,5

3

M 18x1,5-6g

60°

13

ø 25

27

SW

2 1

S 2 1

2,5 24,4

0 281 002 504 1800 bar

Pin 3

F

6 30

3

Pin 1

60,4 ± 2

9

21,5 ± 2

17,1 15 °

Pin 2

ø12,6

ø15,5

3

M 18x1,5-6g

60°

ø 25

27

SW

2 1

S 2 1

2,5 30

F

6 60,8 ± 2

Pin 1

3

Pin 3

49

22223_1021En_050-051

50

12.07.2001

10:03 Uhr

Seite 50

A

Temperature sensors

B

NTC temperature sensors Measurement of air temperatures between –40 °C and +130 °C ϑ R P Measurement with temperature-dependent resistors. P Broad temperature range.

1

2

3

Range NTC temperature sensor NTC resistor in plastic sheath

Temperature sensor (principle). 1 Electrical connection 2 Housing 3 NTC resistor

Block diagram.

1

Steel housing Screw fastening

0 280 130 039

Polyamide housing Plug-in mounting Plug-in mounting

0 280 130 092 0 280 130 085

2 R(ϑ )

Accessories For 0 280 130 039; .. 085 Connector 1 237 000 036 For 0 280 130 092 DesigFor cable nation cross-section Plug housing – Contact 0.5...1.0 mm2 pins 1.5...2.5 mm2 Individual 0.5...1.0 mm2 gaskets 1.5...2.5 mm2

Part number 1 928 403 137 1 987 280 103 1 987 280 105 1 987 280 106 1 987 280 107

Note Each 2-pole plug requires 1 plug housing, 2 contact pins, and 2 individual gaskets. For automotive applications, original AMP crimping tools must be used. Explanation of symbols: R Resistance ϑ Temperature

3

Technical data Part number Illustration Characteristic curve Measuring range Permissible temp., max. Electrical resistance at 20 °C Electrical resistance at –10 °C Electrical resistance at +20 °C Electrical resistance at +80 °C Nominal voltage Measured current, max. Self-heating at max. permissible power loss P = 2 mW and stationary air (23 °C) Thermal time constant 1) Guide value for permissible vibration acceleration (sinusoidal vibration) Corrosion-tested as per

°C °C kΩ kΩ kΩ kΩ V mA

0 280 130 039 1 1 –40...+130 +130 2.5 ±5 % 8.26...10.56 2.28...2.72 0.290...0.364 ≤5 1

0 280 130 085 2 2 –40...+130 +140 2.4 ±5.4 % – 2.290...2.551 – ≤5 1

0 280 130 092 3 1 –40...+130 +130 2.5 ±5 % 8.727...10.067 2.375...2.625 – ≤5 1

K s

≤2 ca. 20

– ≤ 5 2)

≤2 44

100 DIN 50 018

≤ 300 DIN 50 018

m · s–2 100 DIN 50 018

1) At 20 °C. Time required to reach 63% of final value for difference in resistance, given an abrupt increase in air temperature; air pressure 1000 mbar; air-flow rate 6 m · s–1. 3) Time constant τ –1 63 in air for a temperature jump of –80 °C to +20 °C at an air-flow rate of ≥ 6 m · s .

22223_1021En_050-051

12.07.2001

10:03 Uhr

Seite 51

A

B

Temperature sensors

51

Dimension drawings.

2

1

4,5 6 2,5

30°

M 12x1,5

ø15

ø8,5

ø5,2 ±0,2

SW19

0 280 130 085 B Mounting screw X Thread in contact area L Air flow ø9,7-0,1

0 280 130 039 SW A/F size

-0,2

0 R1

4,5 3,5 26

ø 15

15 22

5

R9 h12

48,5

R5

ø 6,6 10

55

15 ± 0,1

4,5

ø 9,3

3

0 280 130 092

44

18

20,5 +0,5 9 B

X

Characteristic curve 1.

Characteristic curve 2. Ω

Ω

10 4

Resistance R

10 4 Resistance R

6,5

H8

10 3

10 3

10 2

10 2

10 0

20 40 60 80 100 120°C Temperature ϑ

101 -40 -20

R

5

° 30 10

min. 8 max. 20

ø22

11,9

L

1

4 ±0,3

–20

L

ø 12,5

33,7

+0,1 -0,3

,5 R1

ø16

ø20 ±0,3

22

15 +0,1

M6

ø 12 h12

ca.ø6

ø5,2 ±0,2

30,7 +0,5

0

20 40 60 80 100 120°C Temperature ϑ

Design and function NTC sensor: The sensing element of an NTC temperature sensor (NTC = Negative Temperature Coefficient), is a resistor comprised of metal oxides and oxidized mixed crystals. This mixture is produced by sintering and pressing with the addition of binding agents. For automotive applications, NTC resistors are enclosed in a protective sheath. If NTC resistors are exposed to external heat, their resistance drops drastically and, provided the supply voltage remains constant, their input current climbs rapidly. This property can be utilised for temperature measurement. NTC resistors are suitable for an extremely wide range of ambient conditions, and with them it is possible to measure a wide range of temperatures. Installation instructions Installation is to be such that the front part of the sensing element is directly exposed to the air flow.

22223_1021En_052-053

52

12.07.2001

10:06 Uhr

Seite 52

A

Temperature sensors

B

NTC temperature sensors Measurement of liquid temperatures from –40 °C to +130 °C ϑ R P For a wide variety of liquidtemperature measurements using temperature-dependent resistors.

Design and function NTC sensor: The sensing element of the NTC temperature sensor (NTC = Negative Temperature Coefficient) is a resistor comprised of metal oxides and oxidized mixed crystals. This mixture is produced by sintering and pressing with the addition of binding agents. For automotive applications, NTC resistors are enclosed in a protective housing. If NTC resistors are exposed to external heat, their resistance drops drastically and, provided the supply voltage remains constant, their input current climbs rapidly. This property can be utilised for temperature measurement. NTC resistors are suitable for use in the most varied ambient conditions, and with them it is possible to measure a wide range of liquid temperatures. Note Each 2-pole plug requires 1 plug housing, 2 contact pins, and 2 individual gaskets. For automotive applications, original AMP crimping tools must be used. Explanation of symbols R Resistance ϑ Temperature

Temperature sensor (principle) 1 Electrical connection 2 Housing 3 NTC resistor

Diagram.

1

2 R(ϑ )

3

Characteristic curve. Ω

10 4 Resistance R

NTC temperature sensor Plastic-sheathed NTC resistor in a brass housing

10 3

10 2

10 –20

0

20 40 60 80 100 120°C Temperature ϑ

12.07.2001

10:06 Uhr

Seite 53

A

Temperature sensors

Dimension drawing. S Plug F Blade terminal SW A/F size

0 281 002 209

60,9 28

0 280 130 026

S

SW19 S

1,2 ±0,1

15

F

7,5

M12x1,5

6,45 ±0,15

17

SW 19

5

0 280 130 093, 0 281 002 170

0 281 002 412

57,9 28

60,9

5

28

17

S

32,9

15

20°

1,2 ±0,1 SW 19

7,5

15

F

M14x1,5

6,45 ±0,15 7,5

M12x1,5

1,2 ±0,1

5

16

S

6,45 ±0,15

F

5

17

15

7,5 -0,3

M12x1,5

50,5

28

53

20°

B

SW 19

20°

22223_1021En_052-053

Technical data Part number Application/medium Measuring range Tolerance at +20 °C +100 °C Nominal resistance at 20 °C Electrical resistance at –10 °C +20 °C +80 °C Nominal voltage Measured current, max. Thermal time constant Max. power loss at ∆T ≈ 1K and stationary air 23 °C Degree of protection 1) Thread Corrosion-tested as per Plugs Tightening torque 1) With single-conductor sealing 2) Saline fog 384 h

°C °C °C kΩ kΩ kΩ kΩ V mA s

0 280 130 026 Water –40...+130 1.2 3.4 2.5 ±5 % 8.26…10.56 2.28…2.72 0.290…0.364 ≤5 1 44

0 280 130 093 Water –40...+130 1.2 3.4 2.5 ±5 % 8.727...10.067 2.375...2.625 – ≤5 1 44

0 281 002 170 Oil/Water –40...+150 ±1.5 ±0.8 2.5 ±6 % 8.244...10.661 2.262...2.760 0.304…0.342 ≤5 1 15

0 281 002 209 Water –40...+130 ±1.5 ±0.8 2.5 ±6 % 8.244...10.661 2.262...2.760 0.304…0.342 ≤5 1 15

0 281 002 412 Water –40...+130 ±1.5 ±0.8 2.5 ±6 % 8.244...10.661 2.262...2.760 0.304…0.342 ≤5 1 15

m · s–2

100

Nm

M 12 x 1.5 DIN 50 018 Jetronic, Tin-plated pins 25

≤ 300 IP 54A M 12 x 1.5 DIN 50 018 Compact 1, Tin-plated pins 18

≤ 300 IP 64K M 12 x 1.5 DIN 50 021 2) Compact 1, Gold-plated pins 18

≤ 300 IP 64K M 12 x 1.5 DIN 50 021 2) Compact 1.1, Tin-plated pins 25

≤ 300 IP 64K IP 64K M 14 x 1.5 DIN 50 021 2) Compact 1.1, Tin-plated pins 20

Accessories For 0 280 130 026 Designation

Part number

Connector

1 237 000 036

For 0 280 130 093, 0 281 002 170 DesigFor cable Part number nation cross-section Plug housing – 1 928 403 137 Contact 0.5 ... 1.0 mm2 1 987 280 103 pins 1.5 ... 2.5 mm2 1 987 280 105 Individual 0.5 ... 1.0 mm2 1 987 280 106 gaskets 1.5 ... 2.5 mm2 1 987 280 107

For 0 281 002 209, 0 281 002 412 DesigFor cable Part number nation cross-section Plug housing – 1 928 403 874 Contact 0.5 ... 1.0 mm2 1 928 498 060 pins 1.5 ... 2.5 mm2 1 928 498 061 Individual 0.5 ... 1.0 mm2 1 928 300 599 gaskets 1.5 ... 2.5 mm2 1 928 300 600

22223_1021En_054-055

54

12.07.2001

10:05 Uhr

Seite 54

A

Air-mass meters

B

Hot-film air-mass meter, type HFM 2 Measurement of air-mass throughflow up to 1080 kg / h Qm U P Measurement of air mass (gas mass) throughflow per unit of time, independent of density and temperature. P Extensive measuring range. P Highly sensitive, particularly for small changes in flow rate. P Wear-free since there are no moving parts. P Insensitive to dirt and contamination.

Characteristic curves.

Operating principle.

V 1

2

3

Design and function The sensor element comprises a ceramic substrate containing the following thick-film resistors which have been applied using silk-screen printing techniques: Air-temperature-sensor resistor Rϑ, heater resistor RH, sensor resistor RS, and trimmer resistor R1. The heater resistor RH maintains the platinum metallic-film resistor RS at a constant temperature above that of the incoming air. The two resistors are in close thermal contact. The temperature of the incoming air influences the resistor Rϑ with which the trimmer resistor R1 is connected in series. Throughout the complete operating-temperature range it compensates for the bridge circuit’s temperature sensitivity. Together with R2 and Rϑ, R1 forms one arm of the bridge circuit, while the auxiliary resistor R3 and sensor resistor RS form the other arm. The difference in voltage between the two arms is tapped off at the bridge diagonal and used as the measurement signal. The evaluation circuit is contained on a second thick-film substrate. Both hybrids are integrated in the plastic housing of the plug-in sensor. The hot-film air-mass meter is a thermal flowmeter. The film resistors on the ceramic substrate are exposed to the air mass under measurement. For reasons associated with flow, this sensor is far less sensitive to contamination than, for example, a hot-wire air-mass meter, and there is no need for the ECU to incorporate a self-cleaning burn-off function.

Output voltage UA

5

4

C4

4

R5

Uk R3

3

R2 + -

Application Measurement of air-mass flow rate to provide data needed for clean combustion. Air-mass meters are suitable for use with other gaseous mediums.

+ -

2

RT

RH RS

1 0 0

200

400

600

800

kg . h -1

R1

1 2 3 4

Mass rate of flow Qm

Technical data / Range Part number Characteristic curve Installation length L mm Air-flow measuring range Accuracy referred to measured value Supply voltage Input current at 0 kg · h–1 at Qm nom. Time constant 1) Temperature range Sustained Short-term Pressure drop at nominal air mass hPa Vibration acceleration max. 1)

0 280 217 102 0 280 217 120 0 280 217 519 0 280 217 801 0 280 217 107 1 2 3 4 130 130 130 130 96

kg · h–1 10...350

10...480

12...640

20...1080

% V

±4 14

±4 14

±4 14

±4 14

A A ms

≤ 0,25 ≤ 0,8 ≤20

≤ 0,25 ≤ 0,8 ≤20

≤ 0,25 ≤ 0,8 ≤20

≤ 0,25 ≤ 0,8 ≤20

°C °C

–30...+110 –40...+125

–30...+110 –40...+125

–30...+110 –40...+125

–30...+110 –40...+125

mbar

1) and “rich” (λ