Bosch Rexroth 1070092392-AA / 1070089906-GI1 Modules

Technical Dossier

Product Details And Specifications

Bosch Rexroth CL 400 Series: Comprehensive Module Range and Technical Overview

The Bosch Rexroth CL 400 programmable logic controller series is a modular, rack-based automation platform deployed extensively across global heavy industry sectors including petrochemical refining, nuclear power auxiliary systems, offshore oil & gas processing, and continuous-process chemical manufacturing. Its deterministic scan-cycle architecture, robust backplane bus, and wide operating temperature tolerance made it a preferred control platform for safety-critical and high-availability installations throughout the 1990s and 2000s. Installed base density remains high in brownfield facilities across Europe, Asia-Pacific, and the Middle East, where full system replacement is economically or operationally impractical. The 1070092392-AA (CPU/controller board) paired with the 1070089906-GI1 (group interface / I/O expansion module) represents a core processing and I/O coupling assembly within this architecture.

The Evolution of Rexroth CL 400 Architecture

The CL 400 series was introduced by Bosch Rexroth (formerly Bosch Automation / Robert Bosch GmbH industrial controls division) as a successor to the CL 300 line, incorporating a higher-throughput parallel backplane bus and expanded memory addressing. Early revisions used EPROM-based program storage; subsequent hardware revisions (AA, AB, BA suffixes) transitioned to battery-backed SRAM and later Flash-based retention. The GI (Group Interface) module family — including the GI1, GI2, and GI3 variants — was introduced to decouple remote I/O racks from the central CPU rack, enabling distributed topology across large plant footprints via RS-485 and proprietary Rexroth serial bus protocols.

Compatibility constraints are significant: CPU modules are revision-specific to firmware versions, and GI modules must match the rack generation (400-series racks are not backward-compatible with CL 300 backplanes). As the series entered end-of-life status, Bosch Rexroth designated the IndraLogic / IndraControl XM/L series as the migration path, though direct hardware substitution requires full I/O remapping and software recompilation.

Rexroth CL 400 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified components within the Bosch Rexroth CL 400 ecosystem, classified by functional category:

CPU & Controller Modules

• 1070092392-AA: Central processing unit board, CL 400 rack, primary program execution and I/O scan controller.
• 1070092392-AB: CPU board revision AB, extended Flash memory, enhanced diagnostic register set.
• 1070092392-BA: CPU board revision BA, increased SRAM capacity, revised watchdog timer circuit.
• 1070077766-101: CL 400 CPU module with integrated Ethernet port, firmware v4.x compatible.
• 1070077766-102: CPU module variant with dual serial interface, used in redundant CPU configurations.

Group Interface (GI) / I/O Expansion Modules

• 1070089906-GI1: Group Interface module GI1, single-channel remote I/O bus master, supports up to 8 remote racks.
• 1070089906-GI2: Group Interface module GI2, dual-channel bus master, redundant I/O path configuration.
• 1070089906-GI3: Group Interface module GI3, high-speed variant, reduced cycle latency for time-critical I/O loops.
• 1070089907-101: Remote I/O bus coupler, slave-side termination module for GI1/GI2 bus segments.

Digital Input (DI) Modules

• 1070083462-101: 16-channel 24 VDC digital input module, sink/source configurable, CL 400 rack mount.
• 1070083462-102: 32-channel 24 VDC digital input module, high-density I/O expansion.
• 1070083463-101: 16-channel 120 VAC digital input module, optically isolated, for legacy AC field wiring.

Digital Output (DO) Modules

• 1070083464-101: 16-channel 24 VDC transistor output module, 0.5 A per channel, short-circuit protected.
• 1070083464-102: 16-channel relay output module, 2 A per channel, for inductive load switching.

Analog Input / Output (AI/AO) Modules

• 1070083470-101: 8-channel analog input module, 4–20 mA / 0–10 V selectable, 12-bit resolution.
• 1070083471-101: 4-channel analog output module, 4–20 mA, 12-bit DAC, loop-powered field devices.

Power Supply Modules

• 1070079876-101: CL 400 rack power supply, 24 VDC input, 5 VDC / 3.3 VDC backplane output, 10 A rated.
• 1070079876-102: Redundant power supply module, hot-swap capable, for high-availability rack configurations.

Communication & Network Modules

• 1070084210-101: PROFIBUS-DP master module, CL 400 rack, supports up to 125 slave nodes.
• 1070084211-101: Modbus RTU/TCP gateway module, serial and Ethernet dual-port, for SCADA integration.

Sourcing Hard-to-Find & Obsolete Rexroth CL 400 Parts

Bosch Rexroth formally discontinued active production of CL 400 series hardware. OEM spare parts availability through authorized distribution channels is effectively exhausted for the majority of CPU, GI, and I/O module variants. DriveKNMS maintains a dedicated inventory of tested, pull-from-service, and new-old-stock (NOS) CL 400 components sourced through controlled industrial decommissioning programs and verified secondary market channels.

For facilities operating CL 400 systems under long-term maintenance contracts or deferred migration schedules, DriveKNMS provides: confirmed part identification by full part number and hardware revision suffix; cross-reference verification against Rexroth engineering documentation; and lead-time commitment for hard-to-locate variants including GI2, GI3, and high-revision CPU boards. Minimum order quantities are not required for spare part procurement. Emergency same-day quotation is available for critical plant shutdown scenarios.

Quality Control for the Rexroth CL 400 Range

CL 400 modules present specific test challenges due to their proprietary backplane bus protocol and revision-dependent firmware handshake sequences. DriveKNMS applies the following verification procedures to all CL 400 inventory prior to dispatch:

• Backplane bus continuity and impedance verification using CL 400-compatible rack test fixtures.
• CPU module boot sequence validation: POST completion, memory self-test pass, and watchdog timer reset confirmation.
• GI module bus master enumeration test: slave rack discovery cycle executed and logged against expected node count.
• I/O module channel-level functional test: each DI/DO channel exercised at rated voltage; AI/AO modules calibrated against NIST-traceable reference signals.
• Visual and X-ray inspection for capacitor degradation, solder joint fatigue, and conformal coating integrity on boards with known field aging profiles.
• Firmware revision identification and documentation included with each CPU module shipment.