Bosch Rexroth 1070092392-AA / 1070089906-GI1 Modules

Technical Dossier

Product Details And Specifications

Bosch Rexroth CL 400 Series Technical Notes

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.

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.