Bosch Rexroth DSA User manual

Instruction manual
RE95133-01-B/2020-09-03, EN
Speed sensor
DSA

© BoschRexrothAG 2020. All rights reserved,
also regarding any disposal, exploitation,
reproduction, editing, distribution, as well
as in the event of applications for industrial
property rights.
The data specified within only serves
to describe theproduct. No statements
concerning acertain condition orsuitability
for acertain application canbederived from
our information. Theinformation given does
notrelease the user from the obligation of
own judgment and verification. It must be
remembered that our products are subject to
anatural process of wear and aging.
The cover shows an example application.
Theproduct delivered may differ from the
image on the cover.
The original instruction manual was created in
the German language.

RE95133-01-B/2020-09-03, Bosch Rexroth AG
Contents | DSA 3/24
Contents
1 About this documentation ������������������������������������������������������������������������ 4
1.1 Validity of the documentation ...................................................................... 4
1.2 Required and supplementary documentation............................................... 4
1.3 Representation of information...................................................................... 4
1.3.1 Safety instructions ....................................................................................... 4
1.3.2 Symbols ....................................................................................................... 5
1.3.3 Designations ................................................................................................ 6
1.3.4 Abbreviations ............................................................................................... 6
2 Safety instructions ����������������������������������������������������������������������������������� 7
2.1 About this chapter........................................................................................ 7
2.2 Intended use ................................................................................................ 7
2.3 Improper use................................................................................................ 8
2.4 Personnel qualifications ............................................................................... 8
2.5 General safety instructions .......................................................................... 9
2.6 Product-specific safety instructions ........................................................... 10
2.7 Personal protective equipment................................................................... 10
3 General instructions on property damage and product damage ������������� 11
4 Scope of delivery������������������������������������������������������������������������������������ 12
5 About this product ��������������������������������������������������������������������������������� 13
5.1 Product description ................................................................................... 13
5.2 Product identification................................................................................. 14
6 Transport and storage ���������������������������������������������������������������������������� 15
6.1 Storing the speed sensor ........................................................................... 15
7 Installation��������������������������������������������������������������������������������������������� 16
7.1 Unpacking .................................................................................................. 16
7.2 Installation conditions................................................................................ 16
7.3 Installing the speed sensor ........................................................................ 16
7.3.1 Preparation ................................................................................................ 16
7.3.2 General instructions................................................................................... 16
7.3.3 Installation ................................................................................................. 17
7.3.4 Notice on wiring and circuitry .................................................................... 17
7.3.5 Electrically connecting the speed sensor ................................................... 18
8 Commissioning��������������������������������������������������������������������������������������� 19
9 Operation ����������������������������������������������������������������������������������������������� 19
10 Maintenance and repair�������������������������������������������������������������������������� 19
10.1 Cleaning and care ...................................................................................... 19
10.2 Inspection and maintenance ...................................................................... 20
10.3 Repair ........................................................................................................ 20
11 Removal and replacement ���������������������������������������������������������������������� 20
12 Disposal ������������������������������������������������������������������������������������������������� 20
13 Extension and conversion����������������������������������������������������������������������� 20
14 Troubleshooting ������������������������������������������������������������������������������������� 21
14.1 Malfunction table ....................................................................................... 21
15 Technical data ���������������������������������������������������������������������������������������� 23
16 Alphabetical index ��������������������������������������������������������������������������������� 23

4/24 DSA | About this documentation
Bosch Rexroth AG, RE95133-01-B/2020-09-03
1 About this documentation
1�1 Validity of the documentation
This documentation is valid for the following product:
• Speed sensor DSA
This documentation is intended for machine/system manufacturers, assemblers and
service engineers.
This documentation contains important information on the safe and proper
transport, installation, commissioning, operation, maintenance, disassembly and
simple troubleshooting of the product.
▶ Read this documentation completely, in particular chapter2 "Safety instructions"
on page7 and chapter 3 "General instructions on property damage and
product damage" on page11 before you start working with the product.
1�2 Required and supplementary documentation
▶ Only commission the product if the documentation marked with the book symbol
is available to you and you have understood and observed it.
Table 1: Required and supplementary documentation
Title Document number Document type
Speed sensor DSA
Contains the permissible technical data,
ports, main dimensions and circuit diagrams
of standard versions.
95133 Data sheet
1�3 Representation of information
Uniform safety instructions, symbols, terms and abbreviations are used throughout
this documentation to ensure safe and proper use of the product. For clarification,
they are explained in the sections below.
1�3�1 Safety instructions
This documentation contains safety instructions in chapter 2.6 "Product-specific
safety instructions" on page 10 and in chapter 3 "General instructions on property
damage and product damage" on page 11, as well as before asequence of actions
or an instruction for action involving arisk of personal injury and property damage.
Always follow the measures for danger prevention associated with the use of this
product.

RE95133-01-B/2020-09-03, Bosch Rexroth AG
About this documentation | DSA 5/24
Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger!
Consequences of noncompliance
▶ Danger prevention measures
•Warning sign: draws attention to the danger
•Signal word: identifies the degree of the danger
•Type and source of danger: indicates the type and source of the danger
•Consequences: describes what occurs if safety instructions are disregarded
•Precautions: states how the danger can be avoided
Table 2: Hazard classes as defined in ANSI Z535�6
Warning sign, signal word Meaning
DANGER Identifies adangerous situation that will result in death or
serious injury if it is not avoided.
WARNING Identifies adangerous situation that may result in death or
serious injury if it is not avoided.
CAUTION Identifies adangerous situation that may result in minor to
moderate injury if it is not avoided.
NOTICE Property damage: The product or surrounding area may be
damaged.
1�3�2 Symbols
The following symbols indicate notices that are not safety-relevant but increase
understanding of the documentation.
Table 3: Meaning of symbols
Symbol Meaning
If this information is disregarded, the product cannot be used and/or
operated to its full extent.
▶ Single, independent action
1�
2�
3�
Numbered instruction:
The numbers indicate that the actions must be completed in order.

6/24 DSA | About this documentation
Bosch Rexroth AG, RE95133-01-B/2020-09-03
1�3�3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
DSA Speed sensor
As ageneric term for the "speed sensor DSA", the designation "product" or "sensor"
will be used in the following.
1�3�4 Abbreviations
This documentation uses the following abbreviations:
Table 5: Abbreviations
Abbreviation Meaning
ANSI American National Standards Institute is an organization that coordinates
the development of voluntary standards in the United States
DIN Deutsches Institut für Normung (German Institute for Standardization)
EMC Electromagnetic compatibility
ISO International Organization for Standardization
RE Rexroth document in the English language

RE95133-01-B/2020-09-03, Bosch Rexroth AG
Safety instructions | DSA 7/24
2 Safety instructions
2�1 About this chapter
The product has been manufactured in accordance with generally accepted
engineering standards. There is still, however, adanger of personal injury or
property damage if this chapter and the safety instructions in this documentation are
not observed.
▶ Read this documentation completely and thoroughly before working with the
product.
▶ Keep this documentation in alocation where it is accessible to all users at all
times.
▶ Always include the required documentation when passing the product on to
thirdparties.
2�2 Intended use
The sensor is intended as acomponent for application in mobile working machines.
It is used to detect frequency and direction of rotation signals.
The sensor may only be commissioned after it has been installed in the
machine/system for which it is intended and the safety of the entire system has been
established in accordance with the Machinery Directive.
▶ Generally, the sensor must be operated within the operating ranges specified
and approved in the datasheet 95133, particularly with regard to voltage,
temperature, vibration, shock and other described environmental influences.
▶ Its use outside of these specified and approved boundary conditions may result
in danger to life and/or cause damage to components which could result in
sequential damage to the mobile working machine.
▶ Serious personal injury and/or damage to property may occur in case of
non-compliance with the appropriate regulations.
▶ Observe the corresponding IP protection class.
▶ The sensor is media resistant for the following media in the connector zone:
HLP, HVLP, HETG, HEPG, HEES, HFA, HFB, HFC, HFD, 10W-40MC, Fertilizer,
AdBlue, RME (Biodiesel), SAE80W-90, antifreeze, brake fluid, SAE20W20,
gasoline, diesel, tar remover and cleaner solvent
▶ The sensor is media resistant for the following media in the sensor zone:
HLP, HVLP, HETG, HEPG, HEES, HFA, HFB, HFC and HFD
NOTICE! The compatibility of the sensor compared to other media can be evaluated.
Please contact your local contact person. You can find their contact information at
www.boschrexroth.com/addresses
The product is intended only for professional use and not for private use.
Intended use includes having fully read and understood this documentation,
especially chapter 2 "Safety instructions" on page 7.
Connector zoneSensor zone

8/24 DSA | Safety instructions
Bosch Rexroth AG, RE95133-01-B/2020-09-03
2�3 Improper use
Any use other than that described as intended use is considered improper.
BoschRexrothAG is not liable for damages resulting from improper use. The user is
solely responsible for any risks arising from improper use.
The following foreseeable forms of faulty usage are also considered improper
(thislist is not exhaustive):
• Use outside the operating parameters approved in the datasheet
(unlesscustomer-specific approval has been granted)
• Use of non-approved fluids, e.g.water or hydraulic fluids containing water
• Use of the sensor under water
• Application of the sensor in explosive environments
• Use of the sensor in acorrosive atmosphere
2�4 Personnel qualifications
The activities described in this documentation require basic mechanical,
electronical/electrical and hydraulic knowledge, as well as knowledge of the
associated technical terms. In order to ensure safe use, these activities should only
be performed by skilled personnel or an instructed person under the direction and
supervision of skilled personnel.
Skilled personnel refers to persons who possess the professional training,
knowledge and experience, as well as the understanding of the regulations relevant
to the work to be done that are necessary to recognize possible dangers and take
the appropriate safety measures. Skilled personnel must follow the rules relevant
to their field and have the necessary expert knowledge of mechatronics, electronics
and hydraulics, if applicable.
Expert knowledge means, for instance:
• Being able to read and fully understand electrical circuit diagrams and hydraulic
diagrams, if applicable,
• in particular, fully understanding the relationships with regard to safety devices,
• as well as to carry out the wiring of electronic components correctly and
• to have knowledge of the function and interaction of electronic, mechanical and
hydraulic components.
Only trained and experienced specialists who are adequately familiar with both the
components used and the complete system should implement system developments
or install and commission electronic systems for controlling hydraulic drives.
BoschRexroth offers you measures supporting training in specific areas.
Youcanfind an overview of the training contents on the Internet at:
www.boschrexroth.com/training.

RE95133-01-B/2020-09-03, Bosch Rexroth AG
Safety instructions | DSA 9/24
2�5 General safety instructions
• Observe applicable accident prevention and environmental protection regulations.
• Observe the safety regulations of the country in which the product is used/operated.
• Use Rexroth products only when they are in good working order.
• Do not install, operate, disassemble or maintain Rexroth products if under the
influence of alcohol, drugs or medication that may affect your reaction time.
• Only use approved accessories and original spare parts from Rexroth in order to
exclude hazards to persons due to unsuitable spare parts.
• Observe the technical data and ambient conditions specified in the product
documentation.
• If unsuitable products are installed or used in applications that are of relevance to
safety, unexpected operating conditions may occur in the application, which could
result in personal injury or property damage. For this reason, only use the product
in safety-relevant applications if this use is expressly indicated and approved
in the product documentation, e.g.in safety-related parts of acontrol system
(functionalsafety).
• Only commission the product if it has been determined that the end product
(e.g.machinery/system) in which the Rexroth products are installed complies
with the country-specific provisions, safety regulations and standards for the
application.
• Use tools appropriate for the work being performed and wear appropriate
protective clothing to prevent punctures and cuts (e.g.when removing protective
covers, disassembly).
• The proposed circuits do not imply any technical liability for the system on the part
of BoschRexroth.
• Opening the sensor or carrying out modifications to or repairs on the sensor
is prohibited. Modifications to or repairs on the wiring can lead to dangerous
malfunctions.
• The sensor may only be installed/disassembled in ade-energized and
depressurized state.
• Make sure that nobody is in the machine’s danger zone.
• Do not use defective components or components which are not in aproper working
order. If the sensor fails or demonstrates afaulty operation, it must be replaced.
• Despite the greatest care being taken when compiling this document, it is not
possible to consider all feasible applications. If notices for your specific application
are missing, please contact BoschRexroth.

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Bosch Rexroth AG, RE95133-01-B/2020-09-03
2�6 Product-specific safety instructions
The following safety instructions apply to chapters 6 to 14.
WARNING
System/machine under pressure!
Risk of death or serious injury when working on unsecured machines/systems!
Property damage!
▶ Switch off the relevant machine/system part and secure it against reactivation
according to the parameters by the machine/system manufacturer.
▶ Ensure that all relevant components of the hydraulic system are depressurized.
For this purpose, observe the parameters indicated by the machine/system
manufacturer.
▶ Please note that the hydraulic system might still be pressurized even after
separation from the actual pressure supply.
▶ Do not diskonnect any line connections, ports and components as long as the
hydraulic system is under pressure.
CAUTION
Improper cable and line routing!
Risk of stumbling and property damage! Improper routing of cables and lines
can cause arisk of stumbling as well as damage to equipment and components,
e.g.due to lines and connectors being torn off.
▶ Always install cables and lines in away that nobody can fall over them, that
they are not bend or twisted, do not chafe on edges and are not guided through
ducts with sharp edges without sufficient protection.
Danger due to malfunctions!
Risk of injury and property damage as well as machine damage due to malfunctions
of the sensor!
▶ Carry out arisk assessment of your machine and determine the possible
safety-relevant functions.
▶ Make sure that the expected rotational speed signal (frequency) is provided
with the correct value.
▶ Before operation, check whether the direction of rotation is correctly detected.
▶ Take suitable measures to ensure safety in applications relevant to safety,
e.g.sensor redundancy, plausibility check, emergency switch, etc.
▶ Product data that is required for the safety assessment of the machine is
included in datasheet 95133.
2�7 Personal protective equipment
The personal protective equipment is the responsibility of the user of the product.
Observe the safety regulations in your country.
All pieces of personal protective equipment should be intact.

RE95133-01-B/2020-09-03, Bosch Rexroth AG
General instructions on property damage and product damage | DSA 11/24
3 General instructions on property
damage and product damage
The following notices apply to chapters 6 to 14.
NOTICE
Environmental pollution due to incorrect disposal!
Careless disposal of the product and the packaging material could lead to
environmental pollution!
▶ Dispose of the product and packaging in accordance with the national
regulations in your country.
Electrical voltage!
Damage to property due to electrical voltage!
▶ Always disconnect the voltage supply to the relevant machine/system part
before installing the product and/or connecting or disconnecting the connector.
Protect the machine/system against being re-energized.
The warranty exclusively applies to the delivered configuration.
The warranty will be voided if the product is incorrectly installed, commissioned or
operated, or if it is used or handled improperly.

12/24 DSA | Scope of delivery
Bosch Rexroth AG, RE95133-01-B/2020-09-03
4 Scope of delivery
5
1
4
1
2
3
Fig. 1: DSA speed sensor
The scope of delivery of the installation set includes the following:
• Speed sensor DSA(1) with O-ring (2) and protective cap (3).
• Instruction manual (4)
• Mounting bolt (5)
In the installed condition, (3) and (4) are omitted.

RE95133-01-B/2020-09-03, Bosch Rexroth AG
About this product | DSA 13/24
5 About this product
5�1 Product description
In conjunction with agear wheel, the DSA speed sensor is suitable for generating
frequency signals proportional to the speed. The sensor exhibits astatic behavior,
i.e. it guarantees pulse generation up to aspeed equating to afrequency of 0 Hz.
Themonitoring element comprises aHall-ASIC supplying two square-wave signals.
The internal two-channel structure requires perfect alignment of the sensor.
Due to its compact, sturdy design the sensor is suitable for integrated use with
Rexroth axial piston units among other things.
The evaluation and assessment of the sensor signals of the speed sensor is
incumbent on the higher-level system. Various different BODAS controllers with
application software are available for this purpose. Further information can also be
found on the Internet at www.boschrexroth.com/mobile-electronics.
A6VM axial piston variable motor with mounted DSA speed sensor:
Fig. 2: A6VM with dismounted speed sensor
• DSA1 returns asquare-wave signal that is proportional to the speed as well as
aswitching signal for detecting the direction of rotation.
• DSA2 returns two square-wave signals (at least 15° phase shift) for redundant
recording of the rotational speed. In addition, this can be used, for example,
tocalculate the direction of rotation using aRexroth control unit.
Sample applications
Example
Two basic variants
available

14/24 DSA | About this product
Bosch Rexroth AG, RE95133-01-B/2020-09-03
5�2 Product identification
Depending on the scope of the order, there are the following different
identificationoptions:
The product can be identified using the material number (1) on the label of the
packaging unit.
1
Fig. 3: Material number on sticker
The product is to be identified by means of the material number (2) on the
connector of the sensor.
2
Fig. 4: Material number on sensor connector
The material number on the connector of the sensor differs from the material
number on the packaging unit as the packaging unit consists of several
components.
Order sensor with
installation set
Order sensor only

RE95133-01-B/2020-09-03, Bosch Rexroth AG
Transport and storage | DSA 15/24
6 Transport and storage
Check the sensor for transport damage. If there are obvious signs of damage,
pleaseinform the transport company and BoschRexroth immediately.
If the sensor is dropped, it is not permissible to use it any longer, as invisible
damage could have anegative impact on reliability.
6�1 Storing the speed sensor
Storage time: 5 years at an average relative humidity of 60% and atemperature
between -10°C and +30°C. Short-term for up to 100hours astorage temperature
of-20°C to+40°C shall be permissible.
Requirement

16/24 DSA | Installation
Bosch Rexroth AG, RE95133-01-B/2020-09-03
7 Installation
Prior to installation, the following documents should be to hand:
• Data sheet of the product (contains the permissible technical data,
maindimensions and circuit diagrams of standard versions)
7�1 Unpacking
NOTICE! Danger due to electrostatic discharge!
When unpacking the sensor, there is adanger of damage to the electronic
components of the sensor due to electrostatic discharge.
▶ During unpacking, the sensor is to be protected against electrostatic discharge.
▶ Remove the packaging from the speed sensor.
▶ Check the sensor for transport damage and completeness, see chapter4
"Scope of delivery" on page12.
▶ Dispose of the packaging in accordance with the regulations in your country.
7�2 Installation conditions
The installation position and position of the speed sensor essentially determine the
procedures for installation and commissioning.
▶ Do not install the sensor close to parts that generate considerable heat
(e.g.exhaust).
▶ Lines are to be routed with sufficient distance from hot or moving vehicle parts.
▶ A sufficient distance to radio systems must be maintained.
▶ Before electric welding and painting operations, the sensor must be diskonnected
from the power supply and the sensor connector must be removed.
▶ Cables/wires must be equipped with an individual seal to prevent water from
entering the sensor.
7�3 Installing the speed sensor
7�3�1 Preparation
1� Use the material number on the sticker of the packaging unit or directly on
the sensor connector to check whether the correct speed sensor is available,
seechapter 4 "Scope of delivery" on page12.
2� Compare the material number with the details in the order confirmation.
If the material number of the speed sensor does not match the one in the order
confirmation, contact your local contact person for clarification. You can find their
contact information at
www.boschrexroth.com/addresses
7�3�2 General instructions
For information on gear wheel specifications, please refer to datasheet95133.

RE95133-01-B/2020-09-03, Bosch Rexroth AG
Installation | DSA 17/24
7�3�3 Installation
1� The protective cap is to be removed before installation. The sensor must be
handled with care to prevent damage to the front side.
2� Insert the speed sensor into the intended installation bore and make sure that
the O-ring is not damaged during insertion.
3� Completely press the speed sensor into the installation bore by hand until it is
firmly seated.
4� Fasten the speed sensor using the included or specified mounting bolt, required
tightening torque 8 Nm ±2 Nm (maximum tightening torque 10 Nm).
7�3�4 Notice on wiring and circuitry
• Lines from the sensor to the electronics must not be routed close to other
power-conducting lines in the machine.
• The wiring harness should be mechanically secured in the area in which the sensor
is installed (distance < 150 mm). The wiring harness should be secured so that
in-phase excitation with the sensor occurs (e.g.at the sensor mounting point).
• If possible, lines should be routed in the machine interior. If the lines are routed
outside of the machine, their secure mounting is to be ensured.
• Lines must not be kinked or twisted, must not rub against edges and must not be
routed through sharp-edged ducts without protection.

18/24 DSA | Installation
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7�3�5 Electrically connecting the speed sensor
1
23
4
Connector
DEUTSCH DT04-4P
View Y
Y
Fig. 5: Pin Assignment
Table 6: Pin Assignment
Pin Port
1 Supply voltage UB
2 Weight GND
3 frequency S1
4Direction of rotation D (DSA1) / frequency S2 (DSA2)
1� Make sure that the DEUTSCH mating connector is in de-energized condition.
2� Connect the mating connector of the wiring harness to the sensor connector
until it engages noticeably and observe the correct plug-in position.
3� The sensor is ready for operation within 2 ms after the voltage supply is applied
and outputs the frequency signal(s) at the latest after two mechanical flanks.
4� Upon completion of the internal calibration (standard three, maximum eight
mechanical flanks), the phase offset between the frequencies S1 and S2 in the
working range or the direction of rotation signal in the working range is also
completed.

RE95133-01-B/2020-09-03, Bosch Rexroth AG
Commissioning | DSA 19/24
8 Commissioning
During all work for commissioning the speed sensor, observe the general
safetyinstructions and intended use detailed in chapter 2 "Safety instructions"
from page7 on.
▶ When commissioning the sensor, the machine may pose unforeseen dangers.
Before commissioning the system, you must therefore ensure that the vehicle and
the hydraulic system are in asafe condition.
▶ Commission the machine and check the correct functioning of the sensor
(e.g.direction of rotation and rotational speed).
9 Operation
This product is acomponent which requires no settings or changes during operation.
For this reason, this chapter of the manual does not contain any information on
adjustment options. Use the product only within the performance range specified in
the technical data.
10 Maintenance and repair
10�1 Cleaning and care
NOTICE
Damage to seals and electronics/electrics due to mechanical effects!
The water jet of ahigh-pressure cleaner may damage the seals and
electronics/electrics of the sensor!
▶ Do not point the high-pressure cleaner directly towards sensors.
For cleaning and care of the sensor, observe the following:
▶ Check whether all the seals and fittings on the plug-in connections are securely
seated to ensure that no moisture can penetrate into the sensor and the
installation space during cleaning.
▶ Use only water and, if necessary, amild cleaning agent to clean the sensor.
Neveruse solvents or aggressive cleaning agents.

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Bosch Rexroth AG, RE95133-01-B/2020-09-03
10�2 Inspection and maintenance
No special activities are necessary.
10�3 Repair
The sensor cannot be repaired.
When replacing the sensor, make sure that no contamination can penetrate the
hydraulic system and that the sealing surface of the sensor is not damaged.
▶ Only use original spare sensor from Rexroth, otherwise the functional reliability
cannot be guaranteed, and the warranty will be voided.
▶ Spare parts can be found online at www.boschrexroth.com/eshop
Address all questions regarding repair to your responsible BoschRexroth service.
11 Removal and replacement
▶ Only disassemble the speed sensor when de-energized and depressurized.
12 Disposal
Careless disposal of the speed sensor can lead to environmental pollution.
▶ Dispose of the speed sensor and the packaging material in accordance with the
national regulations in your country.
13 Extension and conversion
Do not convert the speed sensor.
The warranty from BoschRexroth only applies to the configuration as delivered.
Entitlement to warranty cover will be rendered void in case of conversion,
extension or asoftware modification.