Bosch Rexroth BODAS DSA/12 User manual

Instruction manual
RE95290-01-B/2021-09-13, replaces: 2021-07-26, EN
BODAS speed sensors
DSA/12 DSA/20 DSM/10
DSM/20 DST/10 HDD/20

© BoschRexrothAG2021. 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 German.

RE95290-01-B/2021-09-13, BoschRexrothAG
Contents | BODAS speed sensors 3/36
Contents
1 About this documentation ........................................................................ 5
1.1 Validity of the documentation ......................................................................5
1.2 Required and supplementary documentation...............................................5
1.3 Representation of information......................................................................6
1.3.1 Safety instructions .......................................................................................6
1.3.2 Symbols .......................................................................................................7
1.3.3 Designations ................................................................................................7
1.3.4 Abbreviations ...............................................................................................7
2 Safety instructions ................................................................................... 8
2.1 About this chapter........................................................................................8
2.2 Intended use ................................................................................................8
2.3 Improper use..............................................................................................10
2.4 Personnel qualifications .............................................................................10
2.5 General safety instructions ........................................................................11
2.6 Product-specific safety instructions ...........................................................12
2.7 Personal protective equipment...................................................................13
3 General instructions on property damage and product damage.............. 14
4 Scope of delivery.................................................................................... 15
4.1 Scope of delivery DSA/12 ..........................................................................15
4.2 Scope of delivery DSA/20...........................................................................16
4.3 Scope of delivery DSM/10..........................................................................16
4.4 Scope of delivery DSM/20..........................................................................17
4.5 Scope of delivery DST/10...........................................................................17
4.6 Scope of delivery HDD/20 ..........................................................................18
5 About this product ................................................................................. 19
5.1 Product description DSA/12 and DSA/20...................................................19
5.2 Product description DSM/10 and DSM/20 .................................................20
5.3 Product description DST/10.......................................................................21
5.4 Product description HDD/20......................................................................22
5.5 Identification of speed sensors ..................................................................23
5.5.1 Identification DSA/12 .................................................................................23
5.5.2 Identification DSA/20 .................................................................................24
5.5.3 Identification DSM/10 ................................................................................24
5.5.4 Identification DSM/20 ................................................................................24
5.5.5 Identification DST/10 .................................................................................25
5.5.6 Identification HDD/20 ................................................................................25
6 Transport and storage ............................................................................ 26
6.1 Storing the speed sensor ...........................................................................26
6.1.1 Requirements.............................................................................................26
7 Installation............................................................................................. 27
7.1 Unpacking ..................................................................................................27
7.2 Installation conditions................................................................................27
7.3 Installing the speed sensor ........................................................................27
7.3.1 Preparation ................................................................................................27
7.3.2 General instructions...................................................................................28
7.3.3 Installation .................................................................................................28
7.3.4 Information on wiring and circuitry ............................................................28
7.3.5 Electrically connecting the speed sensor ...................................................29

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BoschRexrothAG, RE95290-01-B/2021-09-13
8 Commissioning....................................................................................... 30
9 Operation ............................................................................................... 30
10 Maintenance and repair.......................................................................... 30
10.1 Cleaning and care ......................................................................................30
10.2 Inspection and maintenance ......................................................................31
10.3 Repair ........................................................................................................31
11 Removal and replacement ...................................................................... 31
12 Disposal ................................................................................................. 31
13 Extension and conversion....................................................................... 31
14 Troubleshooting ..................................................................................... 32
14.1 Malfunction table for DSA/12 and DSA/20 .................................................32
15 Technical data ........................................................................................ 34
16 Alphabetical index ................................................................................. 35

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About this documentation | BODAS speed sensors 5/36
1 About this documentation
1.1 Validity of the documentation
This documentation is valid for the following products:
• BODAS speed sensor DSA, series 12
• BODAS speed sensor DSA, series 20
• BODAS speed sensor DSM, series 10
• BODAS speed sensor DSM, series 20
• BODAS speed sensor DST, series 10
• BODAS speed sensor HDD, series 20
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8 and chapter 3 "General instructions on property damage and
product damage" on page14 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, series 12
Contains the permissible technical data,
ports, main dimensions and circuit diagrams
of standard versions.
95133 Data sheet
Speed sensor DSA, series 20
Contains the permissible technical data,
ports, main dimensions and circuit diagrams
of standard versions.
95126 Data sheet
Speed sensor DSM, series 10
Contains the permissible technical data,
ports, main dimensions and circuit diagrams
of standard versions.
95132 Data sheet
Speed sensor DSM1, series 20
Contains the permissible technical data,
ports, main dimensions and circuit diagrams
of standard versions.
95136 Data sheet
Speed sensor DST, series 10
Contains the permissible technical data,
ports, main dimensions and circuit diagrams
of standard versions.
95131 Data sheet
Speed sensor HDD, series 20
Contains the permissible technical data,
ports, main dimensions and circuit diagrams
of standard versions.
95135 Data sheet

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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12 and in chapter3 "General instructions on property
damage and product damage" on page14, 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.
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.

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About this documentation | BODAS speed sensors 7/36
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.
1.3.3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
DSA/12 BODAS speed sensor DSA, series 12
DSA/20 BODAS speed sensor DSA, series 20
DSM/10 BODAS speed sensor DSM, series 10
DSM/20 BODAS speed sensor DSM, series 20
DST/10 BODAS speed sensor DST, series 10
HDD/20 BODAS speed sensor HDD, series 20
As ageneric term for the "speed sensor ", 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
EN European Norm (standard)
ISO International Organization for Standardization
RE Rexroth document in the English language

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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.
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.
The sensors have the following functions/properties:
Table 6: Functions/properties
Functions/properties DSA/12 DSA/20 DSM/10 DSM/20 DST/10 HDD/20
Speed sensing x x x x x x
Detection of the direction of rotation xxxxxx
additional diagnostic information x x
Temperature measurement x x
2 wire current interface x x x
redundant voltage output x x x
▶ Generally, the sensor must be operated within the operating ranges specified and
approved in the respective datasheet, see Table 1 "Required and supplementary
documentation" on page 5, 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.

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Safety instructions | BODAS speed sensors 9/36
▶ The DSA/12 and DSM/20 sensors are 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 DSA/12 and DSM/20 sensors are media resistant for the following media in
the sensor zone:
HLP, HVLP, HETG, HEPG, HEES, HFA, HFB, HFC and HFD
Connector
zone
Sensor
zone
Fig. 1: Connector and sensor zone at DSA/12 and DSM/20
▶ The DSA/20 and DST/10 sensors are media resistant for the following media in
the connector and cable zone:
Hydraulic fluids based on mineral oils according to DIN 51524, HETG, HEPG,
HEES, HFA and HFB (only suitable for HNBR seal), HFC, HFD (only suitable for
FKM seal), HFE, 10W-40MC, fertilizer, AdBlue, battery acid, SAE80W-90,
antifreeze, brake fluid, SAE20W20, gasoline, diesel, RME (biodiesel),
tar remover, cleaner solvent.
The DSA/20 and DST/10 sensors are media resistant for the following media in
the sensor zone:
Hydraulic fluids based on mineral oils according to DIN 51524, HETG, HEPG,
HEES, HFA and HFB (only suitable for HNBR seal), HFC, HFD (only suitable for
FKM seal), HFE.
Connector
zone
Sensor
zone
Connector
zone
Sensor
zone
Fig. 2: Connector and sensor zone at DSA/20 (left) and DST/10 (right)
▶ The DSM/10 sensor is media resistant for the following media:
NPK (7.5 / 7.5 / 7.5), ethylene glycol, diesel according to ISO16750-5, engine oil
according to ISO16750-5, biodiesel, hydraulic oil, cleaner solvent, antifreeze,
brake fluid according to ISO16750-5, spirit, coffee.
DSA/12 and DSM/20
DSA/20 and DST/10
DSM/10

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The HDD/20 sensor is media resistant for the following media:
HLP, HVLP, HETG, HEES and HFD
NOTICE! The compatibility of the sensors with other media can be evaluated.
Please contact your local contact person. You can find their contact information at
https://addresses.boschrexroth.com
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 8.
2.3 Improper use
Any use other than that described as intended use is considered improper.
BoschRexrothAG is not liable for damage 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 (if the sensor is nevertheless to be submerged
under water for ashort time, this must be tested on acase-by-case basis,
please consult your proper contact person at BoschRexroth)
• 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.
HDD/20

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Safety instructions | BODAS speed sensors 11/36
System developments, installations and commissioning of electronic systems for
controlling hydraulic drives must only be carried out by trained and experienced
specialists who are sufficiently familiar with both the components used and the
complete system.
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.
2.5 General safety instructions
• Observe the country-specific 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 speed sensor contains electronic components and may thus be damaged by
electrostatic discharge. Comply with the handling regulations for electronically
sensitive components, see respective data sheet (Table 1 "Required and
supplementary documentation" on page 5)
• The proposed circuits do not imply any technical liability for the system or the
machine 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.
• You may open connections in the hydraulic system only if the system is
depressurized.
• 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.

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• 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.
• Protect the sensor during transport, processing and/or assembly against the
ingress of humidity, paints or other substances into the connector chamber.
• The sensor contains astrong solenoid. As most types of electronic storage
media are sensitive to magnetic fields, they have to be stored separately from
permanent magnets. Persons with implanted cardiac pacemakers must take
special precautions.
• Despite the greatest care being taken when compiling this document, it is
impossible to consider all feasible applications. If information on your specific
application is missing, please contact BoschRexroth.
• If other or more specifications apply to the marketing of the product or if there
is marketing outside the specified target markets, you must demand compliance
with the target market-specific regulations from BoschRexroth or ensure their
compliance yourself.
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 disconnect any line connections, ports or components as long as the
hydraulic system is under pressure.

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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 95126(DSA/20),95131(DST/10), 95132(DSM/10),
95133(DSA/12), 95135(HDD/20) and 95136(DSM/20).
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.

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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.
Secure the machine/system against being turned back on.
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.

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Scope of delivery | BODAS speed sensors 15/36
4 Scope of delivery
4.1 Scope of delivery DSA/12
4
1
1
2
3
Fig. 3: Speed sensor DSA/12
The scope of delivery of the installation set includes the following:
• Speed sensor DSA/12(1) with O-ring (2) and protective cap (3)
• Mounting bolt(s) (4)

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4.2 Scope of delivery DSA/20
1
2
Fig. 4: Speed sensor DSA/20
Included in the scope of delivery:
• Speed sensor DSA/20(1) with O-ring (2)
4.3 Scope of delivery DSM/10
1
2
Fig. 5: Speed sensor DSM/10
Included in the scope of delivery:
• Speed sensor DSM/10(1) with O-ring (2)

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4.4 Scope of delivery DSM/20
1
2
Fig. 6: Speed sensor DSM/20
Included in the scope of delivery:
• Speed sensor DSM/20(1) with O-ring (2)
4.5 Scope of delivery DST/10
1
2
Fig. 7: Speed sensor DST/10
Included in the scope of delivery:
• Speed sensor DST/10(1) with O-ring (2)

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4.6 Scope of delivery HDD/20
1
3
2
4
Fig. 8: Speed sensor HDD/20
The scope of delivery of the installation set includes the following:
• Speed sensor HDD/20(1) with O-ring (2) and protective cap (3)
• Mounting bolt(s) (4)
In the installed condition (3) is omitted.

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About this product | BODAS speed sensors 19/36
5 About this product
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 online at www.boschrexroth.com/mobile-electronics.
5.1 Product description DSA/12 and DSA/20
In conjunction with agear wheel, the speed sensor DSA/12 and DSA/20 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 consists of aHALL-ASIC supplying
two output signals. The internal two-channel structure requires a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.
A6VM axial piston variable motor with mounted DSA/12 speed sensor:
Fig. 9: A6VM with mounted speed sensor DSA/12
• DSA1 series 12 returns asquare-wave signal which is proportional to the
speed as well as aswitching signal for detecting the direction of rotation.
• DSA2 series 12 provides two square-wave signals (at least 15°phase shift)
for the redundant recording of the rotational speed. In addition, this can be
used, for example, to calculate the direction of rotation using acontrol unit from
Rexroth.
Application examples
Example DSA/12
Two basic variants
available for DSA/12

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A6VM axial piston variable motor with mounted DSA/20 speed sensor:
Fig. 10: A6VM with mounted speed sensor DSA/20
• DSA1 series 20 returns asquare-wave signal which is proportional to the speed
as well as aswitching signal for detecting the direction of rotation.
• DSA2 series 20 provides two square-wave signals (90°±20°phase shift)
for the redundant recording of the rotational speed. In addition, this can be
used, for example, to calculate the direction of rotation using acontrol unit from
Rexroth.
• Additionally, both variants comprise of an NTC thermistor, which enables
measuring the temperature in the installation location of the sensor.
5.2 Product description DSM/10 and DSM/20
The Hall effect-based speed sensor DSM/10 and DSM/20 collects the rotational
speed signal of ferromagnetic gear wheels or punching sheets. As an active sensor,
it delivers asignal with aconstant amplitude that is independent of the rotational
speed. The sensor distinguishes itself not only due to the fact that it can detect
the direction of rotation, but also because of its additional diagnosis functions
such as:
• Standstill detection
• Critical air gap
• Critical installation position
Due to its compact, sturdy design the sensor is suitable e.g. for integrated use
• In the wheel bearing for wheel speed acquisition
• In the transmissions or gear stages
• Fan drives in buses, trucks and construction machinery (7 to 20kW)
• In vibration drives for road rollers and pavers
Example DSA/20
Two basic variants
available for DSA/20
Application examples