Speed sensor DSA - Hydba · Sensor output signals S1 and S2 are connected to con-trol unit inputs for measuring frequency using active speed sensors. Sensor output signal D is connected

ContentsProduct description 2Type code 6Technical data 7Electrical connection 8Dimensions 9Project planning information 10Information 14Accessories 26Safety Instructions 27

Speed sensorDSA

RE 95133/12.2018Replaced: 09.2018

Hall-measurement principle Measuringrange0 … 20 kHz Output signal voltage square-wave signals Supplyvoltage8 … 32 V Protection class IP67 / IP69K

Features Two versions

- Withtwofrequencysignals. - Withfrequencysignalanddirectionofrotationsignal foreasyconnectiontocontrolunits

Diagnosisoptionsincombinationwiththecontrolunitinput circuit - Cablebreak - Shortcircuit - Standstilldetection

12Vand24Vnominalvoltage Sealingforpressuretomaximum10bar Compactdesign Robustdesignthankstofullmetalhousing Simpleinstallationwithoutsettingwork

RE 95133, 12.2018, Bosch Rexroth AG

Product description

Description

Inconjunctionwithagearwheel,theDSAspeedsensorissuitableforgeneratingfrequencysignalsproportionaltothespeed.Thesensorexhibitsastaticbehavior,i. e.itgua-rantees pulse generation up to a rotational speed equating toafrequencyof0 Hz.ThemonitoringelementcomprisesaHall-ASICsupplyingtwosquare-wavesignals.Theinternaltwo-channelstructurerequiresperfectalignmentofthesensor.Thefrequency“f”ofthesquarewavevoltageoutputbythesensoriscalculatedfromthenumberofteeth“z”onthecircumferenceofthegearwheelandtherotationalspeed“n”ofthedriveoroutputshaftaccordingtothefollowingformula:

f =z × n60

Key

f Frequency [Hz]

n Rotational speed [min-1]

z Numberofteeth

Thenumberofteetharespecifiedinthedatasheetsofthe respectiveaxialpistonunit.

Output signals Push-pulloutputs:Imax≤ ±50 mA Frequencysignalscanbeevaluatedinthemeasuring

rangefrom0Hzto20kHz.

Assigning the direction of rotation to the sensor

[mm]

0.3

... 2

.0

B AA = clockwiseB = counter-clockwise

DSA | Speed sensorProduct description

2

Bosch Rexroth AG, RE 95133, 12.2018

Two basic variants available DSA1returnsasquare-wavesignalthatisproportional

tothespeedaswellasaswitchingsignalfordetectingthedirectionofrotation.

DSA2returnstwosquare-wavesignals(atleast15°phaseshift)forredundantrecordingoftherotationalspeed.Inaddition,thiscanbeused,forexample,tocalculatethedirectionofrotationusinganRCcontrolunitfromRexroth.

Signal output DSA1 Onesquare-wavesignal(S1)andonedigitalrotary

directionsignal(D)

Clockwise

S1

UOut

D

2 V

360°-phase Time t

Anti-clockwise

S1

UOut

D

2 V

360°-phase Time t

Signal output DSA2 Twophase-shiftedsquare-wavesignalswithminimum

definedphaseshiftof15°betweenoutput 1(S1)andoutput2(S2).

Clockwise

S1

UOut

S2

2 V

min. 15°360°-phase Time t

Anti-clockwise

S1

UOut

S2

2 V

min. 15° 360°-phase

Time t

Speed sensor | DSAProduct description

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DSA1 rotary direction signal D RIL = 22 Ω; RIH = 18 Ω

DSA1 frequency signal S1 DSA2 frequency signal S1, S2 RIL = 22 Ω; RIH = 18 Ω

~18 ... 22 Ω

GND

RPU

UB

RPD

UOut

UOut Low ≈ 0.7 V +(UB − 0.7 V) × RIL

RPU + RIL

UOut High ≈ (UB − 0.9 V) × RPD

RPD + RIH

UOut Low ≈UB × RIL


RPD + RIH

RPU + RIL

RIL~22 Ω

GND

UB

RPU

UOut

UOut Low ≈ 0.7 V +(UB − 0.7 V) × RIL

RPU + RIL

UOut High > USupply − 1.2 V

UOut Low ≈UB × RIL

UOut High > USupply − 1.2 V

RPU + RIL

RPD

RIH~18 Ω

GND

UB

UOut

UOut Low < 0.6 V


RPD + RIH

UOut Low < 0.6 V


RPD + RIH

DSA | Speed sensorProduct description

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Output voltage UOut depends on sensor resistance RI and theexternalloadresistancesRPU,RPDandthesupplyvoltage.Thecalculationisperformedusingthefollowingformulas.

Connection to the control units

Sensor output signals S1 and S2 are connected to con-trolunitinputsformeasuringfrequencyusingactivespeed sensors.

Sensor output signal D is connected to digital control

unitinputswhennoshort-circuitdetectionisnecessary.Ifshort-circuitdetectionisnecessary,thesensorshouldbe connected to a corresponding analog input.

Short-circuit protection for DSA1 and DSA2Theoutputstageincludesathermalshort-circuitlimitation. Thisworksasfollows: Iftheoutputstageisoverloadedbyanoutputcurrent

overthemaximumspecified50 mA,theoutputstageisdeactivated.Itbecomeshigh-impedancefor50 μs.

Fromthismomentuntiltheoutputstageisreactivated,theoutputlevelisexclusivelydeterminedbytheloadattheoutputterminal(pull-up/pull-down).

Afterthe50 µs,theoutputstageisreactivatedtoshowthesignallevel(highorlow)validatthismoment.

Thisshutdownprocessisrepeatedforaslongastheoutputstageisthermallyoverloaded.

Thetimebehavioroftheshutdownresultsfromthetemperatureconditionsontheoutputstageandisdependent– ontheambienttemperatureandcooling– oftheshort-circuitcurrent– Signalpath(ratiohigh/lowfrequency)

Theoutputvoltageondetectionofshort-circuitisdepen-dentonthe(short-circuit)resistancesattheoutputandcanbecalculatedusingtheformulas,(see“Outputsignals”chapter).

Cable break detection for DSA1 and DSA2Intheeventofalinebreak(supplyand/orground),bothsignaloutputlevelsbecomehigh-impedance. Intheeventofalinebreak(signal1or2),thecorrespon-dingsignaloutputlevelbecomeshigh-impedance. Intheeventofanerror,thevoltageisonlydeterminedbythevoltagedivideroftheexternalevaluationunit.

Speed sensor | DSAProduct description

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Type code

01 02 03 04 05 06 07

DSA D / 12 P

Type

01 Hall-effectspeedsensor DSA

Version

02Onefrequencyoutput,oneoutputfordirectionofrota-tion 1

Twofrequencyoutputs 2

Shaft length

0318.4 mm S18

32 mm S32

Cable length

04250 mm K0250

1500 mm K1500

Connection

05 ConnectorDEUTSCHDT04-4P-EP04 D

Series

06 Series1,index2 12

Seal

07 HNBR(nitrilerubber) P

Type Material number

DSA1S18K0250D/12P R917010937

DSA1S18K1500D/12P R917010938

DSA1S32K0250D/12P R917010939

DSA1S32K1500D/12P R917010940

DSA2S18K0250D/12P R917010941

DSA2S18K1500D/12P R917010942

DSA2S32K0250D/12P R917010943

DSA2S32K1500D/12P R917010944

DSA | Speed sensorType code

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Technical data

Type DSA

Nominal voltage 12 V and 24 VDC

Maximumresidualripple DIN 16750-2:2010 ±2 V DC

Supply voltage UB 8 V … 32 V

Inputcurrent maximum 15mAat24VDC(withoutload)

Currentcapacityofoutputs ≤ ±50 mA

Frequency range 0 Hz … 20 kHz

Short-circuitresistanceoftheoutputsagainsteveryotherconnection Yes

Polaritymismatchprotection Yes

Electromagnetic compatibility

Line-borneinterference ISO 7637-1/-2/-3 Valuesonrequest

Load dumpat 12 V 70 V

at 24 V 123 V

Stripline DIN 11452-5 0.01 MHz … 1000 MHz,220 V/m

Freefield DIN 11452-2 80 MHz … 4000 MHz,150 V/m

Overvoltage resistance 33 V

Isolation Housing and electronics are electrically isolated

VibrationresistanceOscillation,sinusoidal IEC 60068-2-6

2 mm/5 Hz … 57 Hz 30 g/57 Hz … 2000 Hz10 cyclesperaxis

Oscillation,noise IEC 60068-2-64:2008 0.1 g2/Hz 20 Hz … 2000 Hz

ShockresistanceTransportshock IEC 60068-2-27:2008 50 g/11 ms

3 x eachdirection(positive/negative)

Continuousshock IEC 60068-2-27:2008 40 g/6 ms1000 x eachdirection(positive/negative)

Moisture resistance 95%(25 °C … 55 °C)

Salt spray resistance DIN EN ISO 9227 240 h

Fortypeofprotection(EN60529)wheninstalledandplugged,seematingconnectorDT06-4S-EP04 IP67 and IP69K

Operating tempera-ture range

Sensorzone -40 °C … +125 °C

Cablezoneandconnector -40 °C … +115 °C

Storage temperature range IEC 60068-2-1:2007,IEC 60068-2-2:2007 -40 °C … +50 °C

Pressureresistanceofmeasuringsurface 3barnominal,10barmaximum(momentarypressurepeaks)

ROHS EU-RoHS2-compliant

Speed sensor | DSATechnicaldata

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Electrical connection

DEUTSCH connector DT04-4PPinAssignment

14

23

Pin Connection

1 Supply voltage UB

2 Weight GND

3 Frequency S1

4 Directionofrotation D (DSA1)/frequency S2 (DSA2)

Thematingconnectorisnotincludedinthescopeofdelivery.ThiscanbesuppliedbyBoschRexrothonrequest(seeChapter“Acces-sories”)

DSA | Speed sensorElectrical connection

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Dimensions

[mm]

4.7±0.15

13.220

.4

5.2

9.4±0.1

10.25±0.03

13±0.1

6.6+0

.1

R7

±5°

12

0.05

0.02

0.2

18.4 -0.1+0.05

32 -0.1+0.05

250±10

1500±50

L2

L1

b

r

B

A

A

B

B

1

23

4

DEUTSCH DT04-4Pconnector

O-ring 8.5 × 1HNBR 70 Shore A

Shaft length L1

Cable length L2

Tighteningtorqueformountingbolt: Maximum 10 Nm Recommended: 8 Nm±2 Nm

Speed sensor | DSADimensions

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Project planning information

Sample applicationsDuetoitscompact,sturdydesign,thesensorissuitable,forexample,forintegratedusewithRexrothaxialpistonunits:VariousdifferentBODAScontrollerswithapplication

softwareareavailableforevaluatingtheDSAspeedsensor.FurtherinformationcanalsobefoundontheInternetatwww.boschrexroth.com/mobile-electronics.

ExampleA6VMaxialpistonvariablemotorwithmountedDSAspeedsensor

Installation instructions

General instructions Theprotectivecapistoberemovedbeforeinstalla-

tion.Thesensormustbehandledwithcaretopreventdamagetothefrontside.

Wheninstallingthesensor,theO-ringcouldbedama-ged.

Thesensorinnotsensitivetooilandlubricationgrease. Thesensorisreadyforoperationwithin2 msafterthe

voltagesupplyisappliedandoutputsthefrequencysignal/frequencysignalsatthelatestaftertwomechani-calflanks.

Oncetheinternalcalibrationiscomplete(standard3,maximumeightmechanicalflanks),thephaseshiftbet-weenS1andS2orthedirectionofrotationsignalintheworkareaarealsocomplete.

Ideal gear wheel Thegearwheelmaterialmustbemagneticallysoft. Thefollowinghavebeentestedtodate:

– non-alloy steel– tempered steel– Nitridingsteel(e.g.St37,USt37,C45R,

34CrAlMo5-10)

Notice FunctiononlyapprovedwithRexrothaxialpistonunit.

Deviatingairgapandeccentricitiescanimpedethefunctionofthesensor.Consultationisthereforerequi-redbeforeuseinotherapplications.

DSA | Speed sensorProjectplanninginformation

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Installation cavity

[mm]

10.31+0.025

1.8

8

x

15°v

w0.15⊥ A

10.31

0.1⁄⁄ A

A

v=

v=

Ra 3.2Rmax16

w=

w=

Ra 25

x=

x=

Ra 3.2

(Tolerance specification is applicable for centering hole and general bore)

Middle axis of gear wheel

Speed sensor | DSAProjectplanninginformation

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Toothing data valid for basic number of teeth 48

Nominal pressure permissible deviation

z Basicnumberofteeth48

tSpacing > 4.1 mm

Spacingoptimalfor90°phaseshift 6.3 mm

tp Individual spacing deviation ±4%

Tp Total spacing deviation 4%

A/t Ratiooftoothtipwidthtospacing A/t = 0.4 … 0.5 ±10%

dk Outside diameter 60 mm … 120 mm

h Toothheight > 2.5 mm ±0.1 mm

A Widthoftoothtip CalculatedfromA/t 10%

b Pulsewheelwidth > 5 mm

α Pressure angle 0 … 20 ±1

Ra Radiusattoothtip < 0.3 mm (with A = 2 mm) … < 0.6 mm (with A = 6 mm)

Rc Radiusattoothdepth < 0.6 mm ±0.2 mm

Toothshape Rectangularandtrapeze Othershapeinagreement

Distance gear wheel to the sensor

Spacing Distance

4.1 mm … 6.3 mm 0.3 mm … 1.4 mm

6.3 mm … 10.0 mm 0.3 mm … 2.0 mm

>10.0 mm Case-by-caseexaminationrequired

DSA | Speed sensorProjectplanninginformation

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Gear wheel specifications

MaterialTheimpulsewheelsmustbeelectricallyconductive.Thematerialshouldbemagneticallysoft.Machiningsteels,heat-treatedsteelsandsinteredsteelshavebeentestedtodate(e. g.St37,9SMn28,C45,GG20,GGG40,X8Cr17).

t

t

CA

h

Rc

αRa

dk

b

dodk dk

bA

Rz 25

A

A A

Standard gear wheel

[mm]

120°

(3x)

139

1 ×

45°

6.5

84

±0.0

25

R10.

25 ×

45°

0.5

× 45

°

30

H7

7.5°

44±0.1

71±0.05

79±0.025

4.5 (3×)

5°±1°

R0.3±0.1

(6.3)

2.5±0.10

R0.2–0.1

A

A

A‒A

Detail B

Detail E

Detail D

Detail BDetail E

Detail D

Start of erosion at teeth gap

Speed sensor | DSAProjectplanninginformation

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Information

Manufacturer confirmation of MTTFD DSA values Theproductmeetsthebasicandprovensafetyrequire-mentsasperISO13849-2:2008-09suchastheyapplytotheproduct.

TheproducthasbeendevelopedaccordingtoISO13849-1:2015andISO13849-1:2008-12;however,itisnotasafetycomponentinthesenseoftheMachineryDirective2006/42/EC.

Constant temperature [°C]

MTTFD value [years]

DSA1 DSA2

10 17733.8 17769.9

30 6505.3 6547.4

40 3874.7 3908.7

50 2301.8 2327.1

60 1369.1 1387.1

70 817.9 830.2

80 491.8 500.1

90 298.2 303.7

100 182.6 186.3

110 113.1 115.5

125 56.3 57.5

Thespecificationsreferredtointhetablearevalidunderthefollowingconditions: Componentsareusedundertheresponsibilityofthe

user. Specificationsrelatingtoinstallationandoperatingcon-

ditions must be observed. Theusermusttakeintoaccounttherequirementsof

ISO13849-1:2015(suchasCCF,DC,software,systema-ticerrors).

Intheinterestofpreventivemaintenance,itisadvisa-bletoreplacethecomponentswithinthemaximum10yearsperiodofuse.

ThefundamentalsafetyprinciplesofISO 13849-2forimplementingandoperatingthecomponentmustalsobe met.

ThefundamentalsafetyprinciplesasperISO 13849-2forimplementingandoperatingthecomponentmustalsobemetforcategories1,2,3or4.

Thecomponentsmustbereplacedonlybysparepartsthathavethepropertiesspecifiedforthecomponentsbeingchangedasaminimum.

DSA | Speed sensorInformation

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Manufacturer confirmation of MTTFD DSA1 values

Ambient temperature of control unit [°C] Self-heating [°C] Temperature profile, operating time share [%]

1 2 3 4 5 6 7 8 9 10 11 12 13

10 5 1 1 1 1 1 0 0 0 0 0 0 0 0

30 5 2 2 2 2 1 0 0 0 0 0 0 0 0

40 5 3 3 3 3 1 0 0 0 0 0 0 0 0

50 5 4 3 3 3 1 100 0 0 0 0 0 0 0

60 5 5 3 3 3 1 0 100 0 0 0 0 0 0

70 5 6 3 3 3 1 0 0 100 0 0 0 0 0

80 5 79 85 3 3 1 0 0 0 100 0 0 0 0

90 5 0 0 82 3 1 0 0 0 0 100 0 0 0

100 5 0 0 0 79 92 0 0 0 0 0 100 0 0

110 5 0 0 0 0 0 0 0 0 0 0 0 100 0

125 5 0 0 0 0 0 0 0 0 0 0 0 0 100

MTTFDvalue[years]during operation

Electronics computed 573 552 346 219 195 2302 1369 818 492 298 183 113 56

4hrs/day 3438 3312 2073 1313 1172 13811 8215 4907 2951 1789 1096 679 338

8hrs/day 1719 1656 1037 656 586 6905 4107 2454 1475 895 548 339 169

16hrs/day 860 828 518 328 293 3453 2054 1227 738 447 274 170 84

CalculationusingpartscountmethodasperISO13849-1:2015andSN29500-1,-2,-3,-4,incl.operatingtimesasspecified.

Manufacturer confirmation of MTTFD DSA2 values

Ambient temperature of control unit [°C] Self-heating [°C] Temperature profile, operating time share [%]

1 2 3 4 5 6 7 8 9 10 11 12 13

10 5 1 1 1 1 1 0 0 0 0 0 0 0 0

30 5 2 2 2 2 1 0 0 0 0 0 0 0 0

40 5 3 3 3 3 1 0 0 0 0 0 0 0 0

50 5 4 3 3 3 1 100 0 0 0 0 0 0 0

60 5 5 3 3 3 1 0 100 0 0 0 0 0 0

70 5 6 3 3 3 1 0 0 100 0 0 0 0 0

80 5 79 85 3 3 1 0 0 0 100 0 0 0 0

90 5 0 0 82 3 1 0 0 0 0 100 0 0 0

100 5 0 0 0 79 92 0 0 0 0 0 100 0 0

110 5 0 0 0 0 0 0 0 0 0 0 0 100 0

125 5 0 0 0 0 0 0 0 0 0 0 0 0 100

MTTFDvalue[years]during operation

Electronics computed 583 561 352 223 199 2327 1387 830 500 304 186 116 58

4hrs/day 3496 3368 2111 1339 1195 13963 8323 4981 3001 1822 1118 693 345

8hrs/day 1748 1684 1056 669 598 6981 4161 2491 1500 911 559 347 173

16hrs/day 874 842 528 335 299 3491 2081 1245 750 456 279 173 86

CalculationusingpartscountmethodasperISO13849-1:2015andSN29500-1,-2,-3,-4,incl.operatingtimesasspecified.

Speed sensor | DSAInformation

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Table Basic safety principle A1 Comment Manufacturer assessment

A.1.1Useofsuitablematerialsandappropriatemanufac-turing processes

Selectionofthematerials,manufacturingandtreatmentprocessestakingintoconsideration,e.g. tension,durability,elasticity,friction,wear,corrosion,temperature.

Verifiedbytesting

A.1.2 Correctsizingandconfigu-ration

Accountingfore.g. tension,expansion,fatigue,surfaceroughness,tolerances,snagging,manufacturingprocesses. Verifiedbytesting

A.1.3

Suitableselection,com-bination,arrangement,assemblyandinstallationofthecomponents/system

Considerationofthemanufacturer'sapplicationinstruc-tions,e.g.catalogsheets,installationinstructions,speci-fications,aswellasapplicationofproventechnicalexpe-riencewithsimilarcomponents/systems.

Userfollowsinstallationinstructions.Correspondingdocumentationinthedatasheet.

A.1.4 Applicationoftheprincipleofenergyseparation

Safestateisachievedbydisconnectingfromenergy.SeeauthoritativeshutdownprocedureinISO12100:2010,6.2.11.3. Energyisrequiredtoinitiatemovementinamechanism.Seeauthoritativestart-upprocedureinISO12100:2010,6.2.11.3. Accountingforvariousoperatingstates,e.g. operatingmode,maintenancemode. IMPORTANT-Thisprincipleshouldnotbeappliedifalossofpowerwouldcauseahazard,e.g. lossofclampingforcereleases tool.

Thesensorstoresnoenergythatmustbedisconnected.Applicationoftheprincipleofenergyseparationathighersystemle-vel may be necessary.

A.1.5 Adequatemounting

Manufacturer'sapplicationinstructionsmustbeobservedwhenusingscrewlocks.Anappropriatetorquelimitationmethodcanbeusedtopreventexcessivestressandtoachieveadequateresistancetopreventtheconnectionfromloosening.

Userfollowsinstallationinstructions.Correspondingdocumentationinthedatasheet.

A.1.6Limitationofthegenerati-onand/ortransmissionofforceandlikeparameters

Examplesincludeshearpin,shearplate,torquelimitingcoupler. IMPORTANT-Thisprincipleshouldnotbeappliedifthecontinuedintegrityofthecomponentsisessentialformain-tainingthenecessarylevelofcontrol.

Thesensorneithergeneratesnortrans-mitsforceorlikeparameters.

A.1.7 Limitationoftherangeofenvironmental parameters

Temperature,airhumidityandcontaminationattheins-tallationlocationareexamplesoftheseparameters.SeeISO 13849-2:2003,Section10andthemanufacturer'sapplication instructions.

Thesensormeetsthespecificationsaccordingtothedatasheet.Theusermustensurethattheseconditionsarenotexceeded.Thedatasheetmustbeobserved.

A.1.8 Limitationofspeedandsimilar parameters

Observethespeed,accelerationanddecelerationthatarerequiredbytheapplication.

Thismustbedoneinthehigher-levelsys-tem.

A.1.9 AdequatereactiontimeObservanceof,e.g.reductionofspringforce,friction,lubri-cation,temperature,inertiaduringaccelerationanddecele-ration,combinationoftolerances.

Thesensorcontainsnomechanicalpartswithreactiontime.

A.1.10 Protectionagainstunexpec-ted start-up

Accountingforunexpectedstart-upcausedbystoredener-gyandafterreestablishmentofenergysupplyfordifferentoperatingstates,suchasoperatingmode,maintenancemode,etc. Aspecialmechanismfordischargingstoredenergymaybenecessary. Specialapplications,e.g.,forsavingenergyforclampingdeviceorforensuringofapositionhavetobeconsideredseparately.

Thesensoritselfcannotproduceanyun-expectedstart-up.Thehigher-levelsystemmustbedesignedtopreventunexpectedstart-up.


16


Table Basic safety principle A1 Comment Manufacturer assessment

A.1.11 Simplification Avoidanceofunnecessarycomponentsinsafety-relatedsystems.

Thesensoriskeptasmechanicallysimpleaspossible,therearenomovingparts.Thesensorpossessesnomechanicalsaf-etyfunction.

A.1.12 Isolation Isolationofsafety-relatedfunctionsfromotherfunctions. Thesensormustperformnomechanicalsafetyfunction.

A.1.13 Adequatelubrication Observanceofthenecessityoflubricationmechanisms,specificationsonlubricantsandlubricationintervals. Thesensormustnotbelubricated.

A.1.14 Adequateprotectiontokeepoutfluidsanddust ObservanceofIPtypeofprotection(seeIEC60529). Verifiedbytesting


17



18


Table Proven safety principle A2 Comment Manufacturer assessment

A.2.1Useofcarefullyselectedmaterialsandmanufacturingprocesses

Selectionofsuitablematerialsfortheapplication,aswellasappropriatemanufacturingandtreatmentprocesses. Verifiedbytesting

A.2.2 Useofcomponentswithdefinedfailurebehavior

Thepredominantfailurebehaviorofacomponentisknowninadvanceandisconsistent.SeeISO12100:2010,6.2.12.3.

Notrelevantsincethesensorhasnoelectronicfunctionandmustexhibitnomechanicalfailurebehavior.

A.2.3 Oversizing/safetyfactorThesafetyfactorsspecifiedinthestandardsorbasedonexperiencewithsafety-relatedapplicationsshouldbeapplied.

Nomechanicalfunctionrequiringover-sizing.

A.2.4 Secured position

Themobileelementofthecomponentismechanicallyheldinasecureposition(frictionaloneisinsufficient).Theapplicationofforceisrequiredformovementoutofthesecuredposition.

Thesensorisscreweddownandhasnomechanicalmovingparts.Specificationsarenotedinthedatasheet.

A.2.5 IncreasedOUTforce Asafeposition/safestateisachievedbyincreasingtheOUTforceinrelationtotheINforce. Notrelevantforthesensor.

A.2.6

Carefulselection,combina-tion,arrangement,assem-blyandinstallationofthecomponents/systemsfortherelevant application

-/-Observanceofthespecificationsforinstallationandintendeduse,aswellasdocumentationinthedatasheet.

A.2.7Carefulselectionofthemountingtypeforeachapplication

Avoidanceofmountingbyfrictiononly. Thesensorisfastenedinplace.Specifi-cationsarenotedinthedatasheet.

A.2.8 Positivemechanicalaction

Inordertoachievepositivemechanicalaction,allmechani-calmovingpartsnecessaryforperformingthesafetyfunc-tionmustalsomoveconnectedcomponents,e.g. atripthatdirectlyopensthecontactsofanelectricswitchinsteadofaspring-basedconnection(seeSO12100:2010,6.2.5).

Thesensorisscreweddownandhasnomechanicalmovingparts.

A.2.9 MultiplicationofpartsReductionintheimpactoffailuresbyusingseveralpartsofthesametypethatactinparallel,e.g.,thefailureofoneofmanyspringsdoesnotresultinahazardousstate.

Nomechanicalfunctionrequiringredun-dant parts

A.2.10 Useofprovensprings

Aprovenspringrequires: theuseofcarefullyselectedmaterials,manufacturingprocesses(e. g. staticanddynamicsettingbeforeuse)andtreatmentprocesses(e. g. rollingandshot-blasting) asufficientguideforthespring asufficientsafetyfactorforcontinuoususe(i. e. highprobabilityofnobreakage) Provencompressionspringscanalsobedesignedwith: theuseofcarefullyselectedmaterials,manufacturingprocesses(e. g. staticanddynamicsettingbeforeuse)andtreatmentprocesses(e. g. rollingandshot-blasting) asufficientguideforthespring adistancebetweenthecoilsforunloadedspringsthatissmallerthanthewirediameter sufficientforcemaintainedafterbreakageorafterseveralbreakages(i. e. breakage/breakagesdoes/donotresultinahazardousstate). NOTE:Compressionspringsarepreferred.

Thesensorrequiresnospringsorsimilarforproperfunction. Notapplicabletothesensor.


19


Table Proven safety principle A2 Comment Manufacturer assessment

A.2.11 Reducedrangeofspeedandsimilar parameters

Settingtherequiredlimitationdependingonexperienceandtherespectiveapplication.Examplesincludeshearpin,shearplateandtorquelimitingcoupler. IMPORTANT-Thisprincipleshouldnotbeappliedifthecontinuedintegrityofthecomponentsisessentialformain-tainingthenecessarylevelofcontrol.

Thesensorgeneratesandstoresnoforceorsimilarparameters.Notappli-cabletothesensor.

A.2.12 Reduced speed range and similar parameters

Settherequiredlimitationdependingaccordingtoexpe-rienceandtherespectiveapplication.Examplesincludecentrifugalgovernor,securemonitoringofspeedandtravellimitation.

Ifnecessary,thismustbedoneinthehigher-levelsystem.Notapplicabletothesensor.

A.2.13 Reduced environmental para-meters range

Determiningthenecessarylimitations.Examplesaretem-perature,airhumidityandcontaminationduringinstallati-on.ISO 13849-2:2003,observesection10andthemanu-facturer'sapplicationinstructions.

Observanceofthespecificationsforinstallationandintendeduse,aswellasdocumentationinthedatasheet.Thesensormeetsthespecificationsaccor-dingtothedatasheet.Theusermustensurethattheseconditionsarenotexceeded.

A.2.14 Reducedreactiontimerange,hysteresislimitation

Determinationofthenecessarylimitations.Observanceof,e. g.reductionofspringforce,friction,lubrication,tempe-rature,inertiaduringaccelerationanddeceleration,combi-nationoftolerances.

Thesensorcontainsnomechanicalpartswithreactiontime.


20


Table Basic safety principle D1 Comment Manufacturer assessment

D.1.1Useofsuitablematerialsandmanufacturingproces-ses

Selectionofthematerials,manufacturingandtreatmentprocesseswithconsiderationto,e.g.tension,durability,elasticity,friction,wear,corrosion,temperature,conduc-tivity,mechanicalstrengthoftheinsulatingmaterials.

Verifiedbytesting

D.1.2 Correctsizingandshape Accountingfor,e.g.,tension,expansion,fatigue,surfaceroughness,tolerances,manufacturingprocesses. Verifiedbytesting

D.1.3

Suitableselection,combi-nation,arrangement,as-semblyandinstallationofthecomponents/system

Followingthemanufacturer'sapplicationinstructions,e.g.,catalogsheets,installationinstructions,specifications,aswellasapplicationofproventechnicalexperience.

Instructionsforinstallationandintendedusearedescribedinthedatasheet.

D.1.4 Correctprotectiveconduc-tor connection

Onesideofthecontrolcircuit,oneterminalofeachelec-tromagneticallyactuateddeviceoroneterminalofotherelectricdevicesisconnectedtoaprotectiveconductor(seeIEC60204-1:2005,9.4.3.1).

Thesensorpossessesnoprotectivecon-ductorconnection,thusnotapplicabletothissensor.

D.1.5 Insulation monitoring

Amechanismformonitoringinsulationshouldbeusedthateitherindicatesagroundfaultorautomaticallyinterruptsthecircuitfollowingagroundfault(seeIEC60204-1:2005,6.3.3).

Thereisnomechanismformonitoringinsulation,thusnotapplicabletothissensor

D.1.6 Applicationoftheprincipleofenergyseparation

Asafestateisachievedbydisconnectingallimportantequipmentfromtheenergysource,e.g.,byusinganor-mallyclosed(NC)contactforinputs(contactandpositionswitches)andanormallyopen(NO)contactforrelays(seealsoISO12100:2010,6.2.11.3). Exceptionscanbemadeinsomecases,e.g.ifafailureoftheelectricalsupplypresentsanadditionalhazard. Time-delayingfunctionsmaybenecessarytoensurethatasafestateofthesystemisachieved(seeIEC60204-1:2005,9.2.2).

Thesensorisamechanismwhoseenergymustbeseparatedfromthehigher-levelsystem.Thesensoritselfpowersnocom-ponents.

D.1.7 Suppressionofvoltagepeaks

Amechanismforsuppressingvoltagepeaks(RCelement,diode,varistor)shouldbeusedparalleltotheappliedloadbutnotparalleltothecontacts. NOTE:Theswitch-offtimeisincreasedbyadiode.

Verifiedbytesting

D.1.8 Reduction in response time Minimizationofdelaywhenswitchingoffcomponentsusedforswitching.

Thesensorhasaminimaldelaythatisshorterthanthemaximumscannablerota-tionalspeedfrequency.

D.1.9 Compatibility Useofcomponentsthataresuitableforthevoltagesandcurrents used.

Componentspecificationscorrespondtotherequiredspecificationsinthedatasheet.

D.1.10 Resistance to environmen-tal stresses

Designofmechanismssothattheycanfunctioninallexpectedoperatingenvironmentsandinunfavorableconditions,e.g.temperature,humidity,vibrationandelec-tromagneticinterference(EMI)(seeISO 13849-2:2003,Section 10).

Thesensormeetsthespecificationsac-cordingtothedatasheet.Theusermustensurethattheseconditionsarenotexceeded.


21


Table Basic safety principle D1 Comment Manufacturer assessment

D.1.11 Securemountingofinputdevices

Theinputdevicesaretobesecured(e.g.withlockingswitches,positionswitches,marginalswitches,proximityswitches)sothattheposition,orientationandswitchto-lerancesareobservedunderallexpectedconditions,e.g.vibration,standardwear,intrusionofforeignparticles,tem-perature.SeeISO14119:2013,section5.

Thesensorisfastenedtothemechanismwithscrews.Thismustbeensuredbytheuser.Thedatasheetmustbeobserved.

D.1.12 Protectionagainstunex-pected start-up

Protectionofunexpectedstart-up,e.g.,afterrestoringtheenergysupply(seeISO12100:2010,6.2.11.4,ISO14118,IEC60204-1).

Thesensoritselfcannotproduceanyun-expectedstart-up.Thehigher-levelsystemmustbedesignedtopreventunexpectedstart-up.

D.1.13 Protectionofthecontrolcircuit

ThecontrolcircuitshouldbeprotectedinaccordancewithIEC60204-1:2005,7.2and9.1.1.

Thesensorisnotrequiredtoprotectcon-trolcircuitfunction.Thesensoritselfisonlyaconsumerandispoweredbythecontrol circuit.

D.1.14

Useofsequentialswitchingforcircuitswithseriesconnectionsofredundantsignals

Topreventthecommoncausefailureofbothcontactsdu-ringwelding,nosimultaneousswitchingonandoffoccurs,therebyensuringthatonecontactalwaysoperateswithoutpower.

Thismustbedoneinthehigher-levelsystem.Thesensormustnotmeetthisrequirement.


22


Table Proven safety principle D3 Comment Manufacturer assessment

D.3.1 Contactswithpositive mechanicalconnection

Useofcontactswithpositivemechanicalconnection,e.g.,formonitoringfunctioninCategory2,3and4systems(seeEN50205,IEC60947-4-1:2001,AppendixF,IEC60947-5-1:2003+A1:2009,AppendixL).

Thesensorpossessesnocontactswithpositivemechanicalconnection,thusnotapplicabletothissensor.

D.3.2 Avoidanceoffaultsincables

Toavoidshortcircuitsbetweentwoadjacentlines,either: Usecableswithshieldingthatisconnectedtotheprotective conductor system on every single line. Useaprotectiveconductorbetweenallsignallinesinflatcables

Thesensorcablemustbeplacedbytheuserinsuchawaythatthisrequirementis met.

D.3.3 Distances between electrical conductors

Useofsufficientdistancebetweenterminals,componentsand lines to prevent any unintentional connections

Thesensorcablemustbeplacedbytheuserinsuchawaythatthisrequirementis met.

D.3.4 Energy limitation Acapacitoristobeusedtosupplyalimitedamountofenergy,e.g.,whenusingatimecyclecontrol.

Thismustbetakenintoaccountbytheuserinthehigher-levelsystem.Thedatasheetmustbeobserved.

D.3.5 Limitationofelectrical parameters

Limitingofthevoltage,current,energyorfrequenciesinordertorestrictmovement,e.g.bytorquelimitation,off-set/time-limited running and reduced speed to prevent any unsafecondition.

Thismustbetakenintoaccountbytheuserinthehigher-levelsystem.Thedatasheetmustbeobserved.

D.3.6 Preventionofundefined conditions

Undefinedconditionsinthecontrolsystemshouldbeavoi-ded.Thecontrolsystemmusthaveastructuraldesignthatenablesallexpectedcontrolsystemoperatingconditions,e.g.output/outputs,tobepredetermined.

Thismustbetakenintoaccountbytheuserinthehigher-levelsystem.Thesensordoesnotrepresentthecontrolsystem.

D.3.7 Positive actuation mode

Directactuationistransferredbypositivefit(notbytrac-tion)withoutelasticelements,i.e.,nouseofspringsbet-weentheactuatorandcontacts(seeISO14119:2013,5.1,ISO12100:2010,6.2.5).

Notapplicabletothissensorsinceitpossesses no positive actuation mode.

D.3.8 Stateswitchoverineventoffailure

Ifpossible,allmechanisms/circuitsshouldtransitiontoasafestateorbesafetooperate.

SeeseparatetablebelowforDSA1andDSA2.

D.3.9 DirectedfailureIffeasible,componentsorsystemsshouldbeusedwhosefailuretypeisknowninadvance(seeISO12100:2010,6.2.12.3).

SeeseparatetablebelowforDSA1andDSA2.

D.3.10 Oversizing

Componentsthatareusedinprotectioncircuitsshouldbeunderloaded,e.g.,by: thecurrentthatrunsthroughtheswitchcontactandthatshouldbelessthanhalfofthenominalcurrent theswitchingfrequencyofthecomponentsthatshouldbelessthanhalfofthenominalswitchingfrequency thetotalnumberofcircuitsexpected,whichisnomorethan10%ofthenumberofcircuitsforwhichthiselectricalmechanismisdesigned. NOTE: Under-loading may depend on practical design.

Thesensorandthecomponentsitcon-tainsareover-sized.Allcomponentshaveahigherelectricalandtemperaturespecificationthanrequiredfortherangeofapplicationsinthedatasheet.


23


Table Proven safety principle D3 Comment Manufacturer assessment

D.3.11 Reductionofpossiblefaults Separationofsafety-relatedfunctionsfromotherones.

Thesensoriskeptassimpleaspos-sibleandisnotmorecomplexthannecessary.Thedirectionofrotationandtherotationalspeed(DSA1)arerunoutseparatelyintwolines.TheDSA2con-tainstwoseparatelinesforbothrotatio-nal speed signals.

D.3.12 Balancebetweencomplexity/simplification

Abalanceshouldbestruckbetween: Thecomplexityofthedevicesinordertoachievebettercontrol. Thesimplificationofthedevicesinordertoimprovetheirreliability.

Thesensoriskeptassimpleaspos-sibleandisnotmorecomplexthannecessary.


24


DSA1

Component Output 1 (F1) failure mode Output 2 (direction of rotation) failure mode

VoltageregulatorforHallICsupplies0V Low level Low level

VoltageregulatorforHallICishighresistance Low level Low level

Voltageregulatorforcapacitorsislowre-sistance Low level Low level

Dflip-flopfaulty Highlevelorlowlevel,notspecifiedbymanufacturer

Highlevelorlowlevel,notspecifiedbymanufac-turer

HallICfaulty Highlevelorlowlevel,notspecifiedbyHallICmanufacturer

Highlevelorlowlevel,notspecifiedbyHallICmanufacturer

OutputDriver1(F1)faulty Notdetermined,notspecifiedbyoutputdrivermanufacturer Normalfunction

OutputDriver2(directionofrotation)faulty Normalfunction Notdetermined,notspecifiedbyoutputdrivermanufacturer

Doublediodeoutput(directionofrotation)faulty Normalfunction

Positivedirectiondiodeishighresistance:highlevel preset by load/voltage divider Negativedirectiondiodeishighresistance:lowlevel preset by load/voltage divider Positivedirectiondiodeislowresistance:Short-circuit detection by control unit1) Negativedirectiondiodeislowresistance:Short-circuit detection by control unit1)

EMCmeasuresonOutput1(F1)Overvoltagediode is low resistance Low level Normalfunction

EMCmeasuresonOutput2(directionofrotation)Overvoltagediodeislowresistance Normalfunction Low level

EMCmeasuresonsupplyvoltageOvervoltagediode is low resistance

Outputlevelispresetbyexternalload/voltagedivider(linebreakage)


EMCmeasuresonOutput1(F1)Capacitorislow resistance Low level Normalfunction

EMCmeasuresonOutput2(directionofrota-tion)Capacitorislowresistance Normalfunction Low level

EMCmeasuresinsupplyvoltageCapacitorislow resistance



EMCmeasuresinsupplyvoltageFerriteishighresistance



EMCmeasuresonOutput1(F1)Ferriteishighresistance

Outputlevelispresetbyexternalload/voltagedivider(linebreakage) Normalfunction

EMCmeasuresonOutput2(directionofrotation)Ferriteishighresistance Normalfunction Outputlevelispresetbyexternalload/voltage

divider(linebreakage)

1) Ifthecontrolunitsupportsthisfeature,otherwisenormalfunction


25


DSA2

Component Output 1 (F1) failure mode Output 2 (F2) failure mode

VoltageregulatorforHallICsupplies0V Low level Low level

VoltageregulatorforHallICishighresistance Low level Low level

Voltageregulatorforcapacitorsislowre-sistance Low level Low level

HallICfaulty Highlevelorlowlevel,notspecifiedbyHallICmanufacturer

Highlevelorlowlevel,notspecifiedbyHallICmanufacturer

OutputDriver1(F1)faulty Notdetermined,notspecifiedbyoutputdri-vermanufacturer Normalfunction

Outputdriver2(F2)faulty Normalfunction Notdetermined,notspecifiedbyoutputdri-vermanufacturer

EMCmeasuresonOutput1(F1)Overvoltagediode is low resistance Low level Normalfunction

EMCmeasuresonOutput2(F2)Overvoltagediode is low resistance Normalfunction Low level

EMCmeasuresonsupplyvoltageOvervoltagediode is low resistance



EMCmeasuresonOutput1(F1)Capacitorislow resistance Low level Normalfunction

EMCmeasuresonOutput2(F2)Capacitorislow resistance Normalfunction Low level

EMCmeasuresinsupplyvoltageCapacitorislow resistance



EMCmeasuresinsupplyvoltageFerriteishighresistance



EMCmeasuresonOutput1(F1)Ferriteishighresistance

Outputlevelispresetbyexternalload/voltagedivider(linebreakage) Normalfunction

EMCmeasuresonOutput2(F2)Ferriteishighresistance Normalfunction Outputlevelispresetbyexternalload/voltage

divider(linebreakage)

Accessories

Mating connector

Designation Number Ordering details

Housing 1 DT06-4S-EP04

Wedge 1 W4S

Sockets 4 0462-201-16141

Thematingconnectorisnotincludedinthescopeofdelivery.ThiscanbesuppliedbyBoschRexrothonrequest.

DSA | Speed sensorAccessories

26


Safety Instructions

General instructions Beforefinalizingyourdesign,requestabindinginstalla-

tion drawing. Theproposedcircuitsdonotimplyanytechnicalliability

forthesystemonthepartofBoschRexroth. Openingthesensororcarryingoutmodificationstoor

repairsonthesensorisprohibited.Modificationsorrepairstothewiringcouldleadtodangerousmalfunc-tions.

Thesensormayonlybeassembled/disassembledinadeenergizedstate.

Onlytrainedandexperiencedspecialistswhoareade-quatelyfamiliarwithboththecomponentsusedandthecompletesystemshouldimplementsystemdevelop-mentsorinstallandcommissionelectronicsystemsforcontrollinghydraulicdrives.

Whencommissioningthesensor,themachinemayposeunforeseenhazards.Beforecommissioningthesystem,youmustthereforeensurethatthevehicleandthehydraulicsystemareinasafecondition.

Makesurethatnobodyisinthemachine’sdangerzone. Donotusedefectivecomponentsorcomponentsnot

inproperworkingorder.Ifthesensorshouldfailordemonstratefaultyoperation,itmustbereplaced.

Despiteeverycarebeingtakenwhencompilingthisdocument,itisnotpossibletoconsiderallfeasibleapplications.Ifinstructionsforyourspecificapplicationaremissing,youcancontactBoschRexroth.

Theuseofsensorsbyprivateusersisnotpermitted,sincetheseusersdonottypicallyhavetherequiredlevelofexpertise.

Notes on the installation location and position Donotinstallthesensorclosetopartsthatgenerate

considerableheat(e.g.,exhaust). Linesaretoberoutedwithsufficientdistancefromhot

ormovingvehicleparts. Asufficientdistancetoradiosystemsmustbemaintai-

ned.

Beforeelectricweldingandpaintingoperations,thesen-sormustbedisconnectedfromthepowersupplyandthesensorconnectormustberemoved.

Cables/wiresmustbesealedindividuallytopreventwaterfromenteringthesensor.

Notes on transport and storage Pleaseexaminethesensorforanydamagewhichmay

haveoccurredduringtransport.Ifthereareobvioussignsofdamage,pleaseinformthetransportcompanyandBoschRexrothimmediately.

Ifitisdropped,thesensormustnotbeusedanylonger,asinvisibledamagecouldhaveanegativeimpactonreliability.

Notes on wiring and circuitry Linestothesensorsmustbedesignedsothattheyare

asshortaspossibleandshielded.Theshieldingmustbeconnectedtotheelectronicsononesideortothemachineorvehiclegroundviaalow-resistanceconnec-tion.

Thesensormatingconnectormustonlybepluggedandunpluggedwhenitisinadeenergizedstate.

Thesensorlinesaresensitivetospuriousinterference.Forthisreason,thefollowingmeasuresshouldbetakenwhenoperatingthesensor:– Sensorlinesshouldbeattachedasfarawayaspos-

siblefromlargeelectricmachines.– Ifthesignalrequirementsaresatisfied,itispossible

toextendthesensorcable.

Linesfromthesensortotheelectronicsmustnotberoutedclosetootherpower-conductinglinesinthemachineorvehicle.

Thewiringharnessshouldbefixatedmechanicallyintheareainwhichthesensorisinstalled(spacing <150 mm).Thewiringharnessshouldbesecuredsothatin-phaseexcitationwiththesensoroccurs(e.g.atthesensormountingpoint).

Ifpossible,linesshouldberoutedinthevehicleinterior.Ifthelinesareroutedoutsidethevehicle,makesurethattheyaresecurelyfixed.

Linesmustnotbekinkedortwisted,mustnotrubagainstedgesandmustnotberoutedthroughsharp-ed-gedductswithoutprotection.

Speed sensor | DSASafetyInstructions

27


Intended use Thesensorisdesignedforuseinmobileworkingmachi-

nes provided no limitations/restrictions are made to certainapplicationareasinthisdatasheet.

Operationofthesensormustgenerallyoccurwithintheoperatingrangesspecifiedandapprovedinthisdatasheet,particularlywithregardtovoltage,temperature,vibration,shockandotherdescribedenvironmentalinfluences.

Useoutsideofthespecifiedandapprovedboundaryconditionsmayresultindangertolifeand/orcausedamagetocomponentswhichcouldresultinsequentialdamagetothemobileworkingmachine.

Serious personal injury and/or damage to property may occurincaseofnon-compliancewiththeappropriateregulations.

Improper use Anyuseofthesensorotherthanthatdescribedinthe

chapter"Intendeduse"isconsideredtobeimproper. Useinexplosiveareasisnotpermitted. Damageswhichresultfromimproperuseand/orfrom

unauthorized,unintendedinterventionsinthedevicenotdescribedinthisdatasheetrenderallwarrantyandliabilityclaimswithrespecttothemanufacturervoid.

Use in safety-related functions Thecustomerisresponsibleforperformingariskanaly-

sisofthemobileworkingmachineanddeterminingthepossiblesafety-relatedfunctions.

Insafety-relatedapplications,thecustomerisrespon-siblefortakingpropermeasurestoensuresafety(sen-

sorredundancy,plausibilitycheck,emergencyswitch,etc.).

Productdatathatisrequiredtoassessthesafetyofthemachineisincludedinthisdatasheet.

Further information Furtherinformationaboutthesensorcanbefoundat

www.boschrexroth.de/mobilelektronik. Thesensormustbedisposedofinaccordancewiththe

nationalregulationsofthecountryinwhichitisused.

DSA | Speed sensorSafetyInstructions

28


Bosch Rexroth AGRobert-Bosch-Straße271701SchwieberdingenGermanyServiceTel. [email protected]

© Bosch Rexroth AG 2018.Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellasintheeventofapplicationsforindustrialpropertyrights.Thedataspecifiedaboveonlyservetodescribetheproduct.Nostatementsconcerningacertainconditionorsuitabilityforacertainapplicationcanbederivedfromourinformation.Theinformationgivendoesnotreleasetheuserfromtheobligationofownjudgmentandverification.Itmustberemem-beredthatourproductsaresubjecttoanaturalprocessofwearandaging.

Documents

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