Bosch Rexroth HDS02.2-W040N-HT20-01-FW – High-Performance AC Servo Drive Controller | DIAX04 / HDS Series Platform
Engineering Background: The Bosch Rexroth HDS Series (High Dynamic Servo) represents the company’s flagship digital servo drive platform, engineered for demanding closed-loop motion control in industrial machinery. The HDS02.2 generation introduced enhanced firmware architecture and improved thermal management, making it the preferred choice for OEMs requiring deterministic torque and velocity response across multi-axis configurations.
Product Positioning: The HDS02.2-W040N-HT20-01-FW is a 40 A continuous-output AC servo amplifier designed to operate within the DIAX04 modular drive system. It accepts resolver and encoder feedback, communicates via SERCOS or analog interfaces, and is built to IEC/EN 61800 standards. This model is widely deployed in CNC machining centers, injection molding machines, and high-speed packaging lines where sub-millisecond current-loop response is mandatory.
Complete Technical Specifications
- Part Number: HDS02.2-W040N-HT20-01-FW
- Series: HDS (High Dynamic Servo) — DIAX04 Platform
- Manufacturer: Bosch Rexroth AG (Germany)
- Drive Type: AC Servo Amplifier / Digital Servo Drive Controller
- Continuous Output Current: 40 A
- Supply Voltage: 3 × 400–480 V AC, 50/60 Hz
- DC Bus Voltage: 540–750 V DC (via Rexroth power supply module)
- Feedback Interface: Resolver, Hiperface, EnDat 2.1 encoder
- Communication: SERCOS I/II fiber-optic, analog ±10 V, digital I/O
- Control Loops: Current, velocity, position (all digital, configurable)
- Current Loop Cycle Time: ≤ 62.5 µs
- Firmware: FW variant — field-programmable via Rexroth IndraWorks
- Cooling: Forced air (internal fan) + heatsink (HT20 thermal class)
- Protection Class: IP20
- Operating Temperature: 0 °C to +45 °C (derating above 40 °C)
- Storage Temperature: −25 °C to +70 °C
- Humidity: 5–95 % RH, non-condensing
- Dimensions (H × W × D): ~365 × 100 × 270 mm (standard HDS02.2 frame)
- Weight: ~3.0 kg
- Certifications: CE, UL, cUL
- Country of Origin: Germany
Proven Application Environments
- CNC Machining Centers: Spindle and feed-axis control requiring high dynamic stiffness and minimal following error at rapid traverse rates up to 60 m/min.
- Injection Molding Machines: Clamp, injection, and ejector axes demanding precise force/pressure profiling with fast reversal.
- High-Speed Packaging Lines: Flying-shear and registration control where synchronization accuracy is critical across 4–16 axes.
- Robotics & Gantry Systems: Multi-axis coordinated motion with SERCOS ring topology for deterministic cycle times.
- Printing & Converting Machinery: Web tension control and register correction requiring sub-millisecond torque response.
- Semiconductor & Electronics Assembly: Pick-and-place and wafer-handling stages needing ultra-smooth velocity profiles.
Engineering Advantages
- Digital Current Loop: 62.5 µs cycle eliminates analog drift and enables consistent torque delivery across the full speed range.
- SERCOS Fiber-Optic Bus: Noise-immune, deterministic communication eliminates EMI-induced position errors in harsh shop-floor environments.
- Modular DIAX04 Architecture: Shared DC bus with Rexroth HVR/HVE power supply modules reduces cabinet footprint and regenerative braking losses by up to 30 %.
- FW Firmware Variant: Field-configurable via IndraWorks DS software — no hardware swap required for parameter changes or axis re-tuning.
- HT20 Thermal Class: Enhanced heatsink design sustains 40 A continuous at 45 °C ambient without derating, extending MTBF in high-duty-cycle applications.
- Integrated Safety: Safe Torque Off (STO) function compliant with EN 954-1 Cat. 3 / IEC 62061 SIL 2 (firmware-dependent).
System Architecture & Signal Flow
The HDS02.2-W040N-HT20-01-FW operates as a slave node on the DIAX04 drive bus. The signal flow is as follows:
- Power Stage: AC mains → HVR/HVE power supply → shared DC bus → HDS02.2 IGBT inverter → servo motor
- Command Path: CNC/PLC → SERCOS fiber ring (or ±10 V analog) → HDS02.2 position/velocity setpoint register → digital current controller → PWM output
- Feedback Path: Motor encoder/resolver → HDS02.2 feedback card → position actual value → SERCOS telegram back to CNC
- Safety Path: Safety relay or PLC safety output → STO input terminals → IGBT gate disable (hardware-level, firmware-independent)
Sourcing & Quality Verification
- All units sourced from verified industrial surplus channels, OEM overstock, or authorized distributors.
- Each drive undergoes incoming inspection: visual check, firmware version verification, and DC bus capacitor ESR measurement.
- Functional power-on test performed where test bench infrastructure is available.
- Original Rexroth labels, serial number plates, and firmware stickers intact and traceable.
- Packaging: anti-static bag + foam-lined export carton; humidity indicator card included.
Procurement Process
- Step 1: Confirm part number HDS02.2-W040N-HT20-01-FW matches your existing DIAX04 system firmware revision.
- Step 2: Submit RFQ via support@konmask.com or add to cart directly.
- Step 3: Receive proforma invoice with lead time (typically 1–5 business days for in-stock units).
- Step 4: Payment via T/T, PayPal, or trade-term arrangement (FOB Xiamen).
- Step 5: Shipment via DHL / FedEx with full tracking; export documentation provided.
Technical FAQ
Q: Is this drive compatible with IndraDrive Cs or Mi series?
A: No. The HDS02.2 belongs to the DIAX04 generation and is not electrically or firmware-compatible with IndraDrive Cs/Mi. Verify your power supply module (HVR/HVE) and SERCOS generation before ordering.
Q: Can the FW firmware be updated in the field?
A: Yes. Using Rexroth IndraWorks DS software and a serial/USB-serial adapter connected to the X2 diagnostic port, firmware can be flashed without removing the drive from the cabinet.
Q: What motor types are compatible?
A: Rexroth MHD, MKD, MKE, and MSK servo motor families with resolver or EnDat/Hiperface encoders. Third-party motors require custom feedback parameterization.
Q: What is the warranty?
A: Konmask provides a 90-day functional warranty on all tested units. Extended warranty and repair services available on request.
Q: Do you provide the mating connectors and cables?
A: Connector kits and pre-made motor/feedback cables for common Rexroth motor families are available as add-on items — contact us for a bundled quote.
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