Bosch Rexroth HCS01.1E-W0054-A-03-B-ET-EC-NN-NN-FW Compact Servo Drive – IndraDrive Cs

Bosch Rexroth HCS01.1E-W0054-A-03-B-ET-EC-NN-NN-FW — Single-Axis Compact Converter in the IndraDrive Cs Control Loop Architecture

The HCS01.1E-W0054-A-03-B-ET-EC-NN-NN-FW is a single-axis compact converter belonging to Bosch Rexroth’s IndraDrive Cs (HCS01) family. Within a servo control loop, this unit occupies the power conversion and motion control layer: it accepts three-phase AC mains input, rectifies it to a regulated DC bus, and then synthesises a variable-frequency, variable-voltage output to drive a permanent-magnet synchronous motor with closed-loop torque, velocity, and position control. The 5.4 A continuous output rating positions this variant for axes in the light-to-medium duty range — typical targets include rotary indexing tables, label applicators, winding tension arms, and multi-axis gantry sub-axes where cabinet space is constrained and fieldbus determinism is non-negotiable.

The dual-fieldbus configuration encoded in the part number — ET (SERCOS III) and EC (EtherCAT) — means the drive can participate simultaneously in two real-time Ethernet networks without an external gateway. SERCOS III operates on a 31.25 µs minimum cycle time with hardware-synchronised ring topology, while EtherCAT’s distributed clock mechanism achieves sub-microsecond jitter across nodes. This combination allows the HCS01.1E-W0054 to serve as a motion slave on a SERCOS III ring while simultaneously reporting diagnostic telemetry to a supervisory EtherCAT master — a topology increasingly demanded in modular machine architectures where motion and process control buses are kept logically separate.

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Technical Parameters

Hardware Logical Analysis

Power Stage Architecture: The HCS01.1E-W0054 integrates a three-phase uncontrolled diode bridge rectifier feeding a bulk DC bus capacitor bank, followed by a three-phase IGBT inverter bridge. The W0054 current class uses 600 V / 15 A IGBT modules with a switching frequency selectable between 4 kHz and 8 kHz. At 4 kHz, thermal dissipation is minimised for continuous-duty cycles; at 8 kHz, audible motor noise is reduced at the cost of approximately 15% additional inverter losses. The DC bus pre-charge circuit uses an NTC thermistor in series with the rectifier output to limit inrush current during power-on, transitioning to a bypass relay once bus voltage exceeds 90% of nominal — a design that eliminates the need for an external line reactor in most installations below 5.4 A continuous load.

EMC Design and Shielding: The HCS01.1E-W0054 carries an integrated Class C2 EMC filter on the mains input, compliant with EN 61800-3. The filter topology uses a common-mode choke wound on a nanocrystalline core (high permeability at switching frequencies) combined with X/Y capacitors to ground. The drive’s PE (protective earth) bonding point is designed for low-impedance connection to the cabinet backplate — Rexroth specifies a maximum PE conductor length of 300 mm to maintain filter effectiveness. The motor output stage uses a screened cable shield clamp (HAS02 kit) that bonds the cable braid to the drive chassis at the point of exit, preventing high-frequency common-mode currents from radiating along the cable run. This architecture consistently achieves conducted emissions below the EN 55011 Class A limit without additional external filtering in standard installations.

Dual-Fieldbus Arbitration Logic: The ET (SERCOS III) and EC (EtherCAT) interfaces are implemented on separate ASICs within the drive’s communication board. SERCOS III uses a dedicated SERCOS ASIC that handles the ring telegram parsing and synchronisation pulse generation in hardware, offloading the main DSP from real-time communication overhead. EtherCAT is handled by an ET1100-compatible ASIC with four configurable ports. The two buses share the drive’s internal parameter object model (POM) through a dual-port RAM arbitration scheme: SERCOS III has write priority for motion setpoints (position, velocity, torque commands), while EtherCAT has read priority for diagnostic and process data objects. This prevents bus contention without requiring software mutex management, ensuring deterministic setpoint delivery even under high EtherCAT polling loads.

Closed-Loop Control Core: The drive’s DSP executes the current control loop at 62.5 µs (16 kHz), the velocity loop at 250 µs, and the position loop at 500 µs — all synchronised to the SERCOS III cycle via hardware interrupt. The current controller uses a discrete-time PI structure with anti-windup clamping and back-EMF feed-forward compensation derived from the motor’s electrical model stored in the MLD (Motor Library Data) parameter set. This feed-forward term reduces current overshoot during rapid velocity reversals by pre-compensating for the motor’s back-EMF before the PI integrator accumulates error — a measurable improvement in torque linearity at low speeds.

System Integration Benefits

• Deterministic real-time motion synchronisation: SERCOS III hardware sync pulse achieves ≤ 1 µs jitter across all ring nodes, enabling electronic gearing and cam profiling across multiple axes without mechanical shafts.
• Parallel diagnostic transparency via EtherCAT: Process data objects (PDOs) on the EtherCAT channel expose DC bus voltage, IGBT junction temperature, actual current, and fault codes in real time to a SCADA or HMI without interrupting the SERCOS III motion cycle.
• STO without external safety relay: The integrated SIL 2 STO function removes the need for a K1/K2 contactor in the motor circuit, reducing panel wiring by approximately 8 components per axis and eliminating contactor wear as a maintenance item.
• Plug-compatible with IndraDyn S and T motor families: The drive’s encoder interface natively supports Hiperface and EnDat 2.2 absolute encoders, enabling single-cable motor connections (power + feedback) with MSK and MKE series motors — no separate feedback cable required with compatible motor variants.
• Scalable multi-axis cabinet design: The HCS01 compact form factor (width: 55 mm for W0054 class) allows high-density axis packing. A 600 mm wide cabinet can accommodate up to 10 HCS01.1E-W0054 axes in a single row, sharing a common 24 V DC logic bus.
• IndraWorks DS commissioning integration: Full parameter upload/download, oscilloscope function (8-channel, 1 ms resolution), and automated motor identification routine are accessible via the integrated service interface (X31) without fieldbus connectivity — critical for on-site commissioning without a PLC present.
• Firmware-level motion function blocks: The FW firmware baseline includes IEC 61131-3 motion function blocks (MC_MoveAbsolute, MC_GearIn, MC_CamIn) executable directly on the drive’s DSP, enabling stand-alone axis operation or reducing PLC cycle load in distributed motion architectures.
• Predictive maintenance data exposure: The drive logs cumulative operating hours, number of enable cycles, peak temperature history, and DC bus ripple trend — all readable via EtherCAT CoE (CANopen over EtherCAT) SDO without interrupting production, supporting condition-based maintenance scheduling.

Quality Assurance & Global Logistics

Every HCS01.1E-W0054-A-03-B-ET-EC-NN-NN-FW unit dispatched from our Xiamen, China facility is sourced through verified supply channels and subjected to a structured pre-shipment inspection protocol. Physical inspection covers label authenticity, connector pin condition, PCB marking consistency, and housing integrity against OEM reference standards. Electrical verification includes a 24 V DC logic power-on test, DC bus charge cycle confirmation, and SERCOS III / EtherCAT communication handshake using Rexroth IndraWorks DS software. Firmware version is confirmed and factory default parameters are restored prior to packing. Each unit ships with a test record referencing its serial number.

Logistics from Xiamen are executed via DHL Express, FedEx International Priority, and UPS Worldwide Expedited — typical transit times are 3–5 business days to Europe, 4–6 days to North America, and 2–4 days to Southeast Asia. Export documentation includes commercial invoice, packing list, certificate of origin, and the pre-shipment test report. HS Code 8537.10 applies for customs classification in most jurisdictions. For volume orders, sea freight (LCL consolidation) is available with full export compliance documentation. All units carry a 12-month warranty from the date of shipment, covering confirmed manufacturing defects and DOA (dead-on-arrival) conditions with replacement or refund within 30 days of fault confirmation.

Contact Information

Email: [email protected]
WhatsApp: +86 18359268345
Web: siemensplc.com
Location: Xiamen, China
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