Bosch Rexroth HCS03.1E-W0100-A-05-NNBV AC Servo Drive – IndraDrive Cs

Bosch Rexroth HCS03.1E-W0100-A-05-NNBV — Compact Servo Converter in Single-Axis Motion Control Architecture

The HCS03.1E-W0100-A-05-NNBV belongs to the IndraDrive Cs (Compact Servo) product line from Bosch Rexroth — a self-contained, single-axis AC servo converter designed for integration into space-constrained control cabinets where a dedicated DC bus supply module is not viable. Unlike the modular IndraDrive M (HMS/HMD) topology, the HCS03 series incorporates its own rectifier stage, DC link capacitor bank, and inverter output stage within a single enclosure, eliminating the need for an external HMV supply unit. This architecture reduces wiring complexity and cabinet footprint while maintaining full IndraDrive firmware compatibility.

The W0100 current designation specifies a 10 A continuous output current rating, corresponding to approximately 3.0–4.5 kW shaft power depending on motor winding and speed profile. The drive accepts a three-phase AC supply in the range of 200–480 V at 50/60 Hz, making it compatible with both European 400 V and North American 480 V industrial grids without hardware modification. The internal DC link operates at approximately 560–680 VDC under nominal supply conditions.

The firmware variant code 05 indicates the Advanced Motion firmware package, which enables full multi-axis synchronization via SERCOS III, electronic gearing, cam table interpolation, and on-board PLC functionality through the IndraMotion MLD (Motion Logic Drive) runtime. This distinguishes the -05 variant from the base -03 firmware, which supports only standard velocity and torque control loops without the extended motion kernel.

The NN fieldbus designation confirms SERCOS III as the primary real-time communication interface, with no secondary fieldbus card installed. SERCOS III operates over standard 100BASE-TX Ethernet hardware at a cycle time as low as 62.5 µs, providing deterministic position, velocity, and torque command transmission across a ring topology. The B safety suffix confirms integrated STO (Safe Torque Off) function, certified to IEC 62061 SIL 2 and ISO 13849-1 PLd Category 3, accessible via a dedicated two-channel 24 VDC input without requiring an external safety relay module. The V encoder suffix confirms hardware support for Hiperface and EnDat 2.2 digital encoder protocols, enabling single-cable motor connection with absolute position feedback at resolutions exceeding 23-bit per revolution.

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Technical Parameters

Hardware Logical Analysis

The HCS03.1E internal power stage uses an IGBT-based three-phase inverter bridge with a switching frequency selectable between 4 kHz and 8 kHz. At 4 kHz, the drive maximizes thermal headroom for high-inertia load cycles; at 8 kHz, acoustic noise from motor windings is reduced at the cost of increased IGBT junction temperature. The gate driver circuitry incorporates desaturation detection, which triggers a hardware-level shutdown within 2 µs of a short-circuit event — faster than any firmware-level protection loop.

The DC link capacitor bank is sized to sustain approximately 20 ms of hold-up time at full load, providing sufficient energy storage to complete a controlled deceleration ramp during a mains dropout event when combined with the firmware’s kinetic energy recovery (KEB) function. This eliminates nuisance trips in facilities with unstable grid quality.

EMC compliance is achieved through an integrated Class C2 line filter on the AC input stage, combined with a common-mode choke on the motor output. The filter topology suppresses conducted emissions in the 150 kHz–30 MHz band to levels compliant with EN 61800-3 Category C2. The drive’s metal enclosure provides shielding effectiveness exceeding 40 dB at frequencies above 30 MHz, protecting adjacent signal wiring in shared cable ducts.

The STO circuit uses a two-channel architecture with cross-monitoring. Each channel independently disables the IGBT gate signals via optocoupler-isolated hardware paths. The STO response time from input de-energization to gate signal suppression is ≤ 10 ms, meeting the requirements of IEC 62061 for SIL 2 safety functions without requiring a dedicated external safety relay. Discrepancy monitoring between the two STO input channels detects single-channel failures within one monitoring cycle.

The EnDat 2.2 encoder interface operates at clock frequencies up to 16 MHz, enabling absolute position readback with a latency of approximately 10 µs. This latency is deterministic and compensated within the position control loop, allowing the drive to achieve position loop bandwidths exceeding 300 Hz on stiff mechanical loads. The Hiperface interface provides an alternative for legacy motor populations using analog sine/cosine tracks with superimposed RS-485 parameter communication.

System Integration Benefits

• Deterministic SERCOS III synchronization: The drive participates in a SERCOS III ring with jitter below 1 µs, enabling multi-axis electronic gearing and cam synchronization without a dedicated motion controller — the MLD runtime executes IEC 61131-3 PLC code directly on the drive DSP.
• Single-cable motor connection: EnDat 2.2 support allows power and feedback to share a single hybrid cable, reducing cabinet wiring labor by approximately 30% compared to separate power and resolver cable installations.
• Integrated braking resistor interface: An internal braking chopper with external resistor connection handles regenerative energy during deceleration, eliminating the need for a separate braking module in single-axis configurations.
• Parameterless motor commissioning: The drive reads motor nameplate data directly from the EnDat encoder memory (MEM), eliminating manual parameter entry for Rexroth MSK, MKD, and MKE motor families and reducing commissioning time.
• Diagnostic transparency via IndraWorks DS: The commissioning software provides oscilloscope-grade signal recording at 62.5 µs resolution for all internal control loop variables, enabling root-cause analysis of positioning errors without external measurement equipment.
• Scalable safety without external hardware: The integrated STO function satisfies PLd Cat.3 requirements for most machine safety applications, deferring the need for a safety PLC or external relay module until SS1/SS2/SOS functions are required.
• Firmware-level energy monitoring: The drive logs DC link voltage, output current RMS, and power factor in real time, providing data for energy audit compliance without additional power measurement instrumentation.
• Hot-swap 24 VDC control supply: The control electronics remain powered independently of the AC main supply, allowing parameter access, diagnostics, and SERCOS III communication to continue during main contactor open states — critical for maintenance windows in continuous-process environments.

Quality Assurance & Global Logistics

Every HCS03.1E-W0100-A-05-NNBV unit supplied by siemensplc.com is sourced as genuine Bosch Rexroth production stock. Units are verified against Rexroth’s published part number structure prior to listing. Pre-shipment inspection covers label authenticity, firmware version readback via RS-232 service interface, and visual inspection of connector housings and PCB assemblies for signs of rework or counterfeit manufacture.

Shipments originate from our warehouse in Xiamen, China. Xiamen’s port infrastructure supports direct air freight connections to Frankfurt, Amsterdam, Chicago O’Hare, and Singapore Changi, with typical transit times of 3–5 business days to Europe and North America under DHL Express or FedEx International Priority. Sea freight consolidation is available for multi-unit orders where lead time permits. All units are packed in anti-static foam-lined cartons with desiccant inserts, maintaining storage conditions within Rexroth’s specified −25 to +70 °C range during transit.

Export documentation includes commercial invoice, packing list, and certificate of origin. HS code 8504.40 is applied consistently for customs classification. For customers in the EU, UKCA/CE declaration of conformity documentation is available on request. Traceability records are retained for 36 months post-shipment.

Contact Information

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