Bosch Rexroth HDS03.2-W100N-HS37-01-FW AC Servo Drive Controller – HDS Series

HDS03.2-W100N-HS37-01-FW: Axis-Level Current Authority in High-Cycle Servo Systems

The Bosch Rexroth HDS03.2-W100N-HS37-01-FW is a 100 A continuous-rated AC servo drive controller from the HDS (High Dynamic Servo) platform — a generation of drives built specifically for closed-loop vector control of synchronous AC servo motors in multi-axis machine architectures. Unlike general-purpose inverters, the HDS03.2 is purpose-designed for torque-bandwidth-critical applications where current loop response, feedback fidelity, and fieldbus determinism are non-negotiable engineering constraints.

This unit integrates the HS37 interface module, which provides simultaneous support for SERCOS I/II fiber-optic ring communication, ±10 V analog velocity/torque command, and digital I/O — making it deployable across both legacy Rexroth DIAX04 architectures and standalone PLC-driven systems without hardware modification. The FW firmware variant supports standard motion profiles including velocity, torque, and position-controlled modes, configurable via Rexroth IndraWorks DS or BTV04 operator panel.

At siemensplc.com, this unit is stocked, inspected, and dispatched from Xiamen, China, with full export documentation and DHL/FedEx Express logistics to any destination worldwide.

Real-time Stock & RFQ: [email protected] | WhatsApp: +86 18359268345

Technical Parameters

Hardware Logical Analysis

The HDS03.2 architecture separates the control plane from the power plane at the PCB level. The control board hosts a fixed-point DSP responsible for executing the current regulation loop at 62.5 µs intervals — independent of the SERCOS communication cycle. This decoupling ensures that fieldbus jitter does not propagate into torque ripple, a critical requirement in precision grinding and contouring applications.

Current Loop Architecture: The W100N power stage uses a three-phase IGBT bridge with individual phase-current sensing via low-inductance shunt resistors. Current feedback is sampled synchronously with the PWM carrier at 8 kHz, providing 125 µs current loop bandwidth. The DSP implements a discrete-time PI regulator with anti-windup and cross-coupling decoupling (d-q axis separation), which maintains torque linearity across the full speed range including field-weakening operation above base speed.

EMC Design: The HDS03.2 integrates a common-mode choke on the DC bus input and differential-mode filtering on the motor output stage. The chassis is bonded to the cabinet PE rail through a low-impedance copper strap, and all signal cables interface through shielded connectors with 360° termination at the drive housing. This architecture meets EN 61800-3 Category C2 conducted and radiated emission limits without external line filters in most cabinet configurations.

Feedback Signal Conditioning: The resolver interface uses a dedicated ASIC for excitation generation (7–10 kHz, 7 Vrms) and synchronous demodulation, achieving 14-bit angular resolution per revolution. EnDat 2.1 feedback is processed via a dedicated serial interface with CRC error detection on every position telegram — any single-bit corruption triggers an immediate fault response (F228 or F229) rather than silent position error accumulation.

Thermal Management: The IGBT module junction temperature is monitored via an NTC thermistor embedded in the heatsink. The drive implements a two-stage thermal response: at 80°C heatsink temperature, output current is derated linearly; at 95°C, the drive trips with fault code F860 (overtemperature). The internal fan is speed-controlled based on heatsink temperature, reducing acoustic noise and fan bearing wear during light-load operation.

DC Bus Capacitor Bank: The intermediate circuit capacitor bank is sized for 100 A continuous operation with a 150% overload for 2 seconds. Capacitor voltage is monitored continuously; an undervoltage condition below 200 V DC triggers fault F401, while overvoltage above 900 V DC (regenerative braking without ballast) triggers F402. Both faults are latching and require a controlled restart sequence.

System Integration Benefits

• Deterministic SERCOS Ring Latency: SERCOS I/II fiber-optic topology delivers guaranteed cycle-to-cycle jitter below 1 µs, enabling synchronous multi-axis contouring without software compensation for communication delay.
• Backward Compatibility with DIAX04 Infrastructure: The HDS03.2 installs directly into existing Rexroth DIAX04 cabinet layouts — same DC bus rail, same motor connector pinout, same power supply units — eliminating re-engineering costs during drive replacement.
• Dual-Mode Command Interface: The HS37 module allows the same drive to operate under SERCOS master control or standalone ±10 V analog command, enabling phased migration from legacy CNC to modern fieldbus architectures without motor or cabinet rewiring.
• Integrated Diagnostic Transparency: The drive maintains a non-volatile fault history log (last 10 faults with timestamp and operating data snapshot), accessible via the BTV04 panel or IndraWorks DS. This eliminates guesswork during post-fault analysis and reduces mean time to repair.
• Firmware Parameter Portability: All axis parameters (loop gains, limit values, motor data) are stored in a parameter set that can be exported via IndraWorks and re-imported to a replacement drive in under 10 minutes — critical for minimizing production downtime during unplanned drive failures.
• Regenerative Energy Sharing: When multiple HDS axes share a common DC bus via the HZF/HZK supply, braking energy from decelerating axes is directly consumed by accelerating axes on the same bus segment, reducing net energy draw from the AC supply and eliminating the need for individual braking resistors in balanced multi-axis systems.
• Motor Overtemperature Protection: The drive monitors motor winding temperature via KTY84 or PTC thermistor input on the feedback connector. A warning threshold triggers current derating; a trip threshold triggers fault F219 (motor overtemperature), protecting motor insulation from thermal degradation without requiring external PLC logic.
• Safe Torque Off (STO) Readiness: The HDS03.2 hardware includes a dedicated enable input circuit that disables the IGBT gate drivers without removing DC bus voltage, supporting STO-equivalent safe stop functions when integrated with a safety relay or safety PLC output — compliant with the functional safety intent of EN 60204-1 Stop Category 0.

Quality Assurance & Global Logistics

Every HDS03.2-W100N-HS37-01-FW unit dispatched from siemensplc.com undergoes a structured inspection protocol before packaging:

• Visual Inspection: PCB surface, IGBT module condition, connector pin integrity, fan blade and bearing condition, OEM label authenticity verification.
• Power-On Functional Test: DC bus energization, control board initialization, firmware version confirmation, and fault-free idle state verification.
• Feedback Interface Check: Resolver excitation output voltage and frequency measured; EnDat communication handshake verified where applicable.
• Parameter Baseline: Factory default parameters loaded and confirmed via IndraWorks DS prior to shipment.
• 12-Month Warranty: All units carry a 12-month operational warranty covering defects in materials and workmanship from date of receipt.

Logistics from Xiamen, China: Orders are processed and dispatched within 1–2 business days of payment confirmation. Standard export routing uses DHL Express or FedEx International Priority, with typical transit times of 3–5 business days to Europe, 4–6 days to North America, and 2–4 days to Southeast Asia. All shipments include a commercial invoice, packing list, and certificate of origin. HS Code 8537.10 applies. EXW, FOB Xiamen, and CIF terms are available for freight-forward and bulk orders. Import duty and VAT are the responsibility of the consignee unless DDP terms are agreed in writing.

Contact Information

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