Bosch Rexroth ECODRIVE Cs DKC Series Modules: DKC04.3-200-7-FW

Technical Dossier

Product Details And Specifications

Bosch Rexroth ECODRIVE Cs (DKC) Series: Comprehensive Module Range and Technical Overview

The Bosch Rexroth ECODRIVE Cs series — designated under the DKC product family — represents one of the most widely deployed compact servo drive platforms in global heavy industry. Installed across chemical processing plants, automotive body-in-white lines, paper mills, printing machinery, and packaging automation systems, the DKC series established a benchmark for modular, fieldbus-integrated motion control during its production lifecycle spanning the late 1990s through the 2010s.

The DKC platform operates as a standalone or multi-axis servo drive, accepting feedback from resolver or encoder-equipped motors, and communicating via SERCOS, PROFIBUS-DP, DeviceNet, or analog interfaces depending on firmware variant. Its compact footprint and standardized 24 VDC logic supply made it a preferred choice for machine builders requiring deterministic motion performance without the overhead of a full-scale drive system.

DriveKNMS maintains verified stock of DKC series units including the DKC04.3-200-7-FW, sourced from decommissioned production lines and tested against original Rexroth factory specifications. For facilities still operating DKC-based motion axes, replacement availability is the single most critical factor in avoiding unplanned downtime.

The Evolution of ECODRIVE Cs (DKC) Architecture

The ECODRIVE Cs series was introduced by Mannesmann Rexroth (later Bosch Rexroth following the 2001 merger) as a successor to the DIAX04 drive family. The DKC designation covers the compact controller variant, differentiated from the larger ECODRIVE 03 (DKC03.x) and the earlier ECODRIVE 01/02 generations.

Generation 1 – DKC01.x / DKC02.x: Early ECODRIVE variants with resolver-only feedback and limited fieldbus options. Firmware was stored on EPROM modules; field upgrades required physical chip replacement. Compatible with Rexroth MKD and MHD motor families.

Generation 2 – DKC03.x: Introduced SERCOS II interface support and expanded current ratings. The DKC03.3 sub-variant added PROFIBUS-DP capability. Firmware upgrades moved to serial download via RS-232 interface. This generation saw the widest industrial adoption.

Generation 3 – DKC04.x (current subject): The DKC04.3 represents the final production revision of the compact ECODRIVE Cs platform. It introduced enhanced diagnostic LEDs, improved thermal management, and support for firmware version FW (field-programmable). The DKC04.3-200-7-FW specifically denotes a 200A peak current rating, size 7 housing, with field-upgradeable firmware. This generation is now in end-of-life status; Bosch Rexroth has transitioned customers toward the IndraDrive Cs (HCS) and IndraDrive Mi (KSM) platforms.

Compatibility note: DKC04.x units are not directly interchangeable with DKC01.x or DKC02.x without firmware and parameter migration. Motor cable pinouts and feedback connector assignments differ between generations. Engineering review is required before cross-generation substitution.

ECODRIVE Cs (DKC) Full Catalog & Functionalities – SKU List

The following SKUs represent verified members of the Bosch Rexroth ECODRIVE Cs / DKC product family. Each unit is listed with its primary functional designation.

Compact Servo Drive Controllers – DKC04.3 Series

• DKC04.3-005-7-FW: 5A continuous, size 7, field firmware, single-axis compact servo drive
• DKC04.3-012-7-FW: 12A continuous, size 7, SERCOS/PROFIBUS selectable via firmware
• DKC04.3-040-7-FW: 40A continuous, size 7, resolver and encoder feedback compatible
• DKC04.3-100-7-FW: 100A peak, size 7, suitable for high-inertia servo axes
• DKC04.3-200-7-FW: 200A peak, size 7, field-upgradeable firmware, end-of-life status

Compact Servo Drive Controllers – DKC03.3 Series

• DKC03.3-005-7-FW: 5A, SERCOS II interface, predecessor to DKC04.3-005
• DKC03.3-012-7-FW: 12A, PROFIBUS-DP variant, widely used in automotive transfer lines
• DKC03.3-040-7-FW: 40A, resolver feedback, common in injection molding machinery
• DKC03.3-100-7-FW: 100A, high-current axis control for press and stamping applications
• DKC03.3-200-7-FW: 200A, large-axis drive, direct predecessor to DKC04.3-200-7-FW

Earlier Generation – DKC02.x / DKC01.x

• DKC02.3-040-7-FW: 40A, ECODRIVE 02 generation, EPROM-based firmware
• DKC02.3-100-7-FW: 100A, resolver-only feedback, no SERCOS support
• DKC01.3-012-7-FW: 12A, earliest compact DKC variant, analog command interface
• DKC01.3-040-7-FW: 40A, analog ±10V velocity command, no fieldbus

Associated Power Supply / Regeneration Units

• HVR02.2-W018N: Regenerative power supply unit, compatible with DKC03/04 multi-axis configurations
• HVE02.2-W018N: Non-regenerative supply, standard DC bus feed for DKC compact drives

Sourcing Hard-to-Find & Obsolete ECODRIVE Cs Parts

Bosch Rexroth formally discontinued the ECODRIVE Cs (DKC) product line and directed customers to the IndraDrive platform. For facilities that cannot justify a full motion control migration — due to the cost of re-engineering machine programs, requalifying production processes, or retraining maintenance personnel — the only viable path is securing verified replacement DKC units from the secondary market.

The cost differential is significant. A full axis migration from DKC to IndraDrive Cs, including motor recabling, controller parameter transfer, and production requalification, typically runs between USD 15,000 and USD 60,000 per axis depending on machine complexity. A verified replacement DKC04.3-200-7-FW unit from DriveKNMS eliminates that expenditure entirely and restores production within hours rather than weeks.

DriveKNMS sources DKC units from decommissioned European and North American production facilities, where equipment was maintained under ISO-certified maintenance programs. Each unit undergoes identity verification against the Rexroth serial number database before acceptance into inventory. Units with unknown service history are quarantined for full bench testing before listing.

For facilities managing multiple DKC axes, DriveKNMS recommends establishing a minimum two-unit buffer stock per axis type. The DKC04.3-200-7-FW, as a high-current unit, has a longer lead time on the secondary market than lower-current variants. Procurement delay of 6–12 weeks is common when sourcing reactively after a failure event.

Quality Control for the ECODRIVE Cs (DKC) Range

The DKC series presents specific failure modes that require targeted inspection protocols. Standard power electronics testing is insufficient for a drive platform of this complexity. DriveKNMS applies the following procedures to all DKC units prior to dispatch:

1. DC Bus Capacitor ESR Measurement: Electrolytic capacitors in the DC bus filter bank are the primary age-related failure point in DKC drives. Each capacitor bank is tested for equivalent series resistance (ESR) and capacitance retention. Units with ESR values exceeding 150% of nominal specification are recapped before dispatch.
2. SERCOS / PROFIBUS Communication Verification: The fieldbus interface is exercised using a Rexroth-compatible master controller. Ring integrity (SERCOS) and DP address response (PROFIBUS) are confirmed at rated baud rates.
3. Firmware Version Audit: Firmware version is read via the RS-232 diagnostic port and logged. Customers are advised of the installed version and any known compatibility constraints with specific Rexroth IndraControl or third-party PLC masters.
4. Output Stage Load Test: Each drive is connected to a resistive load bank and exercised through its full current range. Gate driver timing and current regulation linearity are verified against factory test data.
5. Connector and Backplane Inspection: All signal connectors (X1 feedback, X2 motor power, X3 control, X4 fieldbus) are inspected under magnification for pin corrosion, bent contacts, and housing crack. Corroded pins are treated or the connector assembly is replaced.

For stock inquiries, technical compatibility questions, or bulk procurement of ECODRIVE Cs (DKC) series components:

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