Bosch Rexroth HDS Series Drive Controllers: HDS03.2-W100N-HT20-01-FW

Model: HDS03.2-W100N-HT20-01-FW

Brand Bosch Rexroth

Series HDS Series

Model HDS03.2-W100N-HT20-01-FW

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Technical Dossier

Product Details And Specifications

Bosch Rexroth HDS Series: Comprehensive Module Range and Technical Overview

The Bosch Rexroth HDS (High Dynamic Servo) series represents a generation of AC servo drive controllers engineered for high-precision motion control in continuous-duty industrial environments. Deployed across petrochemical refineries, nuclear power auxiliary systems, offshore drilling platforms, and large-scale chemical processing plants, the HDS series has accumulated a substantial installed base in applications where axis positioning accuracy, dynamic torque response, and thermal stability under sustained load are non-negotiable operational parameters.

The HDS series operates within the Rexroth DIAX04 and ECODRIVE03 drive families, sharing a common SERCOS and analog interface architecture that enabled integration into both proprietary Rexroth motion controllers (e.g., DIAX04 HDD, HDS) and third-party CNC/PLC platforms. Its modular power stage design—available in current ratings from 15 A to 200 A continuous—made it a standard selection for multi-axis gantry systems, extruder drives, and winding/unwinding tension control applications throughout the 1990s and 2000s.

The Evolution of HDS Series Architecture

The HDS series was introduced as part of Rexroth's DIAX04 platform, succeeding the earlier HDD and TDM series drives. The architectural progression followed three distinct phases:

Phase 1 — DIAX04 Foundation (mid-1990s): Initial HDS units used analog command interfaces with resolver feedback. Firmware was stored on EPROM modules (e.g., FW suffix in part numbers denotes firmware variant). Communication was primarily via analog ±10 V velocity/torque command with enable/fault discrete I/O.

Phase 2 — SERCOS Integration: Subsequent variants added SERCOS fiber-optic ring support, enabling deterministic real-time position loop closure at the drive level. This allowed HDS drives to participate in synchronized multi-axis profiles managed by Rexroth's DIAX04 controller or compatible third-party SERCOS masters.

Phase 3 — End-of-Life Transition: The HDS series has been formally discontinued by Bosch Rexroth. Replacement platforms include the IndraDrive C (HCS) and IndraDrive M (HMS/HMD) series, which offer backward-compatible motor support for Rexroth MKD, MKE, and MSK motors previously driven by HDS units. Migration requires firmware re-parameterization and, in most cases, new drive mounting hardware. For facilities unable to execute a full drive replacement, lifecycle extension through certified spare parts remains the primary maintenance strategy.

HDS Series Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly sourced models within the Bosch Rexroth HDS series. Models are classified by power stage rating and interface type.

AC Servo Drive Controllers — Standard Current Range:

HDS03.2-W015N-HA12-01-FW: 15 A continuous, SERCOS interface, resolver feedback, standard housing.
HDS03.2-W020N-HA12-01-FW: 20 A continuous, SERCOS interface, resolver feedback, standard housing.
HDS03.2-W040N-HA12-01-FW: 40 A continuous, SERCOS interface, resolver feedback, standard housing.
HDS03.2-W075N-HA12-01-FW: 75 A continuous, SERCOS interface, resolver feedback, standard housing.
HDS03.2-W100N-HT20-01-FW: 100 A continuous, SERCOS + analog interface, resolver/encoder feedback, tall housing (HT20 form factor).
HDS03.2-W150N-HT20-01-FW: 150 A continuous, SERCOS + analog interface, tall housing, high-inertia load optimization.
HDS03.2-W200N-HT20-01-FW: 200 A continuous, maximum current rating in HDS03.2 sub-series, tall housing.

AC Servo Drive Controllers — HDS04 Sub-Series (Enhanced Dynamics):

HDS04.2-W015N-HA12-01-FW: 15 A, enhanced current loop bandwidth, SERCOS interface.
HDS04.2-W020N-HA12-01-FW: 20 A, enhanced dynamics, resolver feedback.
HDS04.2-W040N-HA12-01-FW: 40 A, enhanced dynamics, standard housing.
HDS04.2-W075N-HA12-01-FW: 75 A, enhanced dynamics, SERCOS interface.
HDS04.2-W100N-HT20-01-FW: 100 A, enhanced dynamics, tall housing, high-current bus bar connection.
HDS04.2-W150N-HT20-01-FW: 150 A, enhanced dynamics, tall housing.
HDS04.2-W200N-HT20-01-FW: 200 A, maximum rating in HDS04.2 sub-series, tall housing.

Firmware / Interface Variant:

HDS03.2-W100N-HA12-01-FW: 100 A, standard housing (HA12), SERCOS interface — alternative form factor to HT20 variant.
HDS03.2-W040N-HT20-01-FW: 40 A, tall housing variant for cabinet configurations requiring uniform HT20 depth.

Sourcing Hard-to-Find & Obsolete HDS Series Parts

The HDS series reached end-of-production status, and Bosch Rexroth no longer manufactures new units or provides OEM repair services for most sub-variants. This creates a documented supply gap for facilities operating legacy DIAX04-based motion systems with remaining service life of 5–15 years.

DriveKNMS maintains a dedicated inventory of HDS series drives sourced through controlled decommissioning projects, authorized distributor liquidations, and direct factory surplus channels. Each unit entering our inventory is logged with its firmware revision, hours-of-operation estimate (where available from drive parameter memory), and physical inspection status prior to storage.

For obsolete HDS variants where no direct stock is available, DriveKNMS offers: (1) cross-reference matching to identify functionally equivalent HDS sub-variants with compatible power and interface specifications; (2) coordination with certified Rexroth repair centers for board-level restoration of units with repairable fault conditions; (3) IndraDrive migration consultation for facilities evaluating a controlled platform transition.

Quality Control for the HDS Series Range

HDS series drives present specific test challenges due to their integrated SERCOS fiber interface, multi-axis DC bus sharing architecture, and resolver signal conditioning circuitry. DriveKNMS applies the following test protocol to all HDS units prior to dispatch:

Power Stage Verification: DC bus charge/discharge cycle test at rated voltage (540 VDC nominal). IGBT switching waveform inspection via oscilloscope at 25%, 50%, and 100% of rated current output.

Control Board Functional Test: Firmware boot verification and parameter memory integrity check. SERCOS ring initialization test using a reference SERCOS master controller. Resolver interface signal quality measurement (amplitude, phase, offset).

Thermal Stress Test: 2-hour continuous operation at 70% rated current with thermal imaging to confirm heatsink and IGBT junction temperatures remain within specification.

Final Inspection: Connector pin integrity check (X1, X2, X3, X8 interface connectors). Firmware version documentation and parameter backup where drive memory is accessible. Packaging in anti-static, humidity-controlled enclosure with desiccant.

© 2026 DriveKNMS. All trademarks belong to their respective owners. Specifications are for reference only and subject to change without notice. Verify all parameters against official documentation before installation.