Bosch Rexroth HDS Series Modules: HDS03.2-W075N-HS12-01-FW

Technical Dossier

Product Details And Specifications

Bosch Rexroth HDS Series: Comprehensive Module Range and Technical Overview

The Bosch Rexroth HDS (High Dynamic Servo) series is one of the most extensively deployed AC servo drive controller platforms in global heavy industry. Installed base coverage spans petrochemical refineries, nuclear power auxiliary systems, offshore drilling rigs, steel rolling mills, and large-scale continuous chemical processing plants. The HDS platform operates within the DIAX04 and ECODRIVE03 drive families, sharing a unified firmware and parameter architecture (P-0-xxxx / S-0-xxxx parameter sets) that enables cross-generation commissioning compatibility. Its modular power section design covers continuous output current ratings from 15 A to 210 A, making it applicable to both compact machine-tool servo axes and high-inertia industrial drive applications. The series supports Rexroth SERCOS I/II fiber-optic fieldbus, analog ±10 V command interfaces, and incremental/absolute encoder feedback systems including EnDat 2.1/2.2, Hiperface, and resolver. As of 2026, the HDS series has entered end-of-life status; Rexroth's IndraDrive family (HCS/HMS/HMD) is the designated functional successor. Installed base volumes in legacy plant infrastructure sustain active demand for HDS spare parts and repair services through at least 2035.

The Evolution of HDS Series Architecture

The HDS series was introduced in the mid-1990s as part of Rexroth's DIAX04 drive system, replacing the earlier DDS (Digital DC Servo) and ADS (Analog Drive System) platforms. First-generation HDS units used DIAX04 firmware loaded via RS-232 serial interface, with parameter storage on EEPROM-based option modules. Hardware revision progression from HDS02.x through HDS03.x and HDS04.x introduced: IGBT switching frequency increases from 4 kHz to 8 kHz; expanded Safe Torque Off (STO) functionality compliant with EN 954-1 Category 3; redesigned heatsink extrusions and internal fan assemblies for improved thermal management; and updated gate driver boards with reduced switching losses. The HDS03.2 sub-series — to which the HDS03.2-W075N-HS12-01-FW belongs — is the mature production variant, rated at 75 A continuous output current with an integrated SERCOS II interface (HS12 option) and the FW final stable firmware branch. Full backward compatibility with DIAX04 parameter sets is maintained across all HDS03.x revisions, enabling direct parameter migration from HDS02.x installations without full recommissioning. Migration to IndraDrive (HCS02/HCS03) requires firmware conversion tooling and new motor encoder adaptation cables, making HDS spare part sourcing a cost-effective alternative for plants not yet scheduled for full drive replacement programs.

HDS Series Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly sourced models within the Bosch Rexroth HDS series, classified by functional category and current rating:

High-Power Servo Drive Controllers (75 A – 210 A)

• HDS03.2-W075N-HS12-01-FW: 75 A continuous, SERCOS II (HS12), DIAX04 firmware, standard forced-air cooling
• HDS03.2-W100N-HS12-01-FW: 100 A continuous, SERCOS II interface, enhanced IGBT module assembly
• HDS03.2-W150N-HS12-01-FW: 150 A continuous, high-inertia load rated, SERCOS II, dual fan cooling
• HDS03.2-W210N-HS12-01-FW: 210 A continuous, maximum-power HDS03.2 variant, forced-air cooling
• HDS04.2-W075N-HS12-01-FW: 75 A, HDS04 hardware revision, improved EMC filter stage, SERCOS II
• HDS04.2-W100N-HS12-01-FW: 100 A, HDS04 series, updated gate driver board, SERCOS II
• HDS04.2-W150N-HS12-01-FW: 150 A, HDS04 series, dual fan assembly, extended MTBF rating

Mid-Range Servo Drive Controllers (15 A – 50 A)

• HDS02.2-W015N-HA02-01-FW: 15 A continuous, analog ±10 V command, resolver feedback input
• HDS02.2-W025N-HA02-01-FW: 25 A continuous, analog interface, incremental encoder input
• HDS02.2-W040N-HA02-01-FW: 40 A continuous, analog command, EnDat 2.1 compatible feedback
• HDS03.2-W040N-HS12-01-FW: 40 A, SERCOS II, DIAX04 parameter set, compact chassis footprint
• HDS03.2-W050N-HS12-01-FW: 50 A continuous, SERCOS II, standard HDS03.2 chassis dimensions
• HDS04.2-W040N-HS12-01-FW: 40 A, HDS04 hardware, SERCOS II, updated control board revision

Analog Interface & SERCOS I Variants

• HDS03.2-W075N-HA02-01-FW: 75 A, analog ±10 V command variant, same power section as HS12 model
• HDS03.2-W075N-HS02-01-FW: 75 A, SERCOS I optical interface (2 Mbit/s), DIAX04 firmware
• HDS03.2-W100N-HA02-01-FW: 100 A, analog command interface, Hiperface encoder support
• HDS02.2-W050N-HA02-01-FW: 50 A, analog interface, HDS02 hardware, resolver and incremental encoder

Sourcing Hard-to-Find & Obsolete HDS Series Parts

Bosch Rexroth formally discontinued active production of the HDS series, with end-of-life notifications issued between 2018 and 2022 by sub-series. OEM spare part channels have progressively depleted stock; lead times through authorized distributors for units such as the HDS03.2-W075N-HS12-01-FW now routinely exceed 26 weeks where stock exists at all. DriveKNMS maintains a dedicated inventory program for HDS series lifecycle extension, sourcing units through verified industrial surplus channels, decommissioned plant equipment, and controlled-environment storage facilities. All units undergo full functional testing prior to dispatch. For plants operating on 5–15 year maintenance cycles where full IndraDrive migration is not yet budgeted, DriveKNMS provides a cost-effective alternative to unplanned downtime caused by drive failure. Customers operating multiple HDS axes are encouraged to submit complete drive lists for consolidated sourcing and volume pricing. Emergency same-day dispatch is available for critical process applications.

Quality Control for the HDS Series Range

The HDS series presents specific quality control requirements due to its multi-board architecture: the control board (CSB), power interface board (PIB), IGBT driver board, and option module (SERCOS or analog) are each verified independently before system-level testing. DriveKNMS applies the following protocol to all HDS units: (1) Visual inspection of DC bus capacitor banks for electrolytic degradation and case deformation. (2) IGBT static and dynamic switching tests at rated gate voltage using a dedicated power semiconductor tester. (3) Control board power-up with isolated 24 VDC supply, firmware version verification, and fault memory readout via RS-232 diagnostic interface. (4) Full closed-loop servo test on a motor test bench at 25%, 50%, and 100% rated current, verifying current loop bandwidth, velocity loop stability, and encoder feedback integrity. (5) SERCOS ring integration test (for HS12 variants) confirming phase 2 and phase 4 communication establishment at 4 and 8 Mbit/s. (6) Thermal soak at 45°C ambient for 2 hours under 75% load, with post-soak re-verification of all parameters. Units passing all six stages are issued a DriveKNMS test certificate and dispatched with original or equivalent packaging.

© 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.