Bosch Rexroth DKC Series Modules: DKC03.3-040-7-FW

Technical Dossier

Product Details And Specifications

Bosch Rexroth DKC Series: Comprehensive Module Range and Technical Overview

The Bosch Rexroth DKC series — commercially designated as the DIAX04 / EcoDrive03 platform — represents one of the most widely deployed AC servo drive families in global heavy industry. Installed across petrochemical refineries, nuclear power auxiliary systems, offshore drilling rigs, steel rolling mills, and large-scale chemical processing plants, the DKC platform has accumulated a multi-decade field record in environments demanding continuous duty cycles, high dynamic response, and deterministic motion control. Its modular architecture, standardized SERCOS and PROFIBUS communication interfaces, and broad power range (from 2.5 A to 200 A continuous output current) made it the default servo drive specification for machine builders and plant engineers throughout the 1990s and 2000s. As of 2026, the DKC series is in its end-of-production lifecycle; however, installed base volumes remain substantial, sustaining active demand for spare parts, repair services, and firmware-compatible replacement units.

The Evolution of DKC Series Architecture

The DKC platform evolved through three distinct firmware and hardware generations, each introducing expanded communication options and refined power stage designs:

Generation 1 — DIAX04 Foundation (FW firmware prefix, ~1994–2000): The original DKC hardware used analog resolver feedback and supported SERCOS I fiber-optic ring topology. Firmware versions were identified by the suffix -FW (e.g., DKC03.3-040-7-FW). These units operated on 400 V AC three-phase input and communicated via the SERCOS interface at 2 or 4 Mbit/s. Compatibility with IndraControl L and V controllers was established in this generation.

Generation 2 — EcoDrive03 Expansion (~2000–2008): Introduced PROFIBUS-DP and DeviceNet communication options (firmware suffix -ET, -PB). Power density increased; the physical form factor remained backward-compatible with Generation 1 mounting rails and DC bus bars. Encoder feedback expanded to include EnDat 2.1 and Hiperface digital protocols.

Generation 3 — IndraDrive Migration Path (~2008–present): Bosch Rexroth introduced the IndraDrive C (HCS) and IndraDrive M (HMS/HMD) series as the designated successors. Direct parameter migration tools (IndraWorks DS) were provided to convert DKC project files. The IndraDrive platform supports SERCOS III (Ethernet-based), EtherCAT, and PROFINET, while maintaining functional equivalence for most DKC motion programs.

Compatibility note: DKC units within the same current class (e.g., 040 = 40 A) are generally interchangeable at the hardware level, provided firmware versions match the controller's project file. Cross-generation firmware substitution is not supported without re-parameterization.

DKC Series Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly stocked models within the Bosch Rexroth DKC / DIAX04 / EcoDrive03 product family. Models are classified by functional category.

AC Servo Drive Controllers — SERCOS Interface (FW Firmware)

DKC01.1-030-7-FW: 30 A, SERCOS, single-axis servo drive, resolver feedback, 400 V AC input.
DKC01.1-040-7-FW: 40 A, SERCOS, single-axis servo drive, resolver feedback, standard power stage.
DKC01.1-100-7-FW: 100 A, SERCOS, high-current servo drive for large-frame motors.
DKC01.3-040-7-FW: 40 A, SERCOS, Generation 1.3 hardware revision, enhanced EMC filtering.
DKC02.3-040-7-FW: 40 A, SERCOS, dual-axis capable variant, compact panel footprint.
DKC03.3-040-7-FW: 40 A, SERCOS, Generation 3.3 hardware, improved thermal management, this listing.
DKC03.3-100-7-FW: 100 A, SERCOS, Generation 3.3, high-power single-axis controller.
DKC03.3-200-7-FW: 200 A, SERCOS, maximum current class in the DKC03.3 sub-series.
DKC11.3-040-7-FW: 40 A, SERCOS, economy variant, reduced I/O count, cost-optimized BOM.

AC Servo Drive Controllers — PROFIBUS Interface (ET/PB Firmware)

DKC01.1-040-7-ET: 40 A, PROFIBUS-DP, EcoDrive03 firmware, fieldbus-native parameterization.
DKC03.3-040-7-ET: 40 A, PROFIBUS-DP, Generation 3.3 hardware, direct Siemens S7 integration.
DKC03.3-100-7-ET: 100 A, PROFIBUS-DP, high-current fieldbus drive for heavy-duty axes.

Power Supply / Regenerative Supply Modules

HVR02.2-W018N: Regenerative power supply, 18 kW, DC bus feed for DKC multi-axis configurations.
HVE02.2-W018N: Non-regenerative mains filter supply, 18 kW, standard plant grid interface.
HZK01.1-W0018: DC bus capacitor module, energy buffer for multi-axis DKC installations.

Communication & Feedback Accessories

IKS4044: SERCOS fiber-optic cable assembly, standard ring topology interconnect for DKC nodes.
IKS0223: Resolver feedback cable, pre-assembled, DKC-to-motor standard pinout.

Sourcing Hard-to-Find & Obsolete DKC Series Parts

Bosch Rexroth formally discontinued new production of the DKC series. OEM spare part availability through authorized distribution channels is limited to existing warehouse stock, which continues to deplete. For plant operators running DKC-based motion systems with remaining service lives of 5–15 years, third-party specialist sourcing is the primary procurement channel.

DriveKNMS maintains a dedicated inventory program for the DKC / DIAX04 / EcoDrive03 family, covering the following support categories:

New-Old-Stock (NOS) Units: Factory-sealed DKC modules sourced from decommissioned OEM inventory and authorized surplus channels. Each unit is verified against Bosch Rexroth part number databases before listing.

Tested Serviceable Units: Previously installed DKC drives that have undergone full functional testing, firmware verification, and parameter reset. Supplied with test reports.

Repair & Exchange: Customers may submit failed DKC units for board-level repair. Common failure modes addressed include IGBT power stage failure, DC bus capacitor degradation, resolver interface circuit faults, and SERCOS transceiver failure.

Firmware Matching: DriveKNMS stocks DKC units across firmware generations (-FW, -ET, -PB). Customers are advised to specify the existing firmware suffix when ordering to ensure project file compatibility without re-parameterization.

Quality Control for the DKC Series Range

The DKC series presents specific technical challenges during incoming inspection and functional verification, owing to its SERCOS fiber-optic communication architecture and multi-layer DC bus design. DriveKNMS applies the following test protocol to all DKC units processed through its facility:

Step 1 — Visual and Mechanical Inspection: Examination of power connector condition, DC bus bar contact surfaces, control board capacitor condition (visual bulge/leak check), and fiber-optic transceiver port integrity.

Step 2 — Insulation Resistance Test: 500 V DC megohm test between power terminals and chassis ground. Minimum acceptance threshold: 10 MΩ.

Step 3 — DC Bus Energization (Soft-Start): Controlled ramp-up of DC bus voltage using a variable autotransformer to pre-charge bus capacitors and verify no crowbar or overvoltage fault activation.

Step 4 — Firmware Version Verification: Connection via RS-232 diagnostic port and IndraWorks DS software to read firmware version string, serial number, and parameter set integrity checksum.

Step 5 — SERCOS Ring Communication Test: Integration into a test SERCOS ring with a reference IndraControl L controller. Verification of phase progression (Phase 0 → Phase 4), cyclic data exchange, and drive enable response.

Step 6 — Motor Load Test: Closed-loop operation with a reference servo motor at rated current (40 A for DKC03.3-040-7-FW). Verification of speed regulation accuracy, current loop bandwidth, and thermal performance over a 30-minute duty cycle.

All test data is logged and retained for 24 months. Test reports are available upon request for units supplied to nuclear, pharmaceutical, and defense-regulated facilities.