Description
Rexroth HDS02.2-W040N-HS12-01-FW | 40A Servo Drive
Dynamic Product Introduction
The important detail with this drive is the system architecture. The HDS02.2-W040N-HS12-01-FW is the controller section of a DIAX04 servo system, not a simple wall-powered servo amplifier that can be evaluated in isolation. It uses the shared DC-bus concept of the DIAX04 platform, with the HVE/HVR power-supply family providing the system power architecture. Rexroth documentation lists the HDS02.2-W040N among the drive controllers used with these supply units.
The W040N designation identifies the 40 A class HDS controller, while the complete suffix carries configuration information that matters during replacement. Secondary technical records specifically identify HS12 with the SERCOS interface and describe the unit as an internally fan-cooled HDS controller.
This is therefore a classic migration and spare-parts situation: the correct replacement is determined by the complete type code, firmware, installed option modules, feedback interface, motor data, and machine parameter set. Substituting another 40 A HDS unit solely on current rating can still produce a commissioning failure.
HDS02.2-W040N-HS12-01-FW
Key Technical Specifications
- Full Type Code: HDS02.2-W040N-HS12-01-FW
- Manufacturer: Bosch Rexroth / Indramat
- Drive Family: DIAX04
- Controller Series: HDS02.2
- Rated Current: 40 A
- Cooling Designation: W — internal air cooling / integrated blower
- Control Voltage: 24 VDC class
- Power-System Architecture: Shared DC bus
- Nominal DIAX04 DC Bus: Approximately 510 VDC in secondary technical records
- DC Bus Operating Family: Approximately 530–670 VDC is documented for related DIAX04 drive-controller configurations
- Basic Power Loss: Approximately 45 W
- Power Dissipation at Continuous Current: Approximately 125 W
- Weight: Approximately 6.5 kg
- Protection Class: IP20
- Ambient Rating Reference: +5°C to +45°C for nominal controller data
- HS12: SERCOS-related interface configuration
- Function ID: 12
- Function Version: 01
- Firmware: FW — supplied/selected separately
- Motor Interface: AC servo motor through the DIAX04 drive architecture
- Feedback: Dependent on installed interface/configuration
- Mounting: cabinet/booksize drive arrangement
Rexroth’s published ratings identify 40 A maximum output current for the HDS02.2-W040N and approximately 125 W power dissipation at continuous current. The same documentation gives the HDS unit’s weight as approximately 6.5 kg.
I would not publish a specific motor power in kW for this exact configuration. Motor power depends on the motor voltage, speed, duty cycle, DC-bus conditions, and application configuration; the 40 A controller rating alone does not establish one universal motor-power figure.
Global Sourcing & Live-Test SOP
1. Inbound identity verification
- Photograph the complete type plate.
- Confirm .2–HS12-01-FW character by character.
- Record serial number and hardware revision.
- Confirm the designation rather than assuming the interface from the cabinet position.
- Inspect option/interface modules installed in the controller.
- Check the blower, air passages, terminal blocks, connectors, and mounting hardware.
- Look for heat discoloration around power terminals and DC-bus connections.
- Preserve any original configuration labels.
The configuration type plate is particularly important on equipment because it identifies the configured drive controller, basic unit, software module, and plug-in modules.
2. Electrical inspection
Before applying power:
- Verify the complete power-supply arrangement.
- Confirm DC-bus voltage is appropriate for the installed HDS configuration.
- Inspect DC-bus polarity and cabling.
- Verify the 24 VDC control supply.
- Check protective earth continuity.
- Inspect motor power and feedback connectors.
- Do not energize the controller from an improvised DC source without confirming the applicable Rexroth power architecture.
3. Drive/controller functional test
A proper bench or machine test should verify:
- Controller startup.
- Diagnostic display/status.
- Blower operation.
- DC-bus acceptance.
- Control-voltage operation.
- SERCOS communication where the appropriate master and test architecture are available.
- Feedback recognition.
- Parameter access.
- Fault history.
- Motor identification and configuration.
- Controlled low-speed motor operation before progressing to rated operating conditions.
The legacy .2 platform requires appropriate configuration software and interface hardware; modern laptops should not be assumed to communicate directly with the drive without the correct legacy tooling. A recent technical reference specifically identifies DriveTop as the relevant configuration environment for this generation.
4. Heat-run screening
For used or refurbished inventory, run the controller under a controlled motor/load condition and monitor:
- DC-bus voltage
- 24 VDC control supply
- Motor current
- Drive temperature
- Blower operation
- Diagnostic status
- Feedback stability
- SERCOS communication
- Fault history
A prolonged run is especially useful for detecting blower degradation and thermal faults that will not appear during a five-minute power-up.
5. Final preparation
Record:
- Exact type code
- Serial number
- Firmware identification
- Parameter backup
- Installed option modules
- Feedback configuration
- Test measurements
- Alarm/fault history
Seal the controller in ESD-safe packaging and protect the connectors and blower openings during shipment.
Field Engineer’s Pitfall Guide
❗ Firmware is part of the replacement decision
The final FW designation should not be interpreted as meaning that every .2 controller is automatically ready for the same machine. Rexroth’s configuration system separates the controller hardware from software modules and installed option hardware. The complete configuration type plate therefore matters when selecting a replacement.
For a machine that has been running for years, preserve the original parameter set before attempting a firmware change or migration.
❗ is not a generic Ethernet interface
The configuration is associated with the SERCOS communication architecture. Do not replace it with a visually similar HDS controller carrying a different command/interface configuration and expect the existing CNC or PLC to establish communication.
This is one of those cases where the connector can physically fit while the machine-level communication architecture does not.
❗ Do not confuse controller current with complete machine power rating
The 40 A rating belongs to the .2- controller. It does not by itself tell you the exact motor horsepower/kW that can be connected in every application.
Motor selection, speed, DC-bus voltage, duty cycle, acceleration requirements, regenerative energy, and the associated power supply all affect the usable operating envelope.
Intent-Driven FAQ
What is the .2—01-FW?
It is a Bosch Rexroth Indramat .2 servo drive controller rated at 40 A. The configuration is associated with the SERCOS command/communication architecture.
Is .2—01-FW a complete servo system?
No. It is the drive controller. The complete installation also requires the appropriate power supply/DC-bus architecture, motor, feedback arrangement, command interface, cabling, and application-specific parameters.
What is the current rating?
The .2- is a 40 A class controller. Rexroth’s ratings documentation also lists approximately 125 W power dissipation at continuous current.
What cooling does it use?
The W configuration uses internal air cooling with an integrated blower. A failed or restricted blower should therefore be treated as a serious maintenance issue rather than an incidental noise problem.
Does it use SERCOS?
The configuration is identified with the SERCOS interface in current secondary records. Verify the physical communication module and machine-side SERCOS hardware before ordering a replacement.
Can I replace it with another .2-?
Not solely on the basis of the 40 A rating. Compare the complete type code, interface configuration, installed option modules, firmware/software, feedback system, and machine parameters.
Is the firmware included?
The FW designation refers to the firmware/software configuration, but the actual machine-ready firmware and parameter set must be verified against the specific controller. Do not assume that a surplus controller carrying the same base model is programmed for the customer’s machine.
What should I ask a supplier before purchasing?
Request photographs of the complete type plate, serial number, option/interface modules, and connectors. For a refurbished unit, ask for a powered test report showing DC-bus operation, blower operation, diagnostics, communication, and—where feasible—motor/feedback operation.
Procurement description: Bosch Rexrnat .2-, .2 40 A servo drive controller, /SERCOS configuration, internal blower cooling.
