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The Bosch Rexroth HDS03.2-W100N-HT20-01-FW is a 100 A AC servo drive from the DIAX04 series, engineered for high-dynamic motion control in demanding industrial automation environments. As legacy DIAX04 installations age and original units reach end-of-life, plant engineers and maintenance teams face the challenge of sourcing a verified replacement that preserves existing wiring infrastructure, retains SERCOS II or analog command interface compatibility, and fits within the original control cabinet footprint — all while minimising unplanned downtime.
TOPNLMS maintains ready stock of the HDS03.2-W100N-HT20-01-FW sourced from verified supply channels. Each unit undergoes pre-shipment functional verification and ships with a 12-month warranty, giving procurement teams the confidence to plan both emergency replacements and scheduled retrofit projects.
| Parameter | Legacy / Outgoing Unit | HDS03.2-W100N-HT20-01-FW |
|---|---|---|
| Series | DIAX04 / HDS02 / HDS03 earlier firmware | DIAX04 — HDS03.2 |
| Continuous Output Current | Varies (typically 28 A – 100 A range) | 100 A |
| Command Interface | SERCOS II / Analog ±10 V | SERCOS II / Analog ±10 V |
| DC Bus Connection | HVR / HVE / KDA supply modules | Compatible with HVR02, HVE02, KDA03 supply modules |
| Feedback Interface | DSF / MSF resolver or encoder | DSF / MSF — direct motor cable re-use |
| Control Cabinet Width | Standard DIAX04 slot (100 mm) | 100 mm — no mechanical modification required |
| Firmware Slot | HT (standard motion firmware) | HT20 — compatible with existing NC programs |
| Cooling | Forced air / cabinet-integrated | Integrated fan — same mounting clearance |
| Replacement Recommendation | HDS03.2-W100N-HA20, HDS03.2-W100N-HT10 | Direct drop-in for HT-firmware variants |
| Warranty | — | 12 Months from shipment date |
A successful DIAX04 servo drive migration rarely involves a single component. When replacing the HDS03.2-W100N-HT20-01-FW, the surrounding system architecture must be evaluated holistically to ensure the upgraded drive operates reliably from day one.
On the power supply side, the drive draws its DC bus voltage from a regenerative supply module such as the Bosch Rexroth HVR02.2-W018N or the KDA03.2-W110B-BE23-01 mains filter and supply combination. If the existing supply module shows signs of capacitor aging or has accumulated significant operating hours, replacing it alongside the servo drive eliminates a common root cause of nuisance faults after commissioning.
Motor feedback wiring is retained in most DIAX04 retrofits because the MKD and MKE series servo motors use the same DSF/MSF multi-turn encoder interface supported by the HDS03.2. Technicians can reconnect the existing motor power cable (X6) and feedback cable (X8) directly, reducing field labour time significantly. Where motor cables have been routed through cable trays shared with the HCS02 or HCS03 compact servo drives on adjacent axes, shielding continuity should be verified to prevent EMC-induced encoder errors.
The SERCOS II ring topology used in many DIAX04 installations connects the drive to a Bosch Rexroth CLC-D01 or CSH01 motion controller via fibre-optic SERCOS cable. The HDS03.2-W100N-HT20-01-FW supports SERCOS baud rates of 2, 4, 8, and 16 Mbit/s, so the existing ring configuration and IDN parameter set can be transferred without modification. Engineers working with IndraWorks DS or the legacy BTV04 operator panel will find the firmware parameter structure familiar, minimising re-commissioning time.
For installations where the DIAX04 drive communicates via analog ±10 V torque or velocity command from a third-party CNC controller, the X1 command interface pinout is preserved, and no rewiring of the signal terminal block is required. If the control cabinet also houses Bosch Rexroth DIAX04 HDD or HMS01 multi-axis drives, the DC bus bar connection and 24 V control voltage distribution remain unchanged.
In retrofit projects where the control cabinet is being partially modernised, engineers sometimes introduce a Bosch Rexroth NFD03 mains filter or an updated HNF01 line filter module to meet current EMC standards. These components mount on the same DIN rail or panel structure and do not affect the drive’s X2 mains connection. Similarly, if the project scope includes upgrading the HMI, a Bosch Rexroth VDP16 or VDP40 operator panel can be integrated without changes to the drive’s parameter set.
Terminal modules and I/O expansion cards connected to the drive’s X3 digital I/O interface — such as the Bosch Rexroth DAE01 or DAE02 I/O expansion modules — retain full compatibility, preserving the existing PLC ladder logic and I/O address mapping on the host controller.
Q: Can I reuse the existing motor power and feedback cables?
Yes. The HDS03.2-W100N-HT20-01-FW uses the same X6 motor power connector pinout and X8 DSF/MSF feedback interface as earlier DIAX04 HDS03 variants. No cable modification is required in standard MKD/MKE motor applications.
Q: Will my existing NC program and IDN parameter set transfer without changes?
In most cases, yes. The HT20 firmware slot is backward-compatible with HT10 parameter sets. A full parameter backup from the outgoing drive using IndraWorks DS is recommended before replacement, and the saved file can be loaded directly into the new unit during commissioning.
Q: Is the SERCOS II fibre-optic ring connection compatible?
Yes. The drive supports SERCOS II at all standard baud rates. The fibre-optic cables connect to the same X5 SERCOS interface position, and the drive address is set via the S1 rotary switch — identical to the outgoing unit.
Q: What if my cabinet uses a KDA03 supply module instead of HVR02?
The HDS03.2-W100N-HT20-01-FW is compatible with both KDA03 and HVR02 supply modules. The DC bus bar connection and 24 V logic supply wiring are identical across these supply variants.
Q: How much physical space does the drive require?
The drive occupies a 100 mm wide slot in a standard DIAX04 cabinet section. No additional mounting hardware or cabinet modification is required for a direct replacement.
Q: What if the drive was communicating via analog command rather than SERCOS?
The X1 analog command interface (±10 V, differential) is fully supported. The existing signal wiring and shield connections at the terminal block can be reused without modification.
Every Bosch Rexroth HDS03.2-W100N-HT20-01-FW unit shipped by TOPNLMS is covered by a 12-month warranty from the date of shipment. Prior to dispatch, each drive undergoes a pre-shipment inspection that includes visual examination, power-on verification, and firmware version confirmation. Units that do not pass inspection are not shipped.
In the event of a warranty claim, TOPNLMS provides a replacement unit or full refund based on the fault assessment. Our technical support team responds to warranty enquiries within one business day. Customers are not required to return the faulty unit before a replacement is dispatched in confirmed DOA (dead-on-arrival) cases, minimising additional downtime for critical production lines.
For procurement teams requiring documentation, a certificate of conformity and packing list are included with every shipment. Export packaging is designed for international air and sea freight, with anti-static protection and shock-absorbing foam inserts appropriate for sensitive servo drive electronics.
Bulk orders and standing purchase agreements for maintenance stock are supported. Contact our sales team to discuss volume pricing, lead times, and consignment stock arrangements.
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