Month: February 2026

The official operation manual for Bosch Rexroth IndraControl VDP 16.3/VDP 40.3/VDP 60.3 series operator displays (March 2014 version) revolves around safety specifications, product parameters, assembly wiring, debugging and maintenance, and service support. It specifies that the three models are equipped with 12 inch (800 × 600 pixels), 15 inch (1024 × 768 pixels), and 19 inch (1280 × 1024 pixels) TFT displays, with a protection level of IP65 (front panel)/IP20 (rear panel), supporting touch/button operations and CDI/USB/XSER/XVID interfaces. It provides detailed specifications for 24V power supply connection, cable selection (such as CDI cable with a maximum length of 50 meters), installation spacing (≥ 50mm around the perimeter), and troubleshooting process. The product complies with UL/CSA/CE certification and provides full process operation guidance for professionals in industrial scenarios such as machine tools and packaging machinery.

Core technical parameters

Parameter category VDP 16.3 VDP 40.3 VDP 60.3 Remarks

Display screen specifications include 12 inch TFT, 800 × 600 pixel 15 inch TFT, 1024 × 768 pixel 19 inch TFT, and 1280 × 1024 pixel, all of which support 16.7 million colors

Operation mode: Touch/Button (some models) Touch/Button/Touch+Button Touch Operation button models include 16 M keys (L1-L8/R1-R8)

Protection level: front panel IP65, rear panel IP20, front panel IP65, rear panel IP20, front panel IP65, rear panel IP20 in accordance with DIN EN 60529

Power supply requirement: DC 24V, current consumption: 0.85A DC 24V, current consumption: 1.05A DC 24V, current consumption: 1.7A. The power supply must comply with DIN EN 60742 standard

Power loss 20W, 25W, 40W-

USB interface front panel 1 (some models)+back panel 4 front panel 1 (some models)+back panel 4 front panel 1+back panel 4 single port maximum 500mA, total current ≤ 1A

Equipment weight 4.0kg 5.8kg 7.3kg-

External dimensions (width × height) 350 × 290mm (standard)/360 × 300mm (customized) 407 × 370mm (standard)/417 × 380mm (customized) 483 × 400mm Installation depth of 41mm

Key points of safety regulations

（1） Electrical safety

The power supply must comply with overvoltage category II, and the 230V/400V wiring must strictly distinguish between phase lines, neutral lines, and protective grounding (PE). The cross-sectional area of the protective grounding wire should be ≥ 6mm ² (green/yellow).

It is prohibited to connect power units suitable for low voltage (such as 24V) to non design supply voltage to avoid the risk of electric shock.

Functional grounding (FE) must be connected, otherwise the potential difference between VDP and PC may damage electronic components when the voltage is interrupted and restored.

（2） Operational safety

The touch screen is only allowed to be operated with fingers or a dedicated touch pen (part number 1070923266), and sharp objects are prohibited to avoid damaging the screen or front panel.

Do not use solvents (such as diluents) and high-pressure cleaning equipment during cleaning to prevent damage to the film surface and seals.

The equipment needs to be installed vertically with a maximum deviation of ± 45 °. A space of ≥ 50mm should be reserved around it for heat dissipation and cable layout to avoid blocking the LED indicator lights on the connectors.

（3） Compliance requirements

The product complies with the EMC Directive 2004/108/EC and follows EN 61000-6-4 (emission standard) and EN 61000-6-2 (immunity standard).

It has been certified by UL508 (Industrial Control Equipment) and CSA C22.2 No.142-M1987, with UL document number E210730. The certification is only valid in the delivery state and needs to be revalidated after modification.

Assembly and connection specifications

（1） Installation requirements

Installation Cut Size (Table): | Model | Installation Cut Width × Height (mm) | Installation Bolt Hole Diameter (mm) | Bolt Quantity | | —- | —- | —- | | | | | VDP 16.3 | 335 × 275 | 5 | 8 | | | VDP 40.3 | 392 × 355 | 5 | 8 | | VDP 60.3 | 463 × 370 | 5 | 8|

Tightening torque: 0.4Nm for M2.5 bolts, 0.7Nm for M3 bolts, 1.4Nm for M4 bolts, and 2.8Nm for M5 bolts to avoid damaging mechanical structures due to improper torque.

Cable layout: CDI cables should be kept away from interference sources such as motor cables, with a bending radius of ≥ 4 times the cable diameter (during installation) and ≥ 8 times the cable diameter (during permanent movement), to avoid mechanical stress (tension, torsion, etc.).

（2） Wiring specifications

Power supply connection: Connect a 24V power supply through the X1S1 interface, with pin 1 being+24V, pin 2 being 0V, and pin 3 being empty. Copper wires are required, and it is recommended to use VAP01.1H-W23-024-010-NN power supply unit (part number R911171065).

Control cabinet PC connection: Connected through CDI interface (XSER purple/RJ45 data interface, XVID black/RJ45 image interface), requires the use of 2 dedicated CDI cables, with a maximum distance of VDP 16.3 (80 meters), VDP 40.3 (70 meters), VDP 60.3 (60 meters), exceeding which Y-Repeater (VAC01.1S-YD1-NNN, part number R911171187) is required.

USB connection: USB 2.0 cable up to 5 meters long, high anti-interference USB cable (such as RKB0050/001.0, part number R911172944) is required for noisy environments. XUSBIN interface (Type B) is used to connect to the control cabinet PC, up to 5 meters long.

（3） DIP switch settings

S1/2 switch: OFF (CDI cable length ≤ 30 meters), ON (CDI cable length>30 meters), S1/1 has no function.

USB speed: When the cable is ≤ 5 meters and S1/2=OFF, it supports 480Mb/s (additional USB cable is required); When the cable is greater than 5 meters, the speed is 12Mb/s and USB hubs are not supported.

Debugging and maintenance

（1） Debugging

The product does not require configuration and can be used directly. When starting, the VDP power supply needs to be turned on first or turned on simultaneously with the control cabinet PC to ensure normal screen display.

Resolution setting: The corresponding resolution (VDP 16.3:800 × 600) needs to be set in the graphics card driver of the control cabinet PC; VDP 40.3：1024×768； VDP 60.3:1280 × 1024), after setting, restart the PC to take effect.

（2） Maintenance points

Regular maintenance: Check the tightness of the plug and terminal connection and whether the cable is damaged at least once a year. Damaged parts should be replaced immediately.

Backlight management: The backlight life is about 50000 hours (in a 25 ℃ environment), and the backlight off time can be set through the “Power Options” in the Windows Control Panel to extend its service life.

Cleaning requirements: Use a dry soft cloth for cleaning, avoid solvents and high-pressure water flow, and avoid seal failure that may cause a decrease in protection level.

（3） Troubleshooting (Table)

Possible causes and solutions for the fault phenomenon

No image display power supply not connected, CDI cable reversed, resolution setting error check X1S1 power supply, reconnect CDI cables (XSER-XSER, XVID-XVID), set correct resolution and restart PC

USB devices cannot be used due to excessively long cables, improper DIP switch settings, replacement of ≤ 5-meter USB cables, and setting S1/2 switches based on CDI cable length

Touch screen unresponsive and uncalibrated, driver issues recalibrate touch screen, confirm pre installed English keyboard driver unchanged

Screen resolution error. Improper graphics card driver settings. Select the corresponding model resolution in the graphics card driver and restart the PC

Environmental disposal

The product can be returned to Bosch Rexroth AG for free disposal, provided that there is no oil, grease, or other contaminants. The return address is Bosch Rexroth AG, Electric Drives and Controls, B ü rgermeister Dr. Nebel Stra ß e 2, 97816 Lohr am Main, Germany.

Packaging materials (cardboard, plastic, wood, polystyrene) are recyclable and do not need to be returned; The product contains electronic components and metals, which need to be classified and recycled to avoid environmental pollution.

The official use manual of Bosch Rexroth MSK series synchronous servo motors (including 15 frame sizes and models such as MSK030/040/050) (March 2021), which focuses on safety specifications, product parameters, transportation and storage, assembly wiring, commissioning and operation, maintenance and repair, and environmental protection disposal, defines key specifications such as motor protection level IP65 (optional IP67), ambient temperature 0-40 ℃, insulation level 155, and bearing service life 30000 hours, specifies two installation methods of flange/anchor, power supply/encoder/coolant connection requirements, commissioning measures after long-term storage, and troubleshooting procedures, provides full life cycle operation guidance for professionals, and products comply with low-voltage directive 2014/35/EU and other standards.

Core technical parameters

Parameter category, specific specifications, remarks

Protection level IP65 (standard), IP67 (sealed air accessory) motor housing/output shaft in plugged in state

Environmental conditions: working temperature 0-40 ℃, storage temperature -20~+60 ℃, installation height 0-1000m

Insulation class 155 (EN 60034-1)-

Bearing life nominal L ₁₀ h=30000 hours Permanent lubrication deep groove ball bearings

Sound pressure level ＜ 75dB (A)-

Installation types IM B5 (flange drive side) and IM B35 (foot assembly) comply with EN 60034-7

Encoder type: Single cycle (S1/S2/S3), multi cycle (M1/M2/M3) signal period 16-2048, supporting Hiperface/EnDet 2.1

Keep the brake optional, 24V DC ± 10%, torque 10.0Nm, electric release type

Cooling method: natural convection, surface ventilation (fan unit), liquid cooling (FN model), liquid cooling inlet pressure ≤ 6bar

Key points of safety regulations

（1） Electrical safety

Only skilled electricians are allowed to operate. Before starting work, power off, prevent accidental closing, ground short circuit, and shield adjacent live parts.

When the rotor of a permanent magnet motor rotates, a voltage greater than 60V will be generated at the terminal, and the motor must be stopped before operation. It is forbidden to plug or unplug connectors while they are live.

Encoder, KTY84 and other components contain electrostatic sensitive devices (ESD) and must comply with anti-static measures.

（2） Mechanical safety

Suitable equipment (lifting eye bolts) must be used for lifting. It is strictly prohibited to walk under suspended loads or to grip shafts or fan covers during lifting.

Rotating components need to be equipped with cover plates, and the longitudinal axis needs to be mechanically locked or externally braked to prevent sinking after stopping the machine.

When installing transmission components (couplings/pulleys), it is forbidden to strike the shaft end to avoid exceeding the allowable radial/axial force.

（3） Special protection

Electromagnetic fields pose health risks to wearers of pacemakers and metal implants. Such individuals are prohibited from approaching and should consult a doctor.

The surface operating temperature of the motor may exceed 70 ℃, and it needs to be cooled for at least 15 minutes before touching. If necessary, anti contact protective devices should be installed.

Recharging/disassembling/using open flames is prohibited for batteries, and discarded batteries must be separately recycled.

Transportation and Storage Standards

（1） Transportation requirements

Original packaging is required, in accordance with DIN EN 60721-3-2 classification (2K2, 2B1, etc.), transportation temperature -20~+80 ℃, relative humidity ≤ 75% (+30 ℃).

Before transporting liquid cooled motors, it is necessary to drain the coolant to prevent damage from frost; Fix the lifting ring bolts during lifting to avoid strong vibrations.

（2） Storage requirements

The storage environment should be dry, dust-free, vibration free, and dark, with a temperature of -20~+60 ℃, a relative humidity of 5-95% (no condensation), and no salt spray.

Long term storage measures (table):

Storage duration, motor debugging measures, cable/joint debugging measures

Visual inspection in January showed no damage

Replace the brake surface in December, inspect the electrical contacts, run for 1 hour without load (800-1000rpm) to check the electrical contacts, and visually inspect the cable sockets

Additional replacement of bearings, encoders, and measurement of insulation resistance in June-

Assembly and connection specifications

（1） Installation method

Flange assembly (table):

Installation hole diameter (mm), screw specification, tightening torque (Nm), washer requirements

4.5 M4 × 20 3 None

6.6 M6 × 20 10.1 None

9 M8 × 20 24.6 requires a washer

11 M10 × 30 48 requires washer

14 M12 × 40 84 requires a washer

18 M16 × 35 206 requires a washer

Foot assembly: Align the motor shaft with the centerline of the connecting shaft. Radial force is only effective within ± 15 ° of the vertical installation surface. It is prohibited to transmit force to the foot through gears.

（2） Wiring specifications

Power connection: Supports M23/M40/M58 connectors or junction boxes (RZK3100/RKL1200, etc.), wire cross-sectional area of 1.5-35mm ², tightening torque of 2.5-3.8Nm.

Encoder connection: 8-16 pole connector, the shielding layer needs to be reliably grounded, the equipment connector can rotate 210 °~220 °, and the maximum tightening torque is 12-18Nm.

Coolant connection (liquid cooling model): The inlet/outlet can be freely distributed. The frame size is 071/075, and the tightening torque is 14-15Nm. 101/133 is 18-20Nm. It is prohibited to use Teflon tape for sealing.

（3） Accessory assembly

Fan unit: Supports 115V/230V (single-phase) and 400V (three-phase), connected according to the nameplate voltage, integrated with thermal protection device, and the fan cover needs to reserve an encoder connection cover plate.

Air pressure connector: Working pressure of 0.1 ± 0.05 bar, SUP-M01-MSK (encoder side)/SUP-M02-MSK (power side) kit is required, with a tightening torque of 1.3-3.1 Nm.

Debugging and Running

（1） Debugging prerequisites

Confirm the storage duration of the motor and implement corresponding debugging measures; Check that all connectors are securely connected and that the brake voltage is 24V ± 10%.

Verify that the brake function is normal, the protection key is fixed, and there are no residual transport locking devices.

（2） Operation monitoring

During operation, it is necessary to comply with the environmental and technical parameters in the project planning manual, and monitor abnormal noise and vibration increments.

Regularly check the cleanliness of the motor/fan, the sealing of the coolant interface, pay attention to the diagnostic error messages of the controller, and stop the drive in case of abnormalities.

（3） Troubleshooting (Table)

Possible causes and solutions for the fault phenomenon

Motor not running, controller enable signal missing, power supply voltage missing, brake not released activation enable signal, check power supply, verify brake activation status

Abnormal vibration, poor balance of coupling components, insufficient alignment of shaft end attachments, loosening of installation screws, rebalancing of components, calibration of attachments, and locking of screws according to specifications

High operating noise, foreign objects inside the motor, damaged bearings, and shutdown. Contact the manufacturer for repair after shutdown

Motor temperature exceeds rated load, heat dissipation is damaged, temperature sensor is not connected to reduce load, clean motor/check fan/cooling circuit, connect sensor

Maintenance and environmental disposal

（1） Maintenance points

Cleaning and maintenance: Regularly (no later than 1 year) clean the surface of the motor to avoid dust covering and affecting heat dissipation; The connecting cable needs to be checked for damage, and the drag chain needs to be checked for defects.

Spare parts replacement: It is recommended to replace the bearings after 30000 hours; Visually inspect the shaft sealing ring after 5000 hours and replace it if necessary; Only use Rexroth original spare parts.

（2） Environmental disposal

Product Ingredients: Steel, Aluminum, Copper, Permanent Magnet, Electronic Components, Can be Classified and Recycled; The packaging materials (cardboard/wood/polystyrene) can be routinely recycled.

Permanent magnets need to be demagnetized before disposal, and it is prohibited to transport magnetized rotors; Waste batteries need to be recycled according to the national dedicated system to avoid pollution.

The official troubleshooting guide for Bosch Rexroth ECODRV DKC01.1/DCC11.1 series drive controllers revolves around four categories of diagnostic messages (error/warning/command/status), with detailed definitions of the causes, troubleshooting steps, and solutions for each diagnostic message. It covers 23 types of error messages (such as F218 radiator overheating shutdown), 22 types of warning messages (such as E250 radiator overheating warning), 33 types of command messages (such as C100 communication phase 3 transition check), and 16 types of status messages (such as A100 torque mode). It also provides replacement processes for drives, motors, and cables, as well as global customer service contact information, providing core guidance for maintenance personnel to quickly locate faults and efficiently repair.

Diagnostic message system

（1） Message classification and structure

Classification rules: Divided into four categories based on their functions, distinguished by specific letters starting with them. The priority order is: error message>warning message>command message>status message.

Structure composition: Each diagnostic message contains a “diagnostic number+diagnostic text”, for example, “F2/28 excessive output error”. The number is displayed alternately on the H1 screen, and the complete text can be viewed for parameter S-0-0095.

（2） Detailed Explanation of Core Diagnostic Messages (Table Summary)

The message type represents the core cause of the message and key solutions

Error message (starting with F) F218 radiator overheating shutdown environment temperature>45 ℃, radiator dirty, fan failure cooling cleaning/driver replacement

F219 motor overheating shutdown motor overload, temperature monitoring line fault inspection load/repair circuit

F226 undervoltage error, power interruption, abnormal power supply check, power supply logic/restore power supply

F229 encoder quadrant error encoder cable damage, insulation interference replacement cable/separation of power line and encoder line

F860 power level short circuit overcurrent motor cable short circuit, drive power level fault check cable/replace driver

Warning message (starting with E) E250 radiator overheating warning Internal fan failure, insufficient heat dissipation in control cabinet Replace driver/install air conditioner

E251 motor overheating warning, continuous torque exceeding allowable value, inspection of motor installation/operating conditions

E254 did not return to zero absolute positioning command, did not execute return to zero, executed return to zero operation/selected relative positioning

E256 torque limit=0 parameter setting error, analog channel overload adjustment parameter S-0-0092/reducing analog voltage

Command message (starting with C/D) C101 communication parameter invalid parameter mode switch, invalid parameter connection DriveTop software correction parameter

C600 Drive Control Zero Return Command Activated but Drive Not Enabled Enable Drive Restart Command

D903 inertia detection failed due to low acceleration and excessive load inertia, increasing torque limit/improving positioning speed

Status message (starting with A/J) A100 torque mode drive operates in torque control mode and switches to speed/position mode as required

A203 position mode driver works in position control mode (stepper interface) to confirm that the command signal matches the parameters

The AF drive enable signal has been applied, and the drive is ready to operate normally without intervention

Key troubleshooting points

（1） High frequency fault classification and handling

Temperature related faults

Common reasons: excessive environmental temperature, blocked heat dissipation channels, fan failure, and excessive energy feedback.

Handling principle: Warning types (E250/E251/E252) need to be processed within 30 minutes; Shutdown type (F218/F219/F220) requires root cause investigation before restarting.

Encoder related faults

Core requirement: The amplitude of the encoder signal should be between 12.0-18.0V (F822 fault diagnosis standard).

Wiring specification: The encoder cable should be arranged separately from the power line, and the shielding layer should be reliably grounded.

Parameter related faults

Attention: Executing ‘Load Default Parameters’ (C800) will overwrite all existing parameters and positioning blocks, and backup is required in advance.

Common problem: Torque limit of 0 (E256) and feed rate of 0 (E255) will cause the drive to be inactive, and the parameters need to be reset to>0.

（2） Safety operation standards

Electrical safety: Before disassembly, disconnect the main power supply and take measures to prevent accidental closing. The discharge time of the capacitor should be ≥ 1 minute to avoid high-voltage electric shock.

Parameter operation: After modifying key parameters (such as travel limit and torque limit), it is necessary to verify the operating status of the equipment to prevent mechanical impact.

Replacement specification: When replacing the driver/motor/cable, the replacement part model must be exactly the same as the original equipment. After replacing the motor, the absolute position (absolute encoder type) must be reconstructed.

Component replacement process

（1） Replacement steps (universal framework)

Power off preparation: Turn off the main power supply, set up anti misoperation signs, and wait for the capacitor to discharge for ≥ 1 minute.

Disassembly operation: Separate the relevant cables (power line/encoder line/control line), remove the fixing screws, and remove the faulty components.

Install new components: Fix the new parts and reproduce the connection according to the wiring diagram (ensuring polarity/pin correspondence). The encoder cable should be firmly fixed.

Parameter loading: After replacing the driver, the backup parameter file needs to be loaded (or C700 basic loading needs to be performed), and after replacing the motor, absolute position calibration needs to be performed.

Test run: After powering on, check for no fault codes and conduct a trial run to verify that the function is normal.

（2） Key points for replacing different components

Key precautions and special requirements for replacing components

Drive (DKC) loads the original parameter file and confirms that the firmware version matches the discharge time of ≥ 1 minute

The motor (MKD/MDD) covers the temperature monitoring line of the motor, and the reconstruction of the absolute position joint requires protection (against coolant/oil contamination)

Replace the cable (power/feedback) according to its original length/specifications, and ensure that the shielding layer is reliably grounded to avoid parallel wiring with the power line

The official operation manual for the Bosch Rexroth IndraDrive HMV01 series power supply unit (including two sub series HMV01.1E and HMV01.1R) revolves around safety regulations, rated parameters and dimensions, wiring installation, and service support. It specifies that the product is suitable for industrial environments (compliant with IEC 60204-1/NFPA 79 standards), with a rated input voltage of 3 × 380-480V AC, an output voltage of DC 435-750V, and a maximum output current of 276A. It emphasizes that the operation must be carried out by professional personnel and must comply with safety requirements such as 30 minute capacitor discharge and grounding conductor cross-sectional area ≥ 1.5mm ², providing comprehensive technical guidance for equipment installation, wiring, and operation and maintenance.

Core technical parameters

（1） Key parameters of HMV01.1E series

Parameter Category Unit HMV01.1E-W0030 HMV01.1E-W0075 HMV01.1E-W0120

Rated input current A 51.0 125.0 204.0

Output voltage V DC 435-680 435-680 435-680

Output current A 69.0 173.0 276.0

Control voltage power consumption W 25 30 55

Continuous power consumption W 150.00 340.00 500.00

Equipment width mm 150 250 350

Equipment weight kg 13.50 22.00 32.00

Branch protection fuse A 80 150 250

Recommended Wire Specification (AWG) -6 1 4/0

（2） Key parameters of HMV01.1R series

Parameter category unit HMV01.1R-W0018 HMV01.1R-W0045 HMV01.1R-W0065 HMV01.1R-W0120

Rated input current A 26.0 65.0 94.0 181.0

Output voltage V DC 750 750 750

Output current A 24.0 60.0 87.0 160.0

Control voltage power consumption W 31 41 108 224

Continuous power consumption W 290.00 680.00 800.00 2000.00

Equipment width mm 175 250 350 350

Equipment weight kg 13.50 20.00 31.00 34.50

Branch protection fuse A 40 80 110 225

Recommended Wire Specification (AWG) -10 6 3 3/0

（3） General parameters

Power supply conditions: 3 × AC 380-480V, frequency 50-60Hz (± 2Hz), only applicable to solid ground wye power supply.

Control voltage: DC 24V ± 5%, rated short-circuit current 42000A rms.

Environmental parameters: rated working temperature of 40 ℃, reduced capacity working temperature of 55 ℃; Storage temperature not specified, relative humidity 20-90% (no condensation); Pollution level 2.

Physical universal dimensions: height 440mm, depth 262mm; minimum installation spacing at the top 300mm, bottom 130mm, horizontal spacing 0mm.

Key points of safety regulations

（1） Electrical safety

High voltage protection: The equipment has a dangerous voltage greater than 50V. After power failure, it is necessary to wait for 30 minutes for the capacitor to discharge and measure to confirm that there is no voltage before operation.

Grounding requirements: The grounding conductor must be permanently and reliably connected, with a leakage current greater than 3.5mA, and the minimum cross-sectional area must comply with the following table:

External conductor cross-sectional area (mm ²) Minimum cross-sectional area of a single grounding conductor (mm ²) Minimum cross-sectional area of two grounding conductors (mm ²)

1.5 10 2×1.5

2.5 – 2×2.5

4 – 2×4

6 – 2×6

10 10 –

16 16 –

25 25 –

Wiring safety: Do not plug or unplug connectors or touch electrical contacts when powered on; UL certified J-grade 600V AC fuses are required for branch protection.

（2） Battery safety

Heating, dismantling, charging, or using open flames are prohibited as they may cause explosions, leaks, or burns.

When replacing the battery, use the designated model to avoid damaging the electrical components of the equipment; Waste batteries need to be recycled separately and comply with national environmental regulations.

（3） Operational safety

Only trained professionals are allowed to install, operate, and maintain the equipment, and they must be familiar with safety regulations and equipment functions.

Prohibit unauthorized modification of equipment structure or decompile software components; Only accessories and spare parts approved by Bosch Rexroth can be used.

The equipment needs to be installed in external enclosures such as control cabinets to prevent foreign object intrusion, water ingress, and direct contact.

Installation and wiring specifications

（1） Installation requirements

Installation method: Fixed on the installation surface of the control cabinet, with reserved heat dissipation space (top 300mm, bottom 130mm) to avoid blocking the air inlet and outlet.

Accessory adaptation: It can be paired with optional main power reactors (HNL) and power filters (HNF) to enhance electromagnetic compatibility.

Special model: HMV01.1R-W0120 requires an external fan unit HAB01 and must comply with the corresponding installation size requirements.

（2） Core interface and wiring

Key interface definition:

X3: Main power connection (L1/L2/L3), supporting a maximum wire cross-sectional area of 120mm ², with a tightening torque of 20Nm (M10 thread).

X2: RS232 interface, used for communication connection.

X31: Module bus interface; X32:24V interface power supply and signal input.

X33: Built in main contactor feedback contact (ON/OFF status); X40: External main contactor signal input.

Wiring process: First connect the grounding conductor, then connect the main power supply and control voltage, and finally connect the signal interface; Wiring must comply with NFPA 79 and UL 508A standards, using copper wire (PVC insulated, conductor temperature 90 ℃).

Basic Information

Core product portfolio

SE 200 Controller: The core control unit of the electric tool system, responsible for program selection, job control, and status feedback.

LTH power unit: a frequency converter that provides a variable power/frequency rotating magnetic field for EC motors, available in two specifications: 230V (order number 0 608 750 056) and 110V (order number 0 608 750 064).

Document type and purpose: Official technical manual, covering safe operation, installation and wiring, functional settings, fault handling, etc., suitable for electric tightening/loosening operation systems in industrial assembly scenarios.

Adapt devices and accessories

Suitable motors: EC 37, EC 48 type EC motors (such as ECH12-MG, ECH37-MG, etc., please refer to the appendix for order numbers).

Core accessories: current control board ST1, programming module PM-1, dedicated connection cable (straight 1.6-10m/spiral 6.3-10m).

Core Technical Parameters

Parameter Category Specific Parameters LTH 230V LTH 110V Remarks

Power supply parameters rated voltage 220-240V AC 100-110V AC 50/60Hz ± 10%

Maximum input current 10A 20A-

Power consumption 400VA 400VA-

Output parameters Output voltage range 0-230V 0-230V-

Rated output current 2A 2A-

Maximum output current 12A 12A-

Output frequency range 0-500Hz 0-500Hz, suitable for motor speed regulation

Physical dimensions (length x width x height) 310 × 160 × 310mm 310 × 160 × 310mm-

Weight 13.4kg 13.4kg including installation accessories

Environmental parameters Operating temperature 0-50 ℃ 0-50 ℃-

Storage temperature -20-70 ℃ -20-70 ℃-

Relative humidity 20-90% (no condensation) 20-90% (no condensation)-

Protection and Electromagnetic Compatibility Protection Level IP 42 IP 42 Solid Foreign Object Protection+Splash Protection

EMC level IEC 801 level 4 IEC 801 level 4 Anti electromagnetic interference

Data storage battery specifications: 2 1/2 AA 3.6V lithium batteries, 2 1/2 AA 3.6V lithium batteries, data storage for 8 years

Key points of safety regulations

Electrical safety

After power failure, it is necessary to confirm that there is no voltage before operation to avoid the risk of high voltage electric shock.

It is strictly prohibited to connect the motor to the PE line. Electrical isolation should be achieved by relying on the isolation transformer of the LTH power unit (in accordance with VDE 0551 standard).

The fuse (6.3A slow melting type) is only allowed to be replaced by professionals and unauthorized modification of the circuit is prohibited.

Operational Security

Only trained and qualified personnel are allowed to operate, and they must be familiar with safety regulations and equipment functions.

In environments with severe dust or high humidity, the LTH unit needs to be installed in a control cabinet with an IP 54 protection level.

It is prohibited to connect non specialized equipment (such as coffee makers, toasters, etc.) to IEC sockets.

Equipment Protection

During installation, a ventilation gap of ≥ 40mm should be reserved to avoid overheating caused by poor heat dissipation.

Transportation and storage should avoid severe vibration, condensation, and dust pollution.

Installation and wiring specifications

（1） Installation requirements

Installation method: Hanging installation is carried out through the back hanging ears, without the need to be in close proximity to power tools.

Cable limitation: The maximum length of the cable between the LTH power unit and the motor should not exceed 50m, and original factory specific cables must be used.

Environmental adaptation: Install directly in regular environments, but in harsh environments, an IP 54 control cabinet is required.

（2） Core Interface Definition (Summary of Key Interfaces)

Interface Identification Type Pin Count Core Function Key Pin Description

X1 (Netz) IEC socket 3 (L/N/PE) power input L=phase wire, N=neutral wire, PE=ground wire

X3 (Handschauber) circular plug 19+PE motor connection U/V/W=motor phase line, TMA=motor temperature sensor

X2 (Sensorik SE200) SUB-D socket 15 sensor signal CLK/DATA=RS422 serial signal, 24VSE=control power supply

X7 (Betriebsmittelsteuerung) SUB-D socket 37 material control SSR=tighten start, SLL=loosen start, IO/NIO=job success/failure signal

X8 (Kommandoleitung) SUB-D plug 25 command line ST1-ST3=speed gear, FG=release signal, IM1/IM2=torque measurement

X13 (Benutzerschnittstelle) SUB-D plug 15 user interface SIO=IO count output, SF=system fault, TA=test reset

（3） Wiring process

Connect the interface cable and secure it with screws to ensure reliable contact.

Insert the Amphenol plug into the motor and tighten the locking ring.

Connect the power cable (IEC plug) and secure it with a wire clamp.

By turning on the bottom power switch, the device automatically performs hardware self-test.

Operation and Function Description

（1） Core components of panel operation

Motor selection switch: Switch the EC 37/EC 48 motor type, and the corresponding LED indicator light will light up to confirm.

Program selection mode:

Internal mode: Select the 0-15 program through the panel buttons (even=tighten P0, odd=tighten P1, 15=loosen SLL).

External mode: Select the program using hexadecimal code through the X13 interface, and the “ExternalN” LED will light up.

IO Count Statistician:

Function: Record the number of qualified assignments (0-999999), supporting cumulative/decreasing modes.

Operation: Reset with the red SET button, set preset values with 6 buttons, and display “Lo bat” for low battery.

Fault handling: Reset the fault by pressing the “RESET” button. If the power module fails, the device needs to be restarted.

（2） Core functional parameters

Parameter Name Optional Setting Default Value Function Description

Count mode: Add/SubAdd: Count from 0 to the preset value; Decrease: Count from preset value to 0

Loop mode: On/Off Off On=Delay reset loop after reaching the preset value; Off=continuous counting without looping

Relay output type when NO (normally open)/NC (normally closed) NO count meets the standard

Delay 100/200/300/400/500ms – SIO signal duration when Loop=On

DP (decimal point) with no/1/2 decimal places and no count display

（3） Homework process

Select motor type (EC 37/EC 48) and program mode (internal/external).

Set the preset value and working parameters of the IO counter (accumulate/decrease, loop, etc.).

Trigger the operation (tightening/loosening) through the X7 interface or motor start button.

After the homework is completed, the IO/NIO signal feedback indicates success or failure, and the counter is automatically updated.

When there is a malfunction, the corresponding LED lights up, and after resetting, the operation can be restarted.

Fault diagnosis

（1） Common faults and LED indications

LED identification color fault type handling method

USP red middle circuit overvoltage check power supply voltage, reset device

If the NTF red power module fails, restart the device. If it is ineffective, return it to the factory for repair

TF/TFVM red temperature fault (unit/motor), restart after cooling, check heat dissipation and temperature sensor

FI red current fault (short circuit): Check the motor cable and eliminate the short circuit point

BL red motor stalling check load, eliminate mechanical jamming

​Accessory ordering information (core accessories)

Accessory category Product name Order number Remarks

Power Unit LTH 230V 0 608 750 056-

LTH 110V 0 608 750 064 –

Controller SE 200 Electric Tool Control 0 608 830 123-

Motor ECH37-MG 0 608 841 009 EC 37 type

ECH48-MG 0 608 841 010 EC 48 type

Cable straight cable (4.0m) 0 608 750 067 motor connection

Spiral cable (6.3m) 0 608 750 070 motor connection

Control module current control board ST1 0 608 750 054 optional accessories

Programming module PM-1 0 608 750 055 optional accessories

Basic Information

Covering products

RAC 2 Series: Spindle Drive Controller, compatible with INDRAMAT 2AD asynchronous spindle motors (30-52kW) and 1MB frameless spindle motors, supporting spindle positioning and C-axis operation functions.

CDH1/CGH1/CSH1 series: milling machine type hydraulic cylinder, CDH1 is a differential cylinder, CGH1 is a double piston rod cylinder, CSH1 is a differential cylinder with magnetostrictive position measurement, suitable for various media such as mineral oil and water ethylene glycol.

Core applicable scenarios

Commonly applicable to CNC machine tools, industrial automation equipment, and heavy-duty transmission systems.

RAC 2 focuses on high-precision spindle control; The hydraulic cylinder is compatible with milling machines and hydraulic heavy-duty equipment, supporting multiple installation scenarios.

Comparison of core technical parameters

（1） Key parameters of RAC 2 series

Remarks on the numerical range of parameter items

Rated output power (motor shaft) 30-52kW continuous output

Input voltage 3 × 400V (50Hz ± 15%)/3 × 460V (60Hz ± 10%) directly connected to the three-phase power grid

Position resolution 1/4000000 RPM supports high-precision control of C-axis

Cooling method: Air cooling inside and outside the control cabinet, hose cooling, built-in fan+heat sink

Equipment weight 121kg including installation frame

Environmental temperature 5-45 ℃ (rated), maximum 55 ℃ (reduced capacity), humidity level F (DIN 40040)

（2） Key parameters of hydraulic cylinder series

Remarks on the numerical range of parameter items

Rated pressure 250bar Static test pressure 375bar

Piston diameter (Ø AL) 40-320mm in accordance with ISO 3320 standard

Piston rod diameter (Ø MM) 22-220mm matches with piston diameter

The maximum travel of 6m needs to be combined with anti buckling calculation

Medium temperature -20 ℃~+120 ℃ adjusted according to sealing type

Cleanliness requirements ISO 4406 20/18/15 require a matching filtering device

Protection level IP65 (main body), IP50 (partial output shaft) to prevent solid foreign objects and water splashes

Key points of safety regulations

（1） RAC 2 Security Requirements

Electrical safety

After power failure, wait for 5 minutes for the capacitor to discharge and confirm that the voltage is below 50V before operation.

Grounding conductor cross-sectional area ≥ 10mm ², leakage current>3.5mA, permanent and reliable connection.

Mechanical safety

Safety fences and emergency stop switches need to be installed, and the vertical axis requires additional mechanical locking. The standard motor brake does not meet personnel safety requirements.

The cooling air duct should be kept unobstructed to avoid overheating, and the temperature of the heat sink may exceed 60 ℃.

environmental safety

Pacemaker wearers are prohibited from entering the operating area, with a device protection level of IP10 (EN 60529).

The cooling of the control cabinet should avoid condensation water dripping onto electronic components, and the cooling temperature should not be lower than 40 ℃.

（2） Safety requirements for hydraulic cylinders

Pressure and Buckling Resistance

The maximum working pressure does not exceed 250 bar, and the pressure amplification caused by the area ratio needs to be considered.

When installed vertically, the allowable travel is calculated according to Euler’s formula, with a safety factor of 3.5.

Environment and Protection

The corrosion protection level is divided into CP3-CP7, suitable for conventional to high salt spray environments near the sea.

To avoid lateral forces acting on the piston rod, it is necessary to ensure the mechanical alignment of the motion axis.

Installation and configuration specifications

（1） RAC 2 Installation and Wiring

Installation requirements

The installation of the control cabinet requires the use of M1-RAC 2 installation frame, with a minimum spacing of 150mm at the top and 80mm at the bottom.

The cooling method can be switched to air cooling inside the control cabinet, external air cooling, or hose cooling (M2-RAC accessories required).

core interface

X2 (standard interface): Control signal and analog output, 37 pins.

X3: Motor feedback connection, 15 pins; X4: Speed setpoint (simulated ± 10V/SERCOS).

X5: Additional encoder input, supporting spindle synchronization feedback; X13: Optional RS232/incremental encoder output.

（2） Hydraulic cylinder installation and adaptation

Classification of installation methods

|Installation method | Applicable series | Applicable scenarios|

|MP3 | CDH1/CSH1 | Base rotating earrings require swinging load|

|MP5 | CDH1/CSH1 | Base self-adjusting fork head, compensating for installation deviation|

|MF3 | Full Series | Head Circular Flange, Fixed Installation Axial Load|

|MF4 | CDH1/CSH1 | Circular flange base, integrated installation of the body|

|MT4 | Full Series | Ear Shaft Installation, Heavy Duty Swing Scenario|

|MS2 | Full range | Foot mount installation, horizontal/vertical fixation|

Key configurations

Sealing system: 9 designs (M/G/V/L, etc.), suitable for different media (mineral oil/water ethylene glycol/synthetic oil).

Position measurement: CSH1 supports IO Link/Profinet/SSI interfaces with a maximum resolution of 1 μ m.

Tightening torque: MF3 flange with a piston diameter of 100mm, bolt specification M12, tightening torque 100Nm.

Programming modules and accessories

（1） RAC 2 AS programming module

Core function: Store motor optimization parameters and application parameters, which can be directly reused when replacing the controller without the need for re debugging.

Compatibility: The updated module is compatible with the old module and supports parameter copying (PC or dedicated adapter).

Type code: Example AS 53/004-003, including controller model, software version, and motor adaptation information.

（2） Core components of hydraulic cylinder

Seals: M-type compatible with mineral oil, G-type compatible with mineral oil+water ethylene glycol, V-type compatible with synthetic oil.

Position measurement: IO Link interface powered 24VDC, transmission rate 230.4kBaud; Profinet supports RT/IRT protocols, with a maximum speed of 100MBit/s.

Auxiliary accessories: proximity switch (PNP normally open, IP68 protection), throttle valve, air release measurement connector.

Operations and Services

fault diagnosis

RAC 2 displays faults through the control panel, automatically brakes and loses power when faults occur. Refer to the supplementary documentation for troubleshooting.

Common problems with hydraulic cylinders: seal leakage (replace corresponding medium seals), position measurement deviation (calibrate sensors).

repair and replacement

RAC 2 replacement requires the use of lifting equipment, programming modules can be directly plugged and reused, and faulty equipment needs to be returned with a repair card.

The replacement of hydraulic cylinder seals needs to be selected according to the medium, and corrosion protection requires regular inspection of the coating (CP3-CP7).

The official project planning manual for Bosch Rexroth CDH1/CGH1/CSH1 series milling machine hydraulic cylinders revolves around product technical parameters, installation configuration, seal selection, accessory matching, and safety specifications. It specifies key specifications such as rated pressure of 250 bar, piston diameter of 40-320 mm, and maximum stroke of 6 m. It provides detailed requirements for 6 installation methods, selection of multiple types of sealing systems, and adaptation requirements for position measurement and control interfaces (IO Link/Profinet, etc.), as well as practical points such as tightening torque, anti buckling calculation, and corrosion resistance level, providing comprehensive technical guidance for equipment selection, installation, commissioning, and maintenance.
1、 Basic Information
Covering products
CDH1 series: Single piston rod differential cylinder, supports 6 installation methods, suitable for conventional hydraulic scenarios.
CGH1 series: Double piston rod cylinder, installation methods include MF3/MT4/MS2, suitable for bidirectional symmetrical loads.
CSH1 series: differential cylinder with magnetostrictive position measurement system, supporting multiple digital/analog signal outputs.
Document type and purpose: Project planning manual, used to guide product selection, mechanical/electrical integration, installation, commissioning, and maintenance.
Core applicable scenarios: milling machines, industrial hydraulic equipment, heavy-duty transmission systems, etc., suitable for various hydraulic media such as mineral oil and water ethylene glycol.
2、 Core technical parameters
（1） Summary of Key Specifications
Remarks on the numerical range of parameter items
Rated pressure 250 bar Static test pressure 375 bar
Piston diameter (Ø AL) 40-320 mm in accordance with ISO 3320 standard
Piston rod diameter (Ø MM) 22-220 mm matches with piston diameter
The maximum travel of 6 meters needs to be confirmed in conjunction with anti buckling calculations to allow for travel
Hydraulic media HL/HLP/HFA/HFC/HFDR/HFDU correspond to different sealing systems
The temperature range of the medium is -20 ℃~+120 ℃, adjusted according to the sealing type
Cleanliness requirements ISO 4406 20/18/15 require a matching filtering device
（2） Travel speed limit
Piston diameter (mm) Interface specification Maximum travel speed (m/s)
40 G1/2 0.31
63 G3/4 0.28
100 G1 0.20
200 G1 1/2 0.11
320 G1 1/2 0.04
3、 Installation and fastening requirements
（1） Classification of installation methods and applicable scenarios
Installation method type applicable scenarios
MP3 base rotating earrings require swinging load connection
Scenario of MP5 Base Self Adjusting Fork Head Compensation Installation Deviation
MF3 head circular flange fixed installation, axial load
MF4 base circular flange body integrated installation
MT4 Ear Shaft Installation Heavy Load Swing Scenario
MS2 Foot Seat Installation Horizontal/Vertical Fixed Installation
（2） Key tightening torque (bolt grade 10.9)
Piston diameter (mm) Head/base bolt specifications Tightening torque (Nm)
40 M8 23
100 M12 100
200 M20 410
320 M30 1500

4、 Sealing system and selection
（1） Sealing design types and compatible media
Sealing type adapted to the core characteristics of the medium
M/L/R Mineral Oil HL/HLP/HFA Standard Type/Low Friction/Heavy Industrial Grade
G/T mineral oil+water ethylene glycol HFC servo grade low friction
V/S phosphate ester HFDR/polyol ester HFDU resistant to chemical corrosion
A/B Mineral Oil/Water Ethylene Glycol Lip Seal Kit
（2） Core principles of selection
Medium matching: Select the corresponding sealing design based on the type of hydraulic oil (mineral oil/water-based/synthetic oil).
Temperature adaptation: Choose conventional sealing for -20 ℃~+80 ℃, and high-temperature resistant type (such as V/S) for+80 ℃~+120 ℃.
Working condition requirement: Avoid T/G/L/R/S/V type seals when maintaining static pressure for more than 10 minutes.
5、 Position measurement and control interface
（1） Control interface type
Interface type signal output applicable scenarios
Proximity switch PNP normally open signal simple terminal detection
IO Link Digital Signal (32-bit Position Value) Industry 4.0 Networking
Profinet RT/IRT protocol high-precision synchronous control
SSI 1/5 μ m resolution high-precision position feedback
（2） Key parameters
Supply voltage: 12-30 VDC (IO Link/Profinet)
Protection level: IP67 (after connector installation), IP68 (cable outlet)
Transmission rate: Profinet maximum 100 MBit/s, IO Link 230.4 kBaud
6、 Key points of safety and maintenance
Pressure safety: The maximum working pressure should not exceed the rated value, and pressure amplification caused by area ratio should be considered.
Buckling prevention requirement: When installed vertically, the allowable travel must be calculated according to Euler’s formula, with a safety factor of 3.5.
Corrosion protection: Choose CP3 (conventional) to CP7 (offshore high salt spray) coatings according to the environment.
Medium requirements: The optimal viscosity is 20-100 mm ²/s, with a minimum of 12 mm ²/s to avoid impurity contamination.

The official technical information of Bosch Rexroth MDD series digital AC servo motors and DIAX04 series HDD/HDS second-generation drive controllers revolves around product technical parameters, installation configuration, safety specifications, wiring requirements, transportation and storage, and service support. It clearly defines the applicable scenarios for automation equipment such as machine tools, robots, and packaging machinery, and specifies in detail the rated torque (such as MDD 115 maximum continuous torque 57Nm), speed (such as MDD 021 rated speed 10000min ⁻¹), protection level (mainly IP 65), wiring specifications, and safety operation points of each model, providing comprehensive technical guidance for equipment selection, installation, and maintenance.
1、 Basic Information
Covering products
MDD series: 9 models of digital AC servo motors, including MDD 021/025/041/065/071/090/093/112/115, each with different length specifications (A/B/C/D), supporting natural cooling or surface cooling.
DIAX04 series: Second generation HDD/HDS drive controller, including HDD02.2-W040N-HD32, HDS02.2-W040N and other models, modular design, supporting servo and spindle drive functions.
Core applicable scenarios
Commonly applicable to automation scenarios such as machine tools, textile/printing/packaging machinery, robots, and handling equipment.
MDD motors are classified according to their performance into precision types (such as 090/112), high dynamic types (such as 065/093), and compact types (such as 021/025), which are suitable for different load requirements.
2、 Core security requirements
（1） Electrical safety
High voltage and discharge protection
After the DIAX04 driver is powered off, it is necessary to wait for 5 minutes for the capacitor to discharge. After the MDD motor related equipment is powered off, it is necessary to confirm that the voltage is below 50V before operation.
The grounding conductor needs to use copper wire with a cross-sectional area of ≥ 10mm ², permanently and reliably connected, with a leakage current greater than 3.5mA.
Wiring safety
Do not plug or unplug connectors while powered on. The minimum wire diameter for the control voltage line (24V) is 1mm ², and the minimum wire diameter for loop transmission is 2.5mm ².
The motor cable should use the original factory specifications, with a maximum length of 75m for MDD motor cables, and the shielding layer should be reliably grounded.
（2） Mechanical and Sports Safety
Prevention of dangerous sports
Safety fences, light curtains, emergency stop switches (verified for effectiveness before starting) need to be installed, and additional mechanical locking or external braking devices are required for the vertical axis.
The standard motor brake of MDD motor does not meet the requirements of personnel safety protection and requires additional measures.
Handling and assembly
Heavy duty motors (such as MDD 115 weighing 60kg) require the use of suitable lifting equipment to avoid compression and shear injuries, and protective equipment such as goggles and safety shoes should be worn.
（3） Special protection
Electromagnetic and High Temperature Protection
Pacemakers and metal implant wearers are prohibited from entering the equipment operation/installation area. If they need to enter, they must consult a doctor.
After the equipment is running, the temperature of the casing may exceed 60 ℃. The MDD motor can cool down for up to 140 minutes and needs to be cooled down or operated with protective gloves.
environmental protection
The protection level of MDD motors is mostly IP 65, and some models (such as MDD 021) have an output shaft protection level of IP 50, which is not suitable for dusty and wet environments.
3、 Comparison of core technical parameters
（1） Key parameters of MDD series motors (representative models)
Model Rated speed (min ⁻¹) Continuous torque (Nm) Peak torque (Nm) Protection level Weight (kg)
MDD 021 A 10000 0.30 1.3 IP 50 (output shaft) 1.0
MDD 065 D 4000/6000 2.7/2.7 7.8 IP 65 5.3
MDD 115 D 1500/2000 57.0/57.0 177.3 IP 65 60
（2） Key parameters of DIAX04 series drivers (representative models)
Model Rated current (A) Cooling method Interface type Suitable for motor
HDD02.2-W040N-HD32 40 air-cooled (built-in blower) SERCOS, analog MKD/MHD/MDD series
HDS03.2-W100 100 100 air-cooled SERCOS/ANALOG high-power MDD motor

4、 Installation and wiring specifications
（1） Installation requirements
Spacing and Layout
The minimum distance between the top of MDD motor is 150mm, and the minimum distance between the bottom is 80mm; the minimum distance between the bottom of DIAX04 driver is 100mm to ensure heat dissipation.
The control cabinet should be well sealed to avoid condensation water, and a cooling system should be installed when the ambient temperature exceeds 45 ℃.
Fixed and directional
MDD motors support IM B5 (flange through-hole) and IM B14 (flange thread) installation, which can be installed in any direction. Some models need to avoid liquid accumulation on the output shaft.
Heavy duty motors (MDD 112/115) require the use of lifting screws or cranes for handling, and it is prohibited to grip the blower area.
（2） Wiring specifications
MDD motor wiring
Power connection: including power cable, temperature sensor (PTC), brake device wiring, wire diameter 0.2-25mm ², tightening torque 2.5-3.0Nm.
Feedback connection: 12 pin flange socket, supports Resolving Feedback (RSF) or Digital Servo Feedback (DSF), with a maximum resolution of 2097152 increments per revolution.
DIAX04 driver wiring
Key interfaces: X5 (DC bus/motor/power supply), X6 (brake/temperature monitoring), X10/X11 (SERCOS fiber), X12 (external input).
The default data rate of the fiber optic interface is 2Mbaud, which can be switched to 4Mbaud, and a specified model of fiber optic cable is required.
5、 Transportation, storage, and operation and maintenance
（1） Transportation and Storage
Transportation requirements
The motor needs to be fixed in a tray or cardboard box, secured with square wood and metal straps to avoid collisions, and heavy-duty motors require specialized lifting equipment.
Drivers should avoid severe vibrations and be protected against dust and moisture during transportation.
Storage conditions
Temperature range: -25 ℃~+85 ℃ (MDD motor), -30 ℃~+80 ℃ (cable accessories).
When storing, the protective covers of the connectors and output shafts should be retained until they are removed before installation.
（2） Operations and Services
fault diagnosis
Obtain fault information through device status display lights and SERCOS interface error signals, refer to the corresponding troubleshooting guide.
The MDD motor temperature sensor (PTC) monitors the winding temperature, and the controller will generate an error prompt when overheating occurs.
Service Support
International service hotline:+49 (0) 172-6600406,+49 (0) 171-3338826, supporting 7 × 11 hour service (weekdays).
Repair requires providing information such as product model, fault symptoms, fault codes, etc. The returned product must be accompanied by a repair card.
6、 Model coding rules (example)
（1） MDD motor model (MDD 021 B-N-100-N 2 G-032 F B 0)
Motor series: MDD
Motor size: 021
Motor length: B
Cooling method: N (natural cooling)
Rated speed: 100 (10000min ⁻¹)
Balance level: N (standard level)
Feedback type: G (Resolver feedback)
Output shaft: F (optical axis, no shaft seal)
Braking device: 0 (no braking)
（2） DIAX04 Drive Model (HDS03.2-W100-HS01-FW)
Product series: HDS
Product Line: 03
Version: 2
Cooling method: W (air-cooled)
Rated current: 100 (100A)
Controller family: H (DIAX04)
Interface type: S (SERCOS)
Firmware: FW (to be ordered separately)

The official technical information of Rexroth’s two drive controllers (DIAX04 series HDD/HDS second-generation, EcoDrive 03 series DKC. 3-040/-100/-200) * * revolves around safety operation specifications, product identification and parameters, wiring installation requirements, maintenance and service, clearly targeting professional electrical personnel, emphasizing safety points such as high voltage protection, electrostatic protection, and dangerous motion prevention. It specifies in detail the rated voltage (such as 200-480V AC), current (such as EcoDrive 03 maximum output current of 200A), wiring specifications, installation spacing, and fault diagnosis and service support for each model, providing standardized guidance for the full life cycle use of the equipment.
1、 Basic information of the document
Covering products
DIAX04 series: Second generation HDD/HDS drive controller, including HDD02.2-W040N-HD32, HDS02.2-W040N and other models, supporting servo drive and spindle drive functions.
EcoDrive 03 series: DKC * *. 3-040/-100/-200 drive controller, suitable for scenarios such as machine tools and automation equipment.
Document type and purpose
DIAX04 is a project planning manual that focuses on electrical structure design, control cabinet installation, and drive component deployment.
EcoDrive 03 is an operation manual that focuses on practical guidance for installation, operation, and maintenance.
Target audience: Only electrical installation and maintenance personnel who have received professional training and qualification certification are allowed to operate.
2、 Core security requirements
（1） Electrical safety
High voltage protection
There is a risk of high voltage exceeding 50V in the equipment. After power failure, it is necessary to wait for 30 minutes (EcoDrive 03) or 5 minutes (DIAX04) for the capacitor to discharge. The measured voltage must be below 50V before operation.
The grounding conductor must use copper wire with a cross-sectional area of ≥ 10mm ² and be permanently and reliably connected, with a leakage current greater than 3.5mA.
Overcurrent and short circuit
External overcurrent protection device is required. The EcoDrive 03 branch circuit protection fuse specifications are 20A (040 model) and 70A (100/200 model).
Do not plug or unplug connectors while powered on to avoid short circuit damage to equipment.
（2） Mechanical and Sports Safety
Prevention of dangerous sports
Due to wiring errors, improper parameter settings, etc. that may cause dangerous movements, safety fences, light curtains, and emergency stop switches need to be installed (effectiveness needs to be verified before starting).
The vertical axis requires additional mechanical locking or external braking devices, and the standard motor brake does not meet personnel safety requirements.
Handling and assembly
Use appropriate tools and lifting equipment to avoid squeezing and shearing injuries, and if necessary, wear protective equipment such as goggles and safety shoes.
Do not stand under suspended loads and promptly clean up any leaking liquids to prevent slipping.
（3） Special protection
Electromagnetic and High Temperature Protection
Pacemakers and metal implant wearers are prohibited from entering the equipment operation/installation area. If they need to enter, they must consult a doctor.
After the device is running, the temperature of the casing may exceed 60 ℃. The cooling of EcoDrive 03 takes up to 140 minutes and requires wearing protective gloves or waiting for cooling before operation.
Electrostatic protection
Grounding (human body, tools) is required before contacting electronic components, and sensitive components need to be stored and transported in conductive packaging.
The signal line and power line are wired separately, and shielded wires are required for analog signals to avoid interference.

3、 Key parameters and identification of products
（1） Model code rules
Product Series Model Code Example Core Field Meaning
DIAX04-HDS HDS03.2-W100N-HS01-FW W=air-cooled, 100=rated current 100A, HS=SERCOS interface
EcoDrive 03 DKC03.3-200-7-FW 03=series version, 200=maximum output current 200A, FW=firmware (to be ordered separately)
（2） Comparison of core rated parameters
Parameter unit DIAX04 (HDS03.2-W100N) EcoDrive 03 (DKC03.3-200)
Rated input voltage V 200-480 AC 200-480 AC
Maximum output current A 100 200
Maximum output frequency Hz -1000
Equipment weight kg 11 19.5
Power loss W 280 960
Working environment temperature ℃ 5-45 (rated), maximum 55 (rated), maximum 55 (rated), maximum 55 (rated)
4、 Installation and wiring specifications
（1） Wiring requirements
Key interface definition
X5 interface (shared by both): DC bus, motor and power connection, EcoDrive 03 wiring cross-sectional area of up to 25mm ², tightening torque of 2.5-3.0Nm.
X6 interface (shared by both): motor temperature monitoring (TM+/-), brake control (BR+/-), wire diameter range 0.2-2.5mm ² (single core wire).
SERCOS interface (DIAX04 HDD): Connected via X10/X11 fiber optic cable, with a default data rate of 2Mbaud and switchable to 4Mbaud.
Wire diameter and cable length
The minimum wire diameter for the control voltage line (24V) is 1mm ², and the minimum wire diameter for loop transmission is 2.5mm ².
The maximum length of the motor cable is 75m (4kHz switching frequency), exceeding the required capacity reduction or length shortening (such as 25m for EcoDrive 03 8kHz).
（2） Installation requirements
Control cabinet and spacing
The minimum distance between the top of the equipment is 150mm, and the minimum distance between the bottom is 80mm (EcoDrive 03); The minimum spacing at the bottom of DIAX04 is 100mm.
The control cabinet shall be well sealed to avoid condensation, and the cooling unit shall avoid dripping or spray to electronic components.
Cooling requirements
If the ambient temperature exceeds 45 ℃, a cooling system must be configured, and the set temperature of the DIAX04 cooling system should not be lower than 40 ℃.
When multiple devices are installed side by side, an air guide device should be installed to avoid heat accumulation.
5、 Maintenance and Service
fault diagnosis
The device outputs error messages through status display and SERCOS interface, please refer to the corresponding troubleshooting guide.
DIAX04 provides a 24/7 service hotline, while EcoDrive 03 supports inquiries from global service outlets.
Repair and replacement
Repairs need to be carried out by original service personnel or trained personnel, and parameters need to be re debugged after replacing components.
The DIAX04 software module (HSM) can directly transfer parameters to replacement devices without the need for reprogramming.
Key points: EcoDrive 03 includes instructions for discharging DC bus capacitors, and the discharge resistance must meet the specification of 1000 Ω/1000W; DIAX04 includes transportation and storage requirements, with a temperature range of -30 ℃ to+85 ℃.

1、 The official operation guide for Bosch Rexroth EcoDrive 03 series drive controller (model DKC.3-040/-100/-200) specifies that the document is intended for professionally trained electrical installation personnel. The core content includes safety precautions, product identification rules, rated parameters and dimensions, wiring and installation specifications, reference documents, and appendix instructions. It emphasizes the need to strictly comply with electrical safety and equipment protection requirements during operation. At the same time, it standardizes the installation, use, and maintenance points of key components such as control voltage connection, motor wiring, temperature monitoring, and braking system of the drive.
2、 Safety precautions
Electrical contact safety
There is a high voltage risk in the driver. After power failure, it is necessary to wait for 30 minutes for the capacitor to discharge, and the measured capacitor voltage must be below 50V before operation.
The grounding conductor must use copper wire with a cross-sectional area of ≥ 10mm ² and must be permanently and reliably connected.
Do not touch electrical connection points while powered on. Install a protective cover before turning on the device.
Handling and assembly
Suitable tools and lifting equipment should be used to avoid squeezing and shearing injuries.
Wear protective equipment such as goggles, safety shoes, and gloves when necessary.
Prevention of dangerous sports
Motor wiring errors, improper parameter settings, sensor failures, etc. can all cause dangerous movements.
Safety fences, light curtains and other protective devices need to be installed. The emergency stop switch should be installed within the reach of the operator, and the effectiveness of the emergency stop function should be verified before starting.
The vertical axis requires additional mechanical locking or external braking devices, and the standard motor brake does not meet personnel safety protection requirements.
Electromagnetic and High Temperature Protection
Pacemakers and metal implant wearers are prohibited from entering the equipment operation or installation area. If they need to enter, they must consult a doctor.
The temperature of the motor and driver casing during operation may exceed 60 ℃, and the cooling time can reach up to 140 minutes. Avoid touching high-temperature components.
3、 Product Identification and Supply Scope
Model code rules
Model example: DKC03.3-040-7-FW, where 040 represents the rated current of 40A and FW represents the firmware module that needs to be ordered separately.
Scope of supply
Including firmware modules, contact protection devices, and corresponding connector models, there are differences in connector configurations for different types of drivers.

4、 Rated parameters and dimensions
Core Rated Parameters (Table)
|Parameter | Unit | DKC03.3-040 | DKC03.3-100 | DKC03.3-200|
|Rated control voltage | V | 24 DC | 24 DC | 24 DC|
|Rated input voltage | V | 200-480 AC | 200-480 AC | 200-480 AC|
|Maximum output current | A | 40 | 100 | 200|
|Maximum output frequency | Hz | 1000 | 1000 | 1000|
|Equipment weight | kg | 5.7 | 9.7 | 19.5|
|Maximum ambient temperature (rated data) | ℃ | 45 | 45 | 45|
Installation spacing requirements
The minimum distance between the top of the equipment is 150mm, and the minimum distance between the bottom is 80mm. It is necessary to ensure that the heat dissipation air duct is unobstructed.
5、 Usage and installation specifications
Wiring specifications
Control voltage connection (X1): using 2 × 4 spring contact connectors, with a single core wire cross-sectional area of 0.2-2.5mm ², supporting parallel power supply for multiple drivers, and a maximum loop current of 10A.
DC bus/motor/power connection (X5): M5 screw terminal block is used, with a tightening torque of 2.5-3.0Nm. The maximum length of the motor cable is 75m (at 4kHz switching frequency), and the original cable from Lishle must be used, otherwise the warranty will be lost.
Temperature monitoring and brake connection (X6): responsible for motor temperature monitoring (PTC/NTC resistance) and brake control. The maximum switching voltage of the brake is 40V DC, and the maximum switching current of the DKC * *. 3-200-7 model is 4A.
Programming module connection (X7): includes parameter module and firmware module, set driver address (1-99) through S2/S3 dip switch.
Installation requirements
Proper electrostatic protection is required, and operators and tools must be grounded to avoid electrostatic damage to electronic components.
Signal lines and power lines need to be wired separately, and shielded wires are required for analog signals.
The control cabinet needs to have a reasonable layout of cooling units to avoid condensation water droplets falling onto electronic components.