Product Core Brief

• Model: .2-W040N–01-FW, OEM order part R911190007
• Brand: Bosch Rexroth Indramat
• Series: .2 modular servo amplifier family for DIAX04 motion control system
• Core Function: High-current three-phase power stage to drive permanent magnet synchronous servo motors; execute closed-loop current/velocity/position control synchronized via SERCOS fiber bus with PPC-R22 RECO rack motion CPUs, process Hiperface absolute encoder feedback from MHD series servos
• Product Type: DIN-mount vertical servo power module; suffix breakdown: W=power stage series, 040=40A rated output, =SERCOS fiber + Hiperface encoder interface, 01=hardware revision 1, FW=factory flashed DIAX04 motion firmware
• Key Specs: 40A continuous rated output current | 530–670V DC intermediate bus | SERCOS fiber communication | Integrated blower cooling | Hiperface multiturn encoder support | 24VDC control logic supply
• Note: OEM discontinued new mass production; limited unopened factory surplus and fully load-calibrated refurbished inventory available. Exclusively matched to DIAX04 SERCOS control stacks, incompatible with later IndraDrive CS drives without full system rework.

Key Technical Specifications

• Power Stage Rating
  • Continuous three-phase output current: 40 A RMSIndramat U…
  • Peak overload output: 80 A short-duration acceleration capacity
  • DC intermediate bus input range: 530 VDC ~ 670 VDC from mains rectifier unit
  • Max three-phase output voltage: 500 VAC line-line
  • Maximum output frequency: 1000 Hz for high-speed spindle / rotary axesIndramat U…
• Control Logic Supply
  • Auxiliary control voltage: 26 VDC ±2% unregulated cabinet rail
  • Standby power draw (no motor load): 20 W steady consumption
• Interface Suffix Definition
  • SERCON410 fiber-optic SERCOS bus for real-time motion command exchange with PPC-R22 CPU
  • Native Hiperface multiturn absolute encoder input for MHD series servo motors
  • Onboard digital emergency stop interlock, brake coil output driver (24VDC holding brake)
• Cooling & Mechanical
  • Cooling method: Internal integrated axial blower forced air coolingIndramat U…
  • Mount form factor: Standard 35mm DIN rail vertical rack mount
  • Unit overall weight: 6.5 kg
  • Enclosure protection class: IP10 cabinet-only installation
• Electrical Protection Circuits
  • Phase short-circuit shutdown, overcurrent (OCP), overvoltage (OVP), undervoltage (UVP)
  • Over-temperature thermal shutdown with fault code flagging
  • Motor winding insulation monitoring, encoder cable break detection
• Operating Ambient
  • Continuous operating temperature: +5°C ~ +45°C cabinet runtime
  • Storage temperature: -30°C ~ +60°C, non-condensing humidity 5–95% RH
• Compliance Standards: CE, UL, EN61000 industrial EMC, SEMI S2 certified for semiconductor substrate handling equipment
• Compatible System Components: PPC-R22 RECO rack motion controllers, MHD series permanent magnet servo motors, VEP40 HMI operator panels

Product Introduction

This high-current servo power amplifier delivers heavy continuous torque drive for vertical lift axes, rotary indexing tables and CNC spindle axes deployed on Rexroth DIAX04 control platforms. Integrated forced-air blower cooling sustains full 40A rated output under sustained vertical static loads without performance derating. combined SERCOS fiber + Hiperface feedback eliminates separate encoder signal wiring between drive and motion CPU, while factory preloaded FW firmware delivers native compatibility with VisualMotion Toolkit programming environments. The unit’s robust overcurrent and thermal protection logic prevents catastrophic motor winding damage during wafer processing cycle overload events.

QA & Testing SOP (Transparency Building)

1. Incoming Inspection: Cross-reference serial number against Rexroth OEM vital product databases matching R911190007; visual scan for dented aluminum heat sink fins, cracked blower fan blades, swollen DC bus electrolytic capacitors, corroded motor power and SERCOS fiber connectors. All rear terminal block wiring pin assignments photographed pre-disassembly.
2. Live Bench Testing: Mount unit to DIN rail test rack paired with PPC-R22 motion CPU and MHD115C high-torque servo motor; run continuous 24-hour cyclic load profile alternating 0–40Nm stall hold and 0–6000rpm speed ramps. Fluke power analyzer monitors three-phase winding current balance and blower steady-state operation.
3. Encoder & Communication Validation: Establish SERCOS fiber real-time link to motion CPU; validate full Hiperface multiturn absolute position tracking across 4096 revolutions, measure encoder position tracking error <1 count full travel. Trigger all protection fault modes to verify fault code reporting over SERCOS bus.
4. Power Stage Calibration: Trim current loop gain/offset to OEM factory tolerance; validate OCP/OVP thermal shutdown trigger thresholds match datasheet specifications.
5. Final QC & Packaging: Replace degraded DC bus electrolytic capacitors and worn blower fan assemblies during refurbishment cycles; cap unused fiber and power terminal ports with OEM dust plugs, wrap unit in static-dissipative foam, affix printed QC tag listing output current linearity, SERCOS communication and thermal protection test metrics before sealed wooden crate shipping.

Installation Pitfalls & Guide (Engineer to Engineer)

❗ HS Interface Variant Mismatch Risk: SERCOS/Hiperface hardware cannot directly replace HA analog command .2 variants without full motion program and motor feedback wiring rework. Photograph original SERCOS fiber and encoder cable routing before drive removal to avoid communication loss post-swap.❗ Blower Airflow Blockage Hazard: Cabinet cable bundles covering front/rear cooling ventilation slots create rapid thermal buildup, triggering unplanned thermal shutdown mid-production batch runs. Maintain minimum 50mm clear airflow gap around drive heat sink surfaces.❗ SERCOS Fiber Polarity Reversal Hazard: Misaligned transmit/receive fiber leads break all real-time axis synchronization. Mark fiber cable ends clearly before disconnection; reversed fiber polarity triggers persistent SERCOS bus fault alarms and machine interlock trips.❗ DC Bus Capacitor Derating Risk: Extended operation above 60°C cabinet ambient accelerates electrolytic capacitance degradation, raising output current ripple and widening axis position error bands. Verify cabinet forced cooling airflow meets OEM minimum CFM requirements.❗ Catastrophic Winding ESD Risk: Unshielded Hiperface encoder transceiver and SERCOS fiber ASIC circuits sustain permanent leakage damage from ungrounded handling; certified ESD wrist strap and conductive anti-static mat mandatory before touching rear terminal connectors or fiber transceiver ports.4-Step Replacement Guide:

1. Pre-install: Execute full machine lockout-tagout, fully discharge DC intermediate bus energy via safe bleed circuit, export all motor parameter sets and axis motion loop gains from PPC-R22 CPU via VisualMotion Toolkit offline PC software.
2. Removal: Disconnect SERCOS fiber leads, three-phase motor power cable, 24VDC control logic and brake coil wiring one at a time; release DIN rail bottom snap tab, slide drive vertically free from rack and rest on vibration-dampened ESD foam pad. Record fiber polarity and power terminal wire pin assignments.
3. Install: Snap replacement unit onto standard 35mm DIN rail, ensure unobstructed blower airflow clearance, re-terminate motor power, SERCOS fiber and control wiring matching photographed layout; separate SERCOS fiber trunking from high-current motor power cables per EMC cabinet wiring rules.
4. Power-on Test: Restore cabinet 24VDC control supply and mains rectifier DC bus voltage, confirm front-panel power, SERCOS and blower status LEDs illuminate steady green, upload saved motor parameter library, run 30-minute cyclic torque/speed motion test to validate stable Hiperface position tracking and zero unplanned thermal fault trips.

FAQ (Frequently Asked Questions)

Q: Can this SERCOS drive replace HA analog command .2 variants on identical machine platforms without parameter rework?A: No out-of-box cross-compatibility. HA suffix units use analog ±10V torque setpoint wiring, while relies entirely on digital SERCOS fiber motion commands. Full motor parameter reloading, SERCOS bus address mapping and axis loop gain retuning are mandatory after swap.Q: Does this servo amplifier support hot-swapping while cabinet DC bus and SERCOS fiber bus remain energized?A: The rear power and signal terminal blocks lack staged hot-swap power pin sequencing. Live extraction injects high voltage transients into the DC bus and SERCOS fiber transceiver circuit, corrupting nvRAM stored axis tuning parameters and risking permanent motion CPU hardware damage. Full mains lockout and DC bus bleed-down is required before disconnection.Q: What warranty separates factory surplus stock from fully refured .2- units?A: Unopened original Rexroth-certified surplus carries a 12-month industrial warranty covering power stage current drift, SERCOS communication failure and blower fan premature wear. Refurbished calibrated units ship with a 6-month limited functional warranty; reused DC bus electrolytic capacitors show gradual capacitance loss under continuous cabinet heat.Q: Will swapping this servo drive erase stored motor torque curves and axis position offset values in the motion CPU?A: All motor tuning parameters, motion recipes and loop gain profiles reside in the RECO rack CPU’s onboard Flash and nvRAM memory, independent of the servo power stage hardware. Export a complete parameter backup via VisualMotion Toolkit before disassembly to avoid full axis retuning post-install.Q: Can this hardware operate with legacy VisualMotion Toolkit v4 commissioning software released prior to 2006 without firmware updates?A: SERCOS/Hiperface hardware requires VisualMotion Toolkit v5 minimum software version; v4 builds lack device description files for fiber SERCOS bus communication, leading to missing motion diagnostic register readouts and incomplete axis tuning visibility.Q: What expected service window applies to surplus versus refurbished drives in 24/7 high-volume semiconductor production environments?A: Original surplus units target scheduled DC bus capacitor and blower fan replacement at 41,000 operating hours. Refurbished variants degrade at 32,000 hours; aged electrolytic filter capacitors lose capacitance over time, widening three-phase current ripple and triggering unstable vertical axis hunting during precision wafer transfer cycles.Q: What functional difference separates and HS32 encoder interface suffixes on the same .2 base drive?A: supports single Hiperface multiturn encoder per drive for standard single-motor axes; HS32 adds dual encoder input channels for master-slave dual-feedback synchronous gantry axis configurations, requiring modified terminal block wiring and separate motion program coordinate mapping in the CPU.