Rexroth HCS03.1E-W0210-A-05-NNBV Single-axis servo drive

I. Basic Information

• HCS03.1E: 3rd-generation compact servo platform, integrated brake chopper & DC bus control power supply
• W0210: Peak output current 210A
• A-05: Voltage code for 3×400～500V industrial mains
• NNBV: Integrated brake chopper, 24V control power from DC bus, built-in temperature-controlled cooling fan

Hardware Architecture

1. Main Power Rectifier & Regenerative Inverter UnitAdopts high-power IGBT four-quadrant topology, realizes bidirectional energy flow between the grid and servo motor. Built-in high-precision current sampling and hardware fast overcurrent short-circuit protection. Rated continuous output current 146A, peak 210A with 1.5× short-time overload capacity, suitable for frequent start-stop and impact load conditions. Multiple drives can share the DC bus to balance regenerative energy between axes and improve system energy efficiency.
2. DC Bus-derived 24V Control Power UnitThe control circuit obtains stable 24VDC power directly from the DC bus without independent external control wiring. Equipped with isolation, surge, reverse connection and ESD protection to avoid drive runaway caused by external control power failure.
3. Integrated Brake Chopper & Temperature-controlled Cooling UnitWhen grid energy feedback is limited, the built-in brake chopper consumes excess bus energy to prevent overvoltage damage. Equipped with internal axial fan with temperature adaptive speed regulation, independent air duct design reduces dust accumulation and power device overheating failure risk.
4. Multi-encoder & Safety Signal Acquisition UnitCompatible with Resolver, EnDat, Hiperface, TTL/SSI encoders. Integrated STO safety torque off circuit, multi-channel DI/DO and analog I/O terminals to connect emergency stop, limit switch, fault alarm and analog reference signals to meet mechanical safety interlock requirements.
5. Multi-fieldbus High-performance Motion Control UnitSupports EtherCAT, Profinet, SERCOS III real-time bus via optional communication card. The 32-bit motion controller realizes ultra-short 62.5μs current loop cycle, supports electronic cam, electronic gear, tension control and master-slave synchronization advanced motion functions to reduce upper PLC computing load.

Installation Specifications

• Mains Input: 3×AC 400～500V (-15%～+10%), 50/60Hz
• DC Bus Voltage: 560～700VDC
• Continuous Output Current: 146A; Peak Current: 210A
• Rated Motor Power: 68kW (without line reactor), max 124kW (with line reactor)
• PWM Switching Frequency: 4/8/12/16kHz optional
• Max Output Frequency: 1600Hz for high-speed spindle motors
• Cooling: Built-in temperature-variable forced air cooling
• Protection Class: IP20 (indoor ventilated control cabinet only)
• Dimension: 350mm×406.5mm×313.5mm; Weight: 39kg
• Operating Temperature: 0℃～+45℃ (derating above 1000m altitude)
• Ambient Humidity: 5%～95%RH, non-condensing, no corrosive gas or conductive dust

Supporting System & Application Industries

• Supporting Hardware: Rexroth high-power servo motor, line reactor, DC bus busbar, shielded power/encoder cable, STO safety relay, PLC communication module.
• Commissioning Software: IndraWorks Engineering for parameter setting, motor identification, bus configuration, fault diagnosis and firmware upgrade.
• Upper System: PLC, HMI, motion controller via real-time fieldbus for remote parameter setting and operation control.
• Typical Applications: Heavy-duty CNC machine tools, metallurgical rolling lines, blow molding & stamping equipment, port handling machinery, electro-hydraulic servo energy-saving retrofits, multi-axis common DC bus automation production lines.

Product Features

1. Four-quadrant grid regenerative operation recycles braking energy to reduce power consumption and cabinet heat, eliminating large brake resistor investment and maintenance cost.
2. High current and strong overload capacity ensures stable operation under heavy shock and frequent forward/reverse working conditions.
3. DC bus integrated 24V control power simplifies wiring and avoids sequential power-on fault risks.
4. Dual energy protection via grid feedback + built-in brake chopper guarantees DC bus voltage stability under abnormal working conditions.
5. Wide compatibility with mainstream encoders and industrial real-time buses enables seamless connection with various automation control platforms.
6. Intelligent temperature-controlled fan cooling ensures long-term 24/7 continuous stable operation of heavy-load production equipment.

II. Technical Specifications

2.1 Electrical Parameters

• Model: HCS03.1E-W0210-A-05-NNBV, Part No.: R911308415
• Input Power: 3×AC 400～500V, 50/60Hz
• DC Bus: 560～700VDC
• Continuous Output: 146A; Peak Output: 210A
• Rated Power Range: 47～124kW
• Switching Frequency: 4/8/12/16kHz configurable
• Max Output Frequency: 1600Hz
• Control Power: 24VDC derived from DC bus
• Operation Mode: Four-quadrant regenerative with integrated brake chopper
• Safety Functions: STO, overcurrent, overvoltage, undervoltage, overtemperature, encoder loss, earth short-circuit protection
• Core Functions: Three-loop servo control, common DC bus parallel, electronic cam/gear, tension control, fault data recording, offline motion program execution

2.2 Mechanical & Environmental Parameters

• Mounting: Vertical cabinet installation
• Cooling: Built-in variable-speed forced air cooling
• Protection Class: IP20
• Operating Temperature: 0～45℃; Storage Temperature: -20～60℃
• Altitude: Max 1000m, derating required above 1000m

  
  

III. Key Features

1. Regenerative energy feedback realizes energy circulation between multiple servo axes on common DC bus, greatly reducing system energy consumption and thermal load.
2. High dynamic three-loop control achieves high positioning accuracy and strong load disturbance suppression for precision processing and tension control processes.
3. Integrated STO safety function complies with machinery safety standards, supporting emergency stop safety interlock to prevent accidental motor runaway.
4. Automatic motor parameter identification and resonance suppression function shorten on-site commissioning cycle and improve equipment operation stability.
5. Complete fault data recording and waveform diagnosis facilitate accident traceability and equipment performance optimization.
6. Flexible bus and encoder expansion adapts to diversified industrial automation upgrading and spare parts replacement scenarios.

IV. Working Principle

V. Application Scenarios

1. Spindle and feed axis high-power servo drive for heavy-duty CNC machine tools to realize high-speed precision cutting.
2. Tension control servo system for metallurgical rolling, foil slitting and winding production lines.
3. Large blow molding, stamping and forming equipment with frequent heavy-load start-stop working conditions.
4. Lifting and handling servo system for port and mining heavy machinery to restrain potential energy impact during load descending.
5. Energy-saving renovation of traditional hydraulic equipment into electric servo drive to improve control precision and reduce energy consumption.
6. Common DC bus multi-axis energy-saving transformation and emergency spare replacement of old high-power servo drives.