Bosch Rexroth DKC03.3-040-7-FW | ECO Drive 03 Servo Drive Controller

Description

Core Product Summary (Brand / Model / Key Attributes)

The DKC03.3-040-7-FW is a digital AC servo drive controller from the Bosch Rexroth Indramat ECO DRIVE03 (EcoDrive 03) family, part number R911279428 in its documented configuration. The designation decodes as follows: DKC03 is the drive controller series for the ECO DRIVE03 platform, “.3” is the hardware version, “040” is the rated current class of 40 A, “7” is the 700 V DC bus voltage class, and “-FW” indicates that the firmware is supplied as an external, exchangeable module rather than fixed in the unit.

The controller rectifies a three-phase mains input of 200–480 V AC (±10 %, 50–60 Hz) onto a DC bus with 700 V nominal voltage (500–800 V range) and converts it into regulated phase currents for Indramat servo motors, with a 40 A rated output and a maximum output voltage of 800 V at up to 1000 Hz. It supports position, velocity, and torque control modes, communicates via a PROFIBUS-DP interface module, and integrates into multi-axis ECO DRIVE03 systems powered from a shared DC bus.

Key Technical Specifications

Detailed Product Overview

The ECO DRIVE03 family is Bosch Rexroth Indramat’s modular servo drive platform for industrial motion control, and the DKC03.3-040-7-FW is its 40 A controller for the 700 V DC bus class. In the platform architecture, a mains feed module rectifies the supply onto a shared DC bus, and individual DKC drive controllers hang off that bus to convert intermediate-circuit energy into precisely regulated motor currents. This allows multi-axis machines to share braking energy across the common bus rather than burning it in bleeder resistors.

The drive supports the three classical servo control modes — position, velocity, and torque — making it suitable both for coordinated multi-axis motion under a higher-level controller and for autonomous single-axis positioning tasks. Its compatible motor family is the Indramat MKD series of AC servo motors, alongside other Indramat servo machines matching the voltage and current class.

The “-FW” designation is significant for maintenance: the firmware is housed in a separate module mounted outside the controller housing, so firmware can be inspected, replaced, or upgraded without opening the power section. Firmware versions are application-specific, and the DKC03.3 in particular is associated with the PROFIBUS-DP interface (via the optional DKC03.3-LK-PBK02 card), which provides fast cyclic data exchange with PLCs and HMIs in decentralized motion architectures.

Electrically, the unit accepts a wide 200–480 V AC input range, making one hardware variant usable across regional supply standards, and it carries a UL 508 / CSA listing. Thermal management is by internal blower, and installation requires 150 mm clearance above and 80 mm below the unit for airflow. The 40 A rating applies as the peak/type current class; continuous current depends on the pulse frequency, at 16 A at 4 kHz and 12.5 A at 8 kHz.

Typical applications include material handling systems (conveyors, palletizers), packaging machinery controlling rollers, belts, and feeders, CNC machine tools, and printing presses — machinery classes where ECO DRIVE03 was deployed extensively in the 2000s and which today are maintained through the spares and repair market.

DKC03.3-040-7-FW

DKC03.3-040-7-FW

Engineering Selection Highlights

• Designation decode for ordering — DKC03.3-040–7-FW: series 03, version 3, 40 A current class, 700 V DC bus, external firmware. Each field is an ordering parameter; a mismatched current class or voltage class will not fit the application.
• Firmware module is application-specific — the -FW module carries the application firmware (e.g., PROFIBUS, FLP flying-saw, standard motion firmware); a replacement controller must receive the correct firmware version for the machine, or be exchanged with its original firmware module.
• Continuous vs. peak current — the 40 A figure is the type/peak current; continuous capability is 16 A at 4 kHz and 12.5 A at 8 kHz pulse frequency. Size the motor and duty cycle against the continuous rating at the selected pulse frequency.
• Wide mains range — 200–480 V AC ±10 % covers 230 V and 400/480 V regional supplies; verify the actual supply voltage against the DC bus link (700 V nominal, 500–800 V range) expected by the system’s feed module.
• DC bus sharing — in multi-axis ECO DRIVE03 systems the DKC connects to the common DC bus; when adding or replacing axes, confirm the feed module’s regenerative and bleeder capacity matches the enlarged axis count.
• Thermal installation — internal blower cooling requires 150 mm clearance above and 80 mm below; respect the 45 °C nominal ambient (55 °C with reduced performance) and 1000 m altitude limit.
• Protection and wiring — 20 A branch circuit protection fuse, AWG 12 copper wiring, 42 kA rms short-circuit rating; the control section needs a separate 24 V DC supply (21 W) that must remain available for diagnostics even when mains is removed.
• Motor pairing — verify the motor’s continuous and peak current, voltage class (matching the 700 V bus), and feedback type against the drive’s supported motor list (MKD-series and compatible Indramat servo motors).

Dimensions, Mounting & Connection Notes

• Dimensions: 360 × 261 × 65 mm
• Weight: 5.7 kg
• Mounting: cabinet-mounted drive controller in the ECO DRIVE03 lineup; maintain 150 mm clearance above and 80 mm below for the internal blower cooling
• Power connections: three-phase mains/DC bus per the system configuration; motor output 3-phase up to 800 V, 40 A; AWG 12 copper wiring
• Control connections: 24 V DC control voltage terminal, serial RS-232/RS-485 diagnostic interface, analog interface, and the option slot for the DKC03.3-LK-PBK02 PROFIBUS-DP card
• Firmware module: externally mounted -FW module, accessible without opening the power section
• Protection: 20 A branch circuit fuse required on the supply

System Compatibility & Integration Requirements

FAQ

What is the DKC03.3-040-7-FW?
It is a 40 A digital servo drive controller from the Bosch Rexroth Indramat ECO DRIVE03 family, operating on a 700 V DC bus with an external, replaceable firmware module.

What does each part of the designation mean?
DKC03 identifies the ECO DRIVE03 controller series, “.3” the hardware version 3, “040” the 40 A current class, “7” the 700 V DC bus voltage class, and “-FW” the external firmware module.

What supply does the drive need?
A three-phase mains input of 200–480 V AC (±10 %, 50–60 Hz) at up to 16 A for the power section, plus a separate 24 V DC control supply consuming about 21 W.

How much current can it deliver continuously?
The 40 A figure is the type/peak current class. Continuous output is 16 A at a 4 kHz pulse frequency and 12.5 A at 8 kHz.

What communications does it support?
PROFIBUS-DP via the optional DKC03.3-LK-PBK02 interface card, plus RS-232/RS-485 serial and analog interfaces for setup and single-axis operation.

What does the “-FW” firmware module mean for maintenance?
The firmware resides in a module mounted outside the controller housing, so it can be replaced or transplanted without opening the power section — when swapping a failed drive, the original firmware module is transferred to the replacement to preserve the machine’s application program version.

Which motors does it drive?
Indramat MKD-series AC servo motors and other compatible Indramat servo machines matching the 700 V bus class and 40 A current rating.

What are its approvals and protection ratings?
UL 508 (file E134201),CSA C22.2 名列前茅4-05, CE; 42,000 A rms short-circuit current rating; pollution degree 2; installation up to 1000 m altitude without derating.

Verification & Troubleshooting Notes

• Drive will not enable: verify the 24 V DC control supply is present (the drive needs control voltage before it will respond to enable commands), then check the DC bus voltage is within 500–800 V — an uncharged or undervoltage bus blocks enabling.
• Firmware mismatch after drive exchange: confirm the -FW module from the original drive was transferred and seated correctly; the replacement will not run the machine’s application without its original firmware version.
• Overtemperature or frequent thermal derating: check the 150 mm top / 80 mm bottom clearances, confirm the internal blower runs, clean the fan and heatsink, and verify cabinet ambient stays within 45 °C (55 °C reduced-performance limit).
• PROFIBUS communication errors: verify the DKC03.3-LK-PBK02 card is seated, bus termination is present at both segment ends, and the configured station address and baud rate match the PLC project.
• Motor runs rough or trips on overcurrent: confirm the motor cable and feedback connections match the drive’s configured motor type (MKD series), check the continuous current demand against the 16 A @ 4 kHz / 12.5 A @ 8 kHz rating at the selected pulse frequency, and inspect for short circuits in the motor circuit.
• Mains input problems: the supply must be within 200–480 V AC ±10 % and 50–60 Hz ±2 Hz; the 20 A branch fuse protects the input — verify supply voltage balance on all three phases.
• Diagnostics: use the RS-232/RS-485 serial interface with the EcoDrive 03 diagnostic tooling to read the error history and status before replacing hardware; many faults (bus undervoltage, control voltage, temperature) have external causes.
• The power section works at DC bus voltages up to 800 V — allow the bus to discharge per the specified wait time after removing mains before any wiring or module work, and observe lockout procedures for the shared DC bus in multi-axis cabinets.