Bosch Rexroth DKC01.3-100-7-FW Retrofit Drive for DKC Series

Bosch Rexroth DKC01.3-100-7-FW Retrofit Drive for DKC Series: Legacy-Compatible Servo Upgrade for Industrial Automation

The Bosch Rexroth DKC01.3-100-7-FW is a compact, high-performance AC servo drive from the Indramat DKC series, designed for precision motion control in legacy CNC, robotics, and automated production line applications. As original DKC series drives approach end-of-life and spare parts become increasingly scarce, the DKC01.3-100-7-FW remains one of the most sought-after retrofit-compatible units for engineers tasked with modernizing aging control architectures without full system replacement.

This unit supports a continuous output current of 100A and is firmware-compatible with the FW (firmware) variant designation, making it a direct drop-in candidate for existing DKC01.3 installations. Engineers working on legacy Bosch Rexroth Indramat platforms will find this drive fully compatible with the standard DKC rack and backplane interface, eliminating the need for mechanical modification during replacement.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

When integrating the DKC01.3-100-7-FW into an existing Bosch Rexroth Indramat control environment, a structured retrofit plan is essential to minimize risk and protect production continuity. The DKC series drive typically operates within a coordinated system that includes the HDS power supply module, which must be verified for adequate DC bus capacity before swapping a 100A-rated drive. Engineers should confirm that the HDS unit’s continuous output rating matches or exceeds the combined demand of all DKC axis drives in the cabinet.

The DKC01.3-100-7-FW communicates via SERCOS II fiber-optic ring in most legacy CNC configurations. Before replacement, document the SERCOS ring topology and confirm the drive’s node address matches the original unit. If the control system uses a Bosch Rexroth DIAX04 or Indramat TDM series controller as the master, verify that the firmware version on the replacement DKC01.3-100-7-FW is compatible with the master’s communication cycle time settings.

Terminal wiring adaptation is a critical step. The X1 motor power connector and X2 encoder feedback connector must be re-terminated using the original cable assemblies. If the existing cables use the IKS or IKG series Rexroth encoder cables, inspect the shielding integrity before reconnection, as degraded shielding can introduce encoder noise and cause drive faults. The X8 control voltage connector (24VDC logic supply) should also be verified for correct polarity and voltage level before powering the replacement unit.

For systems that include a Bosch Rexroth BTV or VDP HMI panel, the axis parameter set stored in the HMI or PLC must be re-uploaded to the new drive using IndraWorks DS or the legacy DriveTop commissioning software. Retain a backup of the original parameter file (.par) before any replacement activity. If the original parameter file is unavailable, axis parameters can often be reconstructed from the motor data sheet for the connected MSK, MKD, or MHD series servo motor.

In multi-axis cabinets, the DKC01.3-100-7-FW shares a common DC bus with adjacent DKC02.3 or DKC03.3 drives. Confirm that the bus capacitor bank in the HDS power supply is within service life before energizing the replacement drive. A degraded capacitor bank can cause bus voltage instability and trigger overcurrent faults on the new unit, leading to misdiagnosis of the replacement drive as faulty.

Signal isolation between the DKC drive and the upstream PLC I/O — often a Bosch Rexroth Inline or Beckhoff EtherCAT I/O module — should be verified using a signal isolator or differential probe before final commissioning. Ground loops between the drive cabinet and the PLC panel are a common source of intermittent faults in legacy retrofit projects.

Downtime Control During System Migration

Minimizing unplanned downtime is the primary concern in any DKC series drive replacement project. A structured swap procedure for the DKC01.3-100-7-FW should begin with a full parameter backup from the existing drive using DriveTop or IndraWorks, followed by a controlled shutdown sequence that allows the HDS power supply to discharge the DC bus safely before the drive module is extracted from the rack.

Where production schedules permit, a bench test of the replacement DKC01.3-100-7-FW using a compatible MSK or MKD motor and a test parameter set is strongly recommended before installation in the live cabinet. This pre-installation test confirms that the drive’s power stage, encoder interface, and SERCOS communication are fully functional, reducing the risk of extended downtime caused by a second fault during the live swap.

For critical production lines where even a brief interruption is unacceptable, consider staging a pre-configured spare DKC01.3-100-7-FW with the axis parameters pre-loaded. This allows the physical swap and parameter verification to be completed within a single planned maintenance window, typically under two hours for a single-axis replacement. Coordinate with the machine builder or OEM documentation to confirm the correct enable sequence for the drive after parameter upload, as some legacy CNC systems require a specific axis enable order to prevent position reference errors on startup.

After the replacement drive is installed and parameters are verified, perform a slow-speed jog test on each axis before returning the machine to automatic cycle. Monitor the drive’s diagnostic display for fault codes F2xx (power section) or E2xx (encoder) during the initial jog, and confirm that the actual position feedback matches the commanded position within the system’s tolerance band. Document the completed replacement in the machine’s maintenance log, including the serial number of the replacement DKC01.3-100-7-FW and the date of installation.

Retrofit Support FAQ

Q: Is the DKC01.3-100-7-FW a direct replacement for my existing DKC01.3-100-7-FW unit?
A: Yes. The DKC01.3-100-7-FW is a direct form-fit-function replacement for the same model. The unit uses the same backplane connector, terminal layout, and firmware variant designation. Re-upload your original parameter file using DriveTop or IndraWorks DS after installation to restore axis behavior.

Q: What commissioning software is required to configure the replacement drive?
A: Bosch Rexroth IndraWorks DS or the legacy DriveTop software (version 4.x or later) is required for parameter upload and axis commissioning. The drive communicates via the RS232 service interface (X2 diagnostic port) or via the SERCOS ring depending on the commissioning method used.

Q: Does the unit ship with a pre-shipment functional test?
A: Yes. Every DKC01.3-100-7-FW unit dispatched by NINERMAS undergoes a full functional test prior to shipment, including power stage verification, encoder interface check, and communication link validation. A 12-month warranty is provided from the date of shipment.

Q: What is the typical lead time and stock availability?
A: The DKC01.3-100-7-FW is held in stock and available for immediate dispatch. Standard lead time is 3–5 business days for international shipments. Contact our team to confirm current inventory levels and expedited shipping options for urgent production recovery situations.