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Key Technical Specifications
| Parameter | Value |
|---|---|
| Manufacturer | Bosch Rexroth / Indramat |
| Generic Model Family | DKCXX.3-040-7-FW |
| Product Family | EcoDrive |
| Controller Family | DKC Drive Controllers |
| Design Generation | .3 |
| Rated Current Code | 040 |
| Rated Current | 40 A |
| DC Bus Voltage Code | -7 |
| Nominal DC Bus Voltage | 700 V DC |
| Permitted DC Bus Range | 500–800 V DC |
| Maximum Output Voltage | 800 V |
| Maximum Output Frequency | 1,000 Hz |
| AC Supply Architecture | 200–480 V AC three-phase system, depending on the installed EcoDrive power-supply configuration |
| Control Supply Voltage | 24 V DC |
| Control-Electronics Power | Approximately 21 W |
| Maximum Input Current | 16 A, reported for the 40 A drive class |
| Cooling | Internal blower / forced-air cooling |
| Operating Temperature | 0 to +45 °C at nominal rating; derating may apply above this range |
| Maximum Operating Temperature | Up to +55 °C with derating, subject to the exact DKC version and installation conditions |
| Protection Rating | IP20 |
| Approximate Dimensions | 360 mm H × 65 mm W × 261 mm D |
| Approximate Weight | 5.7 kg |
| Required Top Clearance | 150 mm |
| Required Bottom Clearance | 80 mm |
| Communication and Feedback | Firmware-, option-card-, and exact DKC-version-dependent |
| Replacement Requirement | Match the full DKCxx prefix, firmware, option cards, motor feedback, and parameter set |
“DKCXX.3-040-7” is a family-level identifier, not a complete serviceable ordering number. The “XX” can represent different DKC controller versions, such as DKC01.3, DKC02.3, DKC03.3, or another member of the EcoDrive family. The “040” identifies a 40 A current class, and “7” identifies the 700 V DC-bus category. The complete suffix normally ends with “-FW,” meaning the firmware specification is required.
Public references for the DKCXX.3-040-7-FW family list 40 A rated current, 700 V DC nominal bus voltage, 800 V maximum output voltage, 1,000 Hz maximum output frequency, 24 V DC auxiliary control supply, approximately 21 W control consumption, and an operating range up to +45 °C at nominal rating. Treat these as family-level values until the actual DKC nameplate and documentation are confirmed.
Product Introduction
The Bosch Rexroth Indramat DKCXX.3-040-7-FW is a 40 A EcoDrive servo drive controller family operating from a 700 V DC link. It converts DC-bus energy into controlled three-phase motor output for closed-loop position, velocity, and torque control. These drives appear in CNC machinery, printing equipment, packaging lines, automation cells, material handling systems, and other multi-axis motion applications.
The important point is that DKCXX.3-040-7 is not enough to guarantee a direct replacement. The complete DKC prefix, firmware, motor/encoder interface, communication option, installed software parameters, and power-supply architecture determine whether a spare will commission. A correct-looking 40 A, 700 V drive can still fail at startup if its firmware or feedback hardware does not match.
DKCXX.3-040-7
DKCXX.3-040-7
Troubleshooting Quick Reference
| Symptom | Possible Cause | Relevance to This Part | Quick Check Method | Recommendation |
|---|---|---|---|---|
| Display remains dark after control power is applied | Missing 24 V DC control supply, blown fuse, reversed polarity, loose connector, failed internal control circuit | ✅ High | Measure 24 V DC at the exact control-supply terminals using a CAT-rated multimeter. Verify polarity, upstream fuse continuity, and voltage under load. | Repair the 24 V DC supply path before replacing the controller. The DC bus can be present while control electronics remain unpowered. |
| Drive shows a ready state but motor will not enable | Open safety chain, missing drive-enable command, active emergency stop, PLC inhibit, parameter fault | ❌ Usually low | Check the active drive diagnostic, safety relay contacts, enable input, machine PLC output, and controller interlock logic. | Do not replace the drive first. Most no-enable faults are caused by safety circuits, machine logic, or an external permissive. |
| F218 overtemperature fault | Blocked cooling path, failed internal blower, dirty heatsink, cabinet ambient too high, sustained overload | ✅ High | Confirm blower operation. Inspect cabinet filters and ventilation. Measure cabinet ambient near the drive and verify 150 mm top and 80 mm bottom clearance. | Clean cooling paths and correct the load or cabinet condition. Persistent F218 after airflow checks can indicate a failed fan or internal temperature-sensing issue. |
| F219 motor overtemperature fault | Motor overload, failed motor fan, poor motor cooling, damaged thermistor wiring, incorrect motor-data settings | ❌ Usually low | Check motor temperature sensor continuity and motor-cooling equipment. Trend motor current and torque demand during the fault cycle. | Investigate the motor, mechanical load, and temperature-feedback circuit before replacing the DKC controller. |
| F226 DC-bus undervoltage | Incoming power interruption, line-voltage sag, phase loss, failed supply contactor, loose DC-bus link | ❌ Usually low | Review facility-power events. Measure incoming line voltage under load and inspect the common DC-bus connection, line fuses, and contactor condition. | Correct the power-source fault. Remove the drive-enable command before intentionally removing main power to avoid repeat undervoltage trips. |
| F234 or F434 emergency-stop indication | Emergency-stop device activated, safety relay open, guard switch open, damaged safety wiring | ❌ Low | Check the full safety loop, reset all E-stop devices, inspect safety relay status, and review the machine electrical drawing. | Find the cause of the safety event. Never bridge or bypass the safety input to run the machine. |
| F277 internal hardware fault | Failed internal electronics, current-sensing fault, control-board failure, firmware issue | ✅ High | Record the full fault code and firmware data. Perform one controlled power cycle after checking supply voltage and connections. | If F277 returns, treat the controller as defective. Send it for qualified repair or replace it with a fully matched unit. |
| Motor vibrates, locks, or runs roughly | Encoder feedback error, motor cable issue, brake not releasing, mechanical jam, incorrect motor parameters | ⚠️ Medium | With power isolated, verify motor shaft movement and brake wiring. Inspect encoder and motor cable connectors. Compare installed motor data with the commissioning backup. | Restore correct motor parameters and inspect feedback wiring before condemning the drive. |
| Axis moves in the wrong direction after replacement | Feedback polarity issue, parameter mismatch, command scaling error, wrong motor configuration | ✅ Medium | Stop motion safely. Compare old and replacement drive parameter sets, feedback type, motor model, and direction settings. Conduct only controlled low-speed commissioning moves. | Load the approved parameter backup. Do not tune or reverse wiring by trial and error on an unrestricted axis. |
| Fieldbus communication will not establish | Wrong option card, wrong firmware, incorrect node address, bad cable, missing termination, PLC hardware configuration mismatch | ⚠️ Medium | Inspect the actual interface card and connector. Confirm node address, cable shielding, termination, and PLC diagnostics. | Verify interface hardware and firmware from the old drive before ordering. DKCXX.3-040-7 does not prove PROFIBUS, SERCOS, or another network interface. |
| Replacement drive faults immediately | Wrong DKC version, wrong firmware, mismatched feedback interface, missing parameter data, improper power wiring | ✅ High | Compare the entire old and new nameplates, firmware labels, option cards, motor and encoder references, wiring, and parameter file. | Stop installation until all configuration details match. Order against the complete nameplate, not just the DKCXX.3-040-7 family designation. |
❗ High-voltage warning: DKCXX.3-040-7 controllers use a DC bus with a nominal voltage of 700 V DC and reported operating range of 500–800 V DC. Stored energy can remain after incoming power is removed. Lock out all energy sources, wait for the specified discharge interval, and verify safe voltage with an approved meter before handling power terminals.
❗ Replacement warning: Take a photo of the old drive before disconnecting anything. Capture the entire nameplate, firmware label, option cards, connector layout, encoder cable, bus connector, motor label, and parameter version. A 40 A, 700 V controller with the wrong firmware can create a longer outage than the original fault.
If you need technical support, provide the complete nameplate photo, exact fault code, motor nameplate, parameter backup, fieldbus interface photo, controller diagnostics, and measured values for incoming supply, DC bus, and 24 V DC control power.
Frequently Asked Questions
What does DKCXX.3-040-7 mean?
DKCXX.3-040-7 identifies a family of Bosch Rexroth Indramat EcoDrive servo controllers. “XX” is a placeholder for the specific DKC version, “.3” identifies the design generation, “040” identifies the 40 A current class, and “7” identifies the 700 V DC-bus category. The usual complete designation includes “-FW” because the firmware must be specified.
Is DKCXX.3-040-7 a complete part number?
No. It is not sufficient for a direct replacement order. You need the full prefix, such as DKC01.3, DKC02.3, or DKC03.3; the entire nameplate; firmware designation; communication card; motor-feedback type; and parameter configuration. If the old unit is still readable, photograph every label before removal.
Is DKCXX.3-040-7 always a 40 A drive?
Yes, the “040” code identifies the 40 A rated-current class for this EcoDrive DKC family. However, do not use that number as the expected motor current without checking the specific motor data, duty cycle, acceleration profile, load inertia, and parameterized current limits.
What voltage does DKCXX.3-040-7 use?
It operates from a nominal 700 V DC bus, with public family-level references reporting a 500–800 V DC range. Its control electronics use a separate 24 V DC auxiliary supply. The larger power system is typically fed from a three-phase 200–480 V AC source through the applicable EcoDrive supply architecture.
Does DKCXX.3-040-7 include PROFIBUS?
Not necessarily. The generic DKCXX.3-040-7 designation does not identify the installed communication interface. The actual drive may use PROFIBUS, SERCOS, another option, or a configuration tied to its firmware and hardware. Inspect the old drive’s option card and connector before purchasing a spare.
Can I hot-swap a DKCXX.3-040-7 drive?
No. Do not hot-swap this controller. It is part of a high-energy motion system, and live removal can cause electric shock, arc-flash exposure, equipment damage, uncontrolled motion, or a machine safety trip. Shut down under lockout/tagout, let the DC bus discharge, verify voltage, and follow the OEM maintenance procedure.
Will a replacement drive retain my machine settings?
Do not count on it. The PLC program typically stays in the controller, but the servo drive may require motor data, encoder settings, command-interface configuration, current limits, tuning values, and application parameters. Back up the parameters before removal. If the failed drive cannot be read, obtain the archived commissioning file or a verified backup from a matched axis.
Is DKCXX.3-040-7 obsolete?
It is a legacy EcoDrive product family that is generally sourced through repair, refurbished, and surplus channels. Listings continue to exist, but availability does not prove current manufacture, equal revision status, or long-term OEM support. Treat any shutdown-critical purchase as a configuration-controlled spare-part acquisition.
Why is a New Surplus DKCXX.3-040-7 cheaper than a current drive?
New Surplus units can come from machine-builder spares, canceled projects, unused MRO inventory, distributor overstock, or decommissioned equipment. Their lower price normally reflects age, inventory turnover, and obsolescence risk. Request exact-unit photos, full nameplate data, firmware and option-card photos, a warranty, power-up results, motor-run testing where available, and a clear return policy.
What test evidence should I request for a refurbished drive?
Request an incoming inspection record, capacitor and power-stage assessment where the repair provider performs one, nameplate and firmware photos, 24 V DC control-power verification, internal blower check, diagnostic-display check, DC-bus monitoring, a compatible motor run test, encoder-feedback test, interface communication test for the installed option card, and a documented run period without faults. Final commissioning still requires the correct motor, safety circuit, parameter file, mechanical load, and machine controls.
