Replacing an Indramat HDS Drive

May 08, 2025

Why Replace an HDS Drive?

Indramat HDS servo drives, part of the DIAX04 automation platform by Bosch Rexroth, were widely adopted across the manufacturing sector for their reliability and precise motion control. However, many HDS drives are now decades old, and while still robust, they may exhibit signs of wear, electrical degradation, or incompatibility with modern systems.

Replacing or upgrading an HDS drive isn’t just about equipment longevity—it's also about ensuring continued uptime, eliminating fault risks, and enabling integration with current PLCs, HMIs, and safety protocols.

Signs It’s Time to Replace Your HDS Drive

Frequent fault codes (e.g., F208, F219, F226)
Overheating during normal operation
Unusual vibrations or inconsistent torque output
Loss of encoder feedback or intermittent communication
Obsolete firmware not compatible with newer automation systems
Replacement parts are difficult to source or are end-of-life

If your HDS drive is experiencing any of the above, a planned replacement is a smart alternative to unexpected failure and production halts.

Key Specifications of Indramat HDS Drives

Before ordering a replacement, gather the following from the drive’s nameplate:

Model number (e.g., HDS02.2-W040N)
Power rating and output current
Software module version (firmware type stored in the SERCOS interface)
Feedback and motor type (MAC, MAD, etc.)
Cooling type (internal fan or external blower)

This ensures accurate compatibility when matching with a refurbished unit or an upgraded alternative.

Replacement Options

. Refurbished HDS Drives

Wake Industrial stocks a wide range of professionally refurbished Indramat HDS drives. These are restored to factory standards, tested for performance, and often include warranty options. Refurbished drives are the best fit for facilities not yet ready to migrate their entire automation platform.

. HDS-to-IndraDrive Retrofit

For plants modernizing their automation systems, consider retrofitting your DIAX04 system with the IndraDrive platform. Wake Industrial can assist with:

Hardware mapping (matching legacy motors with new drives)
Adapter cabling
SERCOS-to-EtherNet/IP transition plans
Custom retrofit kits for panel-mount compatibility

Replacing the Drive: What to Expect

Steps for Replacement

Power Down & Lockout/Tagout
Ensure all incoming power is off. Use LOTO procedures.
Label and Disconnect Wiring
Label all power, control, and feedback connections.
Remove the Faulty HDS Drive
Unscrew mounting hardware, disconnect cooling, and safely remove the drive.
Install Replacement Drive
Mount the replacement unit, rewire, and check for correct grounding and spacing for ventilation.
Restore Power and Test
Reboot the system and observe for fault codes, abnormal behavior, or communication issues.

Tip: If you're unsure about firmware compatibility or programming, Wake Industrial can pre-load the correct DSM firmware module or assist with setup parameters based on your HDS drive's application history.

Don’t Forget to Inspect:

The SERCOS loop and fiber optics for degradation
The mating servo motor (check bearings, feedback cable)
The cooling fans or heat sinks
Drive enclosure ventilation and filters

Final Thoughts

Replacing an Indramat HDS drive doesn’t need to be disruptive or costly. With a reliable refurbished unit or a modern upgrade path, you can preserve the integrity of your existing system while extending its operational lifespan. Whether you're in metalworking, printing, robotics, or conveyor automation, Wake Industrial provides the solutions and inventory to keep your lines moving.

For more information , contact PLG Automation:Email: sales@plgautomation.comPhone: 800-906-9271