Rexroth HVE04.2-W075N

Core Technical Specifications

1. Input Electrical Parameters
   • Input Power: Three-phase 380–480V AC, 50/60Hz
   • Rated continuous input power: 75kW
   • Input power factor correction: Active PFC circuit, PF ≥0.98 under full load
   • Input current THD: Less than 5% compliant with EN 61000-3-12 harmonic standards
2. DC Bus Output Parameters
   • Nominal DC bus voltage: 600V DC stabilized output
   • Peak short-time overload capacity: 150% rated power lasting 60 seconds for machine tool rapid traverse
   • DC bus ripple voltage: ≤12V peak-to-peak under full rated load
3. Regenerative Performance
   • Max feedback regenerative power: 75kW bidirectional energy transfer
   • Grid feedback response time: <3ms when axis deceleration generates excess kinetic energy
4. Control & Communication
   • Standard interface: SERCOS II digital servo bus for synchronized multi-axis control
   • Auxiliary I/O terminals: 8 digital input, 4 relay digital output for enable, fault, ready interlock signals
   • Service port: RS232 diagnostic port for IndraWorks engineering software parameter tuning
5. Mechanical & Environmental
   • Mounting: Vertical rack-mounted industrial cabinet installation
   • Dimension: 310(W) × 520(H) × 210(D) mm
   • Weight: 32 kg
   • Operating temperature range: 0°C ~ +45°C; de-rate power by 1% per 1°C above 45°C
   • Protection rating: IP20 cabinet interior only
   • Vibration resistance: 10–150Hz, amplitude ≤0.1mm IEC 60068

Function & Performance Features

• Active power factor correction eliminates reactive power loss, reduces factory transformer capacity consumption and electricity cost
• Bidirectional regenerative grid feedback: Kinetic energy released from decelerating servo axes is converted back to three-phase mains instead of wasting via braking resistors, cutting total system power consumption by 15%–35% for stamping, cutting, packaging equipment
• Centralized shared DC bus architecture: Multiple servo axes share one power supply unit, simplifying cabinet wiring and reducing overall system component quantity
• Multi-layer safety protection logic: Input overvoltage/undervoltage, DC bus overvoltage, output short-circuit, over-temperature, phase loss, earth leakage fault detection with latching fault relay output
• Fast SERCOS bus synchronization: Supports up to 32 servo axes with microsecond-level synchronized motion control for printing, cutting, forming equipment
• Built-in EMC input filter integrated inside module, eliminating need for external separate mains filter to save cabinet space
• Dynamic DC bus voltage stabilization circuit suppresses voltage sag/spike during sudden heavy load switching, avoiding servo axis position deviation
• Non-volatile flash memory stores fault history log including overcurrent, overheat, phase failure records for equipment failure diagnosis

Working Principle

Material & Structural Characteristics

• Outer Enclosure: Thick cold-rolled steel cabinet shell with electrostatic anti-rust paint coating, high mechanical impact resistance for machine workshop environment
• Power Semiconductor Assembly: High-current IGBT power modules mounted on large finned aluminum liquid cooling heat sink (optional forced air cooling variant available)
• Internal Busbar: Tinned copper laminated busbars for low impedance DC power transmission, reduces heat generation under high current load
• Wiring Terminals: Bolt-type heavy-duty copper terminals with locking washers, compatible with large cross-section high-current power cables
• Internal PCB: Multi-layer industrial control circuit board coated with moisture-proof conformal coating to resist workshop oil mist and dust corrosion
• Cooling System: Dual structure; standard air forced convection with built-in variable speed cooling fan, liquid cooling optional for high-temperature cabinet environments

Installation Requirements

1. Strict vertical rack mounting only; horizontal installation blocks heat sink airflow and triggers frequent over-temperature protection
2. Reserve minimum 150mm clearance above and below the unit for cooling air circulation; maintain 50mm side clearance between adjacent power modules
3. Three-phase mains input wiring must use shielded high-current power cable, cable shield single-point grounded at cabinet earth bar
4. Install external three-phase circuit breaker and fast-blow semiconductor fuses on upstream input line to provide external short-circuit isolation protection
5. Separate high-power mains/DC bus wiring and low-voltage SERCOS communication signal wiring into independent cable ducts with minimum 10cm separation gap to avoid EMI interference
6. Cabinet must be equipped with exhaust ventilation fan to keep internal ambient temperature below 45°C for full rated 75kW output performance
7. SERCOS communication cable must use dedicated Rexroth shielded servo bus cable to guarantee multi-axis synchronization precision

Typical Application Scenarios

• High-speed multi-axis metal stamping press servo drive central power supply
• Printing & paper processing machine synchronized multi-servo motion control system
• Automated plastic injection molding multi-axis clamping and injection servo group
• Textile spinning and weaving high-speed loom servo power system
• Laser cutting, water jet cutting precision machine tool multi-axis servo platform
• Automated packaging, palletizing robotic arm multi-servo drive cabinet
• Automotive component CNC machining center high dynamic servo equipment

Operation & Maintenance Precautions

1. Complete mains phase sequence verification before power-on; reversed three-phase input will trigger phase loss fault alarm and lock output
2. Monthly cleaning of cooling fan and aluminum heat sink fins to remove accumulated metal dust and fiber debris, preventing heat dissipation decline
3. Disconnect upstream main circuit breaker and wait minimum 15 minutes for DC bus capacitor complete discharge before opening unit housing for maintenance
4. Do not connect braking resistor to HVE power supply; regenerative energy is directly fed back to grid, external braking resistors are incompatible with this model
5. Annual insulation resistance test for internal power circuit and cooling fan winding to detect aging insulation in high-humidity workshop
6. Firmware upgrade must be executed with stable uninterrupted three-phase mains power supply; power loss during upgrade will corrupt control firmware
7. Record all fault log data before clearing fault memory for equipment failure root cause analysis
8. Never modify internal power circuit wiring or remove built-in EMC filter components; such alterations void CE safety certification and risk grid harmonic pollution