Rexroth Diax 04 Hve and HVR 2nd Generation Power Supply Units

Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
Rexroth Diax 04
R911280641
HVE and HVR Edition 07
2nd Generation Power Supply Units
Application Manual
HVE and HVR 2nd Gen. Power Supply Units
Title DIAX04
HVE and HVR
2nd Generation Power Supply Units
Type of Documentation Application Manual
Document Typecode DOK-POWER*-HVE+HVR**G2-AW06-EN-P
Internal File Reference Document Number, 120-1900-B301-07/EN
Purpose of Documentation The purpose of this documentation is to ....

• choose and calculate the power supply unit for the drive controllers
types DIAX04 (HDD and HDS), which is appropriate for your
applications
• plan the construction of the control cabinet
• mount and connect the power supply units
Record of Revisions Description Release Notes

Date
DOK-POWER*-HVE+HVR**G2-ANW1-EN-P 06.98 first edition
DOK-POWER*-HVE+HVR**G2-ANW2-EN-P 09.98 Revision
DOK-POWER*-HVE+HVR**G2-AN03-EN-P 03.99 Revision
DOK-POWER*-HVE+HVR**G2-AW05-EN-P 09.00 Revision
Copyright  Bosch Rexroth AG, 2003

Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
Validity The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85
http://www.boschrexroth.com
Dept. EDY1/EDH (US, DH)
Note This document has been printed on chlorine-free bleached paper.

HVE and HVR 2nd Gen. Power Supply Units Contents I
Contents
1 System overview 1-1
1.1 AC drive system ............................................................................................................................ 1-1
1.2 Principal working mode of the power supply units........................................................................ 1-2
1.3 Areas of application....................................................................................................................... 1-3
1.4 Overview of the unit features ........................................................................................................ 1-4
2 Important directions for use 2-1

2.1 Appropriate use............................................................................................................................. 2-1
Introduction .............................................................................................................................. 2-1
Areas of Use and Application................................................................................................... 2-2
2.2 Inappropriate Use.......................................................................................................................... 2-2
3 Safety Instructions for Electric Drives and Controls 3-1

3.1 Introduction ................................................................................................................................... 3-1
3.2 Explanations.................................................................................................................................. 3-1
3.3 Hazards by Improper Use ............................................................................................................. 3-2
3.4 General Information ...................................................................................................................... 3-3
3.5 Protection Against Contact with Electrical Parts ........................................................................... 3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) ......................................... 3-6
3.7 Protection Against Dangerous Movements .................................................................................. 3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting ....................................................................................................................................... 3-9
3.9 Protection Against Contact with Hot Parts .................................................................................. 3-10
3.10 Protection During Handling and Mounting .................................................................................. 3-10
3.11 Battery Safety.............................................................................................................................. 3-11
3.12 Protection Against Pressurized Systems .................................................................................... 3-11
4 Technical data 4-1

4.1 Ambient and operating conditions................................................................................................. 4-1
With installation elevations of more than 2000 m above sea level .......................................... 4-1
Storage of the power supply units ........................................................................................... 4-2
Data for vibration test............................................................................................................... 4-2
4.2 Power supply units HVE................................................................................................................ 4-3
4.3 Power supply unit HVR ................................................................................................................. 4-7
4.4 Commutation choke KD .............................................................................................................. 4-11
4.5 Combining filter HZF ................................................................................................................... 4-12
Type code .............................................................................................................................. 4-12
Technical data........................................................................................................................ 4-12
4.6 Tests and certifications ............................................................................................................... 4-13
DOK-POWER*-HVE+HVR**G2-AW07-EN-P
II Contents HVE and HVR 2nd Gen. Power Supply Units
5 Determination of appropriate power supply units 5-1

5.1 Introduction ................................................................................................................................... 5-1
5.2 DC bus continuous power ............................................................................................................. 5-1
5.3 DC bus peak power....................................................................................................................... 5-4
5.4 Regenerated energy ..................................................................................................................... 5-5
5.5 Continuous regenerated power..................................................................................................... 5-6
5.6 Peak regenerated power............................................................................................................... 5-7
5.7 Connected load of the power supply unit...................................................................................... 5-8
5.8 Using the control voltage............................................................................................................... 5-8
6 Additional modules and components 6-1

6.1 Ambient and operating conditions................................................................................................. 6-1
6.2 DC bus choke GLD ....................................................................................................................... 6-2
6.3 Additional capacitance module HZK ............................................................................................. 6-3
Technical Data ......................................................................................................................... 6-3
Dimensioning and unit arrangement........................................................................................ 6-3
Front view................................................................................................................................. 6-4
Unit dimensions ....................................................................................................................... 6-5
6.4 Additional bleeder module HZB .................................................................................................... 6-6
Technical Data ......................................................................................................................... 6-6
X0, Additional component bus ................................................................................................. 6-9
Front view............................................................................................................................... 6-10
Unit dimensions ..................................................................................................................... 6-11
6.5 Additional module HZS ............................................................................................................... 6-12
General information ............................................................................................................... 6-12
Monitoring functions and diagnostic messages ..................................................................... 6-13
Technical data........................................................................................................................ 6-13
Interfaces at the HZS ............................................................................................................. 6-14
Operation with external direct voltage DC bus ...................................................................... 6-23
System operation at the DIAX04 drive system ...................................................................... 6-24
Front view............................................................................................................................... 6-27
Device dimensions................................................................................................................. 6-28
Overall connection diagram ................................................................................................... 6-29
6.6 Additional components SUP-E0x................................................................................................ 6-30
Technical data........................................................................................................................ 6-31
Scope of supply...................................................................................................................... 6-34
7 Mounting 7-1
7.1 Control cabinet planning ............................................................................................................... 7-1
Conditions of use ..................................................................................................................... 7-1
Loss of heat in the control cabinet ........................................................................................... 7-3
7.2 Mounting an HVE or HVR into the control cabinet...................................................................... 7-10
7.3 Optimal EMC installation............................................................................................................. 7-13
HVE........................................................................................................................................ 7-13
HVR........................................................................................................................................ 7-14
7.4 Dimensional data ........................................................................................................................ 7-15
HVE and HVR 2nd Gen. Power Supply Units Contents III
HVE02.2and HVE03.2 ........................................................................................................... 7-15

HVE04.2................................................................................................................................. 7-16
HVR........................................................................................................................................ 7-17
HZF01.1-W010N.................................................................................................................... 7-18
HZF01.1-W025N / HZF01.1-W045N ..................................................................................... 7-19
Commutation choke KD xx .................................................................................................... 7-20
7.5 Mounting the unit......................................................................................................................... 7-21
8 Electrical connection 8-1

8.1 Introduction ................................................................................................................................... 8-1
8.2 Front view and terminal diagram................................................................................................... 8-2
HVE.......................................................................................................................................... 8-2
HVR.......................................................................................................................................... 8-5
HZF .......................................................................................................................................... 8-7
8.3 Mains connection .......................................................................................................................... 8-8
General .................................................................................................................................... 8-8
Mains requirements ................................................................................................................. 8-9
HVE........................................................................................................................................ 8-10
HVR........................................................................................................................................ 8-13
8.4 Fusing with direct mains supply .................................................................................................. 8-17
8.5 Grounding the power supply system........................................................................................... 8-19
8.6 Connecting drive controllers to the power supply unit ................................................................ 8-19
Arranging the units horizontally.............................................................................................. 8-19
Arranging the units vertically.................................................................................................. 8-20
8.7 Fault current protective device.................................................................................................... 8-22
8.8 Earth leakage monitor ................................................................................................................. 8-22
8.9 Interference elimination............................................................................................................... 8-23
8.10 Control cabinet check ................................................................................................................. 8-24
8.11 Applications with HVE0x.2-W0xx power supply unit................................................................... 8-25
Multi-axis operation................................................................................................................ 8-25
Parallel connection of two HVE04 ......................................................................................... 8-26
HVE-L with external capacities .............................................................................................. 8-34
Operating HVE04 with GLD12 ............................................................................................... 8-39
8.12 Operation on mains with outer conductor ground connection (asymmetric mains).................... 8-40
Connecting an isolating transformer before the power supply unit........................................ 8-40
Direct operation on the mains ................................................................................................ 8-40
Recommended connections for phase-grounded mains ....................................................... 8-41
8.13 Reducing interference emissions................................................................................................ 8-42
9 Control mains contactor 9-1

9.1 Control possibilities ....................................................................................................................... 9-1
Shutdowns with faulty drive electronics ................................................................................... 9-1
Braking with emergency stop or power failure......................................................................... 9-1
9.2 Controlling the power supply unit with emergency stop relays ..................................................... 9-2
With DC bus dynamic brake .................................................................................................... 9-2
Without DC bus dynamic brake ............................................................................................... 9-5
IV Contents HVE and HVR 2nd Gen. Power Supply Units
9.3 Control via NC controller ............................................................................................................... 9-7
10 System control 10-1

10.1 Interfaces .................................................................................................................................... 10-1
X0, Additional component bus ............................................................................................... 10-1
X1, Connection for integrated bus connections from neighboring device ............................. 10-3
X2, Service interface.............................................................................................................. 10-3
X3, Emergency stop circuit .................................................................................................... 10-4
X4, Control voltages............................................................................................................... 10-7
X5, Mains connection............................................................................................................. 10-8
X6, Acknowledging the power supply unit mains contactor................................................. 10-10
X7, Ready-to-operate and other messages......................................................................... 10-12
X8, Control voltage supply ................................................................................................... 10-15
X11, DC bus connection ...................................................................................................... 10-17
X12, Ground connection ...................................................................................................... 10-19
X13, Optional choke connection (only HVE)........................................................................ 10-20
10.2 Chronological sequence when switching on and off................................................................. 10-22
When powering up ............................................................................................................... 10-22
When shutting down ............................................................................................................ 10-22
11 Troubleshooting 11-1
11.1 General........................................................................................................................................ 11-1
11.2 Fault diagnostics and resetting faults.......................................................................................... 11-1
11.3 Checking and repairing the unit .................................................................................................. 11-2
11.4 Replacing the unit ....................................................................................................................... 11-3
11.5 Diagnostic Display....................................................................................................................... 11-4
Overview ................................................................................................................................ 11-4
Description, possible cause and troubleshooting .................................................................. 11-5
12 Delivery Status 12-1

12.1 Packaging ................................................................................................................................... 12-1
12.2 Scope of Delivery ........................................................................................................................ 12-1
13 Identifying the Components 13-1

Type Plate Arrangement ........................................................................................................ 13-1
Type Plate Design.................................................................................................................. 13-1
14 Index 14-1
15 Service & Support 15-1

15.1 Helpdesk ..................................................................................................................................... 15-1
15.2 Service-Hotline............................................................................................................................ 15-1
15.3 Internet ........................................................................................................................................ 15-1
15.4 Vor der Kontaktaufnahme... - Before contacting us.................................................................... 15-1
15.5 Kundenbetreuungsstellen - Sales & Service Facilities ............................................................... 15-2
HVE and HVR 2nd Gen. Power Supply Units System overview 1-1
1 System overview
1.1 AC drive system

The AC drive system DIAX04, has been developed by us in a modular
design so that the performance and functionality of the drives will meet
your application requirements. Furthermore, it is possible for you to
operate several drive controllers on one power supply unit; that is, every
drive system, consisting of the power supply unit and drive and control
system(s), needs only one mains connection.
This documentation describes the power supply unit types HVE and HVR
from the DIAX04 family.
Dg5023f1.fh7
Fig. 1-1: Exemplary structure of a modular Rexroth AC drive system
1-2 System overview HVE and HVR 2nd Gen. Power Supply Units
1.2 Principal working mode of the power supply units

Rectification The 3-phase AC voltage is rectified by the power rectifier of the power
supply units HVR and HVE.
The HVR power supply units provide a regulated DC bus voltage whereas
the HVE power supply units provide an unregulated DC bus voltage for
the drive controllers.
Generative operation When using a HVE power supply unit and running in generator mode the
regenerated energy is dissipated as heat via a bleeder resistor.
When using a HVR power supply unit and running in generator mode the
energy is regenerated back into the mains.
Option:DC bus
choke GLD
Softstart-
device L+
drive
power
source
U
Mains
V Rectifier U > Bleeder actuation circuit
threshold section
W
DC bus short-circuit >1
X8 K1 control
2U1 L-
2V1
2W1
2U2
2V2 ~ power supply and
2W2 = drive monitoring
drive ready
& Bb1
AufHVE.fh7 power ready
Fig. 1-2: Structure of the HVE power supply unit
external commutation
choke
Softstart-
device L+
drive
power
L1 U U
external Feed-in and source
Mains
L2 filter V V feedback circuit
modul bridge U > Bleeder section
W W actuation threshold
L3 (HZF)
W4 V4 U4
DC bus short-circuit >1
K1 control
L-
control voltage
~ power supply and
= drive monitoring
drive ready
& Bb1
Aufhvr.fh7
power ready
Fig. 1-3: Structure of the HVR power supply unit
HVE and HVR 2nd Gen. Power Supply Units System overview 1-3
Shutdown With both power supply unit types, motors with permanent magnet
energizing can be braked by the short-circuit bus also in the event of a
fault in the drive electronics.
In the event of a mains failure or shut down power supply unit, motors are
braked controlled by the bleeder in the HVR.
Due to the internal power contactor of the power supply units, the drive
controllers can be separated from the mains.
Control voltage supply HVR and HVE provide the control voltage for all connected drive
controllers.
In the case of a mains failure, the control voltage will be provided by the
DC bus voltage of the power supply unit. In regenerative mode the drive
electronic remains fully operational, supplied by the DC bus voltage.
Monitoring of the drive system HVR and HVE are equipped with substantial monitoring functions. The
power supply units communicate with the drive controllers via the control
bus voltage.
Most important for the functionality of the drive systems is the Bb1
contact. Once closed, the internal power contactor can be connected.
1.3 Areas of application

HVR and HVE power supply units can be connected to mains voltages
consisting of 3 x AC 380 ... 480 V. They are necessary for the power and
control voltage supply by Rexroth drive and control system types HDD
and HDS.
Motors of a maximum continuous mechanical power of 36 kW are
connected to the HVR power supply units, motors of a maximum of
60 kW can be connected to HVE power supply units.
1-4 System overview HVE and HVR 2nd Gen. Power Supply Units
1.4 Overview of the unit features

Direct mains connection HVE and HVR power supply units can be connected to
3 x AC 380 ... 480 V ± 10 %, 50 ... 60 Hz power systems without the need
for transformers.
Small space requirements The high DC bus voltage permits small unit dimensions with high unit
performance.
Contactor integrated into unit A contactor is integrated into power supply unit which shuts down the
shuts down power power supply.
High ON time in brake mode In the case of HVR power supply units, the energy created when braking
possible the drives is fed back into the mains with little loss.
Optimum matching of the power Power supply units of the HVE and HVR line are available in six
requirements to an application variations. This means that the power supply can be optimumly adapted
to a specific application.
Regulated DC bus voltage Power supply units of the HVR line are working with regulated DC bus
voltage, i. e. drive dynamics do not drop with undervoltage.
High short-term operating load Triple output can be generated short-term to accelerate the drives.
Safety even with faulty drive Motors with permanent magnetic excitation can be braked by unit’s
electronics internal DC bus dynamic brake in the event of a fault in the drive
electronics.
Charging current limits Due to unit integrated capacitors, the energizing current does not have to
be considered when the control units are chosen for the power supply.
The service life of the control units is prolonged.
High load capabilities of the Several drive modules can be connected to one power supply unit.
control voltage
Ease of servicing The connection of the signal lines is effected via plug-in terminals.
The power supply units include an alphanumeric display. This display
serves for diagnostics and makes it possible to clear faults more easily.
HVE and HVR 2nd Gen. Power Supply Units Important directions for use 2-1
2 Important directions for use
2.1 Appropriate use
Introduction
Rexroth products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Bosch Rexroth AG, as manufacturer, is not liable for any

damages resulting from inappropriate use. In such cases, the
guarantee and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for
an appropriate use of the products are satisfied:
• Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
• If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are
permitted. It is not permitted to decompile software products or alter
source codes.
• Do not mount damaged or faulty products or use them in operation.
• Make sure that the products have been installed in the manner
described in the relevant documentation.
2-2 Important directions for use HVE and HVR 2nd Gen. Power Supply Units
Areas of Use and Application

Drive controllers made by Rexroth are designed to control electrical
motors and monitor their operation.
Control and monitoring of the motors may require additional sensors and
actors.
Note: The drive controllers may only be used with the accessories
and parts specified in this document. If a component has not
been specifically named, then it may not be either mounted or
connected. The same applies to cables and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware
as specified in the relevant function descriptions.
Every drive controller has to be programmed before starting it up, making

it possible for the motor to execute the specific functions of an application.
The drive controllers are designed for use in single or multiple-axis drive
and control applications.
To ensure an application-specific use, the drive controllers are available
with differing drive power and different interfaces.
Typical applications of drive controllers are:
• handling and mounting systems,
• packaging and foodstuff machines,
• printing and paper processing machines and
• machine tools.
The drive controllers may only be operated under the assembly,
installation and ambient conditions as described here (temperature,
system of protection, humidity, EMC requirements, etc.) and in the
position specified.
2.2 Inappropriate Use

Using the drive controllers outside of the above-referenced areas of
application or under operating conditions other than described in the
document and the technical data specified is defined as “inappropriate
use".
Drive controllers may not be used if
• they are subject to operating conditions that do not meet the above
specified ambient conditions. This includes, for example, operation
under water, in the case of extreme temperature fluctuations or
extremely high maximum temperatures or if
• Bosch Rexroth has not specifically released them for that intended
purpose. Please note the specifications outlined in the general safety
instructions!
HVE and HVR 2nd Gen. Power Supply Units Safety Instructions for Electric Drives and Controls 3-1
3 Safety Instructions for Electric Drives and Controls
3.1 Introduction
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
Do not attempt to install or start up this equipment without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation of the equipment prior to
working with the equipment at any time. If you do not have the user
documentation for your equipment, contact your local Rexroth
representative to send this documentation immediately to the person or
persons responsible for the safe operation of this equipment.
If the equipment is resold, rented or transferred or passed on to others,
then these safety instructions must be delivered with the equipment.
Improper use of this equipment, failure to follow

the safety instructions in this document or
tampering with the product, including disabling
WARNING of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
3.2 Explanations
The safety instructions describe the following degrees of hazard
seriousness in compliance with ANSI Z535. The degree of hazard
seriousness informs about the consequences resulting from non-
compliance with the safety instructions.
Warning symbol with signal Degree of hazard seriousness according
word to ANSI
Death or severe bodily harm will occur.
DANGER
Death or severe bodily harm may occur.
WARNING
Bodily harm or material damage may occur.
CAUTION
Fig. 3-1: Hazard classification (according to ANSI Z535)
3-2 Safety Instructions for Electric Drives and Controls HVE and HVR 2nd Gen. Power Supply Units
3.3 Hazards by Improper Use
High voltage and high discharge current!

Danger to life or severe bodily harm by electric
shock!
DANGER
Dangerous movements! Danger to life, severe

bodily harm or material damage by
unintentional motor movements!
DANGER
High electrical voltage due to wrong

connections! Danger to life or bodily harm by
electric shock!
WARNING
Health hazard for persons with heart

pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING
Surface of machine housing could be extremely

hot! Danger of injury! Danger of burns!
CAUTION
Risk of injury due to improper handling! Bodily

harm caused by crushing, shearing, cutting and
mechanical shock or incorrect handling of
CAUTION pressurized systems!
Risk of injury due to incorrect handling of

batteries!
CAUTION
3.4 General Information

• Bosch Rexroth AG is not liable for damages resulting from failure to
observe the warnings provided in this documentation.
• Read the operating, maintenance and safety instructions in your
language before starting up the machine. If you find that you cannot
completely understand the documentation for your product, please ask
your supplier to clarify.
• Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this equipment.
• Only persons who are trained and qualified for the use and operation
of the equipment may work on this equipment or within its proximity.
• The persons are qualified if they have sufficient knowledge of the
assembly, installation and operation of the equipment as well as an
understanding of all warnings and precautionary measures noted in
these instructions.
• Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and equipment on and off in accordance
with technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid.
• Only use spare parts and accessories approved by the manufacturer.
• Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
• The equipment is designed for installation in industrial machinery.
• The ambient conditions given in the product documentation must be
observed.
• Use only safety features and applications that are clearly and explicitly
approved in the Project Planning Manual.
For example, the following areas of use are not permitted: construction
cranes, elevators used for people or freight, devices and vehicles to
transport people, medical applications, refinery plants, transport of
hazardous goods, nuclear applications, applications sensitive to high
frequency, mining, food processing, control of protection equipment
(also in a machine).
• The information given in the documentation of the product with regard
to the use of the delivered components contains only examples of
applications and suggestions.
The machine and installation manufacturer must
• make sure that the delivered components are suited for his
individual application and check the information given in this
documentation with regard to the use of the components,
• make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
• Startup of the delivered components is only permitted once it is sure
that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.
• Operation is only permitted if the national EMC regulations for the
application are met.
The instructions for installation in accordance with EMC requirements
can be found in the documentation "EMC in Drive and Control
Systems".
The machine or installation manufacturer is responsible for
compliance with the limiting values as prescribed in the national

regulations.
• Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.
3.5 Protection Against Contact with Electrical Parts
Note: This section refers to equipment and drive components with

voltages above 50 Volts.
Touching live parts with voltages of 50 Volts and more with bare hands or
conductive tools or touching ungrounded housings can be dangerous and
cause electric shock. In order to operate electrical equipment, certain
parts must unavoidably have dangerous voltages applied to them.
High electrical voltage! Danger to life, severe

bodily harm by electric shock!
⇒ Only those trained and qualified to work with or on
DANGER electrical equipment are permitted to operate, maintain
or repair this equipment.
⇒ Follow general construction and safety regulations when
working on high voltage installations.
⇒ Before switching on power the ground wire must be
permanently connected to all electrical units according
to the connection diagram.
⇒ Do not operate electrical equipment at any time, even
for brief measurements or tests, if the ground wire is not
permanently connected to the points of the components
provided for this purpose.
⇒ Before working with electrical parts with voltage higher
than 50 V, the equipment must be disconnected from
the mains voltage or power supply. Make sure the
equipment cannot be switched on again unintended.
⇒ The following should be observed with electrical drive
and filter components:
⇒ Wait five (5) minutes after switching off power to allow
capacitors to discharge before beginning to work.
Measure the voltage on the capacitors before beginning
to work to make sure that the equipment is safe to
touch.
⇒ Never touch the electrical connection points of a
component while power is turned on.
⇒ Install the covers and guards provided with the
equipment properly before switching the equipment on.
Prevent contact with live parts at any time.
⇒ A residual-current-operated protective device (RCD)
must not be used on electric drives! Indirect contact
must be prevented by other means, for example, by an
overcurrent protective device.
⇒ Electrical components with exposed live parts and
uncovered high voltage terminals must be installed in a
protective housing, for example, in a control cabinet.
To be observed with electrical drive and filter components:
High electrical voltage on the housing!

High leakage current! Danger to life, danger of
injury by electric shock!
DANGER ⇒ Connect the electrical equipment, the housings of all
electrical units and motors permanently with the safety
conductor at the ground points before power is
switched on. Look at the connection diagram. This is
even necessary for brief tests.
⇒ Connect the safety conductor of the electrical
equipment always permanently and firmly to the
supply mains. Leakage current exceeds 3.5 mA in
normal operation.
⇒ Use a copper conductor with at least 10 mm² cross
section over its entire course for this safety conductor
connection!
⇒ Prior to startups, even for brief tests, always connect
the protective conductor or connect with ground wire.
Otherwise, high voltages can occur on the housing
that lead to electric shock.
3.6 Protection Against Electric Shock by Protective Low

Voltage (PELV)
All connections and terminals with voltages between 0 and 50 Volts on
Rexroth products are protective low voltages designed in accordance with
international standards on electrical safety.
High electrical voltage due to wrong

connections! Danger to life, bodily harm by
electric shock!
WARNING ⇒ Only connect equipment, electrical components and
cables of the protective low voltage type (PELV =
Protective Extra Low Voltage) to all terminals and
clamps with voltages of 0 to 50 Volts.
⇒ Only electrical circuits may be connected which are
safely isolated against high voltage circuits. Safe
isolation is achieved, for example, with an isolating
transformer, an opto-electronic coupler or when
battery-operated.
3.7 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of the connected
motors. Some common examples are:
• improper or wrong wiring of cable connections
• incorrect operation of the equipment components
• wrong input of parameters before operation
• malfunction of sensors, encoders and monitoring devices
• defective components
• software or firmware errors
Dangerous movements can occur immediately after equipment is
switched on or even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid
faulty operation in the connected drives. Regarding personal safety,
especially the danger of bodily injury and material damage, this alone
cannot be relied upon to ensure complete safety. Until the integrated
monitoring functions become effective, it must be assumed in any case
that faulty drive movements will occur. The extent of faulty drive
movements depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of

injury, severe bodily harm or material damage!
⇒ Ensure personal safety by means of qualified and
DANGER tested higher-level monitoring devices or measures
integrated in the installation. Unintended machine
motion is possible if monitoring devices are disabled,
bypassed or not activated.
⇒ Pay attention to unintended machine motion or other
malfunction in any mode of operation.
⇒ Keep free and clear of the machine’s range of motion

and moving parts. Possible measures to prevent
people from accidentally entering the machine’s range
of motion:
- use safety fences
- use safety guards
- use protective coverings
- install light curtains or light barriers
⇒ Fences and coverings must be strong enough to
resist maximum possible momentum, especially if
there is a possibility of loose parts flying off.
⇒ Mount the emergency stop switch in the immediate
reach of the operator. Verify that the emergency stop
works before startup. Don’t operate the machine if the
emergency stop is not working.
⇒ Isolate the drive power connection by means of an
emergency stop circuit or use a starting lockout to
prevent unintentional start.
⇒ Make sure that the drives are brought to a safe
standstill before accessing or entering the danger
zone. Safe standstill can be achieved by switching off
the power supply contactor or by safe mechanical
locking of moving parts.
⇒ Secure vertical axes against falling or dropping after
switching off the motor power by, for example:
- mechanically securing the vertical axes
- adding an external braking/ arrester/ clamping
mechanism
- ensuring sufficient equilibration of the vertical axes
The standard equipment motor brake or an external
brake controlled directly by the drive controller are
not sufficient to guarantee personal safety!
⇒ Disconnect electrical power to the equipment using a

master switch and secure the switch against
reconnection for:
- maintenance and repair work
- cleaning of equipment
- long periods of discontinued equipment use
⇒ Prevent the operation of high-frequency, remote
control and radio equipment near electronics circuits
and supply leads. If the use of such equipment cannot
be avoided, verify the system and the installation for
possible malfunctions in all possible positions of
normal use before initial startup. If necessary, perform
a special electromagnetic compatibility (EMC) test on
the installation.
3.8 Protection Against Magnetic and Electromagnetic Fields

During Operation and Mounting
Magnetic and electromagnetic fields generated near current-carrying
conductors and permanent magnets in motors represent a serious health
hazard to persons with heart pacemakers, metal implants and hearing
aids.
Health hazard for persons with heart

pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING ⇒ Persons with heart pacemakers, hearing aids and
metal implants are not permitted to enter the following
areas:
- Areas in which electrical equipment and parts are
mounted, being operated or started up.
- Areas in which parts of motors with permanent
magnets are being stored, operated, repaired or
mounted.
⇒ If it is necessary for a person with a heart pacemaker
to enter such an area, then a doctor must be
consulted prior to doing so. Heart pacemakers that
are already implanted or will be implanted in the
future, have a considerable variation in their electrical
noise immunity. Therefore there are no rules with
general validity.
⇒ Persons with hearing aids, metal implants or metal
pieces must consult a doctor before they enter the
areas described above. Otherwise, health hazards will
occur.
3.9 Protection Against Contact with Hot Parts
Housing surfaces could be extremely hot!

Danger of injury! Danger of burns!
⇒ Do not touch housing surfaces near sources of heat!
CAUTION Danger of burns!
⇒ After switching the equipment off, wait at least ten (10)
minutes to allow it to cool down before touching it.
⇒ Do not touch hot parts of the equipment, such as
housings with integrated heat sinks and resistors.
Danger of burns!
3.10 Protection During Handling and Mounting

Under certain conditions, incorrect handling and mounting of parts and
components may cause injuries.
Risk of injury by incorrect handling! Bodily

harm caused by crushing, shearing, cutting and
mechanical shock!
CAUTION ⇒ Observe general installation and safety instructions
with regard to handling and mounting.
⇒ Use appropriate mounting and transport equipment.
⇒ Take precautions to avoid pinching and crushing.
⇒ Use only appropriate tools. If specified by the product
documentation, special tools must be used.
⇒ Use lifting devices and tools correctly and safely.
⇒ For safe protection wear appropriate protective
clothing, e.g. safety glasses, safety shoes and safety
gloves.
⇒ Never stand under suspended loads.
⇒ Clean up liquids from the floor immediately to prevent
slipping.
3.11 Battery Safety

Batteries contain reactive chemicals in a solid housing. Inappropriate
handling may result in injuries or material damage.
Risk of injury by incorrect handling!

⇒ Do not attempt to reactivate discharged batteries by
heating or other methods (danger of explosion and
cauterization).
CAUTION
⇒ Never charge non-chargeable batteries (danger of
leakage and explosion).
⇒ Never throw batteries into a fire.
⇒ Do not dismantle batteries.
⇒ Do not damage electrical components installed in the
equipment.
Note: Be aware of environmental protection and disposal! The

batteries contained in the product should be considered as
hazardous material for land, air and sea transport in the sense
of the legal requirements (danger of explosion). Dispose
batteries separately from other waste. Observe the legal
requirements in the country of installation.
3.12 Protection Against Pressurized Systems

Certain motors and drive controllers, corresponding to the information in
the respective Project Planning Manual, must be provided with
pressurized media, such as compressed air, hydraulic oil, cooling fluid
and cooling lubricant supplied by external systems. Incorrect handling of
the supply and connections of pressurized systems can lead to injuries or
accidents. In these cases, improper handling of external supply systems,
supply lines or connections can cause injuries or material damage.
Danger of injury by incorrect handling of

pressurized systems!
⇒ Do not attempt to disassemble, to open or to cut a
CAUTION pressurized system (danger of explosion).
⇒ Observe the operation instructions of the respective
manufacturer.
⇒ Before disassembling pressurized systems, release
pressure and drain off the fluid or gas.
⇒ Use suitable protective clothing (for example safety
glasses, safety shoes and safety gloves)
⇒ Remove any fluid that has leaked out onto the floor
immediately.
Note: Environmental protection and disposal! The media used in the

operation of the pressurized system equipment may not be
environmentally compatible. Media that are damaging the
environment must be disposed separately from normal waste.
Observe the legal requirements in the country of installation.
Notes
HVE and HVR 2nd Gen. Power Supply Units Technical data 4-1
4 Technical data
4.1 Ambient and operating conditions
Note: If the controllers are to be used outside of the indicated range,

then it is necessary to take the "load factors" into
consideration (see chapter 7.1).
Item Symbol Unit Devices:

HVE0x.2-W0xxx
HVR0x.2-W0xxN
HZF01.1-W0xxN
KD xx / KD xx C
HZS01.2-W300N
HZK02.1-W003N
HZB02.2-W002N
GLD xx
SUP-E0x-HVR
Permissible ambient temperature TA1 °C +5....+45
with rated data
Maximum permissible ambient TA2 °C +55
temperature with derated data
Storage and transport temperature TL °C -30....+85
Installation elevation above sea level m 1000

without power reduction
Installation elevation above sea level m 4000
with power reduction
Maximum permissible relative % 95
humidity
3
Maximum permissible absolute g/m 25
humidity
Protection category -- IP10 per EN60529 / IEC529
Degree of dirt contamination -- no dirt contamination, no

condensation
Fig. 4-1: Ambient conditions
With installation elevations of more than 2000 m above sea level

For installation elevations of more than 2000 m, an overvoltage limiter for
transient overvoltage 1.2/50 µs must be installed in the installation or
building in order to limit the voltage
• to 1.0 kV between the outer conductors and
• to 2.5 kV between conductor-ground.
4-2 Technical data HVE and HVR 2nd Gen. Power Supply Units
Storage of the power supply units

The power supply units contain sensitive electrolytic capacitors.
Therefore, in the case of long storage periods, operate the power supply
units once a year for at least 1 hour with power on (DC bus voltage must
be applied).
Data for vibration test

The devices have been designed for the following test values:
Item Devices:
HVE0x.2-W0xxx
HVR0x.2-W0xxN
HZF01.1-W0xxN
HZS01.2-W300N
HZK02.1-W003N
HZB02.2-W002N
GLD xx
SUP-E0x-HVR
Vibration sinus in operation according to EN 60068-2-6
Amplitude and frequency 0,15 mm (peak-peak) at 10...57 Hz
Acceleration and frequency 1,0 g at 57...500 Hz
Vibration distortion (Random) in operation according to IEC 68-2-36
Frequency 20...150 Hz
2
Spectral acceleration density amplitude 0,005 g /Hz, 1 g
Shock test when out of operation (Ea) according to EN 60068-2-27
Half sine 10 g / 11 ms
3 x in pos., 3 x in neg. direction
Tip-over test when out of operation over 6 edges packaging dimensioned for tipping over each edge
according to EN 60068-2-31
Fig. 4-2: Data for vibration test
4.2 Power supply units HVE
Example: HVE 02.2 - W018N

Product HVE
Line 02
03
04
Design 2
Cooling mode
Air, internal (with built-in blower) W
Nominal power
18 kW 018
30 kW 030
75 kW 075
Other design
none N
increased loading capacity for L
external DC bus capacitors:
HVE03.x: up to 100 mF
HVE04.x: up to 200 mF
hve_typenschluessel_en.fh7
Fig. 4-3: Type code of power supply units HVE
A bleeder absorbs the energy regenerated by the HVE power supply

units. Rexroth motors with a continuous mechanical power of 60 kW can
be connected.
The HVE power supply units operate with unregulated DC bus voltage.
The usable unit power depends on the power voltage. Therefore, power
data for the connection to four mains nominal voltages are indicated:
• 3 x AC 380 V,
• 3 x AC 400 V,
• 3 x AC 440 V and
• 3 x AC 480 V.
The power supply units of the HVE series are available in three variations
and 2 other types. The HVE0x.2-W0xxN type can, if necessary, be
combined with the DC bus choke GLD. This makes an optimum adjusting
to the power requirements of the application possible.
The HVE03.2-W030L type can charge DC bus capacitors up to 100 mF,
the HVE04.2-W075L type can charge DC bus capacitors up to 200 mF.
Note: The types HVE03.2-W030L and HVE04.2-W075L always

have to be combined with DC bus chokes of the GLD type.
For the technical data of the DC bus choke GLD see
chapter 6.2.
The HVE02.2 power supply unit is only available in type "N".
PZW [kW] PKB30 [kW] PKB03 PBD [kW] PBS [kW] WMAX [kWs] Mains supply components
[kW] Power supply unit DC bus choke
HVE power data when connected to 3 x AC 380 V
12 19 36 1 100 70 HVE02.2-W018N -
18 29 54 1 100 70 HVE02.2-W018N GLD13
18 36 54 1,5 100 100 HVE03.2-W030N -
28 56 84 1,5 100 100 HVE03.2-W030N/L GLD12
33 66 99 2,5 270 250 HVE04.2-W075N -
70 140 210 2,5 270 250 HVE04.2-W075N/L GLD20
13 20 39 1 100 70 HVE02.2-W018N -
19 30 57 1 100 70 HVE02.2-W018N GLD13
19 38 57 1,5 100 100 HVE03.2-W030N -
30 60 90 1,5 100 100 HVE03.2-W030N/L GLD12
35 70 105 2,5 270 250 HVE04.2-W075N -
75 150 225 2,5 270 250 HVE04.2-W075N/L GLD20
14 22 42 1 100 70 HVE02.2-W018N -
21 33 63 1 100 70 HVE02.2-W018N GLD13
21 42 63 1,5 100 100 HVE03.2-W030N -
32 64 96 1,5 100 100 HVE03.2-W030N/L GLD12
38 76 114 2,5 270 250 HVE04.2-W075N -
82 164 246 2,5 270 250 HVE04.2-W075N/L GLD20
15 24 45 1 100 70 HVE02.2-W018N -
23 36 69 1 100 70 HVE02.2-W018N GLD13
23 46 69 1,5 100 100 HVE03.2-W030N -
35 70 105 1,5 100 100 HVE03.2-W030N/L GLD12
42 84 126 2,5 270 250 HVE04.2-W075N -
90 180 270 2,5 270 250 HVE04.2-W075N/L GLD20
PZW: DC bus continuous power
PKB30: DC bus short-term power (for 30 s)
PKB03: DC bus peak power (for 0,3 s)
PBD: bleeder continuous power
PBS: bleeder peak power
W MAX: maximum regenerated energy
Fig. 4-4: Power data of the HVE power supply units
To accelerate feed and spindle drives it is possible to apply the following

short-term loads to the HVE as illustrated in the diagram below:
Damages due to an overloaded power supply

unit!
⇒ Maximum short-term loads must be taken into
CAUTION consideration during the project planning phase and
may not be exceeded.
300
HVE04 peak load for 0,3 s
HVE03 to accelerate feed drives
HVE02
short-terme load for 30 s

200
to accelerate main drives
160
100 continuous power for

ON time exceeds
load P/%
• 120 s in HVE04
• 60 s in HVE03
• 48 s in HVE02
0,3 2,1 3 30 48 60 90 120

S01HVE.fh7
ON time t/s
Fig. 4-5: Short-term output of the power supply units HVE02.2, HVE03.2 and
HVE04.2
Designation Symbol Unit Designation of the power supply unit

HVE02.2-W018N HVE03.2- HVE04.2-
W030N W030L W075N W075L
Power supply
Input voltage UN1 V 3 x 380 ... 480 (± 10 %)
Frequency fN1 Hz 50 ... 60 (± 2 Hz)
Power factor cos ϕ See Project Planning Manual "Electromagnetic Compatibility
(EMC) in Drive and Control Systems", document typecode
DOK-GENERL-EMV********-PRxx-xx-P
DC bus voltage UZW V 530 ... 670 (± 10 %)
Output power
DC bus continuous power PZW kW see Fig. 4-4: Power data of the HVE power supply units
DC bus peak power (0,3 s) PZWS03 kW
Regenerated power (Bleeder power)
Bleeder continuous power PBD kW 1 1,5 2,5
Bleeder peak power PBS kW 100 100 270
Maximum regenerated energy W MAX kWs 70 100 250
DC bus capacity
Internal capacity (nominal) Cint mF 0,8 1,4 3,75
Maximum DC bus capacity to Cext mF 10 10 100 10 200
be externally connected
Charging time tLade s 1,6 1,6 6 1,6 6
Power loss
DC bus short-time power PKB3 kW 25 60 105
(for 3 s)
Basic losses PVG W 125 175 175
Power losses per kW DC bus PV/kW W/kW 7 6 6
continuous power
Weight m kg 13 16 28
Control voltage supply
Average charging current Ilade A ≤ 14
Charging duration tlade ms ≤5
Max. current pulse/duration ipeak ≤ 35 A for 0,25 ms
Power input with maximum load SN2 VA 500
Control voltage output PSt W 300
Fig. 4-6: Data sheet HVE
4.3 Power supply unit HVR

Example: HVR 02.2 - W010N
Product HVR
Line 02
03
Design 2
Cooling mode
Air, internal (with built-in blower) W
Nominal power
10 kW 010
25 kW 025
45 kW 045
Other design
none N
hvr_typenschluessel_en.fh7
Fig. 4-7: Type code of power supply units HVR
HVR power supply units operate with regulated DC bus voltage. They can
use mains voltages from 3 x AC 380 to 480 V (± 10 %).
To accelerate feed and main drives it is possible to apply the following

short-term loads to the power supply units as illustrated in the diagram
below.
Damages due to an overloaded power supply

unit!
⇒ Maximum short-term loads must be taken into
CAUTION consideration during the project planning phase and
may not be exceeded.
300
peak power for 0.3 s
to accelerate feed drives
200 power limit

short-term load for 3 s
to accelerate main drives
100
load P/%
continuous power for ON time

exceeding 10 s
0,3 3 10
ON time t/s S01HVR.fh7
Fig. 4-8: Short-term output of the power supply unit HVR02.2 and HVR03.2
Designation Symbol Unit Designation of the power supply unit

HVR02.2-W010N HVR02.2-W025N HVR03.2-W045N
Power supply
Power factor cos ϕ See Project Planning Manual "Electromagnetic Compatibility
(EMC) in Drive and Control Systems", document typecode
DOK-GENERL-EMV********-PRxx-xx-P
DC bus voltage UZW V 750
(*1)
Output power
DC bus continuous power (for PZW kW 10 25 45
(*2)
UN1=400 V)
DC bus peak output (for 0,3 s) PZWS03 kW 30 75 135
DC bus short-time power (for PKB3 kW 25 60 105
3 s)
Regenerated power (Bleeder power)
Continuous regenerative power P kW 10 25 45
Peak regenerative power P kW 30 75 90
Bleeder continuous power PBD kW 0 (Bleeder has been designed for Emergency Stop)
Bleeder peak power PBS kW 120
Maximum regenerated energy W MAX kWs 80
DC bus capacity
Internal capacity (nominal) Cint mF 0,8 1,2 2,0
Maximum DC bus capacity to Cext mF 20 20 20
be externally connected
Power loss
Power loss at max. continuous PV W 300 750 1350
output (without bleeder losses)
Basic losses PVG W 150
Power losses per kW DC bus PV/kW W/kW 15 24 27
continuous power

Power input with maximum load SN2 VA 500
(*1): The same values apply to feeding and regeneration
(*2): With mains voltages of less than 400 V, the DC bus continuous power
UN1
is reduced according to the relation: PZW *
400 V
(*3): With installation elevations of more than 2000 m, additional external
components must be used for voltage limitation (1,5 kV). Depending
on the applicable regulation (DIN 0110, CSA, NEMA), an isolating
transformer may be required for voltage limitation.
Fig. 4-9: Data sheet HVR
4.4 Commutation choke KD
Item Symbol Unit Commutation choke

KD 27 KD 28 KD 30
KD 27 C KD 28 C KD 30 C
Continuous nominal current Inenn A 45 80 18
Inductance at Inenn Lnenn mH 0,7 0,5 1,0
Operating frequency f Hz 50...60 ( ±2 Hz )
Power loss
Load dependent losses PV/kW W/kW 10 7 15
Total power loss at maximum PV W 500 600 300
continuous power of the
connected supply unit
Weight m kg 22 42 8
Basic losses: arise with existing DC bus voltage; drives in "AF";
drive is shut down
Load dependent losses: arise per kW DC bus power
Power loss: (total losses) the same values apply to feeding and
regeneration
Fig. 4-10: Commutation choke KD
Note: Commutation chokes of the KD xx C type are required for

operating HVR on asymmetric mains together with SUP-E0x-
HVR!
4.5 Combining filter HZF
Type code
Abbrev. 1
Column 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6
Example: H Z F 0 1 . 1 - W 0 1 0 N
1. Product
1.1 HZF . . . . . . . . . . = HZF
2. Line
2.1 01 . . . . . . . . . . . . . . . . . = 01
3. Design
3.1 1 ........................=1
4. Cooling mode
4.1 natural convection. . . . . . . . . . . .= W
5. Nominal power
5.1 10 kW . . . . . . . . . . . . . . . . . . . . . . . . . . .= 010
5.2 25 kW . . . . . . . . . . . . . . . . . . . . . . . . . . .= 025
5.3 45 kW . . . . . . . . . . . . . . . . . . . . . . . . . . .= 045
6. Other design
6.1 none. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .= N
typenschl_hzf_en.fh7
Fig. 4-11: Type code
Technical data
Item Symbol Unit Commutation choke

HZF01.1-W010N HZF01.1-W025N HZF01.1-W045N
Operating frequency f Hz 50...60 ( ± 2 Hz )
Power loss
Load dependent losses PV/kW W/kW 10 6,0 4,5
continuous power of the
connected supply unit
Basic losses: arise with existing DC bus voltage; drives in "AF";

drive is shut down
Power loss: (total losses) the same values apply to feeding and
regeneration
Fig. 4-12: Data sheet combining filter HZF
4.6 Tests and certifications
CE Mark
CEf1.fh7
Fig. 4-13: CE Mark
C-UL-US listing In accordance with UL508 C

The devices are C-UL-US listed under the item "Rexroth".
Listed component UL file number

HVR02.2-W010N, -W025N, HVR03.2- E 134201
W045N
HVE02.2-W018N, HVE03.2-W030x,
HVE04.2-W075x
HZF01.1-W010N, -W025N, -W045N E 64388
Fig. 4-14: C-UL listing
Tests High-voltage test according to EN50178

routine test with DC 2800 V / 1 s
Insulation test according to EN50178
routine test with DC 500 V / 1 s
Separation between the electrical safe separation according to EN50178
circuits of the control and high voltage
power
Clearances and creepage distances according to EN50178
Vibration test according to EN60068-2-6
Fig. 4-15: Tests
Notes
HVE and HVR 2nd Gen. Power Supply Units Determination of appropriate power supply units 5-1
5 Determination of appropriate power supply units
5.1 Introduction
The mains supply for an AC drive system of the DIAX04 product family
mainly consists of the power supply unit. Depending on the tasks and
design of the supply unit and the conditions of its use, it may be
necessary to add link reactors, auxiliary capacitors, bleeder modules and
transformers as needed.
The mains supply must make available to the drives the DC bus
continuous power and the DC bus peak power for acceleration. During
regenerative operation it must be able to store continuous and peak
regenerated power. The supply unit also makes the control voltage for the
drive controllers available.
Prior to selecting supply unit and auxiliary components it is necessary to
determine the motors and drive controllers which will be used.
It is advisable to carry out calculations in accordance with the following
chapters in order to make sure that the layout of the mains supply is
correct.
5.2 DC bus continuous power
Note: It is possible to connect DC bus chokes of the GLD type to

HVE supply modules so that the usable DC bus continuous
power is increased (see Fig. 4-4).
The DC bus continuous power is calculated from the mechanical power

and based on the efficiency of motor and controller as well as coincidence
factors.
Mechanical power
M * 2 πn
Pm [ W ] = M ∗ ω = or
60
M*n
Pm [kW ] =
9550
Pm: mechanical power
M: torque [Nm]
-1
ω: angular speed [min ]
-1
n: motor speed [min ]
Fig. 5-1: Mechanical power
Continuous mechanical power The effective motor torque and average motor speed are needed to
for servo drives calculate the mechanical continuous power of a servo drive.
The effective motor torque of the servo drive calculations can be
assumed. The average motor speed is determined as follows:
Average motor speed The average motor speed equals approximately 25% of the rapid motion
speed - in the case of servo drive tasks in conventional NC machine tools.
In some cases, however, this approximate estimation is not sufficient. A
precise calculation of the average motor speed is necessary.
5-2 Determination of appropriate power supply units HVE and HVR 2nd Gen. Power Supply Units
If the duration over which the drive is operated at constant speed is

considerably greater than the accel and decel time, then it applies:
Average speed without accel
and decel time n1 * t 1 + n 2 * t 2 + ... + n n * t n
n av =
t 1 + t 2 ... + t n
-1
nav: average motor speed [min ]
-1
n1 ... nn: motor speed [min ]
t1 ... tn: ON time [s]
Fig. 5-2: Average speed; influence of accel and decel time is not taken into
consideration
n1
n2
n3
t1 t2 t3 t4
DGoE.fh7
Fig. 5-3: Speed cycle; influence of accel and decel time is not taken into
consideration
Accel and decel times with short cycle times must be taken into
consideration in such dynamic applications as is the case with rollers and
nibble machines:
Average speed with accel and
decel times n n
* t H + n * t1 + * tB
n av = 2 2
tH + t1 + t B + t 2
-1
-1
n: motor speed [min ]
t: time [s]
tH: accel time [s]
tB: decel time [s]
Fig. 5-4: Average speed; influence of accel and decel time is taken into
consideration
t
tH t1 tB t2
DGmE.fh7
Fig. 5-5: Average speed; influence of accel and decel time is taken into
consideration
Mechanical power for servo

drives M eff * n av
PmSe =
9550
PmSe: continuous mech. power for servo drives [kW]
Meff: effective motor torque [Nm]
-1
Fig. 5-6: Mechanical power for servo drives
Mechanical power for main Main drives are primarily used with constant power over a specific speed
drives range. This means that when planning power supply, nominal power is
important. The mechanical nominal power of the main drives is illustrated
in the operating characteristics or it can be calculated using nominal
speed and torque.
Mn * n n
PmHa =
9550
PmHa: mechanical nominal power for main drives (shaft output) [kW]
Mn: motor nominal torque [Nm]
-1
n n: motor nominal speed [min ]
Fig. 5-7: Mechanical power for main drives
DC bus continuous power for The power supply unit must make the DC bus continuous power available
servo drives to all servo drives. All drives are operated simultaneously in only a few
applications which means that only the simultaneously occurring output
needs to be considered. For the calculation of the required DC bus
continuous power for typical NC feed axes on tool machines, it has
proven in practice that a so-called coincidence factor is included:
Number of Axes 1 2 3 4 5 6
Coincidence factor (FG) 1 1,15 1,32 1,75 2,0 2,25
Fig. 5-8: Coincidence factors
(PmSe1 + PmSe 2 + ... + PmSen ) * 1,25

P =
FG
PZWSe: DC bus continuous power for servo drives [kW]
PmSe1 ... PmSen: cont. mech. power for servo drives [kW]
F G: coincidence factor
1,25: constant for motor and controller efficiency
Fig. 5-9: DC bus continuous power for servo drives
DC bus continuous power for If several main drives are operated on one DC bus, then add the
main drives simultaneously required power:
PZWHa = (PmHa1 + PmHa 2 + ... + PmHan ) * 1,25

PZWHa: DC bus continuous power for main drives [kW]
PmHa1 ... PmHan: mech. cont. power for main drives [kW]
Fig. 5-10: DC bus continuous power for main drives
Chokes and auxiliary capacitors are selected in terms of the actually

required DC bus continuous power. It is fixed by the nominal power of the
spindle drives.
Note: When selecting the power supply unit make sure that the DC
bus continuous power does not limit the short-term power of
the main drives.
DC bus continuous power for If main and servo drives are operated on a power supply unit, the required
main and servo drives DC bus continuous power needs to be added.
It is the spindle drive in a NC machine tool that primarily determines the
DC bus power needed. Therefore, the following equation should be
applied in such applications:
PZW = [PmHa + 0,3 * (PmSe1 + PmSe 2 + ... PmSen )] * 1,25

0,3: experimental value for standard machine tools
PZW : DC bus continuous power [kW]
PmSe1 ... PmSen: continuous mech. servo drive output [kW]
PZWHa: nominal power for spindle drives (shaft output) [kW]
Fig. 5-11: DC bus continuous power for spindle and servo drives in machine
tools
5.3 DC bus peak power

The DC bus peak power is demanded of the power supply unit when, e.g.,
several axes of a machine tool simultaneously accelerate to rapid
traverse and then go to a workpiece after a tool change.
Damages due to overloaded power supply unit!

⇒ Damages to the power supply unit can be avoided, if
the sum of the peak power of all drives does not
exceed the DC bus peak power of the power supply
CAUTION
unit.
(MNC ± MG ) * n eil * 1,25

PZWS =
9550
MNC: acceleration torque in NC mode [Nm]
MG: weight torque in vertical axes [Nm]
-1
neil: speed in rapid traverse [min ]
PZWS: DC bus peak power [kW]
Fig. 5-12: DC bus peak power per drive
∑P ZWS ≤ PZWS 03
PZWS: DC bus peak power [kW]
PZWS03: DC bus peak power of the power supply unit [kW]
Fig. 5-13: Sum of DC bus peak powers
5.4 Regenerated energy

The energy content of all main and servo drives that brake simultaneously
under unfavorable conditions may not be greater than the maximum
regenerated energy of the power supply unit as specified in the data
sheet. If this is not taken into consideration during the layout stage, then
there could be thermal damage to the bleeder resistor in the power supply
unit!
Property damages due to overloaded bleeder

resistor!
⇒ Use a power supply unit that is appropriate for the
CAUTION consumption of the regenerated power which arises
when all the main and servo drives connected to the
power supply unit brake simultaneously.
2
JG  2π 
Wrot = *  n eil * 
2  60 
W rot: rotary energy [Ws]
-1
neil: rapid traverse speed [min ]
J G: inertia of motor and load inertia reduced to shaft [kgm²]
Fig. 5-14: Regenerated energy per drive
∑W rot ≤ WMAX
W MAX: max. permissible regenerated energy of the power supply module
[kWs]
Fig. 5-15: Sum of regenerated energies
Auxiliary capacitance as energy In servo drive applications with numerous accel and decel procedures, as
storage in the HVE is the case, for example, with nibble machines and rollers, it is advisable
to connect additional capacitors to the DC bus. The following advantages
result from this:
• This prevents the bleeder resistor in the HVE power supply unit from
being actuated while braking: The heat dissipated within the control
cabinet is considerably reduced.
• The stored energy can be used to accelerate thus reducing energy
requirements of the installation.
WZW =
C ZW
2
(
* UB2 − U 2ZW )
W ZW : energy stored in the DC bus
CZW : DC bus capacitor [F]
UB: bleeder actuation threshold (approx. 820 V)
UZW : DC bus nominal voltage [in the HVR: UDC=750 V; in the
HVE: UDC=1,41*UN1+10% (overvoltage), (UN1=nominal mains voltage
(380 ... 480 V)]
Fig. 5-16: Energy that can be stored in the DC bus
The auxiliary capacitor must be designed so that it is capable of storing

rotary drive energy:
2Wrot
C Zu ≥
(
UB2 − U 2ZW ) * 1000 − C int
UB: bleeder actuation threshold (approx. 820 V)

UZW : DC bus nominal voltage [in the HVR: UDC=750 V; in the
HVE: UDC=1,41*UN1+10% (overvoltage), (UN1=nominal mains voltage
(380 ... 480 V)]
W rot: rotatory energy [Ws]
CZu: auxiliary capacitor [mF]
Cint: internal capacitance of power supply unit (see Technical Data) [mF]
Fig. 5-17: Required auxiliary capacitance [mF]
In power supply units with regulated DC bus voltage, e.g., HVR,

approximately 75 Ws per mF auxiliary capacitance can be stored.
In power supply units with unregulated DC bus voltage, e.g., HVE, the
auxiliary capacitance should be designed for 10% overvoltage. The
storable energy per mF auxiliary capacitance is listed in the table below.
Mains voltage 3 x AC 380 V 3 x AC 400 V 3 x AC 440 V 3 x AC 480 V

storable energy per mF auxiliary capacitance 145 Ws 126 Ws 86 Ws 41 Ws
Fig. 5-18: Storable energy with auxiliary capacitance on an HVE
5.5 Continuous regenerated power

The average sum of the continuous regenerated power of all drives may
not exceed the continuous regenerated power in the HVR or the
continuous bleeder power in the HVE.
Note: For operation with continuous power, an additional load

caused by DC bus short circuit is no longer allowed.
The processing time in servo drive applications given a typical NC

machine tool, is relatively long in terms of the entire cycle time. There is
little regenerated continuous power. An exact calculation is generally not
required. It suffices if the peak regenerated power is not exceeded.
An exact calculation is needed in specific cases such as, for example:
• servo drive applications with numerous accel / decel procedures such
as is the case in nibble machines and rollers
• machine tools with modular main drives
• applications in which excessive masses must be lowered as is the
case with those overhead gantries used with storage and transport
technologies
To calculate continuous regenerated power, the rotary energy of the
drives and the potential energy of non-compensated masses must be
known.
2
Jg  2π 
Wrot = *  n eil *  *z
2  60 
-1
neil: speed in rapid traverse [min ]
J g: moment of inertia (motor + load) [kgm²]
z: number of decels per cycle
Fig. 5-19: Rotary energy
Wpot = m * g * h * z
W pot: potential energy [Ws]
m: load mass [kg]
g: gravity constant = 9,81 m/s²
h: drop height [m]
z: number of drops per cycle
Fig. 5-20: Potential energy of non-compensated masses
Wpotg + Wrotg
PRD = PRD ≤ PBD
tz
PRD: continuous regenerated power [kW]
PBD: continuous bleeder power [kW]
tz: cycle time [s]
W potg: sum of potential energy [kWs]
W rotg: sum of rotary energies [kWs]
Fig. 5-21: Continuous regenerated energy
5.6 Peak regenerated power

The peak regenerated power usually arises, when an Emergency Stop
signal has been released and all the axes brake simultaneously.
Property damages due to longer braking

periods/paths!
⇒ Choose the power supply unit such that the sum of
CAUTION the peak regenerated power of the all drives does not
exceed the bleeder peak power of the power supply
unit.
The peak regenerated power of the servo drives is listed in the motor
selection documentation.
Roughly estimated, the peak regenerated power can be calculated as
follows:
Mmax * n max
PRS =
9550 * 1,25 ∑P Rs ≤ PBS
PRS: peak regenerated power [kW]

PBS: peak bleeder power [kW]
Mmax: max. drive torque [Nm]
-1
nmax: max. NC usable speed [min ]
Fig. 5-22: Peak regenerated power
5.7 Connected load of the power supply unit

The connected load is calculated to be able to determine mains fuses,
line cross sections and, if needed, commutation chokes and transformers.
The connected load is dependent on the continuous power of the drives
and the functional principle of the power supply unit.
without DC choke (GLD) : S N1 = PZW * 1,6

with DC choke (GLD) : S N1 = PZW * 1,07
SN1: connected load [kVA]
Fig. 5-23: Connected load for power supply units of the HVE line
SN1 = PZW * 1,05

Fig. 5-24: Connected load for power supply units of the HVR line
SN1 * 1000
IN1 =
3 * UN1
IN1: mains current [I]
UN1: mains voltage [U]
Fig. 5-25: Mains current
5.8 Using the control voltage
Property damage due to overloaded control

voltage outlet!
⇒ The control voltage power of the power supply unit
CAUTION may not be overloaded when the drive controller
processes signals. If the control voltages are used
outside of the drive system, e.g., to supply auxiliary
relays, then this must be taken into account (see data
in Fig. 4-6 and Fig. 4-9).
HVE and HVR 2nd Gen. Power Supply Units Additional modules and components 6-1
6 Additional modules and components
Note: When you use the devices beyond the quoted operating
conditions you have to take the load factors into consideration
(see chapter 7.1).
6.1 Ambient and operating conditions

See chapter 4.1
6-2 Additional modules and components HVE and HVR 2nd Gen. Power Supply Units
6.2 DC bus choke GLD

DC bus chokes GLD may be connected to HVE supply modules so that
the usable DC bus power is increased.
The following figures show the unit dimensions and the technical data of
the DC bus chokes. For the DC bus power with or without chokes on the
corresponding supply module types please see figure Fig. 4-4.
electrical
M6x20 (GLD12, 13) connection K
M8x20 (GLD20) circuit diagram:
2.1 1
1.1
1.2 2.2
2
H∅
long hole in
E
"J" direction
H∅
F I MB_GLD_1.fh7
H∅ B J
A
Type Dimensions [mm]

A B C E F H∅ I J K
GLD12 160 121 285 60 100 7 x 14 97 121 -
GLD13 122 90 225 - 60 6 x 10 66 82 -
GLD20 225 170 380 - 135 10 x 18 145 175 190
Fig. 6-1: Dimension drawing of the DC bus chokes GLD
Item Symbol Unit Choke

GLD13 GLD12 GLD20
Inductance at Inenn Lnenn mH 1,0
Power loss
Load dependent losses PV/kW W/kW 1,4 1,7 1,3
continuous power
Connection
Design screw terminal
2
max. cross section A mm 16 / AWG 6 35 / AWG 2 50 / AWG 0
(multi-core with connector sleeve)
Weight m kg 4,8 13,5 35,0
Basic losses: arise with existing bus voltage; drive in "AF"; drive in
shut down
Power loss: consists of the basic losses and the load dependent
losses
Fig. 6-2: Technical data of the DC bus chokes GLD
6.3 Additional capacitance module HZK

The additional capacitance modules HZK fulfill the following
characteristics:
Reduce loss of heat High losses of heat arise on systems whose feed axes need to accelerate
constantly and brake in short intervals (e.g. nibble machines, surface
grinding machines, roll feeds, etc.). With additional capacitance on the
DC bus, the bleeder continuous power and thus the loss of heat can be
reduced.
Increase power in the case of a The possibility to move on a certain traverse path (e.g. for a reverse
power failure motion), even when a power failure occurs, requires the storage of energy
in the DC bus. The storable energy can be increased through additional
capacitance on the DC bus.
Technical Data
Item Symbol Unit Device:

HZK02.1-W003N
Power supply
Input voltage UN1 V System voltage DIAX04 or 500 - 800V DC
Capacitances
Internal capacitance Cintern mF 3,0
Weight m kg 7,0
Fig. 6-3: Technical Data
Dimensioning and unit arrangement

Maximum possible additional It is possible to connect following additional capacitances to the DC bus of
capacitance the supply modules:
HVE (Design "N") HVE (Design "L") HVR

10 mF 100 resp. 200 mF 20 mF
Fig. 6-4: Additional capacitances which can be connected
It is necessary to combine several additional capacitance modules of the

type HZK02.1-W003N so that the above-mentioned additional
capacitance can be realized. Every additional capacitance module of this
type has a nominal capacity of 3 mF. As a result, a maximum of three
HZK modules can be connected to the DC bus of HVE units and a
maximum of six HZK modules can be connected to the DC bus of HVR
units.
Arrangement The HZK modules must be located next to the drives of greatest
performance in the DIAX04 package.
Connection, monitoring and There is no monitoring or diagnosis logic in the HZK available. Therefore,
diagnostics the connection of the X1-bus is only necessary, if other units are mounted
on both sides of the HZK.
It is necessary to connect the DC bus and the operating ground so that a
proper and safe operation can be ensured.
Note: With regard to the control voltage load, the HZK does not
count as an axis.
Front view
X1 Bus connection
DC bus connection
PE bridge
Fa5121f1.fh7
Fig. 6-5: Front view HZK02.1-W003N
Note: The scope of supply includes the copper strand for the DC bus
connection as well as the PE jumper.
The flat cable on the X1 terminal is firmly connected to the unit
(X1 is also the designation of the free multiple contact strip for
looping through the X1 connections).
Unit dimensions
min. 80
50
View without
contact guard
Mounting rail
Mat.-Nr.: 273467
min. 90
+1
468.5
498
Cylindical screw M5x16-DIN912,

min. 100
with washer and spring washer,

contact guard in every second slot
Mb5045f1.FH7
308
Fig. 6-6: Dimension drawing HZK02.1-W003N
6.4 Additional bleeder module HZB

The additional bleeder module is required, if the bleeder power of the
applied HVE supply module is not sufficient for the braking energy arising
in the application.
It can also be applied together with a regenerative HVR supply unit in
order to manage great braking energies in case of power failures.
Unit arrangement The additional bleeder module must always be located next to the supply
unit in the drive package.
Note: A maximum of one additional bleeder module is allowed per

power supply unit.
With regard to the control voltage load, the HZB counts as an
axis.
Technical Data
Item Symbol Unit Device:
HZB02.2-W002N
Nominal input voltage of DC UN1 V System voltage DIAX04 or 500 - 800V DC
bus
Bleeder trigger voltage UBl V 820 V DC (± 20 V)
Regenerated power (bleeder power)
Bleeder continuous power PBD kW 2
Bleeder peak power PBS kW 240
Maximum regenerated power W MAX kWs 250
Power loss
Weight m kg 13,5
Fig. 6-7: Technical data
Connection power supply unit – For communication between HVx power supply unit and additional
additional bleeder bleeder module it is necessary to establish the following connections.
• X0 at power supply unit with X0 at additional bleeder module as in Fig.
6-8
• X1-bus at power supply unit with X1-bus at additional bleeder module
• DC bus L+/L-
The X0-terminal connectors at the powers supply unit (condition as
supplied with jumpers) have to be connected to the remaining unassigned
slots at each last additional module.
Note: Make sure the wiring of the X0-connection between power

supply unit and additional component is correct, because
otherwise the connected components can be damaged!
HZB HVE / HVR HDS / HDD
X0 X0
1 11
5 15
6 16
10 20
X1 X1 X1 X1 X1 X1
L+ L+ L+
L- L- L-
U V W
AP_HZB.fh7
Fig. 6-8: Unit wiring when an HZB unit is used
Regenerated power When operating HVE or HVR together with the additional bleeder module
HZB, please observe the following relations:
• Regenerated continuous power
∑P BD ≤ 0,8 * (PBD,HVE + PBD,HZB )
PBD,HVE : regenerated continuous power HVE

PBD,HZB : regenerated continuous power HZB
• Regenerated peak power

∑P BS ≤ 0,8 * (PBS,HVx + PBS,HZB )
PBD,HVx : regenerated peak power HVE or HVR

PBD,HZB : regenerated peak power HZB
• Regenerated power
∑W ROT,MAX + ∑WPOT,MAX ≤ 0,75 * ( WMAX,HVx + WMAX,HZB )
W MAX,HVx : maximum regenerated power HVE or HVR

W MAX,HZB: maximum regenerated power HZB
Monitored values and diagnostic Monitored values of HZB:

messages
• load of bleeder
• temperature of bleeder
• temperature of power electronics
Note: The following description of the unit monitoring is visualized in

the next figure (Fig. 6-9).
If one of the three monitored values achieves 90% of the permissible

maximum value, a warning will be displayed on the supply module
(additional component warning) as well as on the HZB display.
The warning opens simultaneously the pre-warning contact (terminal X7,
pin 5 and 6) in the supply module HVx.
The warning opens simultaneously the pre-warning contact (terminal X7,
pin 5 and 6) as well as the bleeder pre-warning contact (terminal X7,
pin 7 and 8) open in the HVE.
From the time when the warning occurs, the user has 30 seconds to
prepare countermeasures. If the value does not remain under 90% during
this time, the supply module (HVE only) announces "additional component
error" and the main contactor K1 is deactivated.
If one of the maximum values is reached, the message "additional
component error" will appear immediately. In this case the main contactor
K1 is deactivated as well. The error message is stored in the HZB as long
as it is reset manually by the reset button S1.
The messages of the HZB to the supply module are transmitted via the
X0 and X1 buses.
20 Bleeder overload
>100 % S Q X1 Bus
>1
Bleeder auxiliary component error
1 R Q
utilization Reset
pushbutton S1
>90 % 52 Overload warning
>100 %
>1 S Q 18 Overtemperature
Bleeder
temperature R Q
>90 %
>1 50 Temperature warning
>100 %
Power
electronics
temperature
>90 %
>1 X0 Bus
auxiliary component warning
Fig. 6-9: Monitoring and diagnostic logic HZB02.2-W002N
X0, Additional component bus

Technical data of terminal
X0
1 11
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
Ap_X0_o_bruecken.fh7
Fig. 6-10: Terminal X0 (condition as supplied with connectors)
Design Type Number of poles Type of design

screw terminal 2 x 10 bushing at connector
Fig. 6-11: Design
Connection cross section Cross section Cross section Cross section

single-core multi-core in AWG
[mm²] [mm²] gauge No.:
0,14...1,5 0,25 - 1,5 28...16
Fig. 6-12: Connection cross section
Tightening torque 0,22 Nm
Terminal assignment
HVx0x.2 / HZB02.2
HZS01.2
X4
X2
X0 X0
X3
1 11 1 11
2 12 2 12
3 13 3 13
X0 4 14 4 14 X0
5 15 5 15
6 16 6 16
7 17 7 17
8 18 8 18
9 19 9 19
10 20 10 20
2)
1) 3)
Ap_X0_hzb.fh7
1: terminal connector with jumpers remaining at HVx or HZS

2: wiring to be made by customer
nd
3: 2 terminal connector of HVx or HZS
Fig. 6-13: Terminal assignment of terminal X0 with HZB mounted on right side.
Accordingly when HZB mounted on left side!
Front view
X0 Supply/Communication
Reset pushbutton S1
Display
X2 Service interface
X1 Bus connection
X11 DC bus connection
PE bridge
PE connection
not connected!
Fa5119f1.fh7
Fig. 6-14: Front view HZB02.2-W002N
Note: The scope of supply includes the copper strand for the DC bus
connection as well as the PE jumper.
The flat cable on terminal X1 is firmly connected to the unit
(X1 is also the designation of the free multiple contact strip for
looping through the X1-connections).
Unit dimensions
Mounting rail
Fillister head screw M 5,0x16,0-ISO7045-ZN-MK
(necessary in every second hole)
View without contact guard
X0
499.5
X2
contact guard
X1
L+
L-
262 99.5
304.5 MB5046F1.FH7
Fig. 6-15: Dimension drawing HZB02.2-W002N
6.5 Additional module HZS
General information
The additional module HZS supplies the control voltages and
communication signals for the connected DIAX04 devices. The HZS
contains furthermore capacities for buffering the power DC bus.
High electrical voltage!

⇒ Wait 5 minutes after switching off power to allow
capacitors to discharge before touching the devices.
Measure the voltage on the DC bus connection
DANGER
before beginning to work to make sure that the
equipment is safe to touch.
The power DC bus must be supplied by a power supply unit connected in

the incoming circuit. This power supply unit can be:
• a DIAX04 supply unit HVx (system operation)
(note: HVx = HVE or HVR)
or
• an external device with direct voltage DC bus (externally operated). In
this case observe the allowed input voltage data.
Note: The DC bus connected in series and the supply of the HZS via
its X8 interface must be operated at mains of equal mains
voltage!
Position of the devices DIAX04 drive controllers supplied by the HZS must be positioned on the
right side of the HZS. A maximum of 12 axes can be connected to the
HZS. The exact number depends on the control power consumption (see
chapter 7.2 "Mounting an HVE or HVR into the control cabinet" in the
DOK-POWER*-HVE+HVR**G2-AW06-EN-P Application Manual).
Connecting additional modules It is possible to connect:

• additional bleeder modules HZB
• additional capacitance modules HZK
Please observe the respective requirements for additional modules (see

chapter 6.2 "Additional capacitance module HZK" and chapter 6.3
"Additional bleeder module HZB").
Note: A maximum of one additional bleeder module is allowed per

drive system or supply unit. In the case of a system with HVx
supply unit, the additional bleeder module must be assigned to
the HVx supply unit.
Devices may be damaged under non-specified

operating conditions!
⇒ In the case of a drive system with an HVx supply unit
CAUTION and an HZS additional component you mustn’t
establish any X0 bus connection between these
two devices as otherwise the DC bus short circuit
function and the circuit interruption by means of DC
bus dynamic brake are not available!
Monitoring functions and diagnostic messages

In the additional control voltage module HZS the following states, among
other things, are monitored:
• control voltages for supplying the connected DIAX04 system
• mains input voltage
• DC bus voltage
The diagnoses displayed on the H1 display correspond to the displays of

the HVE supply module (see chapter 11.5 "Diagnostic Display").
In a drive system with HVx supply unit the error messages of the drives
are evaluated by the HVx. The HZS in this case is like an additional
component.
Technical data
Designation Symbol Unit HZS01.2-W300N

Power supply
DC bus direct voltage UZW V system voltage DIAX04 or 500 - 820 V DC
Output power
Operating mode - - external direct voltage DC bus system operation
DC bus continuous power PZW kW 30 kW PZWHVx
DC bus peak power (for 0.3 s) PZWS03 kW 90 kW PZWS03HVx
Capacities
Internal capacity Cint mF 1.41
Power loss
Power losses per kW DC bus PV/kW W/kW 3
continuous power
Weight m kg 8
Power input with maximum SN2 VA 500
load
Fig. 6-16: Technical data of HZS01.2-W300N
Interfaces at the HZS

Terminal X0
X0
1 11
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
Ap_X0_m_bruecken.fh7
Fig. 6-17: Terminal X0 (condition as supplied with connectors and jumpers)

Fig. 6-18: Design

0,14...1,5 0,25 - 1,5 28...16

Terminal assignment
X4
X0
X2
1 11
2 12
X3
3 13
4 14
X0
5 15
6 16
7 17
8 18
9 19
10 20 X7
Ap_X0_hve.fh7
Fig. 6-20: Terminal X0 at additional component HZS
Note: At delivery, terminal 1 is jumpered with 5, 6 with 10, 11 with 15

and 16 with 20.
Enable inputs at X3
For transmitting messages to the drive controllers the HZS needs
information on the operating status (ON or OFF) of the supply unit
connected in series. The information can be provided by one of the two
equal-priority enable inputs at X3.
In the case of system operation, the exchange of information with the HVx
additionally takes place via the control voltage bus X1. To do this a
jumper from X3.1 to X3.2 is sufficient. When the HZS is delivered this
jumper is included.
Terminal X3
1 Bbe
1 2 3 4 5 6
2 Bbe
3 n.c.
4 n.c.
5 Bbe+
6 Bbe-
Ap_X3.FH7
Fig. 6-21: Terminal X3 (condition as supplied with connector and jumper)

screw terminal 1x6 bushing at connector
Fig. 6-22: Design

0,14...1,5 0,25 - 1,5 28...16
Terminal assignment
X4
X3
1
Bbe X2
2
Bbe
3
n.c.
4 X3
n.c.
5 Bbe+
6 Bbe-
X0
X7
Ap_X3_hzs.FH7
Fig. 6-24: Terminal assignment
The two enable inputs are of equal priority but realized differently:
• isolated (X3.1, X3.2)
• non-isolated (X3.5, X3.6)
Isolated enable input (X3.1, X3.2)

The HZS interprets a closed connection between X3.1 and X3.2 as the
readiness of the external power supply unit for power output.
The HZS interprets an open connection between X3.1 and X3.2 as the
shutdown of the external power supply unit.
Requirements for the switch contact X3.1, X3.2:

Switching voltage DC 26 V ± 2 %
Switching current DC 3.5 mA ± 0.5 mA
Fig. 6-25: Switch contact X3.1, X3.2
Non-isolated enable input (X3.5, X3.6)

The HZS interprets a high level at X3.5 as the readiness of the external
power supply unit for power output.
The HZS interprets a low level at X3.5 as the shutdown of the external
power supply unit.
Note: For controlling via voltage output (X3.5, X3.6) the jumper at
X3.1, X3.2 has to be removed.
Reference potential/ground X3.6

Input resistance > 5 kOhm
Voltage range at X3.5 for high level +20 ... +26 V
Voltage range at X3.5 for low level 0 ... 5 V
Minimum required input current 2.5 mA
Fig. 6-26: Non-isolated enable input
Bbe or Bbe+
t
UD > UDmin
t
UD contact
t
UD message to
drive controllers
t
hzs_signalverlauf.fh7
Bbe / Bbe+: enable inputs at X3

UD > UDmin: DC bus voltage higher than minimum value;
the minimum value is calculated from 0.8*mains peak value
UD contact: relay contact at X7.3 to X7.4
UD message to drive controllers: internal message of the drive system via the
control voltage bus X1
Fig. 6-27: Signal curves
X4, Control voltage

See page 10-6
X5, Mains connection

Terminal X5
U V X5 W
X5HZS.fh7
Fig. 6-28: Terminal X5

screw terminal 1x1 bushing at device
Fig. 6-29: Design

2,5...10 2,5...16 12...6
Tightening torque 2 Nm
Terminal assignment
device external device internal
X5
U
V
PE
AP_X5hzs.fh7
X7, Ready-to-operate and other messages

See page 10-12
X8, Control voltage supply

Terminal X8
2u2
1
1
2v2
2
2
2w2
3
3
X8HZS.fh7

Fig. 6-33: Design

0,4...4,0 0,25...4,0 24...10
Terminal assignment
X0
X7
X8
1
L1 X8
2
L2
3
L3
AP_X8HZS.fh7
X11, DC bus connection

See page 10-17
X12, Ground connection

See page 10-19
Operation with external direct voltage DC bus

Principle The drive system consisting of HZS and DIAX04 drive controllers receives
its DC bus voltage from an external power supply unit with direct voltage
DC bus (e.g. REFUdrive).
The HZS monitors the DC bus voltage. Together with the enable signal
sent from the power supply unit connected in series to X3, it transmits the
respective operating status to the connected DIAX04 drive controllers.
devices of
high power low power
these devices are supplied with control voltage by the HZS
external 3) HZS e.g. HDx HDx

DC bus HZB (2nd axis) (12 axes
X3 (1st axis) max.)
X0 X0
X8
X1 X1 X1 X1 X1 X1 X1 X1
max. 1 m
L+ L+ L+ L+ L+
L- L- L- L-
L-
1) 2) shield
(grounded
at both ends)
L1
L2
L3
ap_hzs_anordnung.fh7
PE
1) fusing according to line cross section and/or power
2 2
2) line cross section: min. 16 mm , max. 35 mm
3) enable signal "power ready"
Fig. 6-36: Operation with external direct voltage DC bus
Mains connection (L1, L2, L3) See page 6-15, "Technical data of HZS01.2-W300N" in this
documentation.
Note: The external DC bus and the supply of the HZS via X8 must
be operated at mains of equal mains voltage.
Position of the devices The DIAX04 drive controllers must be positioned on the right side of the
HZS. The higher the power of a device the nearer to the HZS it must be
positioned. A maximum of 12 axes can be connected. (See chapter 7.2
"Mounting an HVE or HVR into the control cabinet")
Distances between the devices Allowed distance between the external power supply unit and the HZS:
1 m maximum
Distances of more than 1 m require additional HZK capacitance modules.
In addition, you have to check for each application whether the allowed
load values of the internal DC bus capacitances have been observed. The
allowed load values are made available on request.
Fusing of the DC supply As a matter of principle, you always have to take measures for fusing the
DIAX04 drive system, in the case of external supply, according to the
cross section of the connection and/or the power.
Allowed continuous power of To make sure the expected service life of the internal DC bus
the total DIAX04 system capacitances is reached, the allowed continuous power, without other
measures, is limited to 30 kW.
The allowed continuous power can be increased by means of additional
capacitance modules HZK. The continuous power, however, is limited to
75 kW because the cross sections of the DC bus connections that can be
connected are limited.
Connecting additional modules When the additional bleeder module HZB is used, the additional
component bus X0 has to be wired according to the description in
chapter 6.4.
System operation at the DIAX04 drive system

Using the HZS together with a DIAX04 supply unit (HVE or HVR) at the
modular drive system allows increasing the allowed number of axes of the
total drive system.
Note: More than 12 axes are only allowed for supply units of the
"HVE" series, if the fact that there is no SUP kit required
additionally results from the calculation formula in chapter 8.11
"Applications with HVE0x.2-W0xx power supply unit"!
For applications with HVR supply units a maximum of 12 axes
is possible.
The allowed number of axes at the DIAX04 supply unit is limited by the
control voltage
• by the driver power of the control signals for 12 axes at the X1 bus
connection
and/or
• by the maximum power of 0.3 kW of the control voltage output of the
supply units
If one of the two limit values (12 axes or 0.3 kW) is exceeded the allowed
number of axes of the total system can be increased by using an HZS. A
maximum of 12 axes can be connected to the HZS. When determining
the control power load of the HVx, the HZS is considered as one axis.
Note: Only one HZS is allowed per drive system!
devices of
high power low power
these devices are supplied with control voltage these devices are supplied with control voltage
by the HVx by the HZS
HVx e.g. HDx HDx HZS e.g. HDx HDx

HZB (2nd axis) (11 axes (12th axis) HZK (1st axis (12 axes
(1st axis) max.) after HZS) max.)
X0 X0
X8
X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1
L+ L+ L+ L+ L+ L+ L+ L+
L- L- L- L- L- L- L- L-
L1
L2
L3
ap_hzs_ano_pak.fh7
PE
Fig. 6-37: Operation at the DIAX04 drive system
Mains connection See page 6-15, "Technical data of HZS01.2-W300N" in this

documentation.
Note: The power and control voltage connection (X5 and X8) of the
HVx connected in the incoming circuit and the control voltage
connection X8 of the HZS must be operated at mains of equal
mains voltage.
Allowed power of the drive The total DC bus power of the drive system mustn’t exceed the allowed
system power data of the supply unit.
Note: With the HZS it is impossible to increase the DC bus power of

the supply unit!
The total power of the drives connected in series to the HZS mustn’t
exceed 30 kW! The total power can be increased by additional
capacitance modules.
The maximum allowed DC bus continuous power is 75 kW!
Position of the devices The above figure shows the position of the devices:
HVx → 11 drive controllers → HZS → a max. of 12 other drive controllers
Connecting additional modules When the additional bleeder module HZB is used, the additional
component bus X0 has to be wired according to the description in
chapter 6.4. The X0 bus connection to the HZS mustn’t be established
because otherwise the DC bus short circuit function and the circuit
interruption by means of DC bus dynamic brake won’t work!
The HZS in this case has to be operated with the jumpers at X0 (condition
as supplied)!
Front view
X4 control voltage outputs
X2 service interface
X3 enable inputs
X0 auxiliary components bus
X7 potential free relay contact
S1 reset key
H1 diagnostic display
X8 control voltage connection
X1 Bus connection
X5 PE connection
not connected
X12 PE bridge
hzs_frontansicht.fh7
Fig. 6-38: Front view HZS01.2
Device dimensions
minimum
min. 80
mounting
clearence
min. 90
498
468.5
min. 100
265
308
100
hzs_maszblatt.fh7
Fig. 6-39: Dimensional drawing HZS01.2
Overall connection diagram
L1
3 x AC 380 - 480 V L2
50 - 60 Hz L3
PE
1
2
3
n.c.
n.c.
n.c.
X5 X8A
2W2
2U2
2V2
U V W
control
voltage
~
X3 supply =
1
Bbe
2
Bbe
3 X0 bridged at
n.c.
4
delivery
n.c. 1 11
5 Bbe+ 2 12
6 Bbe- 3 13
4 14 power supply and
5 15
communication
with auxiliary
6 16 modules (HZN,
7 17 bleeder, etc.)
8 18
HZS01.2 9 19
10 20
X1A X1B
control voltage
supply and
30 pin flat 30 pin flat communication
ribbon cable ribbon cable with drive
controllers
X11
Cu lead 1)
X4
1 L+
+15VM
max. 100 mA 2 power
0VM L-
3 supply
-15VM and ground
4
frei
X12 connection of
5
+24VL 1 drive
max. 2 A 6 controllers
0VL
7 PE bridge connection only 2
frei PE bridge 1)
n/c 3
4
X7
1
ready to Bb1
2
operate
3
power X2
voltage 4 UD service interface
OK 5
prewarning 6 VW
7
n.c.
8
n.c.
1) Cu lead and PE bridge automatically delivered. Ap_hzs.fh7
Fig. 6-40: Overall connection diagram HZS01.2
6.6 Additional components SUP-E0x

Application The additional components "SUP-E0x-HVR" can be used together with
power supply units of the HVR and HVE series.
It is necessary to use "SUP-E0x-HVR"
• when a specific characteristic value is exceeded with multi-axis
operation (only with HVE). See chapter 8.11 "Applications with
HVE0x.2-W0xx power supply unit".
• for reducing the leakage current when using residual-current-operated
protective devices
• when the HVR is operated on asymmetric mains, e.g. in the case of
outer conductor ground connection In this case, HZF are not allowed
for reducing interference emission.
• in order to reduce distortion of the mains voltage due to leakage
currents
mains connection
appropriate
PE
L3
L2
L1
mains filter HDx HDx HDx

HVx0x.2-
L1.1
L2.1
L3.1
W0xxx
PE
X8
U1
V1
W1
1) SUP-E0x-HVR
2 x 470 nF L+
KD xx C U V W PE
L-
U1 U2 SKD
mains connection
load connection
V1 V2
W1 W2
AP_SUP.fh7
1) e.g. NFD03.1 for symmetric mains

2) The two capacitors are not required for SUP-E08-HVR and aren’t
contained in the scope of supply either.
Fig. 6-41: Example of connection SUP-E0x with HVR
(when HVE is used, KD xx – C is not required)
Technical data
Designation Symbol Unit SUP-

E05-HVR E06-HVR E07-HVR E08-HVR
Nominal current Inenn A 18 45 80 140
Nominal voltage Unenn V system voltage DIAX04 or 380 - 480 (±10%)
Frequency f Hz 50...60 (±2%)
Power loss
Power loss at maximum Pv W 150 200 300 500
continuous power and
maximum number of axes
Connection of current compensated choke
Type - - connector sleeve ring cable
lug
2
50 mm /M10
Length of strands l mm 600 250
Voltage stability of strands U V 600
2
Connection cross section A mm 4 / AWG 10 10 / AWG 6 25 / AWG 4 50 / AWG 2
Weight m kg 10 12 14 16
Capacitor
Capacity Cnenn nF 470
Nominal voltage Unenn V 900
Weight m g 40 each
Connections - - to L+ resp. L- via flat push-on connector
6,3 x 0,8; not contained
to ground via stud M8
2
Connection cross section A mm 2,5
Required dielectric strength of U V 600
strands
Fig. 6-42: Technical data SUP-E0x-HVR
Current compensated choke
Connection
X5
SKD
L1 U
mains
V
load
L2
L3 W
AP_X5SKD.fh7
Fig. 6-43: Connection of current compensated choke
Component Mains connection Load connection

SUP-E05-HVR
SUP-E06-HVR 22 24 26 21 23 25
SUP-E07-HVR
SUP-E08-HVR L1 L2 L3 L1.1 L2.1 L3.1
Fig. 6-44: Connection designation of current compensated choke
Dimensions
connection
wires
G
A
B
C
H
F
D
J
MB_SKD.fh7
Fig. 6-45: Dimensional drawing
Choke A B C D E F G H J
SUP-E05-HVR 100 230 200 230 200 6,5 600 -- --
SUP-E06-HVR 140 250 200 250 200 6,5 600 -- --
SUP-E07-HVR 170 250 200 250 200 6,5 600 -- --
SUP-E08-HVR 210 300 280 240 180 6,5 250 150 220
Fig. 6-46: Dimensions
Capacitor
Capacitor connection device external device internal
screw flat X11

bolt connector
L+
L-
X12
mkv_kondensator.fh7
Fig. 6-47: Capacitor connection
Dimensional drawing
mkv_kondensator_abmess.fh7
Fig. 6-48: Dimensional drawing
d l l1 l2
Dimensions [mm] 25 57 8 15
Fig. 6-49: Dimensions
Fixing Fixing the capacitor:

• screw M8
• tightening torque: 4 Nm
Scope of supply
The additional components SUP-E0x-HVR are supplied with:
• 1 piece current compensated choke
• 2 pieces capacitor 470nF/900V (except for SUP-E08-HVR)
• accompanying note with connection diagram
HVE and HVR 2nd Gen. Power Supply Units Mounting 7-1
7 Mounting
7.1 Control cabinet planning
Conditions of use
Ambient temperature and The nominal data for the power supply units (see chapter 4) and
installation elevation additional components (see chapter 6 "Additional modules and
components") apply to
• ambient temperature range of +5 °C to +45 °C and
• installation elevation of 0 to 1000 m above sea level.
Note: All components are built-in devices and only suited for
installation in a control cabinet or housing.
Note: If the power supply unit or additional components are used in

situations that exceed this range, then the "load factors" must
be taken into account. This derates the power data.
Note: The derating begins with elevations of more than 1000 m.

With elevations of more than 2000 m, additional external
components must be provided for voltage limitation (1.5 kV).
Depending on the applicable regulation (DIN 0110, CSA,
NEMA), an isolating transformer is possibly required to limit
the mains voltage.
Damage to the units due to operation outside of

the specified conditions of use!
⇒ Those power supply units or additional components
CAUTION operated outside of the specified conditions of use
can be damaged. Doing so also means that the
guarantee will be forfeited!
Damage to the units due to overloaded power

supply unit!
⇒ If you want to use power supply units or additional
CAUTION components outside of the specified conditions of
use, please check first, whether the performance
data are sufficient. Please check by reading the load
factor(s) from the diagrams in Fig. 7-1 and follow the
instructions below!
7-2 Mounting HVE and HVR 2nd Gen. Power Supply Units
Load factor as dependent on Load factor depending

1
ambient temperature on elevation
1
0,8
Load factor fH
load factor fT
0,8 0,6
0,6
40 45 50 55 0 1000 2000 3000 4000
Ambient temperature in °C Elevations above sea level
DG0005F1.FH7
Fig. 7-1: Load factor as dependent on ambient temperature and elevation
Case 1:
The ambient temperature exceeds the nominal data
- or -
the elevation exceeds the nominal data:
1. Determine the load factor from the figure above.
2. Multiply the nominal data listed in the technical data with the load
factor which has been determined.
3. Ensure that the derated nominal data is not exceeded by your
application.
Case 2:
The ambient temperature exceeds the nominal data
- and -
the elevation exceeds the nominal data:
1. Determine the load factors from the figure above.
2. Multiply the determined load factors.
3. Multiply the nominal data indicated in the technical data by the load
factor calculated in step 2.
4. Ensure that the derated nominal data is not exceeded by your
application.
Protection category The power supply unit and the additional components meet the
requirements as specified for protection category IP10, as per IEC 529.
Mounting of the power supply The power supply unit and the additional components have been
unit designed for mounting into a control cabinet or closed housing (as per EN
50 178, edition dated 4/98).
Note: Take the safety directives governing protection upon contact

into account when laying out the control cabinet. For industrial
applications, also see EN 60 204.
Loss of heat in the control cabinet

With HVE and HVR types and additional components, basic losses due to
control voltages, power losses and probable bleeder losses arise. Basic,
power and bleeder losses produce a loss of heat in the control cabinet
and might not be carried off over the control cabinet surface. They need
to be carried off by an air conditioning unit.
The bleeder power loss depends on the rotary drive energy, the potential
energy of non balanced masses and the programmed machine cycle (see
chapter 5.5).
In the following you’ll find the calculation of a heat loss in the control
cabinet. The data for the calculation stem from this documentation except
for the motor data and the drive and control system data.
Example calculation
The arising losses of heat shall be calculated for the following drive
equipment:
Units in the control cabinet
Power supply unit HVR02.2-W010N,
DC bus continuous power 10 kW;
calculated load 8 kW
Combining filter and commutation Combining filter HZF01.1-W010N,
choke Commutation choke KD30
Drive 1 Motor 2AD104B-...-CS with drive
controller HDS02.2-W040N
Continuous power 5 kW;
Motor constant current 12 A
Drive 2 Motor MHD093C-035 with drive
Constant torque 23 Nm;
Motor constant current 18,5 A
Drive 3 Motor MHD093C-035 with drive
Motor constant current 12 A
Drive 4 Motor MHD112B-024 with drive
Motor constant current 21,9 A
Basic losses and load dependent losses arise in the power supply unit,
the choke, the combining filter and in the drive and control systems.
Basic losses
Type of unit Designation Basic loss [W]
Power supply unit HVR02.2-W010N 150
Combining filter HZF01.1-W010N 100
Commutation choke KD30 150
Drive controller HDS02.2-W040N 45*
Sum 615 W
*: Basic losses consist of the losses for the control voltage and the basic
losses of the power supply.
Fig. 7-2: Basic losses of the units installed in the control cabinet
Load dependent losses The calculation of load dependent losses is based on the fact that the DC
bus is loaded with 8 kW (constant load) and the motor load corresponds
to the respective motor constant torque or motor continuous power.
Note: It is advisable for main drive applications to start from each

motor constant torque/motor continuous power.
If the calculated effective torque for the feeding application is
smaller than the motor constant torque, the motor current can
be reduced proportionally.
Type of unit Designation Load dependent losses [W]

Power supply unit HVR02.2-W010N 8 kW * 15 W/kW = 120 W
Combining filter HZF01.1-W010N 8 kW * 10 W/kW = 80 W
Commutation choke KD30 8 kW * 15 W/kW = 120 W
*1
Drive controller HDS02.2-W040N 12 A * √2 * 5 W/A ≈ 85 W
Drive controller HDS02.2-W040N 18,5 A * 5 W/A ≈ 93 W
Drive controller HDS03.2-W075N 18,5 A * 4,625 W/A ≈ 86 W
Drive controller HDS03.2-W100N 21,9 A * 4,6 W/A ≈ 101 W
Sum 685 W
*1
:With regard to asynchronous motors, the technical data include the
effective value of the phase-to-phase current as motor nominal current.
The loss factor (W/A) indicated in the technical data of the control units
refers however to the peak value so that the motor nominal current is
multiplied by √2.
Fig. 7-3: Load dependent losses of the units installed in the control cabinet
Total power loss The total power loss in the drive package is:
Basic losses + load dependent losses =
615 W + 685 W = 1300 W = PvGes
As a rule, only part of the power loss may be carried off over the control
cabinet surface. Then, it is necessary to use a cooling unit so that the
remaining power loss may be carried off:
PK lim a = PvGes − Psurf = PvGes − [ A * K * ( 45° − Tmax )]

PvGes: Total power
PKlima: Power to be carried off via cooling unit [W]
Psurf: Power carried off over control cabinet surface [W]
A: Isolated control cabinet surface [m²]
K: Heat transmission coefficient (approx. 5 ... 6 W/m²)
Tmax: Maximum ambient temperature
Fig. 7-4: Calculation of the power loss to be carried off via cooling unit
power loss
load dependent losses
basic losses
continuous DC bus power
Verlustleistung.fh7
Fig. 7-5: Power loss depending on the DC bus continuous power
The use of cooling units

The power supply unit without reduced nominal data may only be
operated up to an ambient temperature of 45 °C. This means that it may
be necessary to use a cooling unit.
Avoid dripping and spraying The use of cooling units always means that condensation will occur!
water
When using cooling units, damages to the

power supply unit may be caused by
condensation water!
CAUTION ⇒ Always arrange the cooling units so that
condensation cannot drip into or onto electronic
equipment.
⇒ Position cooling units so that the cooling unit blower
does not blow condensation which has possibly
collected onto electronic equipment.
Note: For the arrangement of a cooling unit please see the following
figures too.
correct incorrect
cooling unit cooling unit
warm cold warm cold
air duct
electronic electronic
equip. equip.
Control cabinet Control cabinet
Eb0001f1.fh7
Fig. 7-6: Cooling unit arrangement on the control cabinet
correct incorrect
control cabinet control cabinet

air inflow air inflow
air air outflow

duct
cooling cooling
unit unit
electronic electronic
equip. equip.
Eb0002f1.fh7
Fig. 7-7: Cooling unit arrangement on the front of the control cabinet
Avoiding condensed water
When using cooling units, damages to the

power supply unit may be caused by condensed
water!
CAUTION ⇒ Set the cooling units at 40 °C and no lower!
⇒ Set cooling units with follow-up temperature in such
a way that the inside temperature of the control
cabinet does not drop below the outside
temperature. Set the temperature limit to 40 °C!
⇒ Use only well sealed control cabinets in order to
avoid condensed water due to incoming humid
outside air.
⇒ If the control cabinets are operated with open doors
(during servicing or start ups), then ensure that the
controllers are never cooler than the air within the
control after the doors are closed as otherwise
condensate could form. For this reason, continue to
run the cooling unit even when the machine is
shutdown until the temperature of the air in the
control cabinet and that of the installed units is the
same.
Construction of uncooled control cabinets

During operation of the units, power losses occur which heat the
surrounding air in the control cabinet. If a power supply unit is operated in
an uncooled and unventilated control cabinet, sufficient clearance must
be provided around the unit or the drive package (at least 300 mm to the
top and 100 mm to the sides). This clearance is necessary in order to
produce an air circulation in the control cabinet (see also the next figure).
100 100
300
HVR/HVE HDS HDS HDS HDS
Eb0004f1.fh7
Fig. 7-8: Control cabinet (uncooled, unventilated) with drive package
Damage to the units due to too high

temperatures!
⇒ Ensure air circulation within the control cabinet air by
CAUTION means of a circulation system. If circulation within
the cabinet is not forced, then layers of air are
generated within the cabinet the temperature of
which depends on how close the layer is to the top of
the cabinet, i.e., the closer the hotter. Without air
circulation the air near the source of the heat
continues to grow hotter to the point where extreme
temperatures could occur. These temperatures can
then damage the unit permanently.
Note: The cooling units inside the unit only cool internally. They do
not have enough power to generate air circulation within the
cabinet.
Efficiency factor of the air The greatest affect is achieved if the air channel is conducted along an
circulation system outside wall of the control cabinet so that the outside surface is used as a
cooling surface. The blowers must blow upward. This may counter natural
convection and the blowers internal blower, but it effects the rapid
movement of cooler air out of the lower part of the cabinet into the upper,
hotter layer of air thus countering pockets of heat very effectively.
Control cabinet
door
Air duct HVE/HVR/

HDS/HDD
Air flow
Blower
Eb0003f1.fh7
Fig. 7-9: Control cabinet with air circulation system
7.2 Mounting an HVE or HVR into the control cabinet

Mounting conditions The power supply units HVE and HVR and their controllers are designed
to be mounted into a control cabinet or closed housing. They meet the
demands of protection category IP 10, as per IEC 529; i. e. the unit is
protected against the ingress of objects with a diameter exceeding
50 mm.
It is not protected against
• water and
• intentional accessing, e.g., with a hand, but will keep larger body parts
and surfaces out.
Mounting position The unit is to mount in such a way that the mains connection is located at
the bottom.
Damage to the units due to faulty mounting!

⇒ Install the unit as it is shown in the front views
(chapter 7.4) so that the unit is prevented from
overheating and damage due to faulty mounting.
CAUTION
Controller arrangement Place those drives with high power and high currents as close to the
supply unit as possible. Ideally, the axes should be distributed
symmetrically on the left and right.
Given a total power of Pmges > 36 kW the axes must be arranged in
accordance with their power equally on both the left and right sides
(exception: single axis with Pm > 36 kW).
Maximum number of axes The maximum number of axes is limited by the drive power of the control
signals at X1
- and/or -
by the maximum power of the control voltage outputs of the unit (X8).
• Driver power of control signals: max. 12 axes
(additional components, such as HZB are considered to be axes)
• Power of control voltage output: 300 W
controllers controllers
low power high power high power low power
supply
module
8 8 8 8
X1 X1 X1 X1
L+ L+ L+ L+
L- L- L- L-
A1 A2 A3 A1 A2 A3 A1 A2 A3 A1 A2 A3
Anordnu.fh7
Fig. 7-10: Recommended unit arrangement within the control cabinet
Safety distance of the bleeder The bleeder resistor in the HVE heats up during operation, in the HVR
resistor after power shutdowns. Materials which could be damaged by heat, such
as lines and cable ducts, must have a minimum clearance of 300 mm to
the top and 40 mm to the aid and front.
40 300
P01hva1B.fh7
Fig. 7-11: Safety distance of the bleeder resistor
7.3 Optimal EMC installation

With regard to an optimal EMC installation, a spatial separation of the
interference-free area (mains connection) and the interference
susceptible area (drive components) is advisable. See the next figure in
this respect.
Note: For an optimal EMC installation see also the connection hints
(chapter 8.9).
HVE
shielded control cabinet

compartment or intermediate
mains PE panel
control
cabinet HVE HDS HDS
connecting
clamps
main
switch
distributor
clamps
fuse
mains
to the motors
Filter earth rail

NFD
power connection
load
B01EMV.fh7
Fig. 7-12: HVE - Separation of interference-free and interference susceptible

areas
HVR
mains PE
ground connection
control
cabinet HZF HVR HDS HDS
connecting
clamps
main
switch control voltage
connection
distributor
clamps
fuse
KD
shielded cable power connection
to the motors
earth rail
shielded control cabinet compartment
or intermediate panel
B02EMV.fh7
Fig. 7-13: HVR - Separation of interference-free and interference susceptible

areas
7.4 Dimensional data
HVE02.2and HVE03.2
262 A
X4
X2
X3
X0
X6
X7
498
X13 X8
X11
X12
X12
308
X5
MBHVE.fh7
Fig. 7-14: Dimension drawings HVE02.2 and HVE03.2
Unit width A Unit types HVE02.2 have a width of 100 mm;

Unit types HVE03.2 have a width of 150 mm
Terminal designations see chapter 10
HVE04.2
262 A
X4
X2
X3
X0
X6
X7
498
X8
X11
X12
X12
308
X13 X5 MBHVE04.fh7
Fig. 7-15: Dimension drawing HVE04.2
Unit width A Unit types HVE04.2 have a width of 250 mm.
HVR
262 A
X4
X2
X3
X0
X6
X7
498
U1
V1
W1
not assigned
X11
L+
X12 L-
X12
308 U V W
MBHVR.fh7
X5
Fig. 7-16: Dimension drawing HVR
Unit width A Unit types HVR02.2 have a width of 175 mm;

Unit types HVR03.2 have a width of 250 mm
HZF01.1-W010N
mounting supply connection

M.Nr.:274773 View without contact guard
mounting rail terminal stud
(part of SUP-M01-HD) for PE
X6
262
150
F2
498
X8 / X8a
contact guard
X1
X11
X12
clamping device
M.Nr.:277830
X5
fillister head screw

M5x16-ISO7045-ZN-MK
fixing angle (part of SUP-M01-HD)
(demountable)
mounting
M.Nr.:274773 Mb5051f1.fh7
Fig. 7-17: HZF01.1-W010N
Terminal designations
Supply X1 X5 X6 X8 X11 X12
connection
4 *1 6 2,5 1,5 *2 *2
*1: Flat cable firmly connected to the unit and/or free multiple contact strip
for looping through the X1-connections
*2: This wiring material will be supplied
Fig. 7-18: Maximum cross sections for connection [mm²]
HZF01.1-W025N / HZF01.1-W045N
View without contact guard

mounting
M.Nr.:274773 supply connection
mounting rail terminal stud
(part of SUP-M01-HD) for PE
262 X6
175
F2
498
X8 / 8a
contact guard
X1
X11
clamping device
M.Nr.:277830
X12
X5
fillister head screw
M5x15-ISO7045-ZN-MK
(part of SUP-M01-HD)
fixing angle
(demountable)
mounting
M.Nr.:274773 Mb5052f1.fh7
Fig. 7-19: HZF01.1-W025N / HZF01.1-W045N
Terminal designations
Type Supply X1 X5 X6 X8 X11 X12
connection
HZF01.1-W025N 16 *1 16 2,5 1,5 *2 *2
HZF01.1-W045N 25 *1 25 2,5 1,5 *2 *2
*1: Flat cable firmly connected to the unit and/or free multiple contact strip
for looping through the X1-connections
*2: This wiring material will be supplied
Fig. 7-20: Maximum cross sections for connection [mm²]
Commutation choke KD xx
H
circuit diagramm:
1 U1 U2
V1 V2
C
W1 W2
PE
F
long hole in a
"B" direction
J
D1 E
b
D B
G
A
MB_KD_1.fh7
1) Capacitors are only available for the KD xx C type.

2
Type Dimensions [mm ] Terminal Weight
cross section [kg]
A B C D D1 E F G* H* [mm²]
KD 30 / D 30 C 180 101/ 205 125 - 76/ 7 x 15 - 150 M5 10 8
173* 148*
KD 27 / D 27 C 285 138 280 170 110 108 11 x 18 50 285 M6 16 22
KD 28 / D 28 C 330 160 390 230 180 130 10 x 18 55 250 M8 35 42
*: KD xx C only
Fig. 7-21: Dimension drawing commutation choke KD xx / KD xx C
7.5 Mounting the unit
air outlet
300 mm free
minimum
A 150 100 50
50
mount
at least every
100 mm screw
M5 x 16 with
disc and
drive controller coil ring
drive controller
with 100 width
controller with
468,5 +1
with 50 width
150 width
100 mm free
minimum
air inlet
unit A
cooling air temperature max. 45 °C
HVE 02.2 100
HVE 03.2 150
HVE 04.2 250
HVR 02.2 175
HVR 03.2 250
Mounting rails: avail. in lengths of 0.75m
(part of mounting accessories kit SUP-M01-HD) 12
25 ±0,2 50 ±0,2 8
5,5 ±0,1
26
11
MZHVE.fh7
5,5
12 3
Fig. 7-22: Mounting the unit
Notes
HVE and HVR 2nd Gen. Power Supply Units Electrical connection 8-1
8 Electrical connection
8.1 Introduction
Note: This chapter includes recommendations of how to install the

unit (by Rexroth as the manufacturer).
The manufacturer’s circuit diagram is decisive for the
installation of the unit!
Note: For the maximum cross sections of the connection lines

please see the following chapters:
HVE, HVR, HZF, KD: chapter 7.4
GLD, HZB, HZK: chapter 6
8-2 Electrical connection HVE and HVR 2nd Gen. Power Supply Units
8.2 Front view and terminal diagram
HVE
view without type plate

cover
X3 mains contactor control
X0 Bus connection
aux. components
Note: X6 mains contactor

- all T25 Torxes aux. contacts
S1 reset key
X13 DC bus choke

connection X8 control voltage connection
X1 Bus connection
X1 Bus connection

X12 PE bridge
U V W
X5 mains connection PE connection FA_HVE.fh7
Fig. 8-1: Front views HVE02.2 and HVE03.2
view without type plate

cover
X0 Bus connection
aux. components
Note:
- all T25 Torxes
X6 mains contactor
aux. contacts
S1 reset key
X8 control voltage connection
X1 Bus connection X1 Bus connection

X12 PE bridge
X13 DC bus choke X5 mains connection PE connection FA_HVE04.fh7

connection
Fig. 8-2: Front view HVE04.2
L1
3 x AC 380 - 480 V L2
50 - 60 Hz L3 bridged at
PE delivery
Q1
6
4
5
1
2
3
X8
2W1
2W2
2U2
2U1
2V1
2V2
X5
W
U
V
K1 control
voltage
~
supply = X0
~ power 1 11
bridged at
delivery
1
X3 = supply 2
3
12
13
power supply &
ZKS 4 14
ZKS 2 5
communication
ZKS 15
with auxiliary
OFF
3
Off HVE02.2, HVE03.2 and 6
7
16 modules (HZN,
4 17 bleeder, etc.)
5
Off HVE04.2 8 18
ON On 9 19
6
On
Power supply units for direct 10 20
mains connection with
X4 integrated mains contactor
1
+15VM
max. 2 X1
100mA 0VM control voltage
3
-15VM supply and
4
n/c
30 pin flat communication
5 ribbon cable with drive
max. +24VL controllers
6
2A 0VL
7
n/c
X11 Cu lead 1)
X6
1 L+
acknowledge
power ON 2 K1 NO power
L- supply
3
and ground
4 K1 NC X12 connection of
acknowledge drive
power OFF 5
1 controllers
6 K1 NC
PE bridge connection only 2
PE bridge 1)
n/c 3
X7 4 DC bus
1 choke
ready to Bb1
operate 2 (Option)
3
X13
power L1
voltage 4 UD
2L+
OK 5 2
prewarning 6 VW bridged at 1L+
7
delivery 2) 1
Bleeder BVW
8 X2
prewarning
service interface
1) Cu lead and PE bridge automatically delivered. AP_HVE.fh7
2) not for HVE04.2
Fig. 8-3: Terminal diagram HVE02.2, HVE03.2 and HVE04.2
Note: Only for HVE04.2: If you do not use a DC choke, you have to
establish a jumper from terminal X13.1L+ to X13.2L+. The
cross section of the jumper must be at least AWG06
2
(10 mm ). Make sure there is sufficient shock protection.
HVR
type plate
X0 bus connection of
auxiliary components
Note: X6 auxiliary contact of

- all T25 Torxes the mains contactor
X7 potential free
relay contact
S1 reset key
X8 control voltage
connection
X1 bus connection X1 bus connection
X12 PE bridge
U V W
X5 mains connection X5 PE connection FA_HVR.fh7
Fig. 8-4: Front view HVR
mains input
L1 L1
3 x AC 380 - 480 V
50 - 60 Hz L2 L2
HZF01.1-W0xxN
Combining filter
L3 L3 F2
U V W L- L+ U4 V4 W4
X12
X5 X11 X8/X8a
PE
Q1
KDxx U1 V1 W1
Cu lead1)
1
2
3
4
U2 V2 W2
X8
n/c
control ~
to the central X5 voltage
=
W
U
ground connection supply

K1 X0 bridged at
delivery
1 11
~ power
2
3
12
13
= supply 4
5
14 supply and
communication
15
X3 with auxiliary
6 16 modules (HZN,
1
ZKS 7 17 bleeder etc.)
ZKS 2 8
ZKS 18
3
OFF 9 19
OFF 4 10 20
OFF
5
ON ON
6
ON
X1
control voltage
supply and
X4 30 pin flat communication
1
ribon cable with
+15VM drive controllers
max. 2
100 mA 0VM
3
-15VM X11
4
n/c Cu lead1)
5 L+
max. +24VL
6
2A 0VL L-
7 power supply
n/c and ground
X12 connection
of drive
1 controllers
X6
1 PE bridge connection only 2
acknowledge PE bridge1)
power ON 2 K1 NO n/c 3
3
acknowledge 4
power OFF 4 K1 NC
HVR02.2 und HVR03.2
power supply units for direct mains X2 to the central
X7 connections with mains regeneration ground connection
1
ready to Bb1
operate 2
3
power
voltage OK 4 UD service
5 interface
prewarning 6 VW
1) Cu lead and PE bridge part of delivery Ap_hvr.fh7
Fig. 8-5: Terminal diagram for HVR02.2 and HVR03.2
Note: Use a twisted cable for the wiring of the commutation choke!
HZF
cable shield connection

mains input
terminal stud
for PE
F2 circuit braker for

control voltage supply
X8/X8a outputs for control

voltage supply
X1 bus connection 1)
PE bridge
X5 mains output (to

commutation choke)
cable shield connection
1) only required, if drive components are mounted on both sides

of the HZF (loop-through function)
Fa5120f1.fh7
Fig. 8-6: Front view HZF
Note: For the connection of the combining filter HZF see the terminal
diagram of the HVR power supply units.
8.3 Mains connection
General
High electrical voltage on the housing!

High leakage current! Danger to life, danger of
injury by electric shock!
DANGER ⇒ Connect the electrical equipment, the housings of all
electrical units and motors permanently with the safety
conductor at the ground points before power is
switched on. Look at the connection diagram. This is
even necessary for brief tests.
⇒ Connect the safety conductor of the electrical
equipment always permanently and firmly to the
supply mains. Leakage current exceeds 3.5 mA in
normal operation.
⇒ Use a copper conductor with at least 10 mm² cross
section over its entire course for this safety conductor
connection!
⇒ Prior to startups, even for brief tests, always connect
the protective conductor or connect with ground wire.
Otherwise, high voltages can occur on the housing
that lead to electric shock.
Direct mains connection Power supply units of the HVE and HVR line can be connected to
grounded three-phase mains with 3 x AC 380 ... 480 V (±10 %);
50 ... 60 Hz (±2 Hz) without the need of a transformer.
Mains fuse protection with direct For more information about the subject "Mains fuse protection with direct
mains connection mains connection" read the recommendations in chapter 8.4.
Connecting the mains via a A transformer is needed if the mains voltage is smaller than 380 V or
transformer greater than 480 V.
The required transformers power must be equal to or greater than the
incoming power (see chapter 5.7).
The isolating transformer must have a short-circuit voltage of UK < 2.5%.
Note: The mains inductance (leakage inductance) of transformers

varies dependent upon power and type.
(Mains) voltage cutoff If no additional capacitance is used, the supply voltage can be cut off for
3 ms in case of nominal load and 3 x AC 380 V mains voltage. More than
1 second should have passed between successive voltage cutoffs.
(Mains) voltage drop-outs With 3 x AC 380 V mains voltage, the supply voltage may drop-out by
20% of the peak voltage for a maximum of 10 ms (in case of higher
supply voltages proportionally more). More than 1 second should have
passed between successive voltage drop-outs.
Mains requirements
Connected load Depending on the connected load, specific short-circuit powers are
required for the mains when using HVx devices.
Connected load Required short-circuit Example of application

[kVA] power SK
[MVA]
6 ... 50 0,6 ... 5 HVx02.2; HVE03.2
50 ... 150 5 ... 15 HVR03.2; HVE04.2
500 ... 2000 50 ... 200 several devices at one
phase
Fig. 8-7: Connected load
These data are taken from the guidelines of the German power supply
industry and are only valid for European power supply systems. If data for
other power supply systems are required, ask the responsible power
supply company for the specific information.
Mains interruption Power supply units of the HVE and HVR series tolerate mains
interruptions up to a duration of 10 ms.
When mains voltage falls below its minimum value (see technical data)
for more than 10 ms or a phase fails for more than 10 ms, the power
supply unit switches off with the device-specific error message.
HVE
Power supply
Direct mains connection [with In case of mains voltages with 3 x AC 380 ... 480 V (±10 %) the power
3 x AC 380 ... 480 V (±10 %)] supply unit can be connected directly to the mains; no other components
are necessary.
Note: For interference suppression we recommend a line filter

NFD03.x.
supply unit
HVE
line filter
NFD03.X
L1 2) U
L2 V
L3
W
PE
1)
1) Like main wires, but not smaller than 10 mm2
2) Twist main wires - cable selections according to EN 60 204
Ap5191f2.fh7
Fig. 8-8: Direct mains connection via line filter NFD03.x
Connecting the mains via If mains voltages are smaller than 3 AC x 380 V respectively greater than
autotransformer (with mains 3 AC x 480 V, it is necessary to use a transformer. To avoid earth leakage
voltages < 3 AC x 380 V e.g. currents by system perturbations, high heat losses and autotransformer
> 3 AC x 480 V) overvoltages, three capacitors (available as SUP-E01-HVR accessories
set) in wye connection must be mounted as shown in the next figure.
supply unit
HVE
line filter
NFD03.X
auto-
transformer
2)
L1
L2
L3
PE
1) SUP-E01-HVR (3*10 µ F)
1) Like main wires, but not smaller than 10 mm2
2) Twist main wires - cable selections according to EN 60 204
Ap5192f1.fh7
Fig. 8-9: Mains connection via autotransformer
Note: When the units are delivered, the mains connections of the
power and control voltage supply are jumpered. Therefore no
additional mains connection is required for the control voltage
supply.
If special cases of application require a separate control
voltage supply (e.g. to be able to save the diagnosis of the
HVE upon shutdown of the power supply), the jumpers
between power and control voltage supply must be removed.
The voltage of the power and control voltage supply must be
the same!
It is necessary to provide a short-circuit protection for the
connection line of the control voltage supply (e.g. power circuit
breaker 3VU1300-.MJ00, 2,6 ... 4 A; Siemens).
L1
L2
L3
F2
Q1 Danger of damage
remove
K2 bridges
6
4
5
1
2
3
X8
2U1
2V1
2W1
2U2
2V2
2W2
X5
W
U
HVE
Control voltage
supply
V02hva1B.fh7
Fig. 8-10: Separate control voltage sources for the HVE
HVR
Power supply
Mains connection with As the power part of the HVR power supply units consists of a clocked
3 x AC 380 ... 480 V (±10 %) 3-phase IGBT jumper, a commutation choke KDxx will always be needed
for the mains connection. In addition, a so-called combining filter
HZF01.1-W0xxN will be required.
L1 L1
3 x AC 380 - 480 V
50 - 60 Hz L2 L2
HZF01.1-W0xxN
Combining filter F2
L3 L3
Mains input U V W L- L+ U4 V4 W4
X12 X5 X11 X8/X8a
PE
twisted
Q1
KDxx
commutation choke U1 V1 W1
U2 V2 W2
twisted 1
2
3
to the central 4
ground connection X8
X5
n/c
control ~
W
U
voltage
K1
supply =
~ power
= supply
Drive controller
X11 HDx
L+
L-
Supply unit X12

HVR0x.2
1
Only for PE bridge connection –2

n/c 3
4
to the central
ground connection
HVR_NetzAP.fh7
Fig. 8-11: HVR: Mains connection via commutation choke and combining filter
Basically, the HZF combining filters to be provided for the mains

connection of the power supply units have two tasks:
• to suppress the current leakages from parasitic capacities of the
construction (motor cable, winding capacities) and
• to ensure a sufficient interference suppression.
The combining filters are exclusively provided for the operation with HVR
supply modules. On the filter outlet side no other devices may be
connected. If other components in the control cabinet are to be
suppressed, it is necessary to employ an appropriate interference
suppression (e.g. a line filter NFD03.x) which should preferably be
installed at the control cabinet entry (see chapter 8.9 "Interference
elimination").
Note:
• It is not advisable to switch an additional interference suppression with
the HZF in series, as non-linear procedures in the interference
suppression filter (saturation of the chokes) could affect the combining
filters’ effect.
• Make sure there aren’t any circuits with resonance produced, for
example, by compensating capacitors, transformers, lines or
capacitive contents of the filters that are not matching.
• Exceeding the allowed limit values for the high-frequency voltage
contents at the filter can damage or destroy the filters.
• Rexroth does not supply HZF filters for asymmetric mains. If required,
the appropriate HZF filters must be selected for the specific
installation.
It is only allowed to operate combining filters within the allowed mains

voltage range. Harmonics (fn) on the mains voltage will lead to a
temperature rise of the dielectric material of the capacitors built in the
filters.
You can calculate the temperature rise using the following formula:
10 x (UMn )
2
∆Tn = [K ]
(UGn )2
UMn: measured voltage value at frequency fn
UGn: voltage limit value for frequency fn
∆Tn: calculated temperature rise of the dielectric material for frequency fn
Fig. 8-12: Calculating the temperature rise of the dielectric material
The temperature rises have to be added up for all frequencies fn ≥ fk

(fk: frequency at which the voltage derating starts; see Fig. 8-14):
10 x (UMv )
m m 2
∆Tges = ∑
v =1
∆Tv = ∑
v =1 (U Gv )2
[K ] ≤ 10 [K ]
UMv: voltage value at frequency fv
UGv: voltage limit value for frequency fv
∆Tges: calculated temperature rise of the dielectric material for all
frequencies
Fig. 8-13: Calculating the temperature rise of the dielectric material for all
frequencies
By means of the above formulas and the measured voltages it is possible

to determine the real load of a filter with voltages of higher frequencies.
To do this, it is necessary to measure by means of Fourier analysis, for all
combinations of line/line and line/PE, the r.m.s. value of the voltage on the
mains side of the filter with all occurring frequencies (higher than fk). You
always have to measure the voltages under conditions of operation at the
nominal working point, the filter having been installed. By means of the
measured values it is then possible to calculate the temperature rise. To
do this, the limit values of the following diagram are read at the respective
frequency and used in the formula together with the measured value.
fk fk
Dg5027f1.fh7
Fig. 8-14: Derating
If the total of the temperature values is greater than 10 K, the harmonics

have to be reduced by means of appropriate measures.
The combining filters are located in a(n) (attachable) housing suitable for
the DIAX04 family. They must be mounted directly next to the supply
module (on the right or left).
The supply line to the HZF must be shielded in order to avoid guided
interference emissions.
The connection cables of the commutation choke have a connected
voltage of high amplitude and frequency. This can result in a possible
interference of sensitive units in the control cabinet. Therefore, the
connection cables need to be kept as short as possible and absolutely
twisted (here it would also be better to use shielded cables).
Mains connection via If a transformer is used, it is possible to connect HVR supply modules to
transformer (with mains networks with mains voltages smaller than 3 x AC 380 V or greater than
voltages < 3 x AC 380 V or 3 x AC 480 V.
> 3 x AC 480 V)
Here, it is also required to use a commutation choke KDxx and a
combining filter HZF01.1-W0xxN just as for the direct mains connection
of the HVR supply modules.
DC bus connection and bus
connection Note: The DC bus connection must always be connected to the
HZF for proper functioning.
The X1 bus connection is looped through and must only be
connected, if there are units arranged on both sides of the
HZF.

A separate control voltage connection is necessary that the HVR may be
operated synchronously to the mains. The control voltage must be tapped
before the commutation choke KDxx. Power and control voltage
connection must be in phase.
As illustrated in the next figure, the combining filter HZF is equipped with
two control voltage outlets. The control voltage outlet X8 must be
connected to the control voltage inlet of the HVR.
A protection switch for the control voltage is integrated in the HZF (F2).
L1
L2
Combining filter HZF F2
L3
U V W U4 V4 W4
X5 X8/X8a
Q1
connection must be
phase coincident
KDxx
1
2
3
4
X5 X8
W
U
n/c
Power supply unit HVR
V01HVA1B.fh7
Fig. 8-15: HVR control voltage
Details of the commutation choke

The commutation chokes are equipped with a temperature contact which
opens at T = 150 °C (connections a - b). The contact can be evaluated by
a controller and is used for example for a regulated shutdown of the unit,
should the control cabinet cooling fail.
Note: You'll find the technical data in chapter 4. The dimension

drawing as well as terminal diagram can be found on page 7-
18.
Details of the combining filter
Note: You'll find the technical data in chapter 4.5.
When operating combining filters at grounded IT mains, the type of

construction causes leakage currents that may cause possibly existing
circuit breakers or voltage monitors to trip. Remedy: Install an isolating
transformer.
8.4 Fusing with direct mains supply

Fusing the mains supply for the power section of the power supply units
HVE and HVR can implement, with direct mains connection, power circuit
breakers or slow-blow fuses of the gL type (semiconductor fuses are not
needed).
Note: Select the fusing according to the mains current too (see
chapter 5.7.
The maximum fusing for the different power supply units (HVR and HVE)
is listed in the following table.
Power supply unit Fuse maximum

in accordance with in accordance with
EN50178 resp. UL508C
EN60204
HVE02.2-W018N 35 A 30 A
HVE03.2-W030N/L 63 A 60 A
HVE04.2-W075N/L 160 A 150 A
HVR02.2-W010N 25 A 20 A
HVR02.2-W025N 50 A 45 A
HVR03.2-W045N 80 A 70 A
Fig. 8-16: Maximum fusing
If the fusing is effected with power protective switches, the following

recommendations apply.
Power supply unit Mains current at Setting Mains connected load at 400 V
1)
400 V 480 V value connected voltage
HVE02.2-W018N
28 A 28 A 28 A 6 mm²
(without GLD 13)
HVE02.2-W018N
28 A 28 A 28 A 6 mm²
(with GLD 13)
HVE03.2-W030N
46 A 46 A 46 A 16 mm²
(without GLD 12)
HVE03.2-W030N
46 A 46 A 46 A 16 mm²
(with GLD 12)
HVE04.2-W075N
80 A 80 A 80 A 25 mm²
(without GLD 20)
HVE04.2-W075N
120 A 120 A 120 A 50 mm²
(with GLD 20)
HVR02.2-W010N 15 A 13 A 18 A 2,5 mm²
HVR02.2-W025N 38 A 32 A 38 A 10 mm²
HVR03.2-W045N 68 A 57 A 68 A 25 mm²
1) Line cross section per EN 60204 – installation type B1 – without
accounting for corrections factors
Fig. 8-17: Recommended fusing
Note: The indications made herein apply to the operation with full
continuous power. If fewer continuous currents are required,
the fusing and thus the connection cross section can be
reduced. It should however be taken into account that the bus
is loaded according to the soft start with each unit peak current
(3-fold continuous power). The period of time during which the
current flows, depends on the bus capacity to be loaded and is
33 ms in the most unfavorable case with the 45 kW unit,
57 ms with the 25 kW unit and 142 ms with the 10 kW unit.
The fuses to be installed or the power protection switches
shall be dimensioned such that faulty releases do not occur.
8.5 Grounding the power supply system

Grounded three-phase mains HVE and HVR can be operated from three-phase systems with grounded
neutral points or phases without control-to-load isolation.
On mains with grounded phases you have to regard the measures
described in chapter 8.12.
Ungrounded three-phase mains With ungrounded mains (IT mains) there is the increased danger that
unacceptably high overvoltages could occur between the phase and the
housing. Both the HVE and HVR can be protected against unacceptable
overvoltages,
• if they are connected via an isolating transformer (the star point of the
output side and the PE connection of the power supply unit are connected
over one grounding rail)
- or -
• if the unit is protected by overvoltage suppressors.
Note: Connecting the HVE and HVR via an isolating transformer

offers the best protection against overvoltage and the greatest
operating safety.
8.6 Connecting drive controllers to the power supply unit
Note: For the connection of the drive and control system to the
power supply unit it is necessary to distinguish between the
arrangement of the units one below the other and one above
the other.
The following descriptions are visualized in "Fig. 8-20:
Connecting the drive controller".
Arranging the units horizontally

Power connection If the units in the control cabinet are arranged horizontally, use the copper
strands and PE jumpers, included in the scope of supply, for the power
connection of the drive and control systems.
Connection to the control Use the flat cable for the connection to the control voltage bus (terminal
voltage supply X1). One side of the flat cable is firmly connected to the unit on one side.
Plug the connector of the free end onto terminal X1 of the next unit.
If the units are not arranged directly horizontally, you will need a longer
cable for the connection of the X1 terminals:
Cable Length Item / Part number

INB648/0250 250 mm 292519
INB648/0800 800 mm 282398
INB648/1000 1000 mm 288731
Fig. 8-18: Cable
Arranging the units vertically
Note: With a combined unit arrangement, it is absolutely necessary

that between the two rows of drive units a baffle is mounted, in
order to prevent the blowers of the upper row from sucking in
the warm air of the bottom row.
Property damages due to overheated units!

⇒ Mount a baffle between the two unit rows. Otherwise
the performance data of the units can decrease and
the units can be damaged with undiminished
CAUTION
performance requirement.
Mains connection If the units in the control cabinet are arranged vertically, you need to use
twisted single conductors for the power connection of the drive and
control systems (terminal X11) instead of the supplied copper strands.
The single conductors for the power connection of the drive and control
systems may have a maximum length of 1 m.
The ground connections of units (unit rows) that are vertically arranged
must be connected by a separate cord. The minimum cross section for
2
this cord is 10 mm .
Connection to the control The control voltage bus must be connected with the designed Rexroth
voltage bus cable (designation: INB0647). Lay the shield of this cable to the unit
grounding bolt (terminal X12) on the supply module.
The cable lengths listed below are available:
Cable length [mm] Item / Part number

800 282 300
1000 287 677
Fig. 8-19: Shielded flat cable for the control voltage bus
GLD (only with HVE)
1
2
twisted
max. 1 m
6
100 mm
4 5 300 mm
7 3
Line cross HVR02.2- HVR02.2- HVR03.2- HVE02.2-

Gewicht HVE03.2- HVE04.2-
section W010N W025N W045N W018N W030N W075N
1 --- --- --- 10
12 mm
2 16 mm2 50 mm2
2 10 mm2 10 mm2 16 mm2 10 mm2 16 mm2 25 mm2
3 10 mm2 10 mm2 16 mm2 10 mm2 16 mm 2 35 mm2
V04hva1b.fh7
3 Lêngth: 1,2 m; designation: INB730/1200

4 Minimum clearance 0,1m
5 Baffle. Prevents the blowers of the upper row from sucking in the warm air of the bottom row.
6 Flat cable designated INB648. This cable will be necessary, if units are not arranged directly next to
each other.
7 Flat cable designated INB647. This cable will be necessary, if units are arranged one below the other
or vertically.
Fig. 8-20: Connecting the drive controller
8.7 Fault current protective device
High electrical voltage! Danger to life, severe

bodily harm by electric shock!
⇒ A residual-current-operated protective device (RCD)
DANGER must not be used on electric drives! Indirect contact
must be prevented by other means, for example, by
an overcurrent protective device.
• In clocked drive controllers, capacitive leakage currents primarily flow

to earth. The extent of this current depends on
• the number of drive controllers used,
• the length of the motor power cable and
• the grounding conditions at the installation.
• If measures are taken to improve the electromagnetic compatibility
(EMC) of the installation (mains filters, shielded lines, etc.), then the
current leakage is inevitably also increased. In order to avoid faulty
releases when inductive loads and capacitance (interference
suppression filters, transformers, contactors, magnetic valves) are
switched on, it is necessary to provide an isolating transformer in the
mains supply line ahead of the power supply unit of the drive system.
The over current protective device must be matched to the impedance
of the fault loop so that a shutdown is effected if a fault occurs. The
star point of the secondary winding must be connected to the
protective circuit of the installation.
8.8 Earth leakage monitor

Earth leakage monitors are often used in IT mains. Spurious releases can
occur when operating electronic equipment.
Experience has shown that electronic drive controllers can only be
operated on systems with earth leakage monitors if an isolating
transformer is situated ahead of the supply unit for the drive system. The
star point of the isolating transformer and the PE connection of the power
supply unit must be applied to the same potential.
8.9 Interference elimination
Note: The subject interference elimination and electromagnetic

compatibility (EMC) is described in detail in a separate
documentation. It is absolutely necessary to read this
documentation for the proper operation of AC-drives!
The document is titled "Electromagnetic compatibility (EMC)
for AC drives". The item number is 259 740.
Note: The control cabinet construction is also important for shielding

the interference emission. For further information please see
the chapter 7.3.
Note: As the HVR power supply unit must be operated together with
the combining filter HZF, the indications concerning the NFD
mains filter arrangement apply above all to the HVE. (The line
filter is already included in the combining filter HZF).
Interference emission To maintain class B limit values (interference suppression N) as per

EN 55011 / 3.91 at the machine (required in residential and light industrial
areas), suitable interference suppression filters must be installed in the
mains supply line in the machine. The motor power cable should be
routed in a shielded manner or a shielded motor power cable should be
used.
Resistance to interference Rexroth drives are characterized by an extensive resistance to mains and
circuit interference. Nonetheless, during installation the following should
be noted to preclude interference affects.
• Always route signal lines shielded.
• With analog signals, connect the shield at one end, over the greatest
possible surface on the unit to mass or housing. With digital signals,
apply shield to both cable ends, over the greatest possible surface to
mass or housing.
• Signal and control lines should be routed at least 10 cm away from the
power cables. Routing in a separate cable duct is recommended.
°
• Signal and control lines should cross power cables at an angle of 90
only.
• Inductive loads such as contactors, relays, magnetic valves should
only be operated with overvoltage limiters.
• Ground drive controllers as per Rexroth guidelines.
8.10 Control cabinet check
Property damages due to overloaded electronic

components!
⇒ Prior to a high-voltage check of the control cabinet,
CAUTION disconnect all power supply unit connections. Only
connect those voltages permitted by data sheets or
interface descriptions.
8.11 Applications with HVE0x.2-W0xx power supply unit
Multi-axis operation
In order to reduce the effects of the leakage currents (increased power
dissipation, mains pollution), it may be necessary, depending on the
application, to connect additional components (SUP kit) to the HVE power
supply units. By means of the following formula and table you can
determine whether it is necessary to connect additional components or
not.
n2
K= *l
2
K: specific value
n: number of connected axes
l: average lengths of the motor cables used of all connected axes
[ ∑(l1...ln)/n ]
HVE02.2-W018N HVE03.2-W030x HVE04.2-W075x

K < 100 > 100 < 200 > 200 < 400 > 400
SUP kit no yes no yes no yes
necessary?
Fig. 8-21: SUP kits for HVE power supply units
Note: In the case of mains with a high degree of inductance (so-

called "non-rigid" supply systems), heavy mains pollution can
occur even if the above conditions are complied with. It is then
necessary to use SUP kits although this may not be required
according to the formula and table.
AC 3 x 380....480 V
HDx HDx HDx

PE
L1
L2
L3
HVE0x.2-W0xxx
NFD0x.x
L1.1
L2.1
L3.1
PE
1)
2 x 470 nF
U V W PE
SKD
SUP-E0x-HVR AP_hve_sup.fh7
Fig. 8-22: HVE0x.2-W0xxx with SUP kit
Component NFD SUP-E0x

HVE02.2-W018N NFD03.1 SUP-E06-HVR
HVE03.2-W030x NFD03.1 SUP-E07-HVR
HVE04.2-W075x NFD03.1 SUP-E08-HVR (without capacitor 2 x 470 nF)
(as an alternative, two SUP-E07-HVR can be connected in parallel for
existing installations)
Fig. 8-23: Combination of power supply unit, NDF and SUP-E0x
Note: An HZF mustn’t be operated at HVE power supply units.
Parallel connection of two HVE04

To increase the available DC bus continuous power it is possible to
connect two HVE04 in parallel. To do this it is necessary to operate the
two HVE04.2 in a master-slave mode.
Required components
2 x HVE04.2-W075x
Both HVE devices have to be of the same type. Operating devices of
different types implies the danger of malfunction in bleeder balancing. The
individual device types can be identified by their serial number.
The following types can be combined:
Master Slave
type N: type N:
SN 284285-0xxxx SN 284285-0xxxx
type N: type N:
SN 291914-0xxxx SN 291914-0xxxx
SN 295191-0xxxx SN 295191-0xxxx
type L: type L:
SN 294601-0xxxx SN 294601-0xxxx
Fig. 8-24: Combinations
• 2 x GLD20 smoothing choke
• 2 x balancing choke KD 0,1mH / 160A [MN00261805]

Installed at the power input of each HVE04.2-W075x. This choke is
always required as the inductance of the supply feeder does not only
depend on cable cross section and length, but also on the kind of
cable laying (twisted, parallel, straight or in loops).
Additional module HZB

When two HVE04 are connected in parallel, it is not allowed to use the
additional module HZB.
Additional capacities on the DC bus

It is possible to connect 10 mF for type N and 200 mF for type L to the DC
bus of the HVE04 power supply units. Even if two HVE04 are connected
in parallel, it is not allowed to connect higher capacity values than 10 or
200 mF to their common DC bus.
Number of axes
The number of axes in the entire package is limited to 12. In order to
reduce the effects of leakage currents, it can be necessary to connect
additional SUP-E08-HVR components to the power supply units. See also
chapter "Multi-axis operation" on page 8-25.
If the necessity of using a SUP kit results from the determination of the
characteristic value K – for which all axes of the entire package have to
be taken into account – the SUP kit has to be installed before the two
HVE devices.
Wiring of emergency stop circuit

In order to have an troublefree soft start (charging process of the DC
bus), it is necessary to operate both HVE04.2 in a master-slave mode.
This operating mode has to be established by means of an appropriate
emergency stop circuit.
Master-HVE04 Slave-HVE04
X3 S1 X7/1
~ 1
X7/2 Bb1
= 2
4
OFF/ON
5
K1
ready-to-
operate X3
X7/1 1
Bb1
=
X7/2
X6/1
2
3
~
K1NO
X6/2 4
X7/3 5
UD
X7/4 6
K1
ready-to-
operate
NOT_ZKS.fh7
Fig. 8-25: Wiring of emergency stop circuit for master-slave operation with DC
bus short circuit
Master-HVE04 Slave-HVE04
X3
~ 1
2
= S1 X7/1
4 X7/2 Bb1
5
OFF/ON
6
K1
ready-to-
operate X3
Bb1
X7/1 1
=
X7/2
X6/1
2
3
~
K1NO
X6/2 4
X7/3 5
UD
X7/4 6
K1
ready-to-
operate
NOT_AUS.fh7
Fig. 8-26: Wiring of emergency stop circuit for master-slave operation without
DC bus short circuit
Note: The maximum Ohmic resistance of the emergency stop circuit

for the HVE04.2-W075N is 350P , with higher resistance
values it is no longer guaranteed that the internal load
contactor will pick up safely. The supply unit might then be
switched off with the error message "16 – soft start error".
The maximum possible connection cross section for the

2
emergency stop wiring is 1,5mm / AWG16. This type of wiring
KDV DQ 2KPLF UHVLVWDQFH RI DSSUR[ P P DW °C. The
resulting maximum cable length for the emergency stop circuit
is 27 m.
Establishing the master-slave connection of the two

emergency stop circuits between the devices requires 6 wire
connections. The maximum distance between the devices
therefore is 4,50 m.
In order to realize bigger distances between the HVE devices,

it is necessary to route the connection of the two emergency
stop circuits via special emergency stop relays.
Arrangement of the devices

2
The DIAX04 DC bus connection (35mm / AWG2) has been designed for
a maximum of 75 kW. In order to avoid an overload of this connection in
the case of parallel connection of two HVE04.2 devices, the two HVE
power supply modules connected in parallel have to be obligatorily
arranged at the outer positions in the drive package.
drive controllers
high power high power
low power
HVE04 HDx HDx HDx HDx HDx HDx HVE04

Master Slave
X3 X3
connection connection
X6 to slave to master
X6
X7 X7
L+
1L+ 2L+ U V W PE
L-
1L+ 2L+ U V W PE
GLD20 GLD20
KD (0,1mH/160A)
KD (0,1mH/160A)
mains mains
choke choke
Fx Fy
AC 3 x 380....480 V HVE04PAR.FH7
Fig. 8-27: Position of the devices with parallel connection of two HVE04
Fusing the DC bus connection between the two drive packages is not
required because in the case of an error both packages will always be
switched off due to the interconnection of the two emergency stop circuits.
The fusing of the two HVE devices corresponds to the fusing used for
operating one device.
Due to increased interference suppression capacity, the EMC filters
(NFDxx) should be positioned of the mains side of the KD balancing
chokes. The position of the filters does not affect the function of the
parallel connection. With regard to their influence on balancing, the filter-
internal components of the Schaffner and LGF filters provided by Rexroth
(current-compensated chokes, Y capacitors) can be neglected.
In order to improve the emission of interference of the entire
arrangement, make sure the DC bus connection and the power wiring
between the device and choke connections are twisted.
Available DC bus power with two HVE04.2-W075

connected in parallel
Due to inevitable unbalances of device-internal components, system
impedances etc., the total DC bus power won’t be distributed over the two
power supply units in equal shares. Depending on the application, it is
therefore necessary to take a reduction of power (derating) into account.
Derating due to "internal" The tolerances of the device-internal power semiconductors and of the
unbalance inductances used (GLD20, KD) cause internal unbalance due to system
that will result in a derating of the parallel connection, related to the
calculated total continuous power PZWsum, even with optimum "external"
conditions in the installation.
This "basic derating" is approx. 10% of the possible total continuous
power. Therefore, the available maximum continuous power in ideal
cases is
PZWmax = PZWsum – 10% = (PZW/HVE1 + PZW/HVE2 ) - 10%
The available DC bus power PZW of the power supply units depends on
the mains connection voltage. The respective values cam be taken from
the table of Fig. 4-4.
Derating due to unbalance in the Further reduction of power is caused by different impedances of both
mains connection wiring mains connection phases which are due to different lengths of lines, kind
of routing etc.
• 0% unbalance á 10% derating (basic derating)
• 100% unbalance á 50% derating (power of an individual HVE)
Derating due to unbalance in DC Additional impedances between both drive packages are caused by the
bus DC bus connection. This causes further reduction of the available total
power.
The length of the DC bus connection between the two drive packages is a
parameter of the derating function:
2
with a line cross section of 35mm / AWG2 to be maintained, every meter
of DC bus connection corresponds to a further derating of 2% of the total
continuous power.
Note: This derating factor does not apply when the wiring is carried
out via a central DC bus rail with identical outgoing circuits
(length of line and cross section) to the individual drive
packages.
The derating then is a function resulting from the unbalance in the supply
feeder with the parameter lZK (length of DC bus connection).
PZWges = f (unbal.mains_connection) with parameter lZK
PZWges = PZWsum * (0,9 - x * 0,4 – lZK * 0,02)

with: 0,9 – basic derating (corresponding to 10%)
x – relative unbalance of mains connections (1 = 100% unbal.)
lZK – length of DC bus connection in meters
PZWges
in %
PZWsum
100%
basic derating due to

system internal asymmetries
90%
lZK = 0 m
80%
lZK = 5 m
70%
lZK = 10 m
60%
lZK = 15 m
50%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
asymmetry
derating_unsymm.fh7
PZWges available DC bus continuous power

PZWsum maximum DC bus continuous power
(total power of both HVE)
lZK length of DC bus connection between the two drive packages
unbalance: relative unbalance in the mains connection from the
device terminals via choke (KD) and EMC filter (NFD) to the
mains supply point
Fig. 8-28: Basic derating due to system-internal unbalance
Regenerative operation
When you operate two HVE04 together at one DC bus the following
relations are valid.
Regenerated continuous ∑ PBD ≤ 0,8 * 2 * PBD,HVE

power
ΣPBD: Regenerated continuous power of complete system [kW]
PBD,HVE: Regenerated continuous power of one HVE [kW]
Fig. 8-29: Regenerated continuous power
Regenerated peak power ∑ PBS ≤ 0,8 * 2 * PBS,HVE

ΣPBS: Regenerated peak power of complete system [kW]
PBS,HVE: Regenerated peak power of one HVE [kW]
Fig. 8-30: Regenerated peak power
Regenerated energy ∑ WROT,MAX + ∑ WPOT,MAX ≤ 0,8 * 2 * WMAX,HVE

W ROT,MAX:Rotary energy [Ws]
W POT,MAX: Potential energy [Ws]
W MAX,HVE: Regenerated energy of one HVE [Ws]
Fig. 8-31: Regenerated energy
Data of commutation choke KD (0,1mH/160A)
3 92
10
8
35
40
25
25
111+-1
105
61
9
163+-1
205
circuit diagram:
118
20 80 +- 1 80 +- 1
200
240
max. 245
MB_KDpar.fh7
Fig. 8-32: Dimensional drawing KD 160A
Designation Symbol Unit Commutation choke

KD 0,1 mH / 160 A
part number -- -- 261805
nominal continuous current Inenn A 160
inductance at Inenn Lnenn mH 0,1
Connection
type ring cable lug M8
2
connection cross section A mm according to the
connection cross section
of the power supply unit
weight m kg 21
Fig. 8-33: Technical data
HVE-L with external capacities

The HVE of the "L" type allows connecting external capacities of up to
200 mF. This means that the following characteristics can be fulfilled.
Reducing heat loss In installations with cyclical reversing duty of the drive axes the
regenerative power is converted to heat via the bleeder. This causes a
high degree of heat loss in the control cabinet. The regenerative power
can be buffered in the additional capacities on the DC bus and used for
cyclical short-time loads. This allows reducing the continuous bleeder
power and therefore the heat loss.
Mains failure; In order to be able to move over a certain distance even if the mains has
emergency stop strategy failed, energy has to be stored in the DC bus. Additional capacities on the
DC bus can increase the energy to be stored.
Storable energy WC The storable energy can be calculated with the formula below.
2 2
(UB min − U ZW )
WC = ∗C
2
W C: storable energy [Ws]
UBmin: lower bleeder trigger level 800V
UZW : DC bus nominal voltage UZW = 1,41 * UN1 +10% [V]
UN1: nominal mains voltage 3 x AC 380...480 V
C: additional capacity [F]
Fig. 8-34: Storable energy W C
30000 4 Storable energy

3 10
4
2.5 10
Energy [Ws]:
4
E UN380( C ) 2 10
E UN400( C )
4
1.5 10
E UN480( C )
4
1 10
5000
0
0
0 0.05 0.1 0.15 0.2
0 C 0.2
DC bus capacity [F]
Fig. 8-35: Storable DC bus energy depending on mains voltage and additional
capacity
Allowed voltage range For dimensioning the additional capacity the allowed voltage range USS on
the DC bus of the power supply unit has to be taken into account.
U SS = UB min − U ZW
USS: voltage range [V]
UBmin: lower bleeder trigger level 800V
UZW : DC bus nominal voltage UZW = 1,41 * UN1 +10% [V]
UN1: nominal mains voltage 3 x AC 380...480 V
Fig. 8-36: Allowed voltage range
This voltage range and the repetition rate are decisive for the service life
of the capacitors. The interdependence of voltage range and allowed
repetition rate at constant service life is illustrated in the figure below.
300
300
200
voltage range [V]
U ss( f )
100
0 0
0 20 40 60 80 100
0 f 100
Repetition rate [Hz]
Fig. 8-37: Allowed voltage range USS on DC bus for load cycles smaller than
mains frequency
Note: Exceeding the allowed voltage range reduces the service life
of the device-internal DC bus capacitors.
Dimensioning the capacitors The voltage range on the DC bus voltage caused by the application and
its repetition rate are affecting the service life of the capacitors.
Note: For dimensioning the additional capacity, the tolerance and the
decrease of the capacity due to age have to be taken into
account. With the voltage ripple and the repetition rate it is
possible to estimate the service life by means of the data of
the capacitor manufacturer.
Due to the dielectric strength of the available capacitors (in most cases a
maximum of 450 V) and the system DC voltage of DIAX04, it is necessary
to connect 2 ore more capacitors in series.
Note: The dielectric strength of the capacitor battery must be at least

900 V.
Note: Observe the manufacturer’s instructions for the balancing of

capacitors that are connected in series.
The discharge time of the DC voltage DC bus can be strongly
increased if there aren’t any sufficiently low-resistance
balancing or discharge resistors connected.
Discharge time of capacitors Increasing the DC bus capacity also increases the discharge time if there
aren’t any appropriate measures taken.
Lethal electric shock caused by live parts with

more than 50 V!
⇒ Wait at least 5 minutes after switching off power to
DANGER allow capacitors to discharge before beginning work
at the devices. Always measure voltage of capacitors
before starting work.
Note: In order to make sure that the DC voltage DC bus is

discharged within 5 minutes and to discharge the capacitors to
a sufficiently low voltage value, Rexroth recommends
"controlling the mains contactor with DC bus dynamic brake"
(see chapter 9).
Observe the allowed frequency of the switch-on/switch-off
cycles according to the data in Fig. 10-13: Number of
switching actuations with aux. capacitance and rotating motor.
If "controlling the mains contactor with DC bus dynamic brake" cannot be

used (e.g. emergency stop strategy in the case of mains failure), calculate
the discharge time approximately according to the formula below:
t entlade ≈ 5 * R Sym * C
tentlade discharge time [sec.]
RSym resulting total resistance of the balancing resistances [Ohm]
C capacity value of the entire capacitor battery [F]
Fig. 8-38: Discharge time
Connecting lines of the capacitor battery

Load capacity of the DC bus
max. voltage DC 900 V
connection at the power supply
unit voltage against ground provided mains voltage
max. continuous current 150 Aeff
Fig. 8-39: Load capacity of the DC bus connection at the power supply unit
Line
line length max. 10 m
line cross section not smaller than cross section of
supply feeder to power supply unit
line routing with low inductance, twisted routing
when capacitor battery is mounted
externally, line routing in the pipe is
recommended
dielectric strength of single strand ≥ 750 V
against ground
(e.g.: strand type – H07)
shielding recommended
Fig. 8-40: Line
According to standard, there isn’t any separate fusing of the capacitor

battery required when the capacitor battery is mounted together with the
HVE-L in the same control cabinet. Rexroth nevertheless recommends
fusing the capacitor battery according to the respectively valid standards
EN50178, EN 60204 and/or UL 508C.
Note: DC voltage!
The fuses used have to be suited for operation with direct
voltage or direct current.
DC bus charging currents with When power is switched on the DC bus is charged via a current-limiting
additional capacities circuit. The generated peak values of the charging current pulses depend,
among other things, on the mains voltage and the additional capacity.
If the HVE-L is operated with nominal load, the DC bus charging currents
do not have to be taken into account for fusing the devices. In the case of
low device load and fusing, the charging current possibly has to be taken
into account for dimensioning the mains circuit breaker.
200
150
Current
peak 100
values [A]
50
0
0 0,05 0,1 0,15 0,2
Additional capacity [F]
3 x AC 380 V 3 x AC 400 V 3 x AC 480 V
Fig. 8-41: Peak values of charging current pulses at soft start with HVE-L
depending on mains voltage and additional capacity
The duration of the soft start with HVE-L is approx. 6 seconds. The
resulting average value of the charging current is illustrated in the
diagram below.
40
35
30
25
Average
current 20
value
[A] 15
10
0
0 0,05 0,1 0,15 0,2
Additional capacity [F]
3 x AC 380 V 3 x AC 400 V 3 x AC 480 V
Fig. 8-42: Average current value at soft start with HVE-L depending on mains
voltage and additional capacity
Operating HVE04 with GLD12

For applications that require lower power (in range between applications
without and with GLD20) it is possible to use the GLD12. This choke,
compared to GLD20, is of clearly smaller size.
The power data below are valid for operating a HVE04 with GLD12.
Mains voltage PZW PKB30 PKB03 Power supply unit DC bus

[V AC] [kW] [kW] [kW] choke
3 x 380 42 84 126 HVE04.2-W075x GLD12
3 x 400 45 90 135
3 x 440 50 100 150
3 x 480 55 110 165
PZW DC bus continuous power
PKB30 DC bus short-time power (for 30s)
PKB03 DC bus peak power (for 0,3s)
Fig. 8-43: Power data HVE04 with GLD12
The values for bleeder continuous power and peak power, as well as for
the maximum regenerative power do not change when the GLD12 is
used.
The technical data and dimensions of the GLD12 can be taken from
chapter 6.2.
8.12 Operation on mains with outer conductor ground

connection (asymmetric mains)
There are two ways of operating power supply units on asymmetric
mains:
• connecting an isolating transformer before the power supply unit
• direct operation on the mains
Connecting an isolating transformer before the power supply unit

The neutral point of the isolating transformer must be connected as a
ground reference.
The isolating transformer must have a short-circuit voltage of UK < 2.5%.
Direct operation on the mains

It is only with additional components that the power supply units can be
operated on asymmetric mains:
• HVR:
commutation choke with filter unit (KDxx-C) and another current
compensated choke with Y capacitors (SUP-E0x-HVR)
• HVE:
current compensated choke with two Y capacitors on the DC bus (SUP-
E0x-HVR)
Note: For direct operation on mains with outer conductor ground

connection the outer conductor voltage of the mains mustn’t
exceed a maximum of 400V +10%!
Note: HZF are not suited for operation on asymmetric mains! The
modules risk heating up unduly! Therefore, alternatively use
SUP-E0x.
Note: Residual current operation of the HVE power supply unit on an

asymmetric mains requires an isolating transformer with
grounded neutral point. Direct operation on the asymmetric
mains would cause false tripping of the residual-current-
operated circuit-breaker.
Recommended connections for phase-grounded mains
mains connection
appropriate
PE
L3
L2
L1
mains filter HDx HDx HDx

HVx0x.2-
L1.1
L2.1
L3.1
W0xxx
PE
X8
U1
V1
W1
1) SUP-E0x-HVR
2 x 470 nF L+
KD xx C U V W PE
L-
U1 U2 SKD
mains connection
load connection
V1 V2
W1 W2
AP_SUP.fh7
1) The two capacitors are not required for SUP-E08-HVR and aren’t
contained in the scope of supply either.
Fig. 8-44: Connection power supply units on asymmetric mains
Note: NFD03.1 filters are not suited for asymmetric mains!
Component Commutation choke SUP-E0x

HVR02.2-W010N KD30-C SUP-E05-HVR
HVE02.2-W018N no KD SUP-E06-HVR
HVE03.2-W030x no KD SUP-E07-HVR
HVE04.2-W075x no KD SUP-E08-HVR
(as an alternative, two
SUP-E07-HVR can be
connected in parallel for
existing installations)
Fig. 8-45: Combination of the components
Note: Using SUP with HVR on mains with outer conductor ground
connection requires commutation chokes of the KD xx C type!
8.13 Reducing interference emissions
Note: Rexroth does not supply EMC filters for asymmetric mains. If
required, the appropriate EMC filters must be selected for the
specific installation.
Frequency range 10 – 80 kHz 50 – 150 kHz 150 kHz – 30 MHz

Kind of mains asymm. TT, TN or IT asymm. TT, TN or IT asymm. TT, TN or IT
HVE02.2-W018N - - SUP-E06-HVR SUP-E06-HVR other NFD03.1
appropriate
HVE03.2-W030x - - SUP-E07-HVR SUP-E07-HVR mains filter
HVE04.2-W075x - - SUP-E08-HVR SUP-E08-HVR
HVR02.2-W010N no measure required SUP-E05-HVR HZF01.1-W010N no measure
required,
HVR02.2-W025N SUP-E06-HVR HZF01.1-W025N because NFD
HVR03.2-W045N SUP-E07-HVR HZF01.1-W045N integrated in
HZF
Fig. 8-46: Overview for reducing interference emissions
Reachable limit values for TN, TT and IT systems

(frequency range: 150 kHz – 30 MHz)
For Rexroth drive systems, the following limit values can be reached with
regard to line-based emission (according to EN 61800-3):
1. Industrial area/second environment, connection I > 100 A
Reachable limit value Type of drive Filter measures

limit value class A, all drive types without additional filters
group 2, I > 100 A
(diagram line 1.1, 1.2)
2. Industrial area/second environment, connection I > 100 A
Reachable limit value Type of drive Filter measures max. motor cable length (1)
limit value class A, HVR+HZF01.1 without additional filters 200 m
group 2, I < 100 A
HDC 1.1 25 m
all others with NFD03.1 filter 180 m per filter
3. Industrial estate and residential area/first environment, restricted

distribution
limit value class A, HVR+HZF01.1 without additional filters 125 m
group 2, I < 100 A
HDC 1.1 25 m
all others with NFD03.1 filter 125 m per filter,
200 m with filters of more
than 130 A
Note: According to IEC 61800-3, the drive controllers are products of

the restricted distribution class In a residential area this
product can cause high-frequency interference. If this
happens, the user can be requested to take appropriate
measures, in order to comply with class B, group 1.
4. Industrial estate and residential area/first environment, general

distribution
limit value class B, HDC 1.1 with NFD03.1 filter 25 m
group 2, I < 100 A
all other drives except for with NFD03.1 filter 50 m per filter
(diagram line 4.1, 4.2) HDC and HVR
HVR with HZF1.1: only no NFD03.1 filter possible -
class A can be reached
Explanatory notes:
• (1) motor cable length: total length of all motor cables of all connected
axes
• The classification according to classes A and B and groups 1 and 2 is
defined in the basic technical standard EN 55011.
• diagram with limit values see following page
• The values apply to mains with neutral grounding at a 4 kHz clock rate
of the drive controllers.
Limit values for line-based disturbances (DIN EN 55011 / DIN EN 61800-3/A11)
class A, group 2 , QSP, I > 100A

1.1 (second environment)
130
125 1.1 1.2
120
1.2 class A, group 2 , AV, I > 100A
115 115 (second environment)
105 class A, group 2 , QSP, I < 100A

100
2.1 (second environment)
2.1
90 2.2
86
class A, group 2 , AV, I < 100A
2.2
79 (second environment)
76
73 class A, group 1 , QSP,
3.1 (first environment, restricted
66 3.2 70 distribution, first environment also if
3.1 60 source of interference in second
environment)
56 60
56 50 class A, group 1 , AV,
46 (first environment, restricted
3.2 distribution, first environment also if
source of interference in second
environment)
4.1 4.2 class B, group 1 , QSP,
4.1 (first environment, general
distribution, first environment also if
environment)
class B, group 1 , AV,

4.2
(first environment, general
distribution, first environment also if
environment)
QSP: quasi peak value

AV: average value
Fig. 8-47: Limit values for line-based disturbances (DIN 55011/DIN 61800-
3/A11)
Phase-grounded mains (example Japan)

Frequency range 50 kHz to 150 kHz
Reduction of the leakage current with phase-grounded mains due to
RCD.
Frequency range 150 kHz to 30 MHz
Interference emission that can be reached with filters in the case of
phase-grounded mains:
The NFD03.1 filters are not suited for phase-grounded mains where low
leakage current is required. Due to the higher asymmetric load with
reference to ground, the mains would be enough to produce a higher
leakage current of typically 150 mA in this case.
For phase-grounded mains we therefore recommend filters with low
ground capacitances, FN 258L-x-29 types, for example, with currents
according to the wild card character "x" = 7, 16, 30, 55, 75, 130, 180 A,
(manufacturer: Schaffner EMV GmbH). With this mains, these filters have
a leakage current of typically 7.5 mA, max. 9 mA.
The interference emission to be obtained in this case has a higher noise
level than with the NFD03.1 filters and depends on the installation
parameters. The interference emission can therefore only be determined
by measurement in the installation.
HVE and HVR 2nd Gen. Power Supply Units Control mains contactor 9-1
9 Control mains contactor
9.1 Control possibilities

The controls of the mains contactor and of the DC bus dynamic brake in
the power supply unit, that are suggested in this documentation, explain
the function principles. In this chapter, several control options are
discussed and explained.
Note: Which control and functions are selected ultimately depend on

the extent of functions required and the range of actions of the
entire installation and is primarily the responsibility of the
manufacturer.
Shutdowns with faulty drive electronics

An additional safety for braked shutdowns of the drives in case of faulty
drive electronics is to short-circuit the DC bus voltage.
If the DC bus voltage is short-circuited, the motors with permanent
energized magnet will always be shut down to a braked condition. This is
the case whether the drive electronics is operative or not.
Note: Asynchronous drives do not brake when DC bus voltage is

short circuited!
If the drive electronics is interfered and the DC bus voltage is not short-
circuited, then the motors with energized permanent magnet will slow
down uncontrolled.
Braking with emergency stop or power failure

In an emergency stop or power failure situation, drives are generally
shutdown by the drive control.
Given an emergency stop or with actuation of the drive-internal monitor,
the drive control command value is set to go to zero and the drives brake
controlled at maximum torque.
In some applications, however, e.g., electronically-coupled gear cutting
machines, it is necessary to bring the drives, given an emergency stop or
power failure, to a standstill controlled by the CNC. In an emergency stop
situation or given the actuation of the drive-internal monitor, the drives are
shutdown position-controlled by the NC control.
9-2 Control mains contactor HVE and HVR 2nd Gen. Power Supply Units
9.2 Controlling the power supply unit with emergency stop

relays
With DC bus dynamic brake

If the mains contactor in the power supply unit is controlled via the
emergency stop relay and the DC bus is short-circuited, you will reach
maximum safety possible thus with very little expenditure. The drive
system monitors are most effectively used. The drive system monitors are
most effectively used.
Applications You should use this mode, if
• only motors with permanent magnetic excitation have been mounted,
• or if motors with permanent magnetic excitation and asynchronous
motors (induction machines) have been mounted,
• or if the emergency stop circuit must be duplicated or if e.g. a
protection door monitor is required,
• or if your drive system includes an extended and substantial
emergency stop chain.
Note: As the energizing current of the mains contactor flows via the
emergency stop chain, the voltage drop must not become too
great. To ensure a reliable energizing, the total resistance of
the emergency stop chain which comes into effect between
the connections X3/1 and X3/6 must be under 1.3 Ω
(HVE02.2, HVE03.2 and HVR0x.2-xx) or 350 mΩ (HVE04.2)!
Features The DC bus dynamic brake can shutdown motors with permanent
magnetic excitation even with a fault in the drive electronics. A
prerequisite, however, is a pertinent programming of the drive controller
(parameter "Shutting down power in the event of a fault"). The DC bus
dynamic brake is only active in the event of drive errors. If the emergency
stop is actuated, asynchronous drives will also brake.
In an emergency stop situation or with actuation of the monitor in the
power supply unit (e.g., power failure), the drives are shutdown by the
drive electronics in the manner set for the specific error reaction.
Property damages due to uncontrolled axis

movements!
The DC bus dynamic brake protects machines against
drive errors. It alone cannot assume the function of
WARNING
protecting personnel. Given faults in the drive and power
supply unit, uncontrolled drive movements are still
possible even if the DC bus dynamic brake is activated
(X3/2 = 0).
Asynchronous machines do not brake if the DC bus is
short-circuited. Depending on the type of machine, injury
to personnel is possible.
⇒ Additional monitoring and protective devices should
be installed in the installation.
Function When actuating the emergency stop key, the mains contactor in the
power supply unit immediately falls off. Drive enables are shut off by the
emergency stop relay or an auxiliary contact of the mains contactor. The
drives are shutdown as per the error reaction set in the drive controller.
A drive error message from the supply module (Bb1-contact), an error
message by the NC control (servo error) or the overtravelling of the end
limit switch causes the mains contactor to be switched off and the DC bus
dynamic brake to be actuated.
X5 U V W
X3/1 J 24 VL
X7/1 max. 20 A
Bb1
X7/2
S2
bleeder K1
control
CNC
X3/2
>1
X11/L+
X3/3
2)
signal
A10 1) processing
X3/4 X11/L-
DC bus
dynamic enable
X3/5 converter
1) brake
K1
X3/6
&
Power supply
K1 unit
ON delay
ready-to- approx. 4 s
operate
1 2 Control voltage
+24V
+/- 10% RF
K4 X6/3
X6/1 HVR/ S11 S4
K1 HVE K1
X6/2
X6/4
X7/3 A10
S1
UD S5
X7/4 S12
safety door
closed
Bb AF AF AF
Drive
U controllers
A10 Emergency-stop relay
K4
0V
Example. Depending on safety requirements at
A10 = Emergency-stop relay the machine, additional monitoring devices and
AF = drive enable of the drive controllers locks may be necessary!
Bb1 = power supply module ready (drive system)
Bb = drive controllers ready
CNC = lag error message of control (use only contacts that do not open with E-stop switch is open)
K1 = mains contactor in power supply module
K4 = drive enable signal control
RF = drive enable signal of the control
S1 = Emergency-stop
S2 = axis end position
S4 = power OFF
S5 = power ON
S11/S12 = safety door monitor
1) K1 control if no emergency-stop switch is used

2) unregulated rectifier in HVE; regulated one in HVR
SS2HVR.fh7
Fig. 9-1: Control of the power supply unit with DC bus dynamic brake in the
event of faulty drive electronics
Without DC bus dynamic brake

Application • If an uncontrolled running out of the drives cannot damage the
installation.
• If only asynchronous drives are connected to the power supply unit.
• If the end positions of the feed axes are sufficiently attenuated.
Features The DC bus voltage is not short-circuited.
In an emergency stop situation, or if the monitors of the power supply unit
are actuated (e.g., power failure), then the drives are shutdown by the
drive electronics as per the set error reaction.
Function The mains contactor in the power supply unit immediately falls off when
the emergency stop sequence is initiated. The drive enable is removed by
the emergency stop relay or by an auxiliary contact of the mains
contactor. The drives are shutdown depending on the set error reaction.
Machine damages due to brakeless slowing

down of the drives in the event of faulty drive
electronics!
CAUTION ⇒ Use motors with mechanical brakes (a holding brake
must not be used as operating brake).
⇒ End positions of feed axes must be sufficiently
attenuated.
X5 U V W
X3/1 ϑ 24 VL X7/1
max. 20 A
Bb1 for diagnostics
X7/2
bleeder K1
control
X3/2
>1
X11/L+
X3/3
2)
signal
A10 1) processing
X3/4 X11/L-
DC bus
dynamic enable
X3/5
brake converter
1) K1
X3/6
&
Power supply
K1 unit
ON delay
operate
1 2 Control voltage
+24V
+/- 10% RF
K4 X6/3
X6/1 HVR/ S4
HVE S11
K1 K1
X6/2
X6/4
X7/3
S1
UD A10
S5
X7/4 S12
safety door
closed
Bb AF AF AF
Drive
U controllers
A10 Emergency-stop
K4
0V
the machine, additional monitoring devices and
A10 = Emergency-stop relay locks may be necessary!
AF = drive enable of the drive controllers
S1 = Emergency-stop
S4 = power OFF
S5 = power ON

2) unregulated rectifier in HVE; regulated one in HVR SS3HVR.fh7
Fig. 9-2: Control of the power supply unit without DC bus dynamic brake
9.3 Control via NC controller

If the mains contactor is controlled via NC controller, it is possible to
provide a position controlled shutdown of the drive via the NC controller in
the event of an emergency stop or as reaction of the internal monitoring of
the drive.
Application This kind of mains contactor control is mostly used with drives which are
electronically coupled and shutdown synchronously when a power failure
occurs.
Features The DC bus voltage is not short-circuited so that power for a position-
controlled shutdown of the drives is available.
Note: The energy stored in the DC bus or the regenerated energy

must be greater than the energy needed to excite
asynchronous machines or for the return motion.
The parameter "Activating NC reactions with a fault" must be

programmed in the drive controller (P-0-0117, bit 0 = 1).
Given an emergency stop or the actuation of the power supply unit
monitor (e.g., power failure), the drives are shutdown position-controlled
by the position controller.
Function Upon initiating the emergency stop sequence, or with the actuation of the
monitor in the power supply unit (e.g., power failure), the mains contactor
in the supply unit falls off.
Drives with SERCOS interface signal the error to the NC control, meaning
that the drives can be shutdown position controlled.
Drives without SERCOS interface require the control to evaluate the UD
contact. If the UD contact is actuated, then the NC control must shut
down the drives.
Machine damages due to brakeless slowing

down of the drives in case of too little DC bus
voltage!
CAUTION ⇒ The controller should evaluate the UD contact and
shut down the drives, when the contact reacts.
X5 U V W
X3/1 J 24 VL X7/1
max. 20 A
Bb1 for diagnostics
X7/2
bleeder K1
control
X3/2
>1
X11/L+
X3/3
signal 2)
A10 processing
1)
X3/4 X11/L-
DC bus
dynamic enable
X3/5 converter
1) brake
K1
X3/6
&
Power
K1
supply unit
ON delay
operate
1 2 3
+24V Control voltage
+/- 10%
X7/3 X6/3
Bb S11 S4
UD K1
RF X7/4
X6/4
S1
S5
S12
safety door
closed
Machine
AF AF AF control
Drive
controller
A10 Emergency-stop ralay
0V
the machine, additional monitoring devices and
A10 = Emergency-stop relay locks may be necessary!
AF = drive enable of the drive controllers
S1 = Emergency-stop
S4 = power OFF
S5 = power ON

2) unregulated rectifier in HVE; regulated one in HVR SS4HVR.fh7
Fig. 9-3: Control for position controlled shutdown of the drives via NC-controller
(without DC bus voltage brake)
HVE and HVR 2nd Gen. Power Supply Units System control 10-1
10 System control
10.1 Interfaces

Terminal X0
X0
1 11
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
Ap_X0.fh7
Fig. 10-1: Terminal X0 (condition as supplied with connectors)

Fig. 10-2: Design

[mm²] [mm²] gauge No:
0,14...1,5 0,25 - 1,5 28...16
10-2 System control HVE and HVR 2nd Gen. Power Supply Units
Terminal assignment
X4
X0
X2
1 11
2 12
X3
3 13
4 14
X0
5 15
6 16
7 17
8 18
9 19
10 20 X7
Ap_X0_hve.fh7
Fig. 10-4: Terminal X0 at the additional component HZS
Note: At delivery, terminal 1 is jumpered with 5, 6 with 10, 11 with 15

and 16 with 20. If there aren’t any additional components HZB
used, the HVx power supply unit has to be operated with these
jumpers.
For further information on X0 see the respective chapters of the additional

components.
X1, Connection for integrated bus connections from neighboring device

Terminal X1
X1
hve_X1

ribbon cable connector 30 pins at device
ribbon cable bushing 30 bushing at ribbon cable
Fig. 10-6: Design
The control electronics of the neighboring drive controllers is supplied via

connector X1. The connection is made starting from the power supply unit
to the drive controllers, by means of the ribbon cables integrated in the
devices. The maximum length of the ribbon cable is 1 m (when using
extensions)!
Note: This is an internal connection between power supply unit and

drive controller.
X2, Service interface

The X2 interface is only used for service purposes. Therefore this manual
does not contain any further information on this interface.
X3, Emergency stop circuit

Terminal X3 1 ZKS
1
2 ZKS
2
3 OFF
3
4 OFF
4
5 ON
5
6 ON
6
X3.fh7

Fig. 10-8: Design

0,14...1,5 0,25 - 1,5 28...16
Terminal assignment
X4
X3
1
ZKS X2
ZKS 2
ZKS
3
OFF
OFF 4 X3
OFF
5
ON
X0
ON 6
ON
X7
R01hva1B.fh7
Fig. 10-10: Terminal assignment X3
The DC bus brake switching is activated via plug-in terminal X3 and the
mains contactor in the power supply unit is switched:
Input "ZKS" If input “ZKS" is open, the DC bus short circuit is activated.
Input "OFF" Only with closed input (Power) "OFF" can the power contactor in the
power supply unit be switched on. If input "OFF" is open, the power
contactor in the power supply unit is immediately switched off.
Input "ON" If the inputs "ZKS" and "OFF" are closed and the unit is internally ready
for operation, the power contactor in the power supply unit is switched on
while the input "ON" is closed.
The ON impulse must be applied for at least 4 s.
Power supply Voltage (DC) [V] Break-away starting Holding current

unit current [A] [A]
HVE02 / 03 24 8 0,45
HVE04 24 20 1
HVR 24 8 1
Fig. 10-11: Technical data of the DC bus
As an additional installation protection in the event of drive electronic

problems, the DC bus is short-circuited with an open DC bus input.
Motors with permanent magnet excitation can, in this case, still be
shutdown in a controlled manner.
Injury to the personnel due to uncontrolled

drive movements!
⇒ In the event of faults in the drive and supply unit,
WARNING uncontrolled drive motions are still possible even if
the DC bus circuit is activated. Therefore provide
additional monitoring and protective equipment to the
system.
Note: As the energizing current of the mains contactor flows via the
emergency stop chain, the voltage drop must not become too
great. To ensure a reliable energizing, the total resistance of
the emergency stop chain, which comes into effect between
the connections X3/1 and X3/6 must be under 1.3 Ω
(HVE02.2, HVE03.2, and HVR0x.2-xx) or 350 mΩ (HVE04.2)!
Number of switching actuations The power of the DC bus brake resistor is needed for the calculation of
the permissible number of switching actuations:
HVE02 HVE03 HVE04 HVR02 and HVR03

1000 W 1500 W 2500 W 400 W
Fig. 10-12: Power of the DC bus brake resistor (PZKS)
2 * PZKS
z= * 60
2C ZU * UB2 + Jg * ω 2
UB: bleeder actuating threshold [V] (820 V)
CZU: DC bus capacitance [F]
J g: total moment of inertia [kgm²]
PZKS: power of the DC bus brake resistor
ω: angular speed [rad/s]
z: number of switching actuations per minute
Fig. 10-13: Number of switching actuations with aux. capacitance and rotating
motor
Note: A maximum number of 16 switching actuations per minute

applies to the internal contactors K1 and K2.
The number of switching actuations (service life of the contact
elements) is 1 million for HVR and HVE units, however only if
the contactor is switched current less. If switched in loaded
condition (e.g. when emergency stop is released), the number
of switching actuations for both unit families and types of
contactors is 400.000.
X4, Control voltages

Terminal X4
+UM
1
1
2 0VM
2
-UM
3
3
4
4
+UL
5
5
6
6 0VL
7
7 n.c.
hve_X4.fh7
Fig.. 10-14: Terminal X4

Fig. 10-15: Design

0,14...1,5 0,25 - 1,5 28...16
Terminal assignment
X4
1
+15 VM
2
max. 100 mA 0 VM X4
3
-15 VM
4
shield1) X2
5
+24 VL
max. 2 A 6 X3
0 VL
7
n/c
X0
X6
X7
R02hva1B.fh7
1) only for HVE

Control voltages 24 VL and ±15 VM can be tapped off of terminal strips

X4/1 ... X4/6. These terminals are intended for measuring and test
purposes.
If these voltages are used outside of the drive system, then make sure
that no interference voltages are coupled in (short, shielded lines). The
load carrying ability of the control voltages is correspondingly reduced by
the drive controllers.
The control voltage outputs are short-circuit proof. The maximum
permissible load must not be exceeded in order not to endanger the
functions of the drives.
X5, Mains connection

Terminal X5
U V X5 W
hvx_X5.fh7
Fig. 10-18: Terminal X5 with HVx02.2 and HVx03.2
U V W
hve04_X5.fh7
Fig. 10-19: Terminal X5 with HVE04.2

screw terminal 1x4 bushing at device
Fig. 10-20: Design
Connection cross section Device Cross section Cross section Cross section
single-core multi-core with in AWG
[mm²] connector sleeve gauge No.:
[mm²]
HVR02.2-W10N
HVR02.2-W25N 2,5...10 2,5...16 12...6
HVE02.2-W18N
HVR03.2-W45N
2,5...16 2,5...35 12...2
HVE03.2-W30N
HVE04.2-W75N 16...50 16...50 6...0
Tightening torque
Device Tightening torque
HVR02.2-W10N 2 Nm
HVR02.2-W25N
HVE02.2-W18N
HVR03.2-W45N 4 Nm
HVE03.2-W30N
HVE04.2-W75N 6 Nm
Fig. 10-22: Tightening torques
Terminal assignment
X5
L1 U
L2 V
L3 W
PE
AP_X5.fh7
X6, Acknowledging the power supply unit mains contactor

Terminal X6 1
1
NO
2 1
1
NO
2
NO
3 2
2
NO
3
NC
4 3
3
NC
4
NC
5 4
4
NC
5
NC
6
6
NC hvr_X6.fh7
hve_X6.fh7
HVE HVR

screw terminal 1 x 4 for HVR bushing at connector
1 x 6 for HVE
Fig. 10-25: Design

0,2...2,5 0,25 - 2,5 24...12
The acknowledge outputs are on terminal X6.
X4
X2
X3
X6
1
acknowledge
power ON 2 K1 NO X0
3
acknowledge
power OFF 4 K1 NC
X6
5
acknowledge
power OFF 1) 6 K1 NC
X7
1) only with HVE, not with HVR

R03hva1B.fh7
Continuous current Starting current

DC 24 V/1 A DC 24 V/1 A
AC 220 V/1 A AC 220 V/1 A
Fig. 10-28: Maximum contact load
Note: The indicated voltages have to refer to potential ground.
"Acknowledge power ON"

At output acknowledge power ON it can be queried as to whether the
mains contactor in the supply unit is on or not. The contact is closed if the
mains contactor is on. It can be used as a precondition for the drive
enable signal.
"Acknowledge power OFF"

At output acknowledge power OFF it can be queried as to whether the
mains contactor in the supply unit has dropped off or not. If it has, then
the contact is closed. This can be used as a precondition to enable the
safety door lock.
There is restricted guidance between the acknowledge power OFF
contact and the main contacts of the mains contactor in the power supply
unit.
On the HVE power supply unit, there are two brake contacts labeled as
"Acknowledge power Off" led to the outside of the unit.
X7, Ready-to-operate and other messages

Terminal X7 1 Bb1 1 Bb1 1 Bb1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6
2 Bb1 2 Bb1 2 Bb1
3 UD 3 UD 3 UD
4 UD 4 UD 4 UD
5 TVW 5 TVW 5 TVW
6 TVW 6 TVW 6 TVW
7 BVW 7 n.c.
hvr_X7.fh7
8 BVW 8 n.c.
hve_X7.fh7 hzs_X7.fh7
HVE HZS HVR


1 x 8 for HVE
Fig. 10-30: Design

single-core multic-core in AWG
0,2...2,5 0,25 - 2,5 24...12
Terminal assignment
X4
X2
X3
X7 X0
1
ready-to- 2 Bb1
operate
3 X6
power voltage OK 4 UD
5 X7
prewarning 6 VW
1) braking resistor 7
prewarning 8 BVW
1) only with HVE, not with HVR and HZS R04hva1b.fh7
Description The terminal X7 contains outputs

• signalizing that the drive systems are ready for operation,
• acknowledging the proper power supply,
• warning that the device is overheated, and
• warning that the regenerated power is too great.
HVE HVR
Continuous current DC 24 V/1 A AC 250 V/1 A DC 24 V/1 A
Starting current DC 24 V/1 A AC 250 V/1 A DC 24 V/1 A
Fig. 10-33: Maximum contact load
Note: The indicated voltages have to refer to potential ground.
Ready-to-operate (Bb1)
The Bb1 contact of the power supply unit is of higher-ranking significance.
It signals that the drive is ready to receive power. Only if closed, the locks
within the unit allow switching the mains contactor to the power supply
unit.
In the event of a fault, the power contactor is shut off and the Bb1 contact
opens. If this contact opens, then there will probably not be a controlled
shutdown of the drives. It can, therefore, be used as a precondition for
letting the DC bus dynamic brake drop in.
The Bb1 contact opens with the following faults:
• faults in the power supply unit and
• faults in the drive controller (power off must be parameterized in the
drive controller).
• faults in additional components.
The Bb1 contact closes if the control voltage at terminal X8 is applied and
no error is pending.
Power supply in order (UD)

The UD contact acknowledges that the power supply is in working order.
It opens in the event of the following faults:
• mains fault
• DC bus voltage is smaller than the permissible minimum value
(HVR: 680 V, HVE: 80% of UNetz)
• when switching off K1
If the installation requires that the drives be shutdown with position control
in the event of a mains fault, then the installation control must evaluate
the UD contact and shut down the drives in a controlled fashion.
Pre-warning (VW)
The pre-warning contact is opened, if the cooling unit temperature in the
power supply unit is too high or a critical value is reached in an additional
component. The mains contactor in the power supply unit interrupts the
power supply after 30 seconds and the Bb1 contact opens.
Note: If the installation requires that the drives are shut down in a
position controlled fashion if there is a fault in the unit, then the
drives must be shutdown within 30 seconds.
Bleeder pre-warning contact (BVW)

The bleeder pre-warning contact only exists in the HVE power supply
units. The bleeder pre-warning contact opens if continuous regenerated
power exceeds 80% of the continuous bleeder power. If the bleeder
power continues to rise, then the mains contactor stops the HVE power
supply unit and the Bb1 contact opens.
X8, Control voltage supply

Terminal X8
2u2 1
1
2v2 2 2u1 1
1
2
2w2 3 2
3
2v1
2
2w1 3
3
2u1 4
1
2v1 5 frei 4
4
2
2w1 6
3
hvr_X8.fh7
hve_X8.fh7
HVE HVR

1 x 6 for HVE
Fig. 10-35: Design

0,2...4,0 0,25 - 4,0 24...10
Terminal assignment
X0 X0
X6
X6
X7
X7
X8
bridged at 2u2
delivery 1
2 2v2
3 2w2
X8 X8
1
4 2u1 L1
X8
2v1 2
5 L2
2w1 3
6 L3
4
n.c.
AP_X8hve.fh7
AP_X8hvr.fh7
HVE HVR
X11, DC bus connection

Terminal X11
DC bus connection X11

X1
L+
L-
Max.Drehmoment/Torque: U,V,W, =2Nm
U V X5 W
hve_X11.fh7

terminal block 2 screw terminal for ring
cable lug M5
Fig. 10-39: Design

-- 35 --
Risk of damage by interchanging the DC bus

connections L+ and L-
⇒ When connecting the DC bus make sure the polarity
CAUTION is correct.
Lines for DC bus connection If in special cases it is impossible to use the DC bus strands provided to
make the connection, the connection must be made using the shortest
possible twisted wires!
line length:
• within a drive package • max. 2 x 1 m
• between two drive packages • max. 2 x 15 m
• HZS application in stand-alone operation • max. 2 x 30 m
2
line cross section min. 10 mm ;
but not smaller than cross
section of supply feeder
line protection by circuit breakers in the mains
connection
dielectric strength of single strand against ≥ 750 V
ground (e.g. strand type - H07)
Fig. 10-41: Lines for DC bus connection
X12, Ground connection

Terminal X12
X1
L+
L+
grounding
bracket
Max.Drehmoment/Torque: U,V,W, =2Nm
U V X5 W
hve_X12.fh7
Design Screw terminal
The ground connection to the drive controllers is double:

• rear panel of device and mounting rail
• grounding bracket on the front (see figure)
Connect the neighboring devices to both sides via the grounding

brackets.
X13, Optional choke connection (only HVE)

Terminal X13
1L+ 2L+
1L+
2L+
hve04_X13.fh7
hve_X13.fh7
HVE02 and HVE03 HVE04

(jumpered at delivery) (not jumpered at delivery)
Design HVE02/HVE03 HVE04

Type screw terminal screw terminal
Number of poles 2 2
Type of design screw terminal for ring multi-core with
cable lug M5 connector sleeve or
single-core
2
Cross section [mm ] 10...25 16...50
Tightening torque 2,5...3,0 6...8
Fig. 10-44: Design
Terminal assignment device external device internal
X13
optional
choke
GLD xx
1L+
2L+
AP_X13.fh7
Condition as supplied • HVE02/HVE03: with jumper from 1L+ to 2L+

• HVE04: without jumper
(if the optional choke is not required, a jumper has to be laid from 1L+
to 2L+; line cross section: see below)
Load capacity max. voltage with reference to L- DC 900 V

voltage with reference to ground provided mains voltage
max. continuous current • HVE02/03: 70 A
• HVE04: 150 A
Fig. 10-46: Load capacity
Line 1L+ and 2L+ to choke line length max. 10 m

line cross section not smaller than cross section of
supply feeder;
minimum cross section: see data
under "Design"
line routing twisted
dielectric strength of single strand ≥ 750 V
against ground
(e.g.: strand type – H07)
Fig. 10-47: Line 1L+ and 2L+
10.2 Chronological sequence when switching on and off
When powering up
Mains feed for control

voltage supply
applied
t1
Bb1 contact closed
t2
Power source ON
t3
Acknowledge
power ON
t4
UD contact closed
t
SV5102f1.fh7
t1: Depends on parameterized function of the drives

t2: Depends on the reaction time of the PLC
t3: On-delay of the K1 mains contactor in the unit (maximum 100 ms)
t4: Time to build up DC bus voltage
- maximum 4,1 s; value applies to maximum DC bus capacitance
(10 mF or 20 mF)
- maximum 6,5 s; value applies to maximum DC bus capacitance
(100 mF or 200 mF)
Fig. 10-48: Chronological sequence when powering unit up
When shutting down
Power OFF
t1
Acknowledge
power OFF
t2
UD contact open
t3
Bb1 contact open;
only opens with
power off with fault
t
SV5103f1.fh7
t1: On-delay of the K1 mains contactor in the unit (maximum 100 ms)
t2: Depends on reduction of DC bus voltage (maximum 500 ms)
t3: Only opens with power shutdown due to a fault (fault in supply unit,
drive controller or due to mains failure); (maximum 25 ms)
Fig. 10-49: Chronological sequence when shutting down the unit
HVE and HVR 2nd Gen. Power Supply Units Troubleshooting 11-1
11 Troubleshooting
11.1 General
Extensive searches for faults and repair of drive components on the
machine are not acceptable due to the production downtime involved.
The modular concept of Rexroth AC drives makes it possible to
completely exchange drive components. Service thus means localizing
problems either on the motor, drive controller or power supply unit and
replacing the part. No further adjustments are needed.
11.2 Fault diagnostics and resetting faults

Fault diagnostics The power supply unit signals operating states, warnings or faults via a
two-place 7-segment display.
A prerequisite for fault diagnoses is a control voltage of +24 V, ±15 V and
+5 V and processors in the supply and drive controllers that are working
properly.
Resetting faults Stored fault messages must be reset before the unit will again operate.
An error can be reset by
• pressing the RESET key on the unit,
• switching the control voltage off or
• generating the reset command of the control via the control voltage
bus.
Destruction of the power supply module, if the

power is switched on to a faulty drive
controller!
CAUTION ⇒ Upon RESET of an over current fault and after
replacement of a defective supply module, the fault
memories of the drive controllers must be read out
prior to switching it on.
Reset key
8 8 Diagnostic display
posdiag.fh7
Fig. 11-1: Position of diagnostic display and reset key
11-2 Troubleshooting HVE and HVR 2nd Gen. Power Supply Units
If either checks or repairs are needed, then it applies:

• Checks and repairs may only be conducted by Rexroth customer
service personnel or such personnel that has been trained to do so.
• Observe the applicable safety regulations when checking the unit.
• Repairing drive components on the machine is very time consuming.
Replace defective drive components completely.
When faults are cleared, damages to the

machine and injury to the personnel may occur!
⇒ Fault clearance should only be conducted by trained
WARNING personnel.
⇒ Protective devices must not be switched off.
⇒ Note the warnings in section 3.
11.3 Checking and repairing the unit

When contacting our service personnel we would like to ask you to
provide the following information so that a quick and precise assistance
can be assured:
• type designations and serial numbers of units and motors,
• the status of the fault,
• any diagnostic displays and
• software status, if necessary.
You’ll find the telephone number of our service hotline in the chapter
"Service & Support".
11.4 Replacing the unit
Note: Replacing the unit requires, depending upon unit weight, a

lifting device and an identical replacement unit.
Electrical shock due to voltage-containing parts

of more than 50 V!
⇒ The unit may only be replaced by qualified
DANGER personnel, which have been trained to perform the
work on or with electrical devices.
Note: Prior to the replacement of the unit please check according to

the type plates, whether these units are of the same types.
Replace only units of the same types.
Proceed as follows:
1. Switch voltage to installation off and secure it against being switched
back on.
2. Using an appropriate measuring device, check whether the
installation is power free. Wait the discharge time.
3. Motors must be standing still.
4. Secure vertical axes against motion.
5. Release all connections from the defective unit.
6. Release the fixing bolts and remove the unit from the control cabinet.
Use the lifting device, if necessary.
7. Hang replacement unit into mounting rails. Use the lifting device, if
necessary.
8. Reconnect the unit as per the terminal diagram of the machine
manufacturer.
9. If vertical axes have been mechanically secured prior to replacement,
then remove these devices at this point.
10. While reading out the fault memories of the connected drive
controllers make sure that the device fault has not been triggered by
the drive controllers (see warnings in chapter 11.2 "Fault diagnostics
and resetting faults").
The unit replacement is completed. The system can be put back into
operation.
11.5 Diagnostic Display
Overview
Anzeige Bedeutung Erläuterung

DISPLAY ACCEPTATION EXPLANATION
- Bereit zur Leistungszuschaltung - Supply and drives are fault-free. Power can be
bb - READY FOR POWER ON - switched on.
- Leistung bereit - Mains contactor is ON. DC bus voltage within
Lb - POWER OK - permissible range.
- Zusatzkomponenten Vorwarnung - WARNING an additional component is being
14 - EXTERNAL COMPONENT WARNING - applied. Power off in 30 s.
- Steuerspg.-Vers.-Temp.-Vorwarnung - 1) Control voltage supply is overloaded. The
15 - CONTROL VOLTAGE TEMP. WARNING - temperature pre-warning contact has opened.
- Softstartfehler - DC bus cannot be loaded.
16 - SOFTSTART-FAULT -
- Leistung Aus / Zwischenkreiskurzschluss - Power is off and DC bus dynamic brake
17 - POWER OFF WITH BUS SHORTING - activated.
- Kühlkörpertemperatur zu hoch - Power off due to excessive heatsink or power
18 - HEATSINK OVERTEMP. FAULT - section temperature.
- Bleeder Überlast - Rotary drive energy (HVR/HVE) or regenerated
20 -BLEEDER OVERLOAD - power (HVE) too high.
- Antriebsfehler - Power of due to drive error.
23 - DRIVE FAULT -
- Zusatzkomponenten-Fehler - Power off due to fault in additional component
24 EXTERNAL COMPONENT ERROR - (bleeder, loading device).
- Rückspeise-Überlast - Continuous regenerated power of the drives
25 - REGEN. POWER OVERLOAD - excessive.
- Einspeise-Überlast - The continuous feed in power of the drive
26 - BUS POWER OVERLOAD - excessive.
- Kühlkörper-Übertemperatur-Warnung - Temperature pre-warning contact is open. Power
50 - HEATSINK TEMP. WARNING - off after a further rise in temperature of 5 °C.
Bleeder Überlast-Warnung 80 % of the allowable bleeder ON time has been
52 - BLEEDER OVERLOAD WARNING - achieved due to excessive regenerated power.
- Überstrom - 1) Short-circuit in supply or drive in motor or in a
60 - OVERCURRENT - cable.
- +24 V / ±15 V / +5 V Fehler - Control voltages faulty.
69 - +24 V / ±15 V / +5 V FAULT -
- Erdschluss - Ground fault in supply or drive unit, in motor or in
80 - SHORT TO GROUND - cable.
- Netzausfall - 1) One or several mains phases missing.
81 - POWER FAILURE -
- Phasenfehler - 2) One or several mains phases missing or the
82 -PHASELOSS FAULT - mains voltage is too low.
- Netzspannungsfehler - Mains voltage exceeds permissible tolerance.
83 - LINE VOLTAGE FAULT -
- Anschlussfehler - 1) No phase coincidence in power and control
84 - MISWIRING - voltage connections.
Line contactor doesn't pick up.
- Netzfrequenzfehler - 1) Mains frequency exceeds permissible tolerance.
85 - LINE FREQUENCY FAULT -
- Steuerspannungsversorgungs-Fehler - 2) The HVE control voltage supply exceeds
87 - CONTROL VOLTAGE SUPPLY FAILURE - permissible tolerance.
- EPROM-Fehler - 1) Hardware or software error in unit.
94 - CHECKSUM ERROR -
- Gerätefehler - Hardware or software error in unit.
. . - DEVICE FAILURE -
- +5 V Fehler 2) +5 V control voltage failure.
__ - +5 V FAILURE -
- Gerätefehler - 2) Hardware or software error in unit.
E1...E9 - DEVICE FAILURE -
1): with HVR only
2): with HVE only
Fig. 11-2: Diagnostic display overview
Description, possible cause and troubleshooting
Display Description Possible cause Troubleshooting

Ready to receive power 1) Power contactor has dropped 1) Release button and switch
bb off because OFF or power contactor on.
Supply unit and drive controller emergency stop key was
are ready. actuated. 2) Check control - at X3/6 for
at least 200 ms +24 V must
2) The power contactor can not be applied.
be activated, as its drive is
faulty (if in principle, the power
cannot be switched on).
Lb Power ready
DC bus voltage within
permissible range. The power
supply unit is ready to supply
power.
Additional component pre- 1) Temperature may be too high. 1) Check additional units.
14 warning
2) The end contactor has not 2) Plug an end contactor to
A warning signal of an additional been plugged to terminal X0. terminal X0 on additional
unit is pending. Power is units.
shutdown after 30 s.
Control voltage supply There may be too many drives Check the dimensioning of the
15 temperature pre-warning
1)
connected. power supply unit.
The control voltage supply is
overloaded. A power shutdown is
pending.
Softstart error The DC bus cannot be loaded 1) Release connections to drive
16 because controller and switch power
on again. Replace unit, if
1) there is a short-circuit in the necessary.
power supply unit or in the
drive controller. 2) Reduce the number of aux.
capacitors or use a separate
2) too many additional loading unit.
capacitances have been
connected. 3) DC bus choke and lines
2) must be checked, replaced if
3) the DC bus choke is cutoff necessary.
4) the main contactor cannot be 4) a) Reduce the number of
2)
activated switching actuations.
a) the permissible number of b) Check the contacts in the
switching on and off emergency stop chain for
actuations has been dirt and corrosion.
exceeded. 5) Connect jumper or DC
b) the maximum permissible choke.
resistance in the emergency
stop chain has been
2)
exceeded.
5) the jumper or DC choke at
terminal X13 is missing.
Power OFF with DC bus The control of the installation has Check the emergency stop
17 dynamic brake triggered a DC bus dynamic sequence of the installation.
braking action.
The power contactor has
dropped off. The DC bus
dynamic brake was activated.

Heatsink temperature too high Power shutdown due to excessive Load and ambient temperature
18 heatsink temperature because the must be checked.
Power shutdown. unit is overloaded or the ambient
temperature is too high. Evaluate prewarn contact of unit.
Bleeder overload The power has been switched off 1) Reduce drive speed. Switch
20 due to excessive bleeder load power OFF or emergency
Power shutdown. because stop in a delayed fashion.
1) the regenerated power on the 2) Increase cycle time, reduce
HVR is too high with switched drive speed or install
off power. additional bleeder.
2) in the HVE, the continuous 3) Replace unit.
regenerated power and/or
rotary drive energy is too high
3) the unit is defective.
3)
Drive error A drive controller has detected a Diagnostic displays of drive
23 fault in the unit, motor or line controllers must be checked.
connections.
Additional component error 1) An error was detected in an 1) Additional components must
24 additional component, such as be checked.
HZB or HZS
2) Jumpers must be checked.
2) Jumpers not inserted into
connector X0.
3)
Regenerated overload The regenerated power of the drive Reduce permissible delay.
25 is excessive.
Use drive controller with smaller
peak current.
3)
Feedin overload The feedin power required by drive Reduce permissible acceleration.
26 is excessive.
Use drive controllers with smaller
peak current.
Heatsink overtemperature-pre- 1) Excessive load 1) Reduce load
50 warning
2) Ambient temperature too high 2) Reduce control cabinet
The permissible heatsink temperature
3) Cooling air flow blocked
temperature has been reached.
3) Unblock cooling air flow
The temperature pre-warning 4) Blower in the unit defective
contact has opened. Power off in 4) Replace unit
30 s.
Bleeder overload warning 80 % of the allowable bleeder ON Reduce the allowable
52 time has been achieved due to acceleration (delay).
excessive regenerated power.
- or-
Reduce drive speed
- or-
Reduce the peak current of the
drive

1)
Overcurrent 1) Short circuit in supply unit, 1) Release power connections
60 drive controller, motor or to the drive controllers step
cable. by step. Replace defective
unit.
2) Too high continuous power.
2) Check machine cycle; check
drive design
69 +24 V / ±15 V / +5 V Fault The control voltages are faulty 1) Release bus connections to
because: drive controllers step by
step.
1) the maximum permissible load
has been exceeded. 2) Release control voltage taps
and check for short circuit.
2) there is a short-circuit in the
wiring of the control voltage 3) Replace unit.
used outside the drive
systems.
3) the unit is defective.
Ground fault Ground fault in power supply unit, Release power connections to
80 drive controller, motor or cable. the drive controllers step by step.
Replace defective unit.
1)
Power failure At least one phase is missing of Check mains fuses and replace,
81 the mains supply. if necessary.
Phase Fault 1) At least one phase is missing 1) Check mains fuse and
82 of the mains supply. replace, if necessary.
2) The mains voltage is too low. 2) Measure the mains voltage
and compare it with the
required data.
Mains voltage fault HVR: Mains voltage exceeds Check mains voltage, use
83 permissible tolerance matching transformer if
(3 x 380 ... 480 V (± 10 %)). necessary.
HVE: The maximum value of the
mains voltage has been exceeded.
1)
Connection fault 1) Power and control voltage 1) Check connection voltage.
84 connections not phase Terminals X5/U and X8/1,
coincident. X5/V and X8/2, X5/W and
X8/3 may not conduct
2) Resistance in the emergency voltage to each other.
stop chain too high; load
contactor cannot close. 2) Check the contacts in your
emergency stop chain for
dirt or corrosion.
1)
Mains frequency fault Mains frequency exceeds
85 permissible tolerance (±2 Hz).
2)
Control voltage fault The control voltage supply exceeds Check mains fuse in control
87 permissible tolerance cabinet and replace, if
(3 x 380 ... 480 V (± 10 %)). necessary.

1)
EPROM fault Unit fault. Replace unit.
94
Unit fault Hardware or software error in unit. Switch control voltage off and on.
.. If error still present, replace unit.
HVR: Processor error
HVE: Circuit error
2)
+5 V error The +5 V control voltage is faulty Replace unit.
-- because of a unit fault.
Unit fault Hardware or software error in unit. Switch control voltage off and on
E1...E9 again. If the error occurs again
during further operation, replace
the device.
1): Error message exists only with HVR units
2): Error message exists only with HVE units
3): Error is not saved
Fig. 11-3: Diagnostic display; acceptance, possible cause and recovery
HVE and HVR 2nd Gen. Power Supply Units Delivery Status 12-1
12 Delivery Status
12.1 Packaging
Packaging Units The components are supplied in separate packaging units.
Packaging Materials The packaging materials consist of cardboard, wood and polystyrene.
They can be easily recycled. For ecological reasons you should not return
the empty packages to us.
Packaging Labels The content of the packed components and the order number may be
identified using the adhesive barcode label on the packaging.
12.2 Scope of Delivery

Supply Units HVx The supply units HVx0x.2-W0xxx resp. the additional components HZS,
Additional Components HZx HZB, HZK and HZF are delivered:
• with connectors plugged on
• with mounted touch guard
• with strands for DC bus connection to neighboring device
• with grounding brackets for ground connection to neighboring device
• the manual „Safety Instructions for Electrical Drives" (HVx only)
Additional Components The additional components GLD resp. KD resp. SUP-E0x-HVR are
GLD, KD and SUP-E0x-HVR delivered without any accessories.
12-2 Delivery Status HVE and HVR 2nd Gen. Power Supply Units
Notes
HVE and HVR 2nd Gen. Power Supply Units Identifying the Components 13-1
13 Identifying the Components

Type Plate Arrangement
Type plate
TS_HVE_en.fh7
Fig. 13-1: Type plate arrangement
Type Plate Design
Device type
HVE03.2-W030N
123456 Made in Germany K25/03
Part number
SN123456-F0001 A15
Hardware Index
Barcode
Serial Number Production week
SN123456-F0002 Example K25/03 means week 25 in year 2003
Prefix
Continued Number Producing Country
Part number
Identification of supplier
typenschild_aufbau_en.fh7
Fig. 13-2: Type plate design
13-2 Identifying the Components HVE and HVR 2nd Gen. Power Supply Units
Notes
HVE and HVR 2nd Gen. Power Supply Units Index 14-1
14 Index
A
additional bleeder module
characteristics 6-6
dimension drawing 6-11
front view 6-10
unit arrangement 6-6
additional capacitance module
arrangement 6-3
characteristics 6-3
front view 6-4
maximum additional capacitance 6-3
operate and monitor 6-3
appropriate use 2-1
areas of application 1-3
auxiliary capacitance
calculating 5-5
B
basic losses 4-9
battery
safety 3-11
C
calculating
connected load 5-8
continuous regenerated power 5-6
peak regenerated power 5-7
CE Mark 4-13
Chronological sequence
switching on and off 10-22
combining filter
data sheet 4-12
commutation choke
Condition as supplied 12-1
connection
electrical 8-1
HVE 8-10
HVR 8-13
mains 8-8
control cabinet check 8-24
control mains contactor 9-1
Control voltages 10-7
controller arrangement 7-10
cooling unit
configuration 7-6
C-UL listing 4-13
D
data sheet
combining filter 4-12
HVE 4-6
HVR 4-10
DC bus choke 6-2
technical data 6-2
DC bus continuous power 4-6
calculate 5-1
for main drives 5-3
for servo drives 5-3
for spindle and servo drives in machine tools 5-4
14-2 Index HVE and HVR 2nd Gen. Power Supply Units
increase 5-1
DC bus dynamic brake 9-2
DC bus peak power
calculating 5-4
DC bus power
increase 6-3
Diagnostic Display 11-4
dimension drawing
DC bus choke 6-2
dimensional data
commutation choke 7-20
HVE02.2 7-15
HVE03.2 7-15
HVE04.2 7-16
HVR 7-17
E
Earth leakage monitor 8-22
electromagnetic compatibility 8-23
EMC
optimal installation 7-13
emergency stop relays 9-2
F
fault current protective device 8-22
front view
HVE02.2 and HVE03.2 8-2
HVE04.2 8-3
HVR 8-5
HZF 8-7
fusing
with direct mains supply 8-17
H
hazards by improper use 3-2
HVE
connection 8-10
data sheet 4-6
power data 4-4
short-term output 4-5
technical data 4-3
HVR
connection 8-13
data sheet 4-10
power loss 4-9
short-term output 4-8
technical data 4-7
HZB 6-6
HZF see combining filter
HZF02.1-W010N 7-18
HZF02.1-W025N 7-19
HZF02.1-W045N 7-19
HZK see additional capacitance module
HZS
dimensional drawing 6-28
overall connection diagram HZS01.2 6-29
technical data 6-13
I
improper use
hazards 3-2
inappropriate use 2-2
consequences, discharge of liability 2-1
increase bleeder power 6-6
interfaces
control voltages 10-7
HVE and HVR 2nd Gen. Power Supply Units Index 14-3
power supply unit mains contactor 10-10

Ready-to-operate and other messages 10-12
interference
elimination 8-14, 8-23
interference elimination 8-23
interference emission 8-23
interference suppression 8-23
L
loss of heat
dimension cooling unit 7-5
example calculation 7-3
M
mains supply
introduction 5-1
manage braking energies see additional bleeder module
modified conditions of use 7-1
mounting conditions 7-10
mounting position 7-10
N
NC controller 9-7
P
Packaging labels 12-1
Packaging Materials 12-1
Packaging units 12-1
power data
HVE 4-4
power loss
HVR 4-9
power supply system
connecting drive controllers 8-19
grounding 8-19
power supply unit
areas of application 1-3
construction 1-2
features 1-4
working mode 1-2
protection
against contact with electrical parts 3-5
against contact with hot parts 3-10
against dangerous movements 3-7
against electric shock by protective low voltage (PELV) 3-6
against magnetic and electromagnetic fields during operation and mounting 3-9
against pressurized systems 3-11
during handling and mounting 3-10
protective device
fault current 8-22
R
reduce heat loss 5-5
reduce loss of heat see additional capacitance module
regenerated energy see auxiliary capacitance
calculating 5-5
Replacing 11-3
resistance to interference 8-23
S
safety instructions for electric drives and controls 3-1
short-term output
HVE 4-5
14-4 Index HVE and HVR 2nd Gen. Power Supply Units
HVR 4-8
Storage 4-2
system control 10-1
system operation 6-12
system overview 1-1
T
technical data
DC bus choke 6-2
HVE 4-3
HVR 4-7
terminal diagram
HVE02.2, HVE03.2, HVE04.2 8-4
HVR02.2, HVR03.2 8-6
Troubleshooting 11-1
U
use
directions for use 2-1
hazards by improper use 3-2
W
warning symbols 3-1
HVE and HVR 2nd Gen. Power Supply Units Service & Support 15-1
15 Service & Support
15.1 Helpdesk
Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am
am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.
Sie erreichen uns Contact us
- telefonisch - by phone: 49 (0) 9352 40 50 60

über Service Call Entry Center Mo-Fr 07:00-18:00
- via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm
- per Fax - by fax: +49 (0) 9352 40 49 41
- per e-Mail - by e-mail: [email protected]
15.2 Service-Hotline
Außerhalb der Helpdesk-Zeiten ist der Service After helpdesk hours, contact our service
direkt ansprechbar unter department directly at
+49 (0) 171 333 88 26

oder - or +49 (0) 172 660 04 06
15.3 Internet
Unter www.boschrexroth.com finden Sie At www.boschrexroth.com you may find

ergänzende Hinweise zu Service, Reparatur und additional notes about service, repairs and training
Training sowie die aktuellen Adressen *) unserer in the Internet, as well as the actual addresses *) of
auf den folgenden Seiten aufgeführten Vertriebs- our sales- and service facilities figuring on the
und Servicebüros. following pages.
Verkaufsniederlassungen sales agencies
Niederlassungen mit Kundendienst offices providing service
Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mit Please contact our sales / service office in your area first.
unserem für Sie nächstgelegenen Ansprechpartner auf.
*) Data in the present documentation may have become
*) Die Angaben in der vorliegenden Dokumentation können obsolete since printing.
seit Drucklegung überholt sein.
15.4 Vor der Kontaktaufnahme... - Before contacting us...

Wir können Ihnen schnell und effizient helfen wenn For quick and efficient help, please have the
Sie folgende Informationen bereithalten: following information ready:
1. detaillierte Beschreibung der Störung und der 1. Detailed description of the failure and
Umstände. circumstances.
2. Angaben auf dem Typenschild der betreffenden 2. Information on the type plate of the affected
Produkte, insbesondere Typenschlüssel und products, especially type codes and serial
Seriennummern. numbers.
3. Tel.-/Faxnummern und e-Mail-Adresse, unter 3. Your phone/fax numbers and e-mail address,
denen Sie für Rückfragen zu erreichen sind. so we can contact you in case of questions.
15-2 Service & Support HVE and HVR 2nd Gen. Power Supply Units
15.5 Kundenbetreuungsstellen - Sales & Service Facilities
Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!

from abroad: don’t dial (0) after country code!
Vertriebsgebiet Mitte
Germany Centre SERVICE SERVICE SERVICE
Rexroth Indramat GmbH CALL ENTRY CENTER HOTLINE ERSATZTEILE / SPARES
Bgm.-Dr.-Nebel-Str. 2 / Postf. 1357 MO – FR MO – FR verlängerte Ansprechzeit
97816 Lohr am Main / 97803 Lohr von 07:00 - 18:00 Uhr von 17:00 - 07:00 Uhr - extended office time -
from 5 pm - 7 am ♦ nur an Werktagen
Kompetenz-Zentrum Europa from 7 am – 6 pm + SA / SO - only on working days -
Tel.: +49 (0)9352 40-0 Tel.: +49 (0)172 660 04 06 ♦ von 07:00 - 18:00 Uhr
Tel. +49 (0) 9352 40 50 60 - from 7 am - 6 pm -
Fax: +49 (0)9352 40-4885 oder / or
[email protected] Tel.: +49 (0)171 333 88 26 Tel. +49 (0) 9352 40 42 22
Vertriebsgebiet Süd Vertriebsgebiet West Gebiet Südwest

Germany South Germany West Germany South-West
Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Landshuter Allee 8-10 Regionalzentrum West Service-Regionalzentrum Süd-West
80637 München Borsigstrasse 15 Siemensstr.1
40880 Ratingen 70736 Fellbach
Tel.: +49 (0)89 127 14-0 Tel.: +49 (0)2102 409-0 Tel.: +49 (0)711 51046–0
Fax: +49 (0)89 127 14-490 Fax: +49 (0)2102 409-406 Fax: +49 (0)711 51046–248
+49 (0)2102 409-430
Vertriebsgebiet Nord Vertriebsgebiet Mitte Vertriebsgebiet Ost Vertriebsgebiet Ost

Germany North Germany Centre Germany East Germany East
Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Walsroder Str. 93 Regionalzentrum Mitte Beckerstraße 31 Regionalzentrum Ost
30853 Langenhagen Waldecker Straße 13 09120 Chemnitz Walter-Köhn-Str. 4d
Tel.: +49 (0) 511 72 66 57-0 64546 Mörfelden-Walldorf 04356 Leipzig
Service: +49 (0) 511 72 66 57-256
Fax: +49 (0) 511 72 66 57-93 Tel.: +49 (0) 61 05 702-3
Service: +49 (0) 511 72 66 57-783 Fax: +49 (0) 61 05 702-444 Tel.: +49 (0)371 35 55-0 Tel.: +49 (0)341 25 61-0
Fax: +49 (0)371 35 55-333 Fax: +49 (0)341 25 61-111
Europa (West) - Europe (West)

vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen
from abroad: don’t dial (0) after country code, Italy: dial 0 after country code
Austria - Österreich Austria – Österreich Belgium - Belgien Denmark - Dänemark

Bosch Rexroth GmbH Bosch Rexroth GmbH Bosch Rexroth AG BEC A/S
Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls Zinkvej 6
Stachegasse 13 Industriepark 18 Industrielaan 8 8900 Randers
1120 Wien 4061 Pasching 1740 Ternat
Tel.: +43 (0)1 985 25 40 Tel.: +43 (0)7221 605-0 Tel.: +32 (0)2 5830719 Tel.: +45 (0)87 11 90 60
Fax: +43 (0)1 985 25 40-93 Fax: +43 (0)7221 605-21 - service: +32 (0)2 5830717 Fax: +45 (0)87 11 90 61
Fax: +32 (0)2 5830731
[email protected]
Great Britain – Großbritannien Finland - Finnland France - Frankreich France - Frankreich

Bosch Rexroth Ltd. Bosch Rexroth Oy Bosch Rexroth SAS Bosch Rexroth SAS
Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls
Broadway Lane, South Cerney Ansatie 6 Avenue de la Trentaine ZI de Thibaud, 20 bd. Thibaud
Cirencester, Glos GL7 5UH 017 40 Vantaa (BP. 74) (BP. 1751)
77503 Chelles Cedex 31084 Toulouse
Tel.: +44 (0)1285 863000 Tel.: +358 (0)9 84 91-11 Tel.: +33 (0)164 72-70 00 Tel.: +33 (0)5 61 43 61 87
Fax: +44 (0)1285 863030 Fax: +358 (0)9 84 91-13 60 Fax: +33 (0)164 72-63 00 Fax: +33 (0)5 61 43 94 12
[email protected] Hotline: +33 (0)608 33 43 28
[email protected]
France – Frankreich Italy - Italien Italy - Italien Italy - Italien

Bosch Rexroth SAS Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth S.p.A.
Electric Drives & Controls Via G. Di Vittoria, 1 Via Paolo Veronesi, 250 Via del Progresso, 16 (Zona Ind.)
91, Bd. Irène Joliot-Curie 20063 Cernusco S/N.MI 10148 Torino 35020 Padova
69634 Vénissieux – Cedex
Tel.: +33 (0)4 78 78 53 65 Tel.: +39 02 92 365 1 Tel.: +39 011 224 88 11 Tel.: +39 049 8 70 13 70
Fax: +33 (0)4 78 78 53 62 +39 02 92 365 326 Fax: +39 011 224 88 30 Fax: +39 049 8 70 13 77
Fax: +39 02 92 365 500
+39 02 92 365 516378
Italy - Italien Italy - Italien Netherlands - Niederlande/Holland Netherlands – Niederlande/Holland
Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth Services B.V. Bosch Rexroth B.V.
Via Mascia, 1 Via Isonzo, 61 Technical Services Kruisbroeksestraat 1
80053 Castellamare di Stabia NA 40033 Casalecchio di Reno (Bo) Kruisbroeksestraat 1 (P.O. Box 32)
(P.O. Box 32) 5281 RV Boxtel
Tel.: +39 081 8 71 57 00 Tel.: +39 051 29 86 430 5281 RV Boxtel
Fax: +39 081 8 71 68 85 Fax: +39 051 29 86 490 Tel.: +31 (0) 411 65 16 40 Tel.: +31 (0) 411 65 19 51
+31 (0) 411 65 17 27 Fax: +31 (0) 411 65 14 83
Fax: +31 (0) 411 67 78 14 www.boschrexroth.nl
+31 (0) 411 68 28 60
[email protected]
Norway - Norwegen Spain - Spanien Spain – Spanien Sweden - Schweden

Bosch Rexroth AS Bosch Rexroth S.A. Goimendi S.A. Bosch Rexroth AB
Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls
Berghagan 1 or: Box 3007 Centro Industrial Santiga Parque Empresarial Zuatzu - Varuvägen 7
1405 Ski-Langhus 1402 Ski Obradors s/n C/ Francisco Grandmontagne no.2 (Service: Konsumentvägen 4, Älfsjö)
08130 Santa Perpetua de Mogoda 20018 San Sebastian 125 81 Stockholm
Barcelona
Tel.: +47 (0)64 86 41 00 Tel.: +34 9 37 47 94 00 Tel.: +34 9 43 31 84 21 Tel.: +46 (0)8 727 92 00
Fax: +47 (0)64 86 90 62 Fax: +34 9 37 47 94 01 - service: +34 9 43 31 84 56 Fax: +46 (0)8 647 32 77
[email protected] Fax: +34 9 43 31 84 27
- service: +34 9 43 31 84 60
[email protected]
Sweden - Schweden Switzerland West - Schweiz West Switzerland East - Schweiz Ost
Bosch Rexroth AB Bosch Rexroth Suisse SA Bosch Rexroth Schweiz AG
Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls
Ekvändan 7 Rue du village 1 Hemrietstrasse 2
254 67 Helsingborg 1020 Renens 8863 Buttikon
Tel.: +46 (0) 42 38 88 -50 Tel.: +41 (0)21 632 84 20 Tel. +41 (0) 55 46 46 111
Fax: +46 (0) 42 38 88 -74 Fax: +41 (0)21 632 84 21 Fax +41 (0) 55 46 46 222
Europa (Ost) - Europe (East)

vom Ausland: (0) nach Landeskennziffer weglassen
from abroad: don’t dial (0) after country code
Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen
Bosch -Rexroth, spol.s.r.o. DEL a.s. Bosch Rexroth Kft. Bosch Rexroth Sp.zo.o.
Hviezdoslavova 5 Strojírenská 38 Angol utca 34 ul. Staszica 1
627 00 Brno 591 01 Zdar nad Sázavou 1149 Budapest 05-800 Pruszków
Tel.: +420 (0)5 48 126 358 Tel.: +420 566 64 3144 Tel.: +36 (1) 422 3200 Tel.: +48 22 738 18 00
Fax: +420 (0)5 48 126 112 Fax: +420 566 62 1657 Fax: +36 (1) 422 3201 – service: +48 22 738 18 46
Fax: +48 22 758 87 35
– service: +48 22 738 18 42
Poland – Polen Romania - Rumänien Romania - Rumänien Russia - Russland

Bosch Rexroth Sp.zo.o. East Electric S.R.L. Bosch Rexroth Sp.zo.o. Bosch Rexroth OOO
Biuro Poznan Bdul Basarabia no.250, sector 3 Str. Drobety nr. 4-10, app. 14 Wjatskaja ul. 27/15
ul. Dabrowskiego 81/85 73429 Bucuresti 70258 Bucuresti, Sector 2 127015 Moskau
60-529 Poznan Tel./Fax:: +40 (0)21 255 35 07 Tel.: +40 (0)1 210 48 25 Tel.: +7-095-785 74 78
Tel.: +48 061 847 64 62 /-63 +40 (0)21 255 77 13 +40 (0)1 210 29 50 +7-095 785 74 79
Fax: +48 061 847 64 02 Fax: +40 (0)21 725 61 21 Fax: +40 (0)1 210 29 52 Fax: +7 095 785 74 77
[email protected] [email protected]
Russia - Russland Turkey - Türkei Slowenia - Slowenien

ELMIS Bosch Rexroth Otomasyon DOMEL
10, Internationalnaya San & Tic. A..S. Otoki 21
246640 Gomel, Belarus Fevzi Cakmak Cad No. 3 64 228 Zelezniki
Tel.: +375/ 232 53 42 70 34295 Sefaköy - Istanbul Tel.: +386 5 5117 152
+375/ 232 53 21 69 Tel.: +90 212 413 34-00 Fax: +386 5 5117 225
Fax: +375/ 232 53 37 69 Fax: +90 212 413 34-17 [email protected]
[email protected]
Africa, Asia, Australia – incl. Pacific Rim
Australia - Australien Australia - Australien China China

AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Shanghai Bosch Rexroth Shanghai Bosch Rexroth
Machinery Services Pty. Ltd. No. 7, Endeavour Way Hydraulics & Automation Ltd. Hydraulics & Automation Ltd.
28 Westside Drive Braeside Victoria, 31 95 Waigaoqiao, Free Trade Zone 4/f, Marine Tower
Laverton North Vic 3026 Melbourne No.122, Fu Te Dong Yi Road No.1, Pudong Avenue
Melbourne Shanghai 200131 - P.R.China Shanghai 200120 - P.R.China
Tel.: +61 3 93 59 0228 Tel.: +61 3 95 80 39 33 Tel.: +86 21 58 66 30 30 Tel: +86 21 68 86 15 88
Fax: +61 3 93 59 0286 Fax: +61 3 95 80 17 33 Fax: +86 21 58 66 55 23 Fax: +86 21 58 40 65 77
Hotline: +61 4 19 369 195 [email protected] [email protected]
[email protected] [email protected]
China China China China

Bosch Rexroth China Ltd. Bosch Rexroth China Ltd. Bosch Rexroth (China) Ltd. Melchers GmbH
15/F China World Trade Center Guangzhou Repres. Office A-5F., 123 Lian Shan Street BRC-SE, Tightening & Press-fit
1, Jianguomenwai Avenue Room 1014-1016, Metro Plaza, Sha He Kou District 13 Floor Est Ocean Centre
Beijing 100004, P.R.China Tian He District, 183 Tian He Bei Rd Dalian 116 023, P.R.China No.588 Yanan Rd. East
Guangzhou 510075, P.R.China 65 Yanan Rd. West
Tel.: +86 10 65 05 03 80 Shanghai 200001
Fax: +86 10 65 05 03 79 Tel.: +86 20 8755-0030 Tel.: +86 411 46 78 930 Tel.: +86 21 6352 8848
+86 20 8755-0011 Fax: +86 411 46 78 932 Fax: +86 21 6351 3138
Fax: +86 20 8755-2387
Hongkong India - Indien India - Indien India - Indien

Bosch Rexroth (China) Ltd. Bosch Rexroth (India) Ltd. Bosch Rexroth (India) Ltd. Bosch Rexroth (India) Ltd.
6th Floor, Electric Drives & Controls Electric Drives & Controls S-10, Green Park Extension
Yeung Yiu Chung No.6 Ind Bldg. Plot. No.96, Phase III Advance House, II Floor New Delhi – 110016
19 Cheung Shun Street Peenya Industrial Area Ark Industrial Compound
Cheung Sha Wan, Bangalore – 560058 Narol Naka, Makwana Road
Kowloon, Hongkong Andheri (East), Mumbai - 400 059
Tel.: +852 22 62 51 00 Tel.: +91 80 51 17 0-211...-218 Tel.: +91 22 28 56 32 90 Tel.: +91 11 26 56 65 25
Fax: +852 27 41 33 44 Fax: +91 80 83 94 345 +91 22 28 56 33 18 +91 11 26 56 65 27
[email protected] +91 80 83 97 374 Fax: +91 22 28 56 32 93 Fax: +91 11 26 56 68 87
[email protected] [email protected] [email protected]
Indonesia - Indonesien Japan Japan Korea

PT. Bosch Rexroth Bosch Rexroth Automation Corp. Bosch Rexroth Automation Corp. Bosch Rexroth-Korea Ltd.
Building # 202, Cilandak Service Center Japan Electric Drives & Controls Electric Drives and Controls
Commercial Estate Yutakagaoka 1810, Meito-ku, 2F, I.R. Building Bongwoo Bldg. 7FL, 31-7, 1Ga
Jl. Cilandak KKO, Jakarta 12560 NAGOYA 465-0035, Japan Nakamachidai 4-26-44, Tsuzuki-ku Jangchoong-dong, Jung-gu
YOKOHAMA 224-0041, Japan Seoul, 100-391
Tel.: +62 21 7891169 (5 lines) Tel.: +81 52 777 88 41 Tel.: +81 45 942 72 10 Tel.: +82 234 061 813
Fax: +62 21 7891170 - 71 +81 52 777 88 53 Fax: +81 45 942 03 41 Fax: +82 222 641 295
[email protected] +81 52 777 88 79
Fax: +81 52 777 89 01
Korea Malaysia Singapore - Singapur South Africa - Südafrika

Bosch Rexroth-Korea Ltd. Bosch Rexroth Sdn.Bhd. Bosch Rexroth Pte Ltd TECTRA Automation (Pty) Ltd.
1515-14 Dadae-Dong, Saha-Gu 11, Jalan U8/82, Seksyen U8 15D Tuas Road 71 Watt Street, Meadowdale
Electric Drives & Controls 40150 Shah Alam Singapore 638520 Edenvale 1609
Pusan Metropolitan City, 604-050 Selangor, Malaysia
Tel.: +60 3 78 44 80 00 Tel.: +65 68 61 87 33 Tel.: +27 11 971 94 00
Tel.: +82 51 26 00 741 Fax: +60 3 78 45 48 00 Fax: +65 68 61 18 25 Fax: +27 11 971 94 40
Fax: +82 51 26 00 747 [email protected] sanjay.nemade Hotline: +27 82 903 29 23
[email protected] [email protected] @boschrexroth.com.sg [email protected]
Taiwan Thailand
Bosch Rexroth Co., Ltd. NC Advance Technology Co. Ltd.
Taichung Branch 59/76 Moo 9
1F., No. 29, Fu-Ann 5th Street, Ramintra road 34
Xi-Tun Area, Taichung City Tharang, Bangkhen,
Taiwan, R.O.C. Bangkok 10230
Tel : +886 - 4 -23580400 Tel.: +66 2 943 70 62
Fax: +886 - 4 -23580402 +66 2 943 71 21
[email protected]. Fax: +66 2 509 23 62
tw [email protected]
[email protected]
[email protected]
Nordamerika – North America

USA USA Central Region - Mitte USA Southeast Region - Südwest USA SERVICE-HOTLINE
Headquarters - Hauptniederlassung
Bosch Rexroth Corporation Bosch Rexroth Corporation
Bosch Rexroth Corporation Electric Drives & Controls Electric Drives & Controls
- 7 days x 24hrs -
Electric Drives & Controls Central Region Technical Center Southeastern Technical Center
5150 Prairie Stone Parkway 1701 Harmon Road 3625 Swiftwater Park Drive
Hoffman Estates, IL 60192-3707 Auburn Hills, MI 48326 Suwanee, Georgia 30124
+1-800-REX-ROTH
Tel.: +1 847 6 45 36 00 Tel.: +1 248 3 93 33 30 Tel.: +1 770 9 32 32 00 +1-800-739-7684
Fax: +1 847 6 45 62 01 Fax: +1 248 3 93 29 06 Fax: +1 770 9 32 19 03
[email protected]
[email protected]
USA East Region – Ost USA Northeast Region – Nordost USA West Region – West
Bosch Rexroth Corporation Bosch Rexroth Corporation Bosch Rexroth Corporation

Electric Drives & Controls Electric Drives & Controls 7901 Stoneridge Drive, Suite 220
Charlotte Regional Sales Office Northeastern Technical Center Pleasant Hill, California 94588
14001 South Lakes Drive 99 Rainbow Road
Charlotte, North Carolina 28273 East Granby, Connecticut 06026
Tel.: +1 704 5 83 97 62 Tel.: +1 860 8 44 83 77 Tel.: +1 925 227 10 84
+1 704 5 83 14 86 Fax: +1 860 8 44 85 95 Fax: +1 925 227 10 81
Canada East - Kanada Ost Canada West - Kanada West Mexico Mexico
Bosch Rexroth Canada Corporation Bosch Rexroth Canada Corporation Bosch Rexroth Mexico S.A. de C.V. Bosch Rexroth S.A. de C.V.
Burlington Division 5345 Goring St. Calle Neptuno 72 Calle Argentina No 3913
3426 Mainway Drive Burnaby, British Columbia Unidad Ind. Vallejo Fracc. las Torres
Burlington, Ontario Canada V7J 1R1 07700 Mexico, D.F. 64930 Monterrey, N.L.
Canada L7M 1A8
Tel.: +1 905 335 55 11 Tel. +1 604 205-5777 Tel.: +52 55 57 54 17 11 Tel.: +52 81 83 65 22 53
Fax: +1 905 335-41 84 Fax +1 604 205-6944 Fax: +52 55 57 54 50 73 +52 81 83 65 89 11
[email protected] [email protected] [email protected] +52 81 83 49 80 91
x
Fax: +52 81 83 65 52 80
[email protected]
Südamerika – South America

Argentina - Argentinien Argentina - Argentinien Brazil - Brasilien Brazil - Brasilien
Bosch Rexroth S.A.I.C. NAKASE Bosch Rexroth Ltda. Bosch Rexroth Ltda.
"The Drive & Control Company" Servicio Tecnico CNC Av. Tégula, 888 R. Dr.Humberto Pinheiro Vieira, 100
Acassusso 48 41/47 Calle 49, No. 5764/66 Ponte Alta, Atibaia SP Distrito Industrial [Caixa Postal 1273]
1605 Munro B1653AOX Villa Balester CEP 12942-440 89220-390 Joinville - SC
Provincia de Buenos Aires Provincia de Buenos Aires
Tel.: +54 11 4756 01 40 Tel.: +54 11 4768 36 43 Tel.: +55 11 4414 56 92 Tel./Fax: +55 47 473 58 33
Fax: +54 11 4756 01 36 Fax: +54 11 4768 24 13 +55 11 4414 56 84 Mobil: +55 47 9974 6645
[email protected] [email protected] Fax sales: +55 11 4414 57 07 [email protected]
[email protected] Fax serv.: +55 11 4414 56 86
[email protected] (Service) [email protected]
Columbia - Kolumbien
Reflutec de Colombia Ltda.

Calle 37 No. 22-31
Santafé de Bogotá, D.C.
Colombia
Tel.: +57 1 368 82 67
+57 1 368 02 59
Fax: +57 1 268 97 37
[email protected]
[email protected]
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 93 52-40-0
Fax +49 93 52-40-48 85
www.boschrexroth.com
Printed in Germany
R911280641 DOK-POWER*-HVE+HVR**G2-AW07-EN-P

Rexroth Diax 04 Hve and HVR 2nd Generation Power Supply Units

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Rexroth Diax 04 Hve and HVR 2nd Generation Power Supply Units

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Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

2nd Generation Power Supply Units

Document Typecode DOK-POWER*-HVE+HVR**G2-AW06-EN-P

Internal File Reference Document Number, 120-1900-B301-07/EN

Purpose of Documentation The purpose of this documentation is to ....

Record of Revisions Description Release Notes

Copyright  Bosch Rexroth AG, 2003

Published by Bosch Rexroth AG

Note This document has been printed on chlorine-free bleached paper.

2 Important directions for use 2-1

3 Safety Instructions for Electric Drives and Controls 3-1

4 Technical data 4-1

5 Determination of appropriate power supply units 5-1

6 Additional modules and components 6-1

HVE02.2and HVE03.2 ........................................................................................................... 7-15

8 Electrical connection 8-1

9 Control mains contactor 9-1

9.3 Control via NC controller ............................................................................................................... 9-7

10 System control 10-1

12 Delivery Status 12-1

13 Identifying the Components 13-1

15 Service & Support 15-1

1.1 AC drive system

1.2 Principal working mode of the power supply units

Fig. 1-2: Structure of the HVE power supply unit

Fig. 1-3: Structure of the HVR power supply unit

1.3 Areas of application

1.4 Overview of the unit features

2 Important directions for use

2.1 Appropriate use

Note: Bosch Rexroth AG, as manufacturer, is not liable for any

Areas of Use and Application

Every drive controller has to be programmed before starting it up, making

2.2 Inappropriate Use

3 Safety Instructions for Electric Drives and Controls

Improper use of this equipment, failure to follow

Death or severe bodily harm will occur.

Death or severe bodily harm may occur.

Bodily harm or material damage may occur.

3.3 Hazards by Improper Use

High voltage and high discharge current!

Dangerous movements! Danger to life, severe

High electrical voltage due to wrong

Health hazard for persons with heart

Surface of machine housing could be extremely

Risk of injury due to improper handling! Bodily

Risk of injury due to incorrect handling of

3.4 General Information

compliance with the limiting values as prescribed in the national

3.5 Protection Against Contact with Electrical Parts

Note: This section refers to equipment and drive components with

High electrical voltage! Danger to life, severe

To be observed with electrical drive and filter components:

High electrical voltage on the housing!

3.6 Protection Against Electric Shock by Protective Low

High electrical voltage due to wrong

3.7 Protection Against Dangerous Movements

Dangerous movements! Danger to life, risk of