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Key Technical Specifications
| Parameter | Value |
|---|---|
| Manufacturer | Bosch Rexroth Indramat |
| Product Family | HVE Power Supply Units |
| Model | HVE04.2-W075N |
| Product Type | Unregulated DC bus power supply |
| Series Application | DIAX04 drive and control systems |
| AC Input | 3 × 380–480 V AC, ±10% |
| Input Frequency | 50–60 Hz |
| DC Bus Voltage | 532–670 V DC, ±10% |
| Nominal Power | 75 kW |
| Continuous DC Bus Power | Approximately 90 kW under specified conditions; verify mains voltage and choke configuration |
| Maximum Regenerated Power | Up to 100 kW; verify duration and installation conditions |
| AC Input Current | Approximately 120 A; verify voltage-dependent value |
| DC Output Current | Approximately 140 A; verify exact operating condition |
| Regeneration Absorption | Internal bleeder resistor |
| Connected Motor Power | Up to approximately 60 kW continuous mechanical motor power |
| Cooling | Internal air cooling with built-in blower |
| DC Bus Regulation | Unregulated |
| Control Voltage | Supplies power and control voltage for compatible Rexroth drive systems |
| Maximum Fuse Rating | Approximately 160 A |
| Protection Rating | IP10 |
| Width | Approximately 250 mm |
| Weight | Approximately 20 kg |
| Relative Humidity | Up to 95%; verify installation limits |
| Compatible Accessories | GLD DC bus choke where required |
| Compatible Drive Families | HDD and HDS drive/control systems |
| Condition | Must be stated as New Original, New Surplus, or Refurbished (tested) |
Bosch Rexroth HVE power supplies connect to three-phase 380–480 V AC mains and provide an unregulated DC bus for compatible HDD and HDS drive systems. The HVE04.2-W075N is the 75 kW-class version.
Published data identifies a 532–670 V DC bus, internal blower cooling, internal regeneration absorption, approximately 90 kW continuous DC-bus power under stated conditions, and up to 100 kW regenerative power. Actual usable power depends on mains voltage, duty cycle, cooling, and whether a GLD DC-bus choke is installed.
Product Introduction
Bosch Rexroth HVE04.2-W075N is a 75 kW HVE power supply unit for DIAX04 HDD and HDS servo-drive systems. It converts three-phase 380–480 V AC into an unregulated 532–670 V DC bus and supplies the shared power and control-voltage architecture for multiple drive modules.
The unit includes internal air cooling and regenerative-energy absorption through a bleeder resistor. Verify the incoming protection, DC-bus capacity, regeneration duty, GLD choke requirement, control-voltage wiring, and connected motor power before commissioning.
HVE04.2-W075N
HVE04.2-W075N
Troubleshooting Quick Reference
| Symptom | Possible Cause | Relevance to This Part | Quick Check Method | Recommendation |
|---|---|---|---|---|
| No DC bus voltage | Missing AC phase, input fuse failure, contactor fault, or supply failure | ✅ High | Measure all three input phases and check the approved DC-bus test points | Diagnose mains and precharge circuitry before replacing the HVE |
| DC bus is too low | Low incoming voltage, phase loss, excessive load, or supply fault | ✅ High | Measure phase-to-phase input and DC bus under load | Correct the incoming supply and check connected drive demand |
| DC bus is too high | Regeneration overload, bleeder fault, or incorrect mains configuration | ✅ High | Record the DC-bus voltage during deceleration and compare it with system limits | Check braking duty, resistor circuit, and supply configuration |
| Supply trips when axes decelerate | Regenerated energy exceeds absorption capability | ✅ High | Trend DC-bus voltage during the fastest deceleration cycle | Reduce deceleration demand or engineer the required regenerative hardware |
| Input fuses open repeatedly | Short circuit, phase imbalance, failed rectifier, or excessive inrush | ✅ High | Isolate downstream drives and test the supply input and DC bus according to OEM limits | Find the short or overload before installing another supply |
| Multiple drives lose power | Shared DC bus fault, HVE shutdown, or control-voltage loss | ✅ High | Check HVE diagnostics, bus voltage, control voltage, and supply-unit status | Diagnose the common supply path before replacing individual drives |
| Blower does not run | Fan failure, control-power problem, or blocked airflow | ✅ High | Inspect the blower and measure its supply during operation | Stop operation if cooling is unavailable; inspect for thermal damage |
| Unit overheats | Blocked air path, high ambient temperature, overloaded bus, or fan failure | ✅ High | Measure cabinet temperature and inspect inlet/outlet clearance | Restore airflow and review the bus load profile |
| Drive modules report undervoltage | HVE output fault, loose bus connection, or excessive bus impedance | ✅ High | Measure DC voltage at the HVE and at the farthest drive module | Check bus bars, cabling, terminals, and supply capacity |
| Control voltage is missing | Auxiliary supply fault, connector problem, or internal supply failure | ✅ High | Measure control voltage at the designated terminals using the wiring diagram | Repair the control-voltage circuit before replacing the HVE |
| Regenerative resistor overheats | Excessive braking energy, failed resistor, or incorrect duty cycle | ✅ High | Inspect resistor temperature and measure resistance only when isolated | Verify braking calculations and resistor rating before restart |
| HVE fails after replacement | Wrong HVE variant, incorrect wiring, missing choke, or parameter/system mismatch | ✅ High | Compare full model, mains rating, bus arrangement, and accessory configuration | Match the complete system design; do not substitute by kW alone |
| Bus remains energized after shutdown | Normal capacitor discharge delay or discharge-circuit fault | ✅ High | Follow the Rexroth discharge procedure and verify voltage with a properly rated meter | Do not touch bus terminals until measured voltage is safe |
Critical warning: This power supply creates a hazardous high-voltage DC bus and can store energy after mains isolation. Use lockout/tagout, wait the manufacturer-specified discharge time, and verify the bus with a properly rated meter before opening the cabinet. If the fault remains, provide input measurements, DC-bus trend data, HVE diagnostic indications, connected-drive list, motor power, and photographs of the supply and bus wiring.
Frequently Asked Questions (FAQ)
What is Bosch Rexroth HVE04.2-W075N?
It is a 75 kW Bosch Rexroth Indramat HVE power supply unit for compatible DIAX04 HDD and HDS drive systems. It generates an unregulated high-voltage DC bus from three-phase 380–480 V AC input.
Is the HVE04.2-W075N a regulated DC supply?
No. HVE units operate with an unregulated DC bus. The bus voltage varies with the incoming mains voltage and operating condition, so connected drive modules must be compatible with the specified 532–670 V DC range.
Does it support regenerative braking?
Yes. The HVE system absorbs regenerated energy through a bleeder resistor. Published data lists up to 100 kW regenerative power, but the allowable duration and duty cycle depend on the exact installation and braking profile.
Is a GLD DC-bus choke required?
Not for every installation, but Bosch Rexroth documentation identifies GLD chokes as compatible accessories used to adjust the power system to application requirements. Confirm the required choke from the system design, supply manual, motor load, and mains conditions.
Which drive systems use this power supply?
The HVE supply family provides power and control voltage for compatible Rexroth Indramat HDD and HDS drive/control systems. Verify the exact drive modules, bus voltage, control wiring, and system generation before substitution.
Can I replace an HVE04.2-W075N with another HVE model?
Not automatically. Compare nominal power, input voltage, DC-bus range, regeneration capacity, fuse rating, control-voltage connections, cooling, dimensions, and GLD choke requirements. A lower-power HVE unit may energize the bus but fail under the installed axis load.
What should I check before ordering?
Confirm the complete HVE model, mains voltage, input protection, DC-bus current, connected motor power, braking duty, internal or external regeneration hardware, blower arrangement, control-voltage wiring, dimensions, and condition. Record the original nameplate and cabinet wiring before removal.
Is the unit new or refurbished?
The model number does not establish condition. State the actual status as New Original, New Surplus, or Refurbished (tested). For refurbished stock, document three-phase input testing, DC-bus regulation behavior, control-voltage output, blower operation, regenerative-braking test, protection trips, insulation checks, and loaded run time.
