Bosch Rexroth HVR03.2-W045N 45 kW Power Supply

Description

Key Technical Specifications

The published Bosch Rexroth technical documentation gives the 45 kW continuous rating, 105 kW three-second rating, 135 kW 0.3-second peak, 45 kW continuous regenerative power, 90 kW peak regenerative power, and 80 kWs maximum regenerated energy.

For the mains connection, Bosch Rexroth specifies the HVR03.2-W045N with the KD28-C commutation choke in the documented configuration.

Product Introduction

The Bosch Rexroth HVR03.2-W045N is a second-generation DIAX 04 HVR regenerative power supply for multi-axis drive systems. It converts three-phase 380–480 VAC input into a regulated 750 VDC drive bus and supplies DC-bus power to compatible drive modules.

Unlike an HVE supply, the HVR architecture is designed for regenerative operation. During machine deceleration, the unit can feed regenerative energy back toward the mains within the specified power and energy limits. The 45 kW continuous rating makes this model suitable for higher-power DIAX 04 motion systems.

HVR03.2-W045N

Installation & Configuration Guide

Stage 1 — Pre-Installation Preparation

Estimated time: 30–45 minutes

1. Record the complete nameplate designation: HVR03.2-W045N.
2. Record the unit serial number and hardware identification.
3. Confirm the incoming three-phase supply is within 380–480 VAC ±10%.
4. Verify the associated DIAX 04 drive modules are compatible with the regulated 750 VDC bus.
5. Check the required mains components, including the specified commutation choke.
6. Inspect cabinet ventilation and blower airflow paths.
7. Back up machine parameters and document the existing DC-bus configuration.

⚠️ The DC bus can remain at a hazardous voltage after mains power is removed. Follow the Rexroth discharge and electrical-safety procedure before touching DC-bus terminals.

Stage 2 — Removing the Existing Power Supply

Estimated time: 30–45 minutes

1. Stop the machine using the normal controlled shutdown procedure.
2. Apply lockout/tagout to the AC supply.
3. Verify absence of AC voltage with an appropriately rated meter.
4. Allow the DC bus to discharge according to the manufacturer’s procedure.
5. Measure the DC bus before disconnecting conductors.
6. Photograph the AC, DC-bus, control, and protective-earth wiring.
7. Label each conductor before removal.
8. Disconnect the power and control connections.
9. Support the approximately 31 kg unit during mechanical removal.

Stage 3 — Installing the HVR03.2-W045N

Estimated time: 45–60 minutes

1. Inspect the replacement unit for shipping damage.
2. Confirm the nameplate again before installation.
3. Mount the power supply in the original cabinet position.
4. Ensure adequate airflow around the intake and exhaust areas.
5. Connect protective earth first according to the approved wiring diagram.
6. Connect the three-phase AC input.
7. Connect the DC-bus conductors with correct polarity.
8. Reconnect control and auxiliary wiring.
9. Verify all terminal connections and tightening torques against the applicable Rexroth manual.
10. Confirm the required mains-side components are installed.

⚠️ Do not substitute an HVR for an HVE merely because the physical dimensions or power rating appear similar. HVR units use a regulated DC bus and regenerative energy path.

Stage 4 — Power-On & Testing

Estimated time: 45–90 minutes

1. Perform a final wiring and insulation inspection.
2. Energize the system under the approved commissioning procedure.
3. Verify correct mains input.
4. Check the DC-bus voltage and confirm regulation near the specified 750 VDC level.
5. Confirm communication/status signals from the power supply.
6. Start the drive system without mechanical load where the machine procedure permits.
7. Check the connected drive modules for fault conditions.
8. Perform controlled acceleration and deceleration.
9. Monitor the DC bus during regenerative operation.
10. Verify that no overvoltage, thermal, or regenerative-energy fault occurs.

⚠️ The 135 kW rating is a 0.3-second peak DC-bus value, not a continuous output rating. Do not size the system using the peak value.

FAQ

1. What is the Bosch Rexroth HVR03.2-W045N?

It is a 45 kW-class regulated regenerative power supply in the second-generation Bosch Rexroth Indramat DIAX 04 HVR family. It provides a regulated DC bus for compatible drive modules and handles regenerative energy.

2. What input voltage does the .2- require?

The documented input is 3 × AC 380–480 V ±10% at 50–60 Hz ±2 Hz.

3. What is the DC-bus voltage?

The .2- provides a regulated 750 VDC bus. Connected drive modules must be rated for the applicable DC-bus voltage.

4. Is the .2- regenerative?

Yes. The HVR architecture supports regenerative operation. Bosch Rexroth documentation specifies 45 kW continuous regenerative power, 90 kW peak regenerative power, and 80 kWs maximum regenerated energy for this model.

5. What is the difference between .2- and an HVE power supply?

The HVR uses a regulated DC bus and regenerative mains feedback architecture. HVE and HVR therefore should not be treated as interchangeable based only on nominal power or physical size. The complete drive-system design must be checked before substitution.

6. What is the continuous power rating?

The documented continuous DC-bus power is 45 kW at the applicable operating conditions. The unit can provide 105 kW for 3 seconds and 135 kW for 0.3 seconds under the specified short-time operating conditions.

7. What should I verify before purchasing a replacement?

Verify the complete .2- nameplate, hardware/revision information, mains voltage, connected DIAX 04 drive modules, DC-bus configuration, cooling arrangement, and associated mains components. Also confirm whether the offered unit is New Original, New Surplus, Refurbished/Tested, or Used Tested; these conditions should not be treated as equivalent.