Bosch Rexroth Diax 04 HVE User manual

Electric Drives
and Controls Hydraulics
Linear Motion and
Assembly Technologies Pneumatics Service
Rexroth Diax 04
HVE and HVR
2nd Generation Power Supply Units
R911320339
Edition 01
Instruction Manual

About this Documentation Reroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
Rexroth Diax 04
HVE and HVR
2nd Generation Power Supply Units
Instruction Manual
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
120-0800-B344-01/EN
This documentation provides information on the installation and operation
of the described products, by persons trained and qualified to work with
electrical installations.
Description Release
Date
Notes
Instruction Manual 03.2007 1st edition
 2007 Bosch Rexroth AG
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).
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.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.com/
Dept. BRC/EDY4 (NN)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revisions
Copyright
Validity
Published by
Note

Rexroth Diax 04 HVE/HVR Contents I
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
Contents
1 Important Notes 1-1
1.1 Safety Instructions ........................................................................................................................ 1-1
General Information................................................................................................................. 1-1
Contact with Electrical Parts.................................................................................................... 1-2
Handling and Assembly...........................................................................................................1-2
Dangerous Movements ........................................................................................................... 1-2
Magnetic and Electromagnetic Fields ..................................................................................... 1-4
Hot Parts.................................................................................................................................. 1-4
1.2 Appropriate Use............................................................................................................................ 1-4
2 Identification 2-1
2.1 Type Code .................................................................................................................................... 2-1
HVE ......................................................................................................................................... 2-1
HVR ......................................................................................................................................... 2-2
Type Plate................................................................................................................................ 2-2
2.2 Scope of Delivery.......................................................................................................................... 2-2
3 Ratings and Dimensions 3-1
3.1 HVE............................................................................................................................................... 3-1
3.2 HVR .............................................................................................................................................. 3-2
4 Reference Documentation 4-1
4.1 Overview ....................................................................................................................................... 4-1
5 Instructions for Use 5-1
5.1 Overcurrent Protection.................................................................................................................. 5-1
5.2 Connections .................................................................................................................................. 5-1
Wiring Diagram (Supply Unit HVE).......................................................................................... 5-1
Wiring Diagram (Supply Unit HVR) ......................................................................................... 5-2
Connection Diagram ................................................................................................................ 5-3
X0, Additional component bus................................................................................................. 5-5
X1, Connection for integrated bus connections from neighboring device............................... 5-6
X2, Service interface ............................................................................................................... 5-6
X3, Emergency stop circuit......................................................................................................5-6
X4, Control voltages ................................................................................................................ 5-8
X5, Mains connection .............................................................................................................. 5-9
X6, Acknowledging the power supply unit mains contactor .................................................. 5-11
X7, Ready-to-operate and other messages .......................................................................... 5-12

II Contents Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
X8, Control voltage supply..................................................................................................... 5-14
X11, DC bus connection........................................................................................................ 5-16
X12, Ground connection........................................................................................................ 5-17
X13, Optional choke connection (only HVE) ......................................................................... 5-17
5.3 Installation................................................................................................................................... 5-19
General Information on How to Install the Drive Controller................................................... 5-19
Sizing of Enclosure and Control Cabinet............................................................................... 5-20
6 Appendix 6-1
6.1 Discharging of DC Bus Capacitors ............................................................................................... 6-1
6.2 Discharging Device....................................................................................................................... 6-2
7 Index 7-1

Rexroth Diax 04 HVE/HVR Important Notes 1-1
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
1 Important Notes
1.1 Safety Instructions
General Information
•Do not attempt to install or commission this device without first reading
all documentations provided with the product. Read and understand
these safety instructions and all user documentation prior to working
with the device. If you do not have the user documentation for the
device, contact your responsible Bosch Rexroth sales representative.
Ask for these documents to be sent immediately to the person or
persons responsible for the safe operation of the device.
•If these documentations contain some information you do not
understand, it is absolutely necessary that you ask Bosch Rexroth for
explanation before you start working on or with the devices.
•Only persons who are trained and qualified for the use and operation
of the device may work on this device 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
this documentation.
•Only trained, instructed and qualified persons are allowed to switch
electrical circuits and devices on and off in accordance with technical
safety regulations, to ground them and to mark them according to the
requirements of safe work practices. These persons must have
adequate safety equipment and be trained in first aid.
•Technical data, connections and operational conditions are specified in
the reference documentations for the product and must be followed at
all times.
•If the products take 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.
•Only use spare parts and accessories approved by Bosch Rexroth.
•Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
•If the device is resold, rented and/or passed on to others in any other
form, these safety instructions must be delivered with the device in the
official language of the user's country.
•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 device. Observe the data contained
in the corresponding product documentations.
WARNING
Improper use of these devices, failure to follow the safety instructions in this
document or tampering with the product, including disabling of safety devices, may
result in material damage, bodily harm, electric shock or even death!
⇒ Observe the following safety instructions!

1-2 Important Notes Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
Contact with Electrical Parts
DANGER
High electrical voltage! Danger to life, electric shock and severe bodily injury!
•Follow general construction and safety regulations when working on power installations.
•Before switching on the device, the equipment grounding conductor must have been
non-detachably connected to all electrical equipment and motors in accordance with the
connection diagram.
The equipment grounding conductor of the electrical equipment and the units must be
non-detachably and permanently connected to the power supply unit at all times. The
leakage current is greater than 3.5 mA.
Over the total length, use copper wire of a cross section of a minimum of 10 mm2for
this equipment grounding connection!
•Before working with electrical parts with voltage potentials higher than 50 V, the device
must be disconnected from the mains voltage or power supply unit. Provide a safeguard
to prevent reconnection.
•Wait 30 minutes after switching off power to allow capacitors to discharge before
beginning to work. Measure the electric 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
device on. Before switching the equipment on, cover and safeguard live parts safely to
prevent contact with those parts.
•A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives!
Indirect contact must be prevented by other means, for example, by an overcurrent
protective device according to the relevant standards.
Handling and Assembly
CAUTION
Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting!
•Observe the general construction and safety regulations on handling and assembly.
•Use suitable devices for assembly and transport.
•Avoid jamming and bruising by appropriate measures.
•Always use suitable tools. Use special tools if specified.
•Use lifting equipment and tools in the correct manner.
•If necessary, use suitable protective equipment (for example safety goggles, safety shoes,
safety gloves).
•Do not stand under hanging loads.
•Immediately clean up any spilled liquids because of the danger of skidding.
Dangerous Movements
Dangerous movements can be caused by faulty control of connected
motors. Some common examples are:
•improper or wrong wiring of cable connections
•incorrect operation of the equipment components
•wrong input of parameters before commissioning
•malfunction of sensors, encoders and monitoring devices
•defective components
•software or firmware errors

Rexroth Diax 04 HVE/HVR Important Notes 1-3
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
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 harm 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.
DANGER
Dangerous movements! Danger to life, risk of injury, severe bodily harm or material
damage!
•For the above reasons, ensure personal safety by means of qualified and tested higher-
level monitoring devices or measures integrated in the installation.
They have to be provided for by the user according to the specific conditions within the
installation and a hazard and fault analysis. The safety regulations applicable for the
installation have to be taken into consideration. Unintended machine motion or other
malfunction is possible if safety devices are disabled, bypassed or not activated.
To avoid accidents, bodily harm and/or material damage:
•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.
•Mount the emergency stop switch in the immediate reach of the operator. Verify that the
emergency stop works before startup. Don’t operate the device if the emergency stop is
not working.
•Isolate the drive power connection by means of an emergency stop circuit or use a safety
related starting lockout to prevent unintentional start.
•Make sure that the drives are brought to a safe standstill before accessing or entering the
danger zone.
•Additionally 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 or
–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 devices 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.

1-4 Important Notes Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
Magnetic and Electromagnetic Fields
WARNING
Health hazard for persons with heart pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
•Persons with heart pacemakers and metal implants are not permitted to enter following
areas:
–Areas in which electrical equipment and parts are mounted, being operated or
commissioned.
–Areas in which parts of motors with permanent magnets are being stored, repaired or
mounted.
•If it is necessary for somebody with a pacemaker to enter such an area, a doctor must
be consulted prior to doing so. The interference immunity of present or future implanted
heart pacemakers differs greatly, so that no general rules can be given.
•Those with metal implants or metal pieces, as well as with hearing aids must consult a
doctor before they enter the areas described above.
Otherwise health hazards may occur.
Hot Parts
CAUTION
Hot surfaces at motor housings, on drive controllers or chokes! Danger of burns!
•Do not touch surfaces of device housings and chokes in the proximity of heat sources!
Danger of burns!
•Do not touch housing surfaces of motors! Danger of burns!
•According to operating conditions, temperatures can be higher than 60 °C (140 °F)
during or after operation.
•Before accessing motors after having switched them off, let them cool down for a
sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated,
the time required for cooling down is five times the thermal time constant specified in the
Technical Data.
•Wear safety gloves or do not work at hot surfaces.
•For certain applications, the manufacturer of the end product, machine or installation,
according to the respective safety regulations, has to take measures to avoid injuries
caused by burns in the end application. These measures can be, for example: warnings,
guards (shielding or barrier), technical documentation.
1.2 Appropriate Use
This product may only be used for the applications mentioned in the
reference documentations (see chapter “Reference Documentations”)
and under the described application, ambient and operating conditions.

Rexroth Diax 04 HVE/HVR Identification 2-1
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
2 Identification
2.1 Type Code
Note: The following figures illustrate the basic structure of the type
codes. Your sales representative will help you with the current
status of available versions.
HVE
HVE 02.2 - W018N
Line
Product HVE
Example:
Other design
Nominal power
30 kW
75 kW
030
075
N
hve_typenschluessel_en.fh7
02
18 kW 018
Design 2
Cooling mode
W
03
04
Air, internal (with built-in blower)
L
none
increased loading capacity for
external DC bus capacitors:
HVE03.x: up to 100 mF
HVE04.x: up to 200 mF
Fig. 2-1: Type code HVE

2-2 Identification Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
HVR
HVR 02.2 - W010N
HVR
25 kW
45 kW
025
045
N
hvr_typenschluessel_en.fh7
02
10 kW 010
2
W
03
Line
Product
Example:
Other design
Nominal power
Design
Cooling mode
Air, internal (with built-in blower)
none
Fig. 2-2: Type code HVR
Type Plate
typenschild_aufbau_en.fh7
A15
SN123456-F0001
K25/03123456
HVE03.2-W030N
Made in Germany
SN123456-F0002
Barcode
Hardware Index
Device type
Prefix
Part number
Continued Number
Identification of supplier
Serial Number
Part number
Example K25/03 means week 25 in year 2003
Production week
Producing Country
Fig. 2-3: Type plate
2.2 Scope of Delivery
The supply units HVx0x.2-W0xxx resp. the additional components HZS,
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)
The additional components GLD resp. KD resp. SUP-E0x-HVR are
delivered without any accessories.
Supply Units HVx
Additional Components HZx
Additional Components
GLD, KD and SUP-E0x-HVR

Rexroth Diax 04 HVE/HVR Ratings and Dimensions 3-1
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
3 Ratings and Dimensions
3.1 HVE
Description Symbol Unit HVE02.2-
W018N
HVE03.2-
W030N
HVE03.2-
W030L
HVE04.2-
W075N
HVE04.2-
W075L
listing according UL-standard (UL) UL 508 C
listing according CSA-standard (UL) Canadian National Standard(s) C22.2 No. 14-05
UL files (UL) E134201
pollution degree (UL) Use in a pollution degree 2 environment
maximum ambient temperature
with nominal data (UL) Tamax °C 45
maximum ambient temperature
with reduced nominal data (UL) Tamax_red °C 55
Weight mkg1316162828
Device height (UL) 1) H mm 498
Device depth (UL) 2) T mm 308
Device width (UL) 3) B mm 100 150 150 250 250
minimum distance on the top of the
device 4) dtop mm 300
minimum distance on the bottom of
the device 5) dbot mm 100
rated control voltage input (UL) 6) UN3 V 3 x 380…480
rated power consumption control
voltage input without holding brake,
without control section at
UN3 = DC 24 V (UL) 7)
PN3 W 500
short circuit current rating, SCCR,
symmetrical amperes (UL) 8) ISCCR A rms 42000
rated input voltage, power (UL) 9) V 3 x 380…480
tolerance rated input voltage (UL) % ±10
input number of phases (UL) 3
input frequency (UL) fLN Hz 50…60
tolerance input frequency (UL) Hz ±2
maximum input current (UL) 10) IL_cont A 30 50 50 120 120
branch circuit protection fuse (UL) 11) 40 70 70 150 150
field wiring material (UL) 12) Use 60/75 °C copper wire only, use class 1 wire only or
equivalent
required wire size according UL 508
A (internal wiring); at IL_cont (UL) 13) ALN AWG6AWG2AWG2AWG0AWG0
maximum output voltage (UL) Uout V 670 dc
maximum output current (UL) Iout_max A 37 60 60 140 140

3-2 Ratings and Dimensions Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
Description Symbol Unit HVE02.2-
W018N
HVE03.2-
W030N
HVE03.2-
W030L
HVE04.2-
W075N
HVE04.2-
W075L
power dissipation at continuous
current Iout_cont and continuous DC
bus power PDC_cont respectively (UL)
14)
PDiss_cont W 1251 1855 1855 3125 3125
1) 2) 3) housing dimension; see related dimension sheet also
4) 5) see fig. "Air intake and air outlet of drive controller"
6) observe supply voltage for motor holding brakes
7) find value for control section in project planning manual
8) Suitable for use on a circuit capable of delivering not more than this
SCCR value, 600 V AC or less. The drive series shall be used with
listed AC input line fuses or listed circuit breakers specified in this
documentation.
9) HDS, HDD, HZB, HZK: DC bus L+, L-; HVE/HVR: mains input
U, V, W
10) at PDC_cont
11) class J branch circuit fuse
12) find value for tightening torque in project planning manual, electrical
terminals
13) copper wire; PVC-insulation (conductor temperature 90 °C); Table
13.5.1; Ta ≤ 40 °C
14) plus dissipation of braking resistor
Abb. 3-1: UL ratings and dimensions
A: air intake
B: air outlet
C: mounting surface in control cabinet
dtop: distance top
dbot: distance bottom
Fig. 3-2: Air intake and air outlet at drive controller
3.2 HVR
Description Symbol Unit HVR02.2-W010N HVR02.2-W025N HVR03.2-W045N
listing according UL-standard (UL) UL 508 C
listing according CSA-standard (UL) Canadian National Standard(s) C22.2 No. 14-05
UL files (UL) E134201
Distances

Rexroth Diax 04 HVE/HVR Ratings and Dimensions 3-3
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
Description Symbol Unit HVR02.2-W010N HVR02.2-W025N HVR03.2-W045N
pollution degree (UL) Use in a pollution degree 2 environment
maximum ambient temperature with
nominal data (UL) Tamax °C 45
maximum ambient temperature with
reduced nominal data (UL) Tamax_red °C 55
Weight m kg 21 21 31
Device height (UL) 1) H mm 498
Device depth (UL) 2) T mm 308
Device width (UL) 3) B mm 175 175 250
minimum distance on the top of the
device 4) dtop mm 300
minimum distance on the bottom of the
device 5) dbot mm 100
rated control voltage input (UL) 6) UN3 V 3 x 380…480
rated power consumption control voltage
input without holding brake, without
control section at UN3 = DC 24 V (UL) 7) PN3 W 500
short circuit current rating, SCCR,
symmetrical amperes (UL) 8) ISCCR A rms 42000
rated input voltage, power (UL) 9) V 3 x 380…480
tolerance rated input voltage (UL) % ±10
input number of phases (UL) 3
input frequency (UL) fLN Hz 50…60
tolerance input frequency (UL) Hz ±2
maximum input current (UL) 10) IL_cont A18 45 80
branch circuit protection fuse (UL) 11) 25 70 100
field wiring material (UL) 12) Use 60/75 °C copper wire only, use class 1 wire only or
equivalent
required wire size section according UL
508 A (internal wiring); at IL_cont (UL) 13) ALN AWG 6 6 2
maximum output voltage (UL) Uout V 750 dc
maximum output current (UL) Iout_max A13 33 60
power dissipation at continuous current
Iout_cont and continuous DC bus power
PDC_cont respectively (UL) 14) PDiss_cont W 450 900 1500
1) 2) 3) housing dimension; see related dimension sheet also
4) 5) see fig. "Air intake and air outlet of drive controller"
6) observe supply voltage for motor holding brakes
7) find value for control section in project planning manual
8) Suitable for use on a circuit capable of delivering not more than this
SCCR value, 600 V AC or less. The drive series shall be used with
listed AC input line fuses or listed circuit breakers specified in this
documentation.
9) HDS, HDD, HZB, HZK: DC bus L+, L-; HVE/HVR: mains input
U, V, W
10) at PDC_cont
11) class J branch circuit fuse
12) find value for tightening torque in project planning manual, electrical
terminals
13) copper wire; PVC-insulation (conductor temperature 90 °C); Table
13.5.1; Ta ≤ 40 °C
14) plus dissipation of braking resistor
Abb. 3-3: UL ratings and dimensions

3-4 Ratings and Dimensions Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
A: air intake
B: air outlet
C: mounting surface in control cabinet
dtop: distance top
dbot: distance bottom
Fig. 3-4: Air intake and air outlet at drive controller
Distances

Rexroth Diax 04 HVE/HVR Reference Documentation 4-1
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
4 Reference Documentation
4.1 Overview
Title Type of documentation Document typecode
DIAX04 HDD and HDS Drive Controllers
2nd Generation
Project Planning Manual DOK-DIAX04-HDD+HDS**G2-PRxx-EN-P
"List of Connecting Cables for DIAX04 and
ECODRIVE03"
Selection lists DOK-CONNEC-CABLE*STAND-AUxx-EN-P
"LWL - Handling" Application Manual DOK-CONNEC-CABLE*LWL-AWxx-EN-P
"Electromagnetic Compatibility (EMC) in Drive
and Control Systems"
Project Planning Manual DOK-GENERL-EMV********-PRxx-EN-P
DIAX04 Drive With Electric Gear Function Functional Description DOK-DIAX04-ELS-05VRS**FKB1-EN-P
DIAX04 Drive With Electric Gear Function Troubleshooting Guide DOK-DIAX04-ELS-05VRS**-WAR1-EN-P
DIAX04 Drive With Servo Function Functional Description DOK-DIAX04-SSE-01VRS**FKB1-EN-P
DIAX04 Drive With Servo Function Troubleshooting Guide DOK-DIAX04-SSE-01VRS**-WAR1-EN-P
DIAX04 Drive With Servo Function Functional Description DOK-DIAX04-SSE-02VRS**FKB1-EN-P
DIAX04- Drive With Servo Function Troubleshooting Guide DOK-DIAX04-SSE-02VRS**-WAR1-EN-P
DIAX04 Drive With Servo Function Functional Description DOK-DIAX04-SSE-03VRS**-FK01-EN-P
DIAX04 Drive With Servo Function Troubleshooting Guide DOK-DIAX04-SSE-03VRS**-WA01-EN-P
DIAX04 Drive With Main Spindle Function,
SERCOS interface
Functional Description DOK-DIAX04-SHS-03VRS**-FK01-EN-P
DIAX04 Drive With Main Spindle Function,
SERCOS interface
Troubleshooting Guide DOK-DIAX04-SHS-03VRS**-WA01-EN-P
DIAX04 Drive With Servo Function, Analog-
and Parallelinterface
Functional Description DOK-DIAX04-ASE-02VRS**FKB1-EN-P
DIAX04 Drive With Servo Function, Analog-
and Parallelinterface
Troubleshooting Guide DOK-DIAX04-ASE-02VRS**-WAR1-EN-P
DIAX04 Drive With Main Spindle Function,
Analog And Parallelinterface
Functional Description DOK-DIAX04-AHS-03VRS**FKB1-EN-P
DIAX04 Drive With Main Spindle Function,
Analog And Parallelinterface
Troubleshooting Guide DOK-DIAX04-AHS-03VRS**-WAR1-EN-P
"Digital AC Motors MKD" Project Planning Manual DOK-MOTOR*-MKD********-PRxx-EN-P
"Digital AC Motors MHD" Project Planning Manual DOK-MOTOR*-MHD********-PRxx-EN-P
"MKE Digital AC Motors for potentially
explosive areas"
Project Planning Manual DOK-MOTOR*-MKE********-PRxx-EN-P
"2AD AC Motor" Project Planning Manual DOK-MOTOR*-2AD********-PRxx-EN-P
"ADF Main Spindle Motors" Project Planning Manual DOK-MOTOR*-ADF********-PRxx-EN-P
"1MB Frameless Spindle Motor" Project Planning Manual DOK-MOTOR*-1MB********-PRxx-EN-P
"Synchronous MBS Kit Spindle Motors" Project Planning Manual DOK-MOTOR*-MBS********-PRxx-EN-P
LAR 070-132 Housing Linear Motor Selection and Project Planning DOK-MOTOR*-LAR********-AWxx-EN-P
"LAF050 – 121 Linear Motors" Selection and Project Planning DOK-MOTOR*-LAF********-AWxx-EN-P
"Linear Synchronous Direct Drives LSF" Project Planning Manual DOK-MOTOR*-LSF********-PRxx-EN-P
"AC Drive Units in Personnel Conveyor
Systems"
Application Manual DOK-GENERL-ANTR*PERSON-ANxx-EN-P
"AC Drive Units in Hazardous Areas (Expl.
Protection)"
Application Manual DOK-GENERL-ANTR*EXPLOS-ANxx-EN-P
1) In the document typecodes, "xx" is a wild card for the current edition
of the documentation (example: "PR01" is the first edition of a
Project Planning Manual)
Fig. 4-1: Documentations - Overview

4-2 Reference Documentation Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P

Rexroth Diax 04 HVE/HVR Instructions for Use 5-1
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
5 Instructions for Use
5.1 Overcurrent Protection
Branch circuit protection has to be provided externally according to the
maximum values (voltage and current or voltage and percent of FLA of
the fuses [FLA: Full Load Ampacity]).
5.2 Connections
Wiring Diagram (Supply Unit HVE)
mains PE
mains
Filter
NFD
load
earth rail
to the motors
power connection
shielded control cabinet
compartment or intermediate
panel
control
cabinet
connecting
clamps
main
switch
distributor
clamps
fuse
B01EMV.fh7
HVE HDS HDS
Fig. 5-1: Wiring Diagram (Supply Unit HVE)

5-2 Instructions for Use Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
Wiring Diagram (Supply Unit HVR)
mains PE
HVR HDS HDS
earth rail
to the motors
shielded control cabinet compartment
or intermediate panel
control
cabinet
connecting
clamps
main
switch
distributor
clamps
fuse
B02EMV.fh7
HZF
power connection
KD
control voltage
connection
shielded cable
ground connection
Fig. 5-2: Wiring Diagram (Supply Unit HVR)

Rexroth Diax 04 HVE/HVR Instructions for Use 5-3
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
Connection Diagram
HVE
L1
L2
L3
PE
U
V W
X5
X8
2U1
2V1 2W1 2U2 2V2 2W2
K1
=
~power
supply
=
~
control
voltage
supply
30 pin flat
ribbon cable
Power supply units for direct
mains connection with
integrated mains contactor
X13
1L+
2L+
L1
1
2
4
(Option)
bridged at
delivery
DC bus
choke
control voltage
supply and
communication
with drive
controllers
1)
Cu lead and PE bridge automatically delivered.
X11
L+
L-
Cu lead 1)
X12
n/c 3
2
1
PE bridge connection only PE bridge 1)
Q1
3 x AC 380 - 480 V
50 - 60 Hz
acknowledge
power ON
acknowledge
power OFF
1
2
3
4
5
6
K1 NO
K1 NC
K1 NC
X6
1
2
3
4
5
6
Bb1
UD
VW
X7
7
8
BVW
power
supply
and ground
connection of
drive
controllers
X1
bridged at
delivery
2)
1 2 3 4 5
6
ready to
operate
prewarning
Bleeder
prewarning
power
voltage
OK
AP_HVE.fh7
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
17
1
19
20
power supply &
communication
with auxiliary
modules (HZN,
bleeder, etc.)
ZKS
Off
ZKS
Off
X3
1
2
3
4
5
6
ZKS
ON
OFF
On
On
1
2
3
4
5
6
max.
100mA
max.
2A
+15VM
-15VM
0VM
+24VL
0VL
7
X4
n/c
n/c
X0 bridged at
delivery
HVE02.2, HVE03.2 and
HVE04.2
X2
service interface
2)
not for HVE04.2
Fig. 5-3: Total connection 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
(10 mm2). Make sure there is sufficient shock protection.

5-4 Instructions for Use Rexroth Diax 04 HVE/HVR
DOK-DIAX04-HVE+HVR*UL*-IB01-EN-P
HVR
U
V W
X5
K1
30 pin flat
ribon cable
HVR02.2 und HVR03.2
power supply units for direct mains
connections with mains regeneration
4
control voltage
supply and
communication
with
drive controllers
1)
Cu lead and PE bridge part of delivery
X11
L+
L-
Cu lead1)
X12
n/c 3
2
1
PE bridge connection only PE bridge
1)
1
2
3
4
5
6
max.
100 mA
max.
2 A
+15VM
-15VM
0VM
+24VL
0VL
7
X4
ZKS
OFF
ZKS
OFF
X3
1
2
3
4
5
6
ZKS
ON
OFF
ON
ON
acknowledge
power OFF
1
2
3
4
K1 NO
K1 NC
X6
1
2
3
4
5
6
Bb1
UD
VW
X7
power supply
and ground
connection
of drive
controllers
X1
ready to
operate
prewarning
power
voltage OK
n/c
power
supply
X2
service
interface
n/c
n/c
X0
11
12
13
14
15
16
17
1
19
20
supply and
communication
with auxiliary
modules (HZN,
bleeder etc.)
1
2
3
4
5
6
7
9
10
bridged at
delivery
L2
L1
L3
L2
L1
L3
=
~
X8
control
voltage
supply
1 2 3 4
=
~
Q1
U1 V1 W1
U2 V2 W2
PE
KDxx
UVWU4 V4 W4
to the central
ground connection
HZF01.1-W0xxN
Combining filter
to the central
ground connection
Cu lead1)
3 x AC 380 - 480 V
50 - 60 Hz
L- L+
Ap_hvr.fh7
F2
X5 X8/X8aX11
mains input
X12
acknowledge
power ON
Fig. 5-4: Total connection diagram HVR02.2 and HVR03
Note: Use a twisted cable for the wiring of the commutation choke!