Bosch Rexroth HVR02.2-W025N Power Supply

Bosch Rexroth HVR02.2-W025N Power Supply: Replacement and Sourcing Information for HVR Automation

The Bosch Rexroth HVR02.2-W025N is a high-efficiency, regenerative power supply module from the HVR series, engineered to deliver stable, clean DC bus power while actively recovering braking energy back to the supply network. Rated at 25 kW continuous output, this module is purpose-built for demanding industrial automation environments where energy efficiency, drive system reliability, and production line uptime are non-negotiable priorities. Every unit shipped from ZYPLC undergoes full functional testing and is backed by a warranty terms confirmed during quotation.

Product Specification Table

System Compatibility and Application

In a modern industrial drive system, the HVR02.2-W025N functions as the energy backbone of the entire axis group. Rather than dissipating regenerated braking energy as heat through braking resistors, this module feeds recovered energy back into the AC supply network — a critical advantage in high-cycle applications such as servo presses, CNC machining centers, and automated assembly lines.

Within a Bosch Rexroth IndraDrive architecture, the HVR02.2-W025N supplies a shared DC bus to multiple axis drives such as the HCS02.1-W0054 and HCS03.1-W0210 servo drive modules. These drives power MSK servo motors (e.g., MSK071C, MSK100B) that execute precision motion on each production axis. The shared DC bus topology means that when one axis decelerates and regenerates energy, that energy is immediately available to accelerate another axis — dramatically reducing peak demand from the grid.

For multi-axis systems requiring coordinated motion, the HVR02.2-W025N integrates seamlessly with the Bosch Rexroth IndraControl L45 or IndraControl XM22 motion controller, which manages axis synchronization, cam profiles, and maintenance-focused motion planning. Communication between the controller and drives is handled via SERCOS III or EtherCAT, enabling real-time cycle-accurate feedback with sub-millisecond latency.

On the monitoring side, the system can be paired with Rexroth IndraMotion MLC or third-party power analyzers connected through the HMS02.1 supply module’s diagnostic interface to track real-time power consumption per axis. This data feeds into predictive maintenance routines — identifying abnormal current draw patterns that indicate bearing wear, mechanical misalignment, or drive derating before they cause unplanned downtime.

I/O expansion for auxiliary equipment — safety relays, cooling fans, lubrication pumps — is managed through Rexroth Inline I/O modules or compatible Beckhoff EK1100 EtherCAT couplers, ensuring that peripheral energy loads are also monitored and controlled within the same automation architecture. HMI visualization of energy KPIs is typically handled by a Rexroth IndraControl VPP40 or a Siemens TP1200 Comfort Panel connected via PROFINET, giving operators real-time visibility into drive efficiency, DC bus voltage stability, and regeneration yield.

Maintenance and Replacement Notes

In injection molding applications, the HVR02.2-W025N significantly reduces operating load during the clamping and ejection phases, where servo-driven axes frequently decelerate from high speeds. Without regeneration, this kinetic energy is wasted as heat. With the HVR02.2-W025N managing the DC bus, recovered energy from the clamping axis directly powers the injection axis during the same cycle — reducing net grid draw per shot by measurable margins across thousands of daily cycles.

In CNC machining centers, rapid traverse movements between cutting operations generate frequent short-duration regeneration events. The HVR02.2-W025N captures these micro-regeneration pulses and redistributes them across the spindle and feed axes, smoothing the overall power demand curve and reducing peak current spikes that would otherwise stress the facility’s power infrastructure and trigger demand charges.

For conveyor and material handling systems, the module enables controlled deceleration of loaded conveyors — particularly on inclined sections — where gravity-assisted descent generates substantial regenerative energy. This recovered power can offset the energy consumed by ascending sections of the same conveyor loop, effectively creating an internal energy recycling circuit within the production line.

From a maintenance perspective, the HVR02.2-W025N’s built-in diagnostics continuously monitor DC bus voltage ripple, input current balance, and thermal status. Deviations from baseline values are logged and can trigger early warnings through the drive controller, enabling maintenance teams to schedule interventions during planned downtime windows rather than reacting to unexpected failures — a key pillar of any predictive maintenance strategy aimed at maximizing Overall Equipment Effectiveness (OEE).

All units supplied by ZYPLC are sourced from verified supply channels, tested under load prior to shipment, and covered by a warranty terms confirmed during quotation. Inventory is maintained in-house for fast dispatch, with typical lead times of 1–3 business days for availability confirmed by RFQ items.

Product Sourcing FAQ

Q1: How much energy can the HVR02.2-W025N recover in a typical servo press application?
In high-cycle servo press applications, regenerative power supply modules in the HVR series can recover Actual operating results depend on the installed system, load profile, and commissioning parameters. The HVR02.2-W025N feeds this recovered energy directly back to the AC grid rather than burning it off as heat, delivering measurable reductions in electricity costs over the equipment lifecycle.

Q2: Is the HVR02.2-W025N compatible with existing Bosch Rexroth IndraDrive systems?
Yes. The HVR02.2-W025N is designed for direct integration into Bosch Rexroth IndraDrive multi-axis systems, sharing a common DC bus with HCS, HMD, and HMS series drive modules. It is compatible with SERCOS III and EtherCAT communication topologies. For mixed-generation systems, compatibility should be verified against the specific firmware and hardware revision of the existing drive modules.

Q3: Can the HVR02.2-W025N replace an older HVR or HVE supply module in an existing cabinet?
In many cases, yes — the HVR02.2-W025N can serve as a direct or near-direct replacement for earlier HVR series supply modules with equivalent power ratings. Cabinet dimensions, DC bus connector compatibility, and control wiring should be verified before installation. ZYPLC’s technical team can assist with cross-reference validation prior to purchase.

Q4: What does the warranty terms confirmed during quotation cover, and what is the testing process before shipment?
Every HVR02.2-W025N unit supplied by ZYPLC undergoes pre-shipment functional testing including DC bus output verification, input rectifier check, regeneration circuit validation, and thermal performance assessment. The warranty terms confirmed during quotation covers manufacturing defects and functional failures under normal operating conditions. Units are shipped with test records upon request. Contact ZYPLC at plc.sales@zyplc.com or +86 19859288691 for warranty claims or pre-sales technical support.