Description
Operating Mechanism and System Value
The unit operates as the central power converter in common DC-bus topologies, rectifying mains voltage and generating a stabilized intermediate circuit for up to twelve downstream HCS01 or HMS inverters. Active front-end technology with low-harmonic feedback maintains mains current THD below 5 %, reducing transformer oversizing and grid penalties. Integrated brake chopper and resistor manage regenerative energy without external components in most applications. This architecture dramatically lowers total installed cable cross-section and cabinet volume versus individual drive solutions, while enabling energy exchange between axes for up to 30 % reduction in peak power demand.
Downtime Risks and Failure Prediction
- Capacitor bank failure in aged or refurbished units can cause total DC-bus collapse, simultaneously disabling all connected axes and triggering multi-hour production loss.
- Non-original firmware or mismatched brake resistors frequently lead to uncontrolled regeneration events and subsequent damage to multiple downstream inverters.
- Grey-market units often lack proper mains filter coordination, causing repetitive nuisance trips and progressive deterioration of upstream switchgear.
Core Competitiveness Analysis
The HCS02.1E-W0028-A-03 achieves exceptional power density (18 kW continuous in only 135 × 440 × 350 mm) through optimized liquid-cooled heatsink design and high-efficiency film capacitors rated for 100 000 hours at 85 °C hot-spot temperature. Latest-generation IGBT modules with 1200 V blocking voltage and integrated temperature/current sensors deliver MTBF figures exceeding 1.5 million hours under rated load. The active front-end employs sinusoidal current control with LCL filter topology, achieving power factor > 0.99 and harmonic distortion far below IEEE 519 limits without additional hardware. Rexroth’s 10-year spare-parts commitment for the entire HCS02 platform—officially documented—protects asset value long after many competitors have declared end-of-life. These factors combine to deliver the lowest total cost of ownership in centralized multi-axis systems for printing, packaging, and metal-forming applications requiring 10–50 kW total power.
Applicable Environments and Operating Conditions Analysis
The converter operates reliably at ambient temperatures 0 °C to +55 °C (derating 1.5 %/K above 40 °C at 8 kHz) and relative humidity 5–95 % non-condensing. It meets EMC category C3 (industrial) and withstands vibration 1 g (10–150 Hz) and shock 15 g / 11 ms. Installation altitude up to 2000 m is supported with minor derating.
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