Baumuller BFN 3-1-0030-001, BFN 3-1-0042-001, BFN 3-1-0016-001, BFN 3-1, BFN 3-1-0056-001 Instruction Handbook Manual
...
Instruction handbook
Language English
Translation
Document-No. 5.09010.03
Part No. 442335
Version 1-Mar-2018
E
5.09010.03
Mains filters
BFN - 3 - 1 - ...
Filters for
mains applications
Read the Instruction handbook before starting!
Copyright This Instruction handbook may be copied by the owner in any quantity, but only for internal
use. This Instruction handbook may not be copied or reproduced, in whole or in part, for any
other purposes.
The use and disclosure of information contained in this Instruction handbook are not permitted.
Designations and company marks contained in this Instruction handbook could be trademarks, the use of which by third parties for their own purposes could violate the rights of the
rights holder.
Preliminary information
Warning Insofar as this document is identified as being preliminary information, the following
applies:
this version is regarded as providing advance technical information to users of the described
devices and their functions at an early enough time in order to adapt to any possible changes
or expanded functionality.
This information must be regarded as being preliminary, as it has not yet passed through
Baumüller's internal review process. In particular, this information is still subject to changes,
thus no legal liability can be derived from this preliminary information. Baumüller assumes no
liability for damages that might arise from this possibly faulty or incomplete version.
If you detect or suspect any content errors and/or major form errors in this preliminary information, we request that you notify the Baumüller support specialist responsible for you.
Please provide us, via this employee, with your insights and comments so that we can take
them into account and include them when transitioning from the preliminary information to
the final information (as reviewed by Baumüller).
The conditions stipulated in the following section under „Obligatory“ are invalid in case of preliminary information.
Obligatory This Instruction handbook is a part of the equipment/machine. This Instruction handbook
must be available to the operator at all times and must be in legible condition. If the equip
ment/machine is sold or moved another location, this Instruction handbook must be passed
on by the owner together with the equipment/machine.
After any sale of the equipment/machine, this original and all copies must be handed over to
the buyer. After disposal or any other end use, this original and all copies must be destroyed.
When the present Instruction handbook is handed over, corresponding sets of Instruction
handbooks of a previous version are automatically invalidated.
Please note that the specifications/data/information are current values according to the
printing date. These statements are not legally binding with regard to measurements,
computation or calculations.
Baumüller Nürnberg GmbH reserves the right, in developing its products further, to change
the technical specifications and handling of it products concerned without prior notice.
No liability can be accepted concerning the correctness of this Instruction handbook unless
otherwise specified in the General Conditions of Sale and Delivery.
-
Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
90482 Nuremberg
Germany
Tel. +49 9 11 54 32 - 0
Fax: +49 9 11 54 32 - 1 30
Email : mail@baumueller.de
Internet: www.baumueller.de
Table of Contents
Table of Contents
1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Information on this Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Copyright protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Guarantee provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.10 Used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Contents of Instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Changes and modifications to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Responsibility of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.8 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.9 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.10 Behavior in case of danger or accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.11 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 System types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 Requirements to the energy supply: power supply . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.3 Required environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.1 Baumüller filters for TN/TT-systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.2 Filters for active mains inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.3 Filters for IT-systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.1 Filters for TN/TT-systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4.2 Filters for IT-systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4 Description of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1.2 Block diagram filters for mains applications (simplified) . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Table of Contents
5 Transport and packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1 Safety notes for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 What to observe at transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.5 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1 Safety notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2 Prepare mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3 Mounting instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1 Safety notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2 Demands on the electrical mains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3 Demands on the connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.4 Grounding conductor connection and RCD-compatibility . . . . . . . . . . . . . . . . . . . . . . 48
7.5 System requirements with regard to EMC-stability . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5.1 General information about converters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5.2 Measures taken to assure EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.6 Procedure of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.7 Connection diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.1 Safety notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.2 Environmental conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9 Spare Parts and Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.1 Mains filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.2 Screening terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.1 Disposal facilities/authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Overview of Revisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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Document No.: 5.09010.03 Baumüller Nürnberg GmbH
1.1 Information on this Handbook
This Handbook provides important information on handling the device. A prerequisite for
safe work is compliance with all specified safety notes and procedural instructions.
Additionally, the valid accident prevention regulations and general safety regulations applicable to the scope of application the device must be complied with.
Read this Handbook, particularly the safety notes chapter, completely before beginning
any work on the device. This Instruction handbook is part of the product and must be kept
accessible to personnel at all times in the immediate vicinity of the device.
1GENERAL INFORMATION
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1.2
Key to symbols
1.2 Key to symbols
Warning notes
Warning notes are identified as symbols in this Handbook. The notes are introduced by
signal words that express the extent of the danger.
It is imperative that these notes be complied with and are conscientiously regarded in order to prevent accidents, personal injury and material damage.
DANGER!
....points out an immediately dangerous situation that will lead to severe injuries or
death if not avoided.
WARNING!
....points out a potentially dangerous situation that could lead to severe injuries or
death if not avoided.
Recommendations
ATTENTION!
....points out a potentially dangerous situation that could lead to minor or slight inju-
ries if not avoided.
NOTICE!
....points out a potentially dangerous situation that could lead to material damage if
not avoided.
NOTE!
....highlights useful tips and recommendations, as well as information for efficient and
problem-free use.
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1.3 Limitation of liability
All specifications and notes in these Instruction Handbook were compiled taking into account the applicable standards and regulations, the State of the Art and our knowledge
and experience of many years.
The manufacturer assumes no liability for damages due to:
m Noncompliance with the Instruction Handbook
m Usage for other than the intended purpose
m Usage by untrained personnel
The actual scope of delivery can vary in case of optional equipment, laying claim to additional order options, or on account of the latest technical changes to the explanations and
representations described herein.
The user bears the responsibility for performing service and initial operation in accordance with the safety regulations of the applicable standards and all other relevant governmental or local regulations concerning the dimensioning and protection of conductors,
grounding, disconnectors, overcurrent protection, etc.
The person who carried out the mounting or installation is liable for any damage incurred
when assembling or connecting the device.
General Information
1
1.4 Copyright protection
The Instruction Handbook must be treated confidentially. It is to be used exclusively by
personnel who work with the device. The consignment of the operating instructions to
third persons without the written permission of the manufacturer is prohibited.
NOTE!
he specific contents, text, drawings, images and other representations are copy-
T
righted and subject to industrial property rights. Any prohibited usage is punishable
by law.
1.5 Other applicable documents
Components of other manufacturers are integrated into the device. For these purchased
parts a risk analysis has been performed by the respective manufacturers. The compliance of the design construction with the applicable European and national regulations
has been declared for the components by the respective manufacturers.
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1.6
Spare parts
1.6 Spare parts
1.7 Disposal
WARNING!
lse or flawed spare parts can lead to damage, malfunction or complete fail-
Fa
ure, thus endangering safety.
Therefore:
m Only use original spare parts of the manufacturer.
Procure spare parts through an authorized dealer or directly from the manufacturer.
See also ZSpare Parts and Part Numbers– on page 59.
Insofar as no take-back or disposal agreement has been made, please disassemble units
correctly and properly recycle the constituent parts.
See ZDisposal– on page 63.
1.8 Guarantee provisions
The guarantee provisions are stated in a separate document of the sales documents.
The devices described herein may only be operated in accordance with the stipulated
methods, procedures and conditions. Anything else not presented here, including the operation of devices in mounted positions, is not permitted and must be cleared with the
plant on a case-by-case basis. If the devices are operated in any other manner than as
described within these Instruction Handbook, then all guarantee and warranty rights are
rendered null and void.
1.9 Customer service
Our customer service is available to provide you with technical information.
Info on the responsible contact persons is available at all times via telephone, fax, e-mail
or the internet.
1.10 Used terms
The terms „Device“ or „BFN“ are used for the Baumüller product „Mains filters“.
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This section provides an overview of all of the important safety aspects for optimum protection of personnel as well as for the safe and problem-free operation.
2.1 Contents of Instruction handbook
Each person who is tasked with performing work on or with the device must have read
and understood the operating instructions before working with the device. This also applies if the person involved with this kind of device or a similar one, or has been trained
by the manufacturer.
2.2 Changes and modifications to the device
n order to prevent hazards and to ensure optimum performance, no changes, additions
or modifications may be undertaken on the device that have not been explicitly approved
by the manufacturer.
2.3 Proper usage
2SAFETY
A device of the series BFN limits the
in the power supply.
WARNING!
nger by Inappropriate Use!
Da
Any use that goes beyond the intended purpose and/or any non-compliant use of the
device can cause dangerous situations.
Therefore:
m Observe all specifications of the Instruction Handbook.
m When configuring, ensure that the device is
tions.
m The device may only be operated in a technically flawless condition.
electrical interferences of the Baumüller converter
always operated within its specifica-
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2.4
Responsibility of the operator
2.4 Responsibility of the operator
The device will be used in commercial areas. Thus, the proprietor of the device is subject
to the legal work safety regulations.
Along with the notes on work safety in these operating instructions, the safety, accident
prevention and environmental protection regulations valid for the area of application of
this device must be complied with. Whereby:
m The proprietor must inform himself about th
lations and ascertain, in a risk analysis, a
the special working conditions in the use area of the device. These must then be implemented in the form of operating instru
m These operating instructions must be kept a
vice at all times in the immediate vicinity of the device.
m The specifications of the operating instruction
without exception!
m The device may only be operated in a technically fa
dition
e applicable work health and safety regu-
ny additional hazards that could arise from
ction for operation of the device.
ccessible to personnel working with the de-
s must be adhered to completely and
ultless and operationally safe con-
2.5 Personnel training
WARNING!
Risk of i
Improper handling can lead to significant personal injury and material damage.
Therefore:
m Certain activities can only be performed by the persons stated in the respective
chapters of these Instruction Handbook.
In this Instruction Handbook the following
activity:
Operating
personnel
Qualified
personnel
n The drive system may only be operated by persons who have been specially trained,
familiarized and authoriz
n Troubleshooting, maintenance, cleaning, main
be performed by trained or familiarized personnel. These persons must be familiar
with the operating instructions and act accordingly.
n Commissioning and training may only be performed by qualified personnel.
n Electrical engineers authorized by Baumüller Nürnberg GmbH, and qualified electri-
cians of the customer or a third party who have learned to install and maintain
umüller drive systems and are authorized to ground and identify electrical power
Ba
circuits and devices in accordance with the safety engineering standards of the company.
n Qualified personnel have had occupational training or instruction in accordance with
the
use of appropriate safety equipment.
njury due to insufficient qualifications!
qualifications are stipulated for various areas of
ed.
tenance and replacement may only
respective locally applicable safety engineering standards for the upkeep and
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2.6 Personal protective equipment
The wearing of personal protective equipment is required when working in order to minimize health and safety risks.
m The protective equipment necessary for each respective type of work shall always be
worn during work.
m The personal safety signs presented in each working area must be observed!
Protective work clothing
must be snug-fitting work clothes, with low tearing resistance, narrow sleeves and
with no extending parts. Wear hair net.
No rings or necklaces.
Hard hat
Protects against objects falling down and flying around objects.
Safety
2
Wear for special
work.
Safety shoes
Protects against heavy objects falling down.
Protective gloves
Protects hands against friction, abrasion, puncturing or more severe injuries, as well
as contact with hot objects.
Protection eye wear
Protect the eyes against flying around objects and splashing liquids.
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2.7
Special hazards
2.7 Special hazards
In the following section, the remaining marginal risks will be stated that have been identified as a result of the risk analysis.
Observe the safety notes listed here and the warning notes in the further chapters of this
manual to reduce health risks and dangerous situations.
Electrical current
DANGER!
Risk of fatal injury from electrical current!
There is an immediate risk of fatal injury if live electrical parts are contacted. Damage
to the insulation or individual components can be life-threatening.
Therefore:
m Switch off the power supply immediately in case of damage to the power supply
m Only allow work on the electrical system to be performed by qualified personnel.
m Switch off the current when any kind of work is being performed on the electrical
m The device must be operated in a control cabinet. The control cabinet must protect
insulation.
system and ensure safety before switching on again.
against direct contact. It must conform to the EN 61800-5-1, chapter 4.2.3.3.
Danger from
residual energy
DANGER!
Risk of fatal injury from electrical current!
Stored electric charge.
Discharge time of the drive system = discharge time of the device with the longest
DC-link discharging time.
Therefore:
m Consider discharge time of the capacitor and do not contact energized parts
m The instructions on the device must be observed.
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2.8 Fire fighting
DANGER!
Risk of fatal injury from electrical current!
Electricity when using a conductive fire fighting appliance.
Therefore:
m Use the following fire fighting device:
ABC powder / CO
2
Safety
2
2.9 Safety equipment
WARNING!
Risk of fatal injury due to non-functional safety equipment!
Safety equipment provides for the highest level of safety in a facility. Even if safety
equipment makes work processes more awkward, under no circumstances may they
be circumvented. Safety can only be ensured by intact safety equipment.
Therefore:
m Before starting to work, check whether the safety equipment in good working order
and properly installed.
2.10 Behavior in case of danger or accidents
Preventive measures
m Always be prepared for accidents or fire!
m Keep first-aid equipment (e.g. first-aid kits, blankets, etc.) and fire extinguishers handy.
m Acquaint personnel with accident alarm, first aid and rescue equipment
And if something
does happen:
respond properly
m Stop operation of the device immediately with an EMERGENCY Stop.
m Initiate first aid measures.
m Evacuate persons from the danger zone
m Notify the responsible persons at the scene of operations.
m Alarm medical personnel and/or the fire department.
m Keep access routes clear for rescue vehicles.
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2.11
Signs and labels
2.11 Signs and labels
The following symbols and information signs are located in the working area. They refer
to the immediate vicinity in which they are affixed.
WARNING!
Risk of injury due to illegible symbols!
Over the course of time, stickers and symbols on the device can become dirty or otherwise unrecognizable.
Therefore:
m Maintain all safety, warning and operating labels on the device in easily readable
condition.
Electrical voltage
Only qualified personnel may work in the marked workspace.
Unauthorized persons may not touch the marked working materials.
DANGER!
Risk of injury due to hot surface!
The surfaces of the device can heat up to temperatures of > 70°C!
Therefore:
m Wear protective gloves
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3.1 Operating conditions
3.1.1 System types
There is a differential structure of current supply systems and it is distinguished between
three basic types, referring to their grounding, which is accordant to DIN VDE0100 part
300 and accordingly to IEC 60364:
m In a TN-system one point is directly grounded
trical installation is connected via protective
tors with this point.
m In a TT-system a point is directly grounded (
installation is connected to ground connections, which, however, are separated from
the signal ground.
m In an IT-system there is no direct connection between activ
N) and grounded parts (PE). The cabinets of the electrical installation are grounded.
The separation is reached, by the use of an isolating transformer or with the use of an
independent current source (generator, battery).
If there is an adequate low-impedance grounding within the TN- or the TT-system, then
a line-side fuse is activated. A high-impedance grounding does not activate the fuse, so
that the ground currents (error current) can be potentially dangerous. For this reason, circuit breakers are used for the error current monitoring.
At a short-circuit to ground, no ground current can flow and the line-side fuses cannot be
activated, by which the operation can be kept up. Only a second short-circuit to ground at
another phase would cause an current error, which can trigger a fuse. In order to detect
the first short-circuit to ground an insulation monitor and for the second short-circuit to
ground, a current error monitoring, are necessary.
3TECHNICAL DATA
(signal ground). The cabinet of the elec-
conductors and accordingly PE-conduc-
signal ground). The cabinet of the electric
e conductors (L1, L2, L3,
Supported system types
NOTICE!
he operation of the mains filters BFN is possible with IT- and TN/TT-systems.
T
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3.1
Operating conditions
3.1.2 Requirements to the energy supply: power supply
Power supply system
(see ZSystem types– from
page 15)
BFN 3-1-XXXX-X01 Industrial system with high- or low-impedance
star point (TN-system or TT-system)
BFN 3-1-XXXX-X02 Industrial system with no star point or a high-
impedance star point (IT-system)
Industrial system with a direct or low impedance
grounded junction of phases
(grounded delta wye)
Rated input supply voltage/frequency
(UAC) 3 x 400 V 50/60 Hz
3 x 480 V 50/60 Hz
Absolute input supply voltage
(UAC) max. 3 x 528 V / 50/60 Hz
Absolute frequency maximum 63 Hz
Harmonic frequencies (mains voltage)
EN 61800-3, chapter 5.2.2.1, table 2
Mains voltage asymmetry
EN 61000-2-4, table 1
Commutation notches
EN 61800-3, chapter 5.2.2.1, table 2
Voltage drops
EN 61000-2-1
Voltage changes/fluctuation
EN 61000-2-1
Notch depth < 40%, area < 250% x degree
THDU b 10 %
max. 3 %
10 % to 100 %
+/-10 %
+10 % to -15 % for b 1 min
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3.1.3 Required environmental conditions
Transport temperature range -25 °C to +85 °C
Storage temperature range - 25 °C to +85 °C
Operational temperature range -25 °C to +85 °C
Technical Data
(rated temperature: 50 °C,
see ZElectrical data– from page 28)
3
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3.2
Dimensions
3.2 Dimensions
NOTE!
Dimensions in mm.
3.2.1 Baumüller filters for TN/TT-systems
BFN 3-1-0007-001
BFN 3-1-0016-001
BFN 3-1-0030-001
BFN 3-1-0042-001
BFN 3-1-0056-001
BFN 3-1-0075-001
BFN 3-1-0100-001
BFN 3-1-0130-001
BFN 3-1-0180-001
Figure 1: Dimensions filters TN/TT-systems
Typ e A B C D E F L G H
PE-connection
BFN 3-1-0007-001 190 40 70 20 180 160 185 5,4 M5 4/6
BFN 3-1-0016-001 250 50 70 25 235 220 245 5,4 M5 4/6
BFN 3-1-0030-001 270 50 85 30 255 240 265 5,4 M5 10/16
BFN 3-1-0042-001 310 50 85 30 295 280 305 5,4 M5 10/16
BFN 3-1-0056-001 250 85 90 60 235 220 258 5,4 M6 16/25
BFN 3-1-0075-001 270 80 135 60 255 240 278 6,5 M6 25/35
BFN 3-1-0100-001 270 90 150 65 255 240 326 6,5 M10 50/50
BFN 3-1-0130-001 270 90 150 65 255 240 326 6,5 M10 50/50
BFN 3-1-0180-001 380 130 180 102 365 350 455 6,5 M10 95/95
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Connection (mm2)
flex./rigid
BFN 3-1-0250-001
BFN 3-1-0250-001
BFN 3-1-320-001
BFN 3-1-400-001
BFN 3-1-600-001
BFN 3-1-0320-001
BFN 3-1-0400-001
BFN 3-1-0600-001
Technical Data
3
Figure 2: Dimensions filters TN/TT-systems
Type A B C D E G H I J K M N Connection
BFN 3-1-0250-001 300 125 180 205 230 120 110 40 62 M10 12 Bolt M10
BFN 3-1-0320-001 300 115 210 235 260 40 120 60 35 20 M12 12 Rail with hole 11
PE: Bolt M12
BFN 3-1-0400-001 300 115 210 235 260 40 120 60 35 20 M12 12 Rail with hole 11
PE: Bolt M12
BFN 3-1-0600-001 300 135 210 235 260 40 120 60 35 20 M12 12 Rail with hole 11
PE: Bolt M12
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3.2
BFN 3-1-0150-001
BFN 3-1-0250-001
BFN 3-1-320-001
BFN 3-1-400-001
BFN 3-1-600-001
Dimensions
BFN 3-1-0320-101
BFN 3-1-0400-101
BFN 3-1-0600-101
Figure 3: Dimensions filters TN/TT-systems
Typ e A B C D E G H I J K M N Connection
BFN 3-1-0320-101 300 116 210 235 260 42 120 120 36 30 M10 12 Rail with hole 11
PE: Bolt M10
BFN 3-1-0400-101 300 116 210 235 260 42 120 120 36 30 M10 12 Rail with hole 11
PE: Bolt M10
BFN 3-1-0600-101 300 116 210 235 260 42 145 120 36 30 M10 12 Rail with hole 11
PE: Bolt M10
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BFN 3-1-1000-101
Technical Data
3
Figure 4: Dimensions filters TN/TT-systems
Type A B C D E G H I J K M N Connection
BFN 3-1-1000-101 350 166 250 275 300 65 290 160 61 40 M12 12 Rail with hole 14
PE: M12
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3.2
PE M10 x 38
Tightening torque 10$1mm
PE M10 x 38
Tightening torque 10$1mm
Terminals 95mm
2
Tightening torque 15−20Nm
Terminals 95mm
2
Tightening torque 15−20Nm
Marking
LoadLine
Dimensions
3.2.2 Filters for active mains inverter
EPCOS
B84143A0150R410
NOTE!
Only for active mains inverter BM5174
Figure 5: Dimensions filters TN/TT-systems EPCOS for BM5174
Type Connection
EPCOS
B84143A0150R410
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Terminals: 95 mm²
PE: Bolt M10
Schaffner
FN 3120H-80-35
FN 3120H-150-40
NOTE!
FN 3120H-80-35 for active mains inverter BM4135,
FN 3120H-150-40 for active mains inverter BM4145
Technical Data
3
Figure 6: Dimensions filters TN/TT-system Schaffner for BM4135, BM4145
Type ABCDEFGH I J K L
FN 3120H-80-35 221 169 140 140 115 155 6.5 1 45 M10 18 55
FN 3120H-150-40 221 169 140 140 115 155 6.5 1 51 M10 13 62
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23
3.2
Dimensions
Schaffner
FN 3100-300-99
NOTE!
FN 3100-300-99 for active mains inverter BM4163
Figure 7: Dimensions filters TN/TT-system Schaffner for BM4163
Typ e A B C D E F G H I J L
FN 3100-300-99 440 200 200 400 420 160 8 1.5 105 M12 70
Typ e W X Y Z
FN 3100-300-99 71.5 22 M12 105
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3.2.3 Filters for IT-systems
BFN 3-1-0150-002
BFN 3-1-0250-002
BFN 3-1-320-002
BFN 3-1-400-002
BFN 3-1-600-002
BFN 3-1-0150-002
BFN 3-1-0250-002
BFN 3-1-0320-002
BFN 3-1-0400-002
BFN 3-1-0600-002
Technical Data
3
Abbildung 8: Dimensions filters IT-systems
Type A B C D E G H I J K M N Anschluss
BFN 3-1-0150-002 300 120 160 185 210 120 55 M10 12 Bolt M10
BFN 3-1-0250-002 300 125 180 205 230 120 110 40 62 M10 12 Bolt M10
BFN 3-1-0320-002 300 115 210 235 260 40 120 60 35 20 M12 12 Rail with hole 11
PE: Bolt M12
BFN 3-1-0400-002 300 115 210 235 260 40 120 60 35 20 M12 12 Rail with hole 11
PE: Bolt M12
BFN 3-1-0600-002 300 135 210 235 260 40 120 60 35 20 M12 12 Rail with hole 11
PE: Bolt M12
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3.2
BFN 3-1-0150-001
BFN 3-1-0250-001
BFN 3-1-320-001
BFN 3-1-400-001
BFN 3-1-600-001
Dimensions
BFN 3-1-0320-102
BFN 3-1-0400-102
BFN 3-1-0600-102
Figure 9: Dimensions filters IT-systems EPCOS
Typ e A B C D E G H I J K M N Connection
BFN 3-1-0320-102 300 116 210 235 260 42 120 120 36 30 M10 12 Rail with hole 11
PE: Bolt M10
BFN 3-1-0400-102 300 116 210 235 260 42 120 120 36 30 M10 12 Rail with hole 11
PE: Bolt M10
BFN 3-1-0600-102 300 116 210 235 260 42 145 120 36 30 M10 12 Rail with hole 11
PE: Bolt M10
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3.3 Weight
Technical Data
TN/TT-System IT-System Weight
BFN 3-1-0007-001 0.6 kg
BFN 3-1-0016-001 1.0 kg
BFN 3-1-0030-001 1.3 kg
BFN 3-1-0042-001 1.6 kg
BFN 3-1-0056-001 1.9 kg
BFN 3-1-0075-001 2.6 kg
BFN 3-1-0100-001 4.0 kg
BFN 3-1-0130-001 4.2 kg
BFN 3-1-0180-001 6.0 kg
EPCOS B84143A0150R410
Schaffner FN 3120H-80-35
Schaffner FN 3120H-150-40
Schaffner FN 3100-300-99
1)
1)
1)
1)
13.5 kg
5.0 kg
6.3 kg
11.8 kg
3
BFN 3-1-0150-002 6.0 kg
BFN 3-1-0250-001 BFN 3-1-0250-002 15 kg
BFN 3-1-0320-001 BFN 3-1-0320-002 21 kg
BFN 3-1-0400-001 BFN 3-1-0400-002 21 kg
BFN 3-1-0600-001 BFN 3-1-0600-002 22 kg
BFN 3-1-0320-101 BFN 3-1-0320-102 7.2 kg
BFN 3-1-0400-101 BFN 3-1-0400-102 7.5 kg
BFN 3-1-0600-101 BFN 3-1-0600-102 7.8 kg
BFN 3-1-1000-101 BFN 3-1-1000-102 18.5 kg
1)
Mains filters only for active mains inverter
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3.4
I
eff
1
T
---
i
2
0
T
dt=
Electrical data
3.4 Electrical data
DANGER!
Danger to life due to high discharge current!
Therefore:
m The cross-section of the protective conductor must be at least 10 mm
NOTE!
Rated current of used filters must be greater or the same with the RMS values of the
actual mains current (actual mains current = RMS value of the mains current during
the total cycle time of the drive). The RMS value is calculated at short-time operation
(S3) as follows:
5-1 chap. 4.3.5.5.2).
2
(EN 61800-
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Technical Data
II
rated
85
environment
35°C
--------------------------------- -–=
3.4.1 Filters for TN/TT-systems
BFN 3-1-... -001 0007 0016 0030 0042 0056 0075 0100 0130 0180
3
Max.
supply voltage
Rated current
= 50 °C)
(at T
B
Peak current
(at T
= 50 °C)
B
3 x 480 V
7 A 16 A 30 A 42 A 56 A 75 A 100 A 130 A 180 A
1,5 x I
for < 1 min à hour
N
+10 %,
AC
50/60 Hz
Current derating
Test voltage Cable - Cable: 2125 VDC / 2 s
Cable - Cabinet: 2125 V
DC
/ 2 s
Connection L1/L2/L3: safe-to-touch screw contact
tion: Bolt M5 / M6 / M10
10
mm
16
2
mm
2
25
mm
50
2
mm
50
2
mm
50
2
mm
Maximum
connection cross-sec-
4
mm
PE-Connec
2
4
mm
10
2
mm
2
tion
Power loss (typical) 4 W 8 W 12 W 15 W 18 W 24 W 24 W 30 W 35 W
Protection class IP 20
2
EPCOS B84143A0150R410
Max.
supply voltage
Rated current
= 50 °C)
(at T
B
Peak current
(at T
= 50 °C)
B
3 x 480 V
1.5 x I
2,5 x I
for < 3 min per hour
N
for < 30 s per hour
N
+10 %,
AC
50/60 Hz
150 A
Test voltage Cable - Cable: 2240 V
Cable - Cabinet: 2720 V
Connection L1/L2/L3: safe-to-touch
screw contact
PE: Bolt M10
Maximum
connection cross-sec
95 mm
-
2
tion
Protection class IP 20
DC
/ 2 s
DC
/ 2 s
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3.4
Electrical data
Schaffner FN 3120H-80-35
for active mains inverter
BM4
135
Max.
supply voltage
Rated current
= 50 °C)
(at T
B
Peak current
(at T
= 50 °C)
B
3 x 480 V
for < 1 min per hour
+10 %,
AC
50/60 Hz
80 A 150 A 300 A
1,5 x I
N
Test voltage Cable - Cable: 2250 V
Cable - Cabinet: 2750 V
Connection L1/L2/L3: safe-to-touch
rew contact
sc
PE: Bolt M10
Maximum
50 mm
2
FN 3120H-150-40
for active mains inverter
BM4145
3 x 480 VAC +10 %,
50/60 Hz
1,5 x IN
for < 1 min per hour
/ 2 s
DC
DC
L1/L2/L3: safe-to-touch
screw contact
PE: Bolt M10
95 mm
2
FN 3100-300-99
for active mains inverter
BM4163
3 x 480 VAC +10 %,
50/60 Hz
1,5 x IN
for < 1 min per hour
/ 2 s
L1/L2/L3: safe-to-touch
screw contact
PE: Bolt M12
150 mm
connection cross-
ion
sect
Protection class IP 20 IP 20 IP 20
2
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Technical Data
BFN 3-1-... -001 0250 0320 0400 0600
3
Max.
supply voltage
Rated current
(at T
= 50 °C)
B
Peak current
(at T
= 50 °C)
B
Test voltage Cable - Cable: 2150 V
Connection Bolt M10 rail with hole 11mm
Power loss (typical) 60 W 40 W 50 W 65 W
Protection class IP 00
BFN 3-1-... -101 0320 0400 0600 1000
Max.
supply voltage
Rated current
(at T
= 50 °C)
B
Peak current
(at T
= 50 °C)
B
250 A 320 A 400 A 600 A
250 A 320 A 400 A 1000 A
3 x 480 V
1,5 x I
for < 1 min / once per hour
N
Cable - Cabinet: 2700 V
3 x 480 V
1,5 x I
2,5 x IN for 30 s per hour
+10 %, 50/60 Hz
AC
4 x I
at switch-on
N
PE: Bolt M12
+10 %, 50/60 Hz
AC
for < 3 min per hour
N
or
DC
DC
/ 2 s
/ 2 s
Test voltage Cable - Cable: 2280 V
Cable - Cabinet: 2690 V
Connection Rail with hole 11mm
PE: Bolt M10
Power loss (typical) 31 W 48 W 84 W
Protection class IP 00
Instruction handbook Mains filters BFN
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DC
/ 2 s
DC
/ 2 s
Rail with hole
14mm
PE: Bolt M12
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3.4
Electrical data
3.4.2 Filters for IT-systems
BFN 3-1-... -002 150 0250 0320 0400 0600
Max.
3 x 480 V
+10 %, 50/60 Hz
AC
power supply
Rated current
(at T
= 50 °C)
B
Peak current
= 50 °C)
(at T
B
Test voltage Cable - Cable: 2150 V
Connection Bolt M10 Rail with hole
150 A 250 A 320 A 400 A 600 A
at switch-on
4 x I
N
1,5 x I
for < 1 min / once per hour
N
Cable - Cabinet: 2700 V
Rail with hole
11mm
PE: Bolt M12
11mm
PE: Bolt M12
DC
DC
/ 2 s
/ 2 s
Rail with hole
11mm
PE: Bolt M12
Power loss (typical) 30 W 60 W 40 W 50 W 65 W
Protection class IP 00
BFN 3-1-... -102 0320 0400 0600 1000
Max.
3 x 480 V
+10 %, 50/60 Hz
AC
power supply
Rated current
= 50 °C)
(at T
B
Peak current
= 50 °C)
(at T
B
Test voltage Cable - Cable: 2280 V
250 A 320 A 400 A 1000 A
1,5 x I
for < 3 min per hour
N
or
2,5 x I
Cable - Cabinet: 2690 V
for 30 s per hour
N
DC
/ 2 s
DC
Connection Rail with hole 11m m
PE: Bolt M10
Power loss (typical) 31 W 48 W 84 W
Protection class IP 00
/ 2 s
Rail with hole
14mm
PE: Bolt M12
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4DESCRIPTION OF THE DEVICES
In this chapter the basic structure of the devices Filter for mains applications BFN and
of the type codes on the devices.
No filters are required for the operation of the power converter.
NOTICE!
m The mains filters may not be used as a motor filter at the converter output.
m Mains filters BFN-3-1-XXX-XXX may not be used with active mains inverters. For
this converter type special filters are available, refer to ZFilters for active mains in-
verter– from page 22.
TN-TT-systems
see ZSystem
types– on page 15
In order to comply with the limit values of the EMC-standards, the use of Baumüller mains
filters BFN-3-1-XXX-X01 is required.
NOTICE!
Baumüller mains filters BFN-3-1-XXX-X01 can be used in
m Grounded industrial systems of hard or low impedance
they can not be used in
m Grounded industrial systems of insulated and high impedance.
m Grounded wye-supply systems
m Grounded industrial systems of hard- or low impedance
In order to allow the compliance with the limit values for the conducted interferences („external“ second environment - EN 61800-3, table 9) in low-impedance grounded low-voltage systems use Baumüller mains filters combined with Baumüller converters, Baumüller
motor cables and Baumüller motors. If all installation- and EMC-notes of this Handbook
are complied with, it is assumed that the interference-suppressed drive accords to the
protection requirements of the EMC-Directive 89/336/EWG and of the EMC-act (EMVG).
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IT-systems
ZSystem types– on
page 15
The use of mains filters in IT-systems is less effective and no EMC limits are defined.
„The use of EMC-filters in an insulated or a grounded industrial distribution system
of high impedance can cause a safety risk. No limit values can be defined at IT-systems,
which are used for complex industrial systems.“ (EN 61800-3, chapter 6.3.2.3, b).
NOTE!
An error case (motor ground connection) can lead to overload and perhaps destruction of the mains filters.
The use of mains filters BFN-3-1-XXX-X02 is possible, but it is not recommended to
apply mains filters in IT-systems. The transient emissions can exceed the limits of
category C3.
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4.1 General information
Mains filters are combinations of capacitors, chokes, resistors and voltage limiters, which
reduce the electromagnetic influence of environment. The power direction is bidirectional,
i. e. the outgoing cable-guided faults from the converter are reduced, but also the interference resistance of the drive against supply faults, as they appear with lightning strokes,
fuse blow or simple switching operations, is improved at the same time.
The mains filters of the series BFN ... were developed for the BAUMÜLLER-power electronics referring to its attenuation behavior. Its application enables the compliance with
the limitation values which are required for the branch of industry (second environment)
of the EMC product standard for variable-speed electrical power drive systems
EN 61800-3 as well as the „Generic Standards“ EN 61000-6-4.
When using the filter series BFN ... in the combination with Baumüller converters,
Baumüller-motor cables and Baumüller motors and under consideration of the installation- and mounting notes in this Instruction Handbook and in the Instruction Handbook of
the power converter, the protection requirements of the European EMC Directive and of
the EMC Act (EMVG) accordant to §3, sec. 1 are fulfilled.
Description of the devices
4
NOTE!
The emission of radio interferences is to a high level dependent of the wiring, the volume expansion and the arrangement of the components in the installation. This is
why the ensuring of the EMC according to the legal regulations only is possible with
the completed installation and therefore is in the responsibility range of the manufacturer of the installation or of the operating authority. (EMVG § 6, sec. 9).
NOTE!
Components of the Baumüller Nürnberg GmbH are intended for installation in commercially available control cabinets.
There are several reasons to operate the components and devices in commercial
control cabinets. Particularly the following is ensured:
m The required contact protection is ensured.
m The thermal environmental conditions (temperatures, relative humidity, cleanli-
ness of the coolants, ...), described in the technical data of the components and
the devices, are ensured.
m The mechanical environmental conditions described in the technical data of the
components and the devices (variations, vibrations, ...), are ensured.
m The notes meeting the EMC-configuration and the EMC-structure (shielding con-
cept, laying principles, implementations,...) described in the technical data of the
components and devices can be implemented.
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4.1
Power supply
Load
4.1.1 Functional description
General information
The resulting impedance of the parts used in the filters leads to an optimum mismatch
between the mains- and the load impedance. Now the interference-current can return to
its interference source. The dropping harmonic voltages at the impedance of the system
can be reduced substantially between the frequency range 150 kHz ... 30 MHz .
WARNING!
Filters cause high discharge currents and are incompatible, if they have RCDs. The
notes of EN 50178 must be considered when configuring. Due to the high discharge
currents the cross-section of the ground conductors at the filter must be at least 10
2
(EN 50178, chapter 5.3.2.1). The grounding conductor must be connected to
mm
the filter before commissioning.
NOTE!
In order to return the interference current with low impedance to its interference
source, mounting must be made on a conductive mounting plate (mounting of the
mains filter and of the power converter, which must be cleared and of the bonded
face-to-face contacting of the motor cable screen). The use of unvarnished mounting
plates provides the best results.
4.1.2 Block diagram filters for mains applications (simplified)
Figure 10: Block diagram
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4.2 Type plate
Type code
Rated current
Description of the devices
4
4.3 Type code
Figure 11: Type plate
Figure 12: Type code
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4.3
Type code
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5.1 Safety notes for transport
NOTICE!
Damage due to unauthorized transport!
Transport handled by untrained personnel can lead to a substantial amount of material damage.
Therefore:
m The unloading of the packages upon delivery as well as the in-house transport
should only be done by trained personnel.
m Contact Baumüller Nürnberg GmbH sales office if necessary.
WARNING!
Danger of physical impact!
Secure devices against falling down.
5TRANSPORT AND PACKAGING
Therefore:
m Take suitable measures, such as supports, hoists, straps, etc., to ensure that de-
vice cannot fall down.
m Use appropriate means of transport.
5.2 What to observe at transport
The device is packed at the manufacturer’s plant for the first transport. If the device is
transported onwards, ensure that the following conditions are met throughout the complete procedure of the transport:
m Temperature range - 25 °C to + 85 °C
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5.3
Transport inspection
5.3 Transport inspection
Upon receiving the delivered goods, immediately examine them for completeness and
transport damage.
If there is externally distinguishable transport damage, proceed as follows:
m Do not accept the delivery or conditi
m Note the extent of the damage on the transport do
the shipping agent.
Immediately file a complaint with the freight carrier. Have the complaint confirmed in writing and immediately contact the responsible representative of Baumüller Nürnberg GmbH.
NOTE!
ere are distinguishable transport damages the device may not be commissioned!
If th
onally accept it with reservations.
cuments or on the delivery note of
5.4 Unpacking
5.5 Disposal
After having received the packaged device:
h Avoid forceful transport agitation and hard jolts, e.g. wh
If no transport damage is visible:
h Open the packaging of the device.
h Verify the delivery scope based on the delivery note.
File a claim with the responsible Baumüller representative if the delivery is incomplete.
NOTE!
Claim each individual deficiency as soon as it has been detected. Damage claims can
only be validly asserted within the claim registration period.
The packaging consists of cardboard, plastic, metal parts, corrugated cardboard and/or
wood.
h When disposing the packaging, comply with the
area.
en putting an item down.
national regulations valid at the use
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Mounting comprises the following steps:
1 Prepare mounting
2 Mount device
6.1 Safety notes
6MOUNTING
(drilling holes, see, ZDimensions– from page 18
(attachment see ZMounting instruction– on page 43)
WARNING!
Danger as a result of faulty mounting!
The mounting requires qualified personnel with adequate experience. Faulty mounting can lead to life-threatening situations or substantial material damage.
Therefore:
m Only allow mounting to be performed by employees of the manufacturer or by oth-
er qualified personnel.
WARNING!
Danger of mechanical impact!
Secure devices against falling down.
Therefore:
m Take suitable measures to ensure that device cannot fall down.
m Use appropriate means of transport.
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6.2
Prepare mounting
6.2 Prepare mounting
Based on the configuration documents and the drilling templates (see ZDimensions–
from page 18), the deviations of the cutout sections and the positions of the attachment
drill holes can be determined.
NOTE!
The following notes must be considered for thermal safety:
m Air supply must be provided.
m Additional heat source may not be near the filters. The temperature range speci-
fied in the technical data must be complied with.
HINWEIS!
m Ensure that the screws are firmly fit.
m Mounting surface must be conductive.
m Mount the power converter, the appropriate mains filters and the bonded face-to-
face screen contacts of the motor cable to the same reference surface. The connection cable must be as short as possible. The connection cable must be
screened at lengths > 30 cm. The screen must be grounded on both sides.
m The input- and output cables of the filters must spatially be divided (at least 30 cm)
m Connect the filter cabinet bonded face-to-face to ground.
m The mains filters BFN ... can be used for global clearance of the installation. In this
case it must be placed directly at the mains supply position on the same mounting
place as the converters, which are to be cleared. The connection cable between
the converter and the filter must be screened (grounded on both sides).
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NOTICE!
Property damage due to conductive contamination.
Therefore:
m When performing installation work of any kind, it must be ensured that no foreign
material (e.g. drill shavings, copper strands, etc.) gets into the device as a result.
m If possible, the drilling holes must be made before mounting the device and the
configuring of the cables must be made outside the control cabinet. If this is not
possible, the device must be appropriately covered.
Remove this covering again prior to starting operation without fail!
Instruction handbook Mains filters BFN
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Mounting
CAUTION!
Eye injury due to catapulting particles.
Metal particles are catapulted when making the drill holes and the cutout sections.
Therefore:
Wear protective eye wear!
h Prepare drill holes.
6
6.3 Mounting instruction
Carry out mounting as follows:
1 Provide suitable transport/lifting equipment as required.
2 Keep suitable fastening components available.
3 Mount device.
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6.3
Mounting instruction
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This chapter describes the electrical installation of the device. The mechanical mounting
is described in ZMounting– from page 41
The technical preconditions must be complied with before installation:
1 Check the requirements to the power supply.
2 Check the requirements to the cables and the availability of the accordant cables.
3 Check the properties of the connections and the configuration of the cables.
7.1 Safety notes
7INSTALLATION
NOTE!
Installation must be made by employees of the manufacturer or by other qualified personnel.
Qualified personnel are persons who – on account of their occupational training, experience, instruction and knowledge of relevant standards and stipulations, accident
prevention regulations and operating conditions – are authorized by the persons responsible for the safety of the facilities, to perform the respective activities that are
necessary. Qualified personnel must recognize and prevent potential risks. The qualifications necessary for working with the device for example are:
m Occupational training or instruction, and the authorization to commission, ground
and mark electrical power circuits and devices in accordance with the standards of
the safety engineering.
m Occupational training or instruction, in accordance with the standards of work safe-
ty, for the care and use of appropriate safety equipment.
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7.1
Danger from residual energy
Safety notes
DANGER
Danger to life from electrical current!
During operation and after operation of this filter, the parts carry dangerous voltage.
DANGER!
Danger to life from electrical current!
Connection cross-section grounding conductor at least 10 mm
5.3.2.1).
2
(EN 50178, chapter
DANGER!
Danger to life from electrical current!
Stored electrical charge.
Therefore:
m Observe the discharge time of the capacitors and do not touch parts under tension.
m Observe the notes on the connected devices.
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7.2 Demands on the electrical mains
For all important data, see ZRequirements for power supply / mains supply– from page
26.
The devices must be operated in industrial environment C2/C3.
The destruction of the device can cause personal injury
DANGER!
isk of fatal injury from electrical current!
R
If the requirements for the electrical mains are not complied, the device can be damaged or destroyed. Thereby persons can be greatly endangered.
Therefore:
m Prior to installation, ensure that the requirements are met by the electrical mains.
Installation
7
Supported mains types
NOTE!
The operation of the mains filters BFN is at IT- and TN/TT-systems possible.
BFN 3-1-XXXX-X01 must be operated at industrial systems with a grounded star
point (TN-system or TT-system) with hard or low impedance.
BFN 3-1-XXXX-X02 must be operated at industrial systems with a star point, which
is not grounded or with a star point, with high impedance (IT-system)
7.3 Demands on the connection cable
h Take into account IEC/EN 60204-1, chapter 13 when selecting the cable.
h The grounding conductor cross-section of the cable must be compliant with IEC/
EN 60204-1, section 5.2, tab. 1.
h A fixed connection for the grounding conductor is mandatorily required for operation of
vice.
the de
h Use copper cable approved for a minimum of 60 °C (drives < 3 x 100 A) or 75 °C
rives 3 x 100 A), if UL 508C is observed.
(d
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7.4
Grounding conductor connection and RCD-compatibility
7.4 Grounding conductor connection and RCD-compatibility
Due to the operating principle discharge current >3.5 mAAC or >10 mA
the protective devices Therefore a stationary grounding conductor connection according
to EN 61800-5-1 is required (see notes for the installation in the Instruction Handbook of
the converter).
Parasitic capacitances in the filter, power unit, motor cable and motor winding cause discharge current of 100 mA and greater.
Therefore power converter can be incompatible with the RCD!
Observe the safety notes in the EN 50178/VDE 0160/4.98, part 5.2.11.2.
7.5 System requirements with regard to EMC-stability
NOTE!
The emission of radio interferences is highly dependent of the wiring, the spatial expansion and the assignment of the components in the system. Therefore the electromagnetic compatibility compliant to the regulations can be assured at the assembled
system only. Therefore the system manufacturer or the operator is responsible for assuring EMC (EMVG §6, chapter 9).
can flow over
DC
7.5.1 General information about converters
In converters of the Baumüller Nürnberg GmbH semiconductors are used. These can
minimize power loss by quick switching. Therefore a compact size of the devices is possible. The semiconductor generates electromagnetic waves due to this quick switching.
Special preconditions must be observed to avoid electromagnetic influences by switching
procedures.
The following causes are the reason for interferences in the drive system:
m Capacitive discharge currents. Here is a great rate of rise of voltages when switching
semiconductors.
m Great currents and rate of rise of voltages in the motor cables. The interference energy
which is bounded into magnetic fields reaches frequencies of a few hertz to about
30
MHz. Due to the great rate of rise of voltages additional electromagnetic fields with
frequencies to about 600
m Great cycle rates and quick logic circuits (electromagnetic field with frequencies of
16
MHz to 1 GHz).
m System perturbation and harmonics. Here commutation procedures and non sinusoi-
dal mains loads occur. This particularly occurs at line-commutated converters (100 Hz
to 20
kHz).
EMC is decisively dependent of the assembly of the individual parts and components in
the control cabinet. The system can be configured compliant to the latest EMC-knowledge described in the following. This way the statutory regulations can be complied with.
MHz occur.
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7.5.2 Measures taken to assure EMC
Power
choke
The following configuration notes must be considered to assure EMC.
Installation
7
Cabling m All conn
side the power converter. If the screening atte
enough (see limit values of the interference emission complying with EMVG for your
system) and if the EMC-compatibility in the internal space is ensured (this can be assumed if the configuration notes of this chapter
can be mounted unscreened.
Consider the information submitted in ZScreening– on page 52.
ected cables must be screened in order to suppress interfering radiation out-
nuation of the control cabinet is high
are complied with), the control cables
Figure 13: Cabling power unit
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7.5
System requirements with regard to EMC-stability
m Use mains filters recommended by Baumüller
m Obser
m If Bau
m T
m T
m The smallest poss
ve the correct sequence of the components:
Mains - fuse - mains filters - power choke (d
verter - motor
müller motor cables and - components are used only, the compliance with the
permitted limit value of the interference immunity and of the interfering radiation can be
assumed.
he maximum length of the motor cable is limited. The length is dependent of the
cross-section of the cable (for example 100 m at 1.5 mm
imum length should be reduced by the factor
are used.
he screened motor cable between the power converter and the motor must be one
piece. The cable may not be interrupted by terminals, contactors, fuses etc.
ible effective height is reached, if the cable is installed bonded face-
to-face on the surface of grounded switching device panels
ependent of power converter) - power con-
1/n, if n-parallel-connected motor cables
2
, 30 m at 35 mm2). The max-
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Figure 14: Cable installation - effective height
m The cables shall be installed as near as possible to the conductors of the grounded
system. Herewith effective loop area for the magnetic coupling is reduced.
Figure 15: Cable installation - loop area
Instruction handbook Mains filters BFN
Document No.: 5.09010.03 Baumüller Nürnberg GmbH
Installation
m A minimum distance of 20 cm should be kept between the conductors at a parallel in-
stallation of signal- and control cables and the power cables.
m The distance between cables with very high interference potential and with cables on
the mains side of the mains filters should be at least 30 cm.
m Try to cross cables with different EMC-categories in a 90°-angle.
m The conductors of each core pair must be twisted at symmetric signal transmission (for
example differential amplifier inputs for the speed value). The core pairs must be twist
ed with the other core pairs.
m Ground connection converter/ground plate should be as short as possible (< 30 cm). It
must be finely stranded. Use great cross-sections (recommended >
m Connect the PE-connection on the load-side of the filter with low impedance to the
mounting plate. A zinc-plated sheet metal bracket or a HF-ground band would be per
fect.
m There should be a distance of at least 20 cm to the power converter and its wirings for
parts, which cause interferences (for example contactors, transformers, chokes) and
for susceptible parts (for example Ps, bus systems).
m Avoid reserve loops at long cables.
m Ground reserve cables at both ends (additional screening effect, avoid capacitively
coupled, dangerous accessible voltages).
10 mm).
7
-
-
Grounding m In order to reduce the influence of high-frequency interferences, which were generated
when operating the power converter, the basic star-grounding does not comply to
EMC. A reference surface is required to connect the devices large-surfaced with the
potential to ground (for example a metallic bright mounting plate and cabinet parts)
m Mount the power converter with its mains filters and the bonded face-to-face screen
contactor of the motor cable to the same reference surface.
m All grounding conductors and screens should be led directly above ground, so that no
ground loops occur.
m Ground the controller-reference potential of the power converter. Connect with a great
cross-section and a short cable (<
m Remove insulating layers (varnish, adhesive) from the ground connections. Use ser-
rated washers (DIN 6798) to reach the surface. This way a durable conductive contact
is achieved. . In order to prevent corrosion of ground connection, select suitable metal
pairs (observe electrolytic series of metals). Keep the conductive electrolytics from the
connection by using a protective coating (for example grease)
m The screens must be bonded at both ends face-to-face and well conductive to ground.
This way the effects of magnetic or highly-frequent interference fields can be attenuat
ed. The receiver should be connected isolated, the transmitter should be connected
capacitive, if problems with ground loops occur (for example double grounding of set
value cable screening).
m When leading external cable screens through walls, contact the different EMC-ranges
separated from one another.
Cables, which are led through walls of screening cabinets without special precautions
(for example filtering), can influence the screening effect of these cabinets. Therefore,
also connect the cable screenings with well conductivity at the cabinet’s outlet with the
screening wall.
30 cm).
-
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7.5
Screening m The cable screen is effective at magnetic fields, if the screen is connected to ground
System requirements with regard to EMC-stability
The distance from the last screening contact point to the cabinet’s outlet must be very
short.
Figure 16: Cable installation - cabinet outlet
on both ends.
m A scre
m F
ening effect at electric fields is already existing, if the screen is connected only
single-sided to ground.
ields with high frequencies always are electromagnetic fields. Thereby it does not
matter, if it is an electric or a magnetic field. Here screening must be made on both
sides.
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Figure 17: Cable installation - apply screen
m Applying the screen to ground on both sides achieves that the cable remains in the
screening „system cabinet“.
he both-sided grounding of cable screenings nearly excludes an influence due to
m T
ground loops (potential differences on the ground system).
e HF-connection of a screen with ground can also take place capacitively. This
m Th
avoids low-frequent errors due to ground loops.
Screening cables which pass different EMC r
nals, because the screening attenuation other
to the next module without interruption.
Instruction handbook Mains filters BFN
Document No.: 5.09010.03 Baumüller Nürnberg GmbH
anges, may not be opened at the termi-
wise decreases highly. They must, lead
Installation
m The screen connection must be made with a large surface area and low impedance.
Cable tails with a length of only 3
with errors in the MHz range up to 30
NOTE
The braided screen must have a coverage of at least 85 %.
The following lines possess an especially high interference potential:
m Motor cable
m Cable to external chopper resistors
m Cable between mains filter and power choke
m Cable between power choke and converter
Available screening terminals see ZScreening terminals– on page 61.
cm (1 cm wire = 10 nH) reduce the screening effect
dB!
7
Figure 18: Proposal for a screening connection
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7.6
Procedure of the installation
7.6 Procedure of the installation
DANGER!
Danger to life due to electrical current!
Energized parts are dangerous to life.
Therefore:
m The device, the mounting range and the parts, which are to be mounted (for exam-
ple supply cables) must be off circuit during complete mounting
m The cross-section of the grounding conductor must be greater than 10 mm
h Install all cables compliant with EMC.
h Connect cables (see ZConnection diagram– on page 55).
(Pay attention to permitted torques!)
2
NOTE!
Installation notes:
m Don’t connect mains filters in parallel.
m Don’t connect mains filters of the same type in series - the attenuation character-
istics will not be approved.
m Connect the PE-terminal on the load-side of the filter with low impedance to the
mounting board. Ideal is a zinc plated L-bracket or with a HF-earth strap.
m Suppress each drive individually from interferences. In case you have to suppress
all of the drives from interferences together, do not interrupt any of the screens between converter and the mains filter. This means the screened lines are not interrupted by fuses, contactors or others, except with eventual necessary power
chokes.
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7.7 Connection diagram
Power
choke, if required
Power converter
Main contactor
Installation
7
Connection
notes
Figure 19: Filter connection
1L1, 1L2, 1L3, PE
2L1, 2L2, 2L3,
Cross-section system connection compliant to
EN 60204-1
Installation of cables see EMC-notes.
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7.7
Connection diagram
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8.1 Safety notes
Basic information
8MAINTENANCE
DANGER!
Risk of fatal injury from electrical current!
Inevitably, when operating this electrical device, certain parts of it are energized with
hazardous voltage.
Therefore:
m Pay heed to areas on the device that could be dangerous during the mainte-
nance.
m Pay heed to areas that could still be electrically energized after operation.
WARNING!
Risk of injury due to improperly performed maintenance work!
Improper maintenance can lead to severe personal injury and material damage.
Therefore:
m Before beginning work, make sure that there is enough space for mounting.
m Make sure that the mounting area is kept clean and orderly. Parts and tools that
are loosely stacked or lying around are a potential accident source.
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8.2
Environmental conditions
8.2 Environmental conditions
The device is maintenance-free, if the specified environmental conditions are complied
with. Information referring to the environmental conditions see ZRequired environmental
conditions– on page 17.
8.3 Repairs
In case of device damage, please inform your sales office or:
Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
90482 Nürnberg
Deutschland
Tel. +49 9 11 54 32 - 0
Fax: +49 9 11 54 32 - 1 30
E-Mail: mail@baumueller.de
Internet: www.baumueller.de
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9.1 Mains filters
for mains inverter/
compact units
9SPARE PARTS AND PART NUMBERS
In this chapter the spare-/accessory parts for the devices of the series Mains Filters are
listed. In case you have questions and suggestions according the accessories, do not
hesitate to contact our product management.
I
rated AC 50 °C
7 A BFN-3-1-0007-001 314277
16 A BFN 3-1-0016-001 314278
30 A BFN 3-1-0030-001 314279
42 A BFN 3-1-0042-001 314280
56 A BFN 3-1-0056-001 314281
75 A BFN 3-1-0075-001 314282
100 A BFN 3-1-0100-001 314283
TN/TT-system Part No.
1000 A BFN 3-1-1000-101 423683
1)
available on request
130 A BFN 3-1-0130-001 314284
180 A BFN 3-1-0180-001 314285
250 A BFN 3-1-0250-001 373891
320 A BFN 3-1-0320-001
1)
439384
BFN 3-1-0320-101 373896
400 A BFN 3-1-0400-001
1)
439385
BFN 3-1-0400-101 373900
600 A BFN 3-1-0600-001
1)
373901
BFN 3-1-0600-101 419997
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9.1
Mains filters
for
active mains
inverter
I
rated AC 50 °C
150 A EPCOS B84143A0150R410
TN/TT-system Part No.
437618
for BM5174
for mains inverter/
compact units
55 A Schaffner FN 3120H-80-35
417872
for BM4135
125 A Schaffner FN 3120H-150-40
416405
for BM4145
300 A Schaffner FN 3100-300-99
418234
for BM4163
I
rated AC 50 °C
IT-system Part No.
150 A BFN-3-1 - 0150 - 002 433177
250 A BFN-3-1 - 250 - 002 373620
320 A BFN-3-1 - 320 - 002 373894
BFN-3-1 - 320 - 102
1)
439386
400 A BFN-3-1 - 400 - 002 373898
BFN-3-1 - 400 - 102
1)
439387
600 A BFN-3-1 - 600 - 002 373902
BFN-3-1 - 600 - 102 439388
1)
available on request
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9.2 Screening terminals
Spare Parts and Part Numbers
Cable diameter (mm) Part No.
2 x 2 - 6 mm 226752
9
3 - 8 mm 226741
4 - 13,5 mm 226745
10 - 20 mm 226749
Abbildung 20: Screening terminals for grounding
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9.2
Screening terminals
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10DISPOSAL
NOTE!
Baumüller products are not subject to the scope of application of the EU's Waste
Electrical and Electronic Equipment Directive (WEEE, 2002/96/EC). Hence,
Baumüller is not obligated to bear any costs for taking back and disposing of old devices.
NOTICE!
Avoid polluting the environment as a result of improper disposal.
Therefore:
m Only dispose in compliance with the health and safety regulations.
m Take heed of any special local regulations. If you are unable to directly ensure safe
disposal yourself, commission a suitable disposal contractor.
m In the event of a fire, hazardous substances could possibly be generated or re-
leased.
m Do not expose electronic components to high temperatures.
m Beryllium oxide is used as inner insulation, for example for various power semicon-
ductors. The beryllium dust that is generated upon opening is injurious to the
health.
Do not open electronic components.
m Dispose of capacitors, semiconductor modules and electronic scrap as special
waste.
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10.1
Disposal facilities/authorities
WARNING!
Danger due to faulty disassembly!
Demounting and disposal requires qualified personnel with adequate experience.
Therefore:
m Only allow disassembly and disposal to be performed by qualified personnel
10.1 Disposal facilities/authorities
Ensure that the disposal is handled in compliance with the disposal policies of your company, as well as with all national regulations of the responsible disposal facilities and authorities. In case of doubt, consult the bureau of commerce or environmental protection
authority responsible for your company.
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Index
A
Accessories 59
Accidents 13
Attention 6
B
Block diagram 36
C
Cable screens 51
Cabling 49
Case of danger 13
Connection cable, Demands on 47
Connection notes 55
Customer service 8
D
Danger 6
DC-link discharging time 12
Disposal 8, 63
E
Electrical current, Danger 12
EMC product standard 35
Energy supply, Requirements 16
Environmental conditions, Requirements 17
F
Fire fighting 13
Function description 36
G
Grounding 51
Grounding conductor 48
Guarantee provisions 8
H
Hard hat 11
I
Installation, procedure 54
Instruction handbook, Contents of 9
K
Key to symbols 6
L
Limitation of liability 7
List of figures 67
M
Mains supply 16
Maintenance 57
Modifications 9
N
Note 6
O
Operating conditions 15
Operating personnel 10
Operator, Responsibility 10
P
Personnel, Operating 10
Personnel, Qualified 10
Protection eyewear 11
Protective equipment 11
Protective gloves 11
Protective work clothing 11
R
Repairs 58
S
Safety equipment 13
Safety shoes 11
Screening 52
Signs 14
Spare parts 8
Special hazards 12
T
Technical data 15
Temperature range 17
Training, Personnel 10
Transport 39
Transport inspection 40
Type code 37
U
Unpacking 40
Usage, Proper 9
W
Warning 6
Warning notes 6
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Index
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List of Figures
List of Figures
Dimensions filters TN/TT-systems ............................................................................................. 18
Dimensions filters TN/TT-systems ............................................................................................. 19
Dimensions filters TN/TT-systems ............................................................................................. 20
Dimensions filters TN/TT-systems ............................................................................................. 21
Dimensions filters TN/TT-systems EPCOS for BM5174 ............................................................ 22
Dimensions filters TN/TT-system Schaffner for BM4135, BM4145............................................ 23
Dimensions filters TN/TT-system Schaffner for BM4163 ........................................................... 24
Dimensions filters IT-systems .................................................................................................... 25
Dimensions filters IT-systems EPCOS....................................................................................... 26
Block diagram ............................................................................................................................ 36
Type plate .................................................................................................................................. 37
Type code .................................................................................................................................. 37
Cabling power unit ..................................................................................................................... 49
Cable installation - effective height ............................................................................................ 50
Cable installation - loop area...................................................................................................... 50
Cable installation - cabinet outlet ............................................................................................... 52
Cable installation - apply screen ................................................................................................ 52
Proposal for a screening connection.......................................................................................... 53
Filter connection......................................................................................................................... 55
Screening terminals for grounding ............................................................................................. 61
Instruction handbook Filter for mains applications
Document No.: 5.09010.03
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List of Figures
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Instruction handbook Filter for mains applications
Document No.: 5.09010.03 Baumüller Nürnberg GmbH
Overview of Revisions
Version Edition Changes
5.09010.01 03-Dec-2012 First edition
5.09010.02 20-Apr-.2017 Revision
5.09010.03 1-Mar-2018 Revision
Overview of Revisions
Instruction handbook Mains filters BFN
Document No.: 5.09010.03
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Notes:
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Instruction handbook Mains filters BFN
Document No.: 5.09010.03 Baumüller Nürnberg GmbH
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