Danfoss EC-LTS1200-410 User manual

User Guide
Liquid cooled heavy duty inductor unit
EC-LTS1200-410
www.danfoss.com

Revision history Table of revisions
Date Changed Rev
July 2021 Updated user guide 0201
User Guide
EC-LTS1200-410
2 | ©Danfoss | July 2021 BC355449988603en-000201

General information Intended use of the user guide................................................................................................................................................... 4
Product naming convention........................................................................................................................................................ 4
Conformity according to standards...........................................................................................................................................4
Warranty.............................................................................................................................................................................................. 5
Terms and abbreviations...............................................................................................................................................................5
Responsibility of the manufacturer........................................................................................................................................... 6
Safety information General safety statement...............................................................................................................................................................7
Safety message signal words....................................................................................................................................................... 7
Safety symbols...................................................................................................................................................................................7
Personal protective equipment.................................................................................................................................................. 8
Safety features...................................................................................................................................................................................9
Electromagnetic compatibility (EMC)....................................................................................................................................... 9
Installation safety..............................................................................................................................................................................9
Operation safety.............................................................................................................................................................................11
Product overview Intended use of the electric device......................................................................................................................................... 13
System introduction..................................................................................................................................................................... 14
Cooling...............................................................................................................................................................................................14
Rating plate......................................................................................................................................................................................14
Tightening torques........................................................................................................................................................................15
Transportation and storage Transportation................................................................................................................................................................................ 17
Receiving and unpacking............................................................................................................................................................17
Lifting................................................................................................................................................................................................. 17
Handling............................................................................................................................................................................................19
Storage...............................................................................................................................................................................................19
Installation Required tools.................................................................................................................................................................................20
Mechanical installation................................................................................................................................................................20
Allowed mounting position..................................................................................................................................................20
Installation procedure.............................................................................................................................................................21
Cooling connections............................................................................................................................................................... 22
Recommended coolants........................................................................................................................................................22
Electrical installation.....................................................................................................................................................................23
Electrical connections.............................................................................................................................................................23
Grounding...................................................................................................................................................................................23
Cable gland assembly and power line connection......................................................................................................25
Cabling and wiring...................................................................................................................................................................31
High voltage connections..................................................................................................................................................... 32
Low voltage connections.......................................................................................................................................................32
Operation Operation conditions....................................................................................................................................................................34
Condition monitoring during operation...............................................................................................................................34
Maintenance Regular maintenance................................................................................................................................................................... 35
Cooling system maintenance....................................................................................................................................................36
Cleaning............................................................................................................................................................................................ 36
Dismounting and disposal of the electric device
Troubleshooting
Aftersales Service policy...................................................................................................................................................................................40
Service parts.....................................................................................................................................................................................40
User Guide
EC-LTS1200-410
Contents
©Danfoss | July 2021 BC355449988603en-000201 | 3

Intended use of the user guide
This user guide contains the installation, operation and maintenance instructions for the EC-LTS1200-410
liquid cooled heavy duty inductor unit.
This user guide contains instructions necessary to safely and properly handle, install and maintain the
electric device. They should be brought to the attention of anyone who installs or maintains the electric
device or associated equipment.
All of the safety warnings and instructions in this user guide must be followed to prevent injury to
personnel or damage to property. Only qualified and authorized personnel, familiar with health and
safety requirements and national legislation, shall be permitted to handle, install and maintain the
device.
This user guide must be kept for future reference during installation, operation and maintenance.
This user guide uses illustrations as examples only. Illustrations in this user guide may not necessarily
reflect all system features.
Product naming convention
In this user guide the EC-LTS external inductance unit is referred to as the electric device.
The following naming convention is used to refer to electric device type code and options:
•EC-LTS1200-XXX
Part of the name Explanation
EC Electric Converter
LTS1200 Type code part 1
XXX Type code part 2
Options are presented in the Table below. Standard options are indicated by a star (*).
EC-LTS1200-410 options
Variant Code Description Additional information
Cable glands * No cable glands No cable glands or plugs
+CG1 M25/M32 cable glands 3x M25 cable glands, 3x M32 cable glands and 2x M32 plugs
in delivery
Marine classification * No marine classification
+CL1 ABS American Bureau of Shipping
+CL2 BV Bureau Veritas
+CL3 DNV
+CL4 LR Lloyd’s Register
+CL5 RINA
Conformity according to standards
The electric device has been designed in accordance with the essential parts of the following directives
and to meet the requirements of the standards:
User Guide
EC-LTS1200-410
General information
4 | ©Danfoss | July 2021 BC355449988603en-000201

Applicable directives and standards
Directives / Standards Explanation
Low Voltage Directive 2014/35/EU Electrical equipment means any equipment designed for use with a voltage
rating of between 50 and 1000 V for alternating current.
The electromagnetic compatibility
(EMC) Directive 2014/30/EU EMC directive ensures that electrical and electronic equipment does not generate, or is affected by, electromagnetic disturbance.
IEC/EN 61800-5-1: 2007 Adjustable speed electrical power drive systems - Part 5-1: Safety
requirements - Electrical, thermal and energy.
EN 13766-1:2018 Construction machinery. Electromagnetic compatibility of machines with
internal electrical power supply.
UN Regulation No. 10 Revision 4 and
Revision 5 Uniform provisions concerning the approval of vehicles with regard to electromagnetic compatibility.
Warranty
Danfoss offers warranty against defects in workmanship and materials for its products for a period of
twelve (12) months from commissioning or eighteen months (18) from delivery (Incoterms-EXW),
whichever occurs first.
In order for the warranty to be valid, the customer must follow the requirements of this and all related
documents, especially those set out in the product installation and maintenance documents, as well as
the applicable standards and regulations in force in each country.
Defects arising from the improper or negligent use, operation, and/or installation of the equipment, non-
execution of regular preventive maintenance, as well as defects resulting from external factors or
equipment and components not supplied/recommended by Danfoss, will not be covered by the
warranty.
The warranty will not apply if the customer at its own discretion makes repairs and/or modifications to
the equipment without prior written consent from Danfoss.
Terms and abbreviations
Following symbols, terms and abbreviations may exist in this user guide.
Term/ Abbreviation Explanation
AC Alternating current
DC Direct current
MCB Miniature circuit breaker
EMC Electromagnetic compatibility
EMI Electromagnetic interference
Symbol Variable Unit
UDC DC link voltage V
Uac AC output voltage V
InRated current Arms
PnRated power kW
fin/out Input / Output frequency Hz
fswitch Switching frequency kHz
Ipeak Overcurrent limit A
QcRated coolant liquid flow l/min
TcRated coolant liquid input
temperature °C
User Guide
EC-LTS1200-410
General information
©Danfoss | July 2021 BC355449988603en-000201 | 5

Symbol Variable Unit
Tamb Rated ambient temperature °C
GND Ground in electrical connections
R Resistance Ω
Responsibility of the manufacturer
Danfoss is responsible for the safety, reliability and performance of the electric device only if:
•Handling, mounting, installation, operation and maintenance are carried out by qualified and
authorized service personnel.
•The installation of the system complies with the requirements of the appropriate regulations.
•The electric device is used in accordance with the instructions in this user guide.
•The electric device is installed, maintained and serviced in accordance with the instructions in this
user guide.
User Guide
EC-LTS1200-410
General information
6 | ©Danfoss | July 2021 BC355449988603en-000201

General safety statement
The electric device is intended for use as a component for industrial and commercial installations. The
end product containing the electric device must conform with all related regulations.
The use of the electric device is prohibited in hazardous areas unless it is expressly designed for such use.
The electric device is intended for installation, use and maintenance by qualified personnel, familiar with
health and safety requirements and national legislation. Ignoring these instructions may invalidate all
applicable warranties.
These instructions must be followed to ensure safe and proper installation, operation and maintenance
of the electric device. They should be brought to the attention of anyone who installs, operates or
maintains the electric device or associated equipment.
High voltage and rotating parts can cause serious or fatal injuries. For the electric device covered by this
user guide, it is important to observe safety precautions to protect personnel from possible injury.
Safety message signal words
Safety message signal words indicate the severity of a potential hazard.
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. CAUTION may also alert against unsafe practices
NOTICE Indicates a potentially hazardous situation which, if not avoided, could result in property
damage.
Safety symbols
The following safety and information related symbols may exist in this user guide and on the electric
device.
Danger
This symbol is identified by a yellow background, red octagonal band and a black
STOP text. It indicates a hazardous situation that causes severe injury or death.
Action indicated by this symbol may not be executed.
General warning
This symbol is identified by a yellow background, black triangular band, and a black
exclamation point symbol. It indicates a general potentially hazardous situation.
Electric shock warning
The symbol is identified by a yellow background, black triangular band, and a black
arrowhead symbol. It indicates dangerous electrical voltage that could cause an
electric shock to a person.
Burn warning
The symbol is identified by a yellow background, black triangular band, and a black
wavy lines- symbol. It indicates a hot device that could cause burns to a person.
The symbol also indicates that the device should be placed and installed so that
contact with its potentially hot surface is not possible.
User Guide
EC-LTS1200-410
Safety information
©Danfoss | July 2021 BC355449988603en-000201 | 7

Magnet warning
The symbol is identified by a yellow background, black triangular band, and a black
magnet symbol. It indicates strong magnetic field that could cause harm to a person
or property.
Poison warning
The symbol is identified by a yellow background, black triangular band, and a skull
and crossbones symbol. It indicates a poisonous substance that could kill or cause an
injury to a person.
Electric shock warning - Read the instructions in the user guide.
General Information.
Read the instructions in the manual.
Personal protective equipment
Personal protective equipment shall be used when necessary during handling, installation and
maintenance of the electric device to avoid injury.
Use eye protective equipment like safety goggles or mask when you work with the electric
device. Permanent damage to the eye could be caused if bearing grease, melted nitrile rubber
(radial lip seal), glycol or other fluids splash.
Use hearing protective equipment when you work on the electric device. Hearing injuries can
be caused by too loud noise (noise in excess of 85 dBA).
Use head protective equipment like helmet when you lift the electric device! Head injuries can
be caused by object impact.
Use cut resistant gloves when you handle and maintain the electric device. There is a risk of
cut injuries.
Use protective footwear when you lift or move the electric device! Foot injuries could be
caused if lifting system or lifting brackets fail.
User Guide
EC-LTS1200-410
Safety information
8 | ©Danfoss | July 2021 BC355449988603en-000201

Safety features
Electromagnetic compatibility (EMC)
When interfacing other equipment, connect only equipment that are specified as part of the
system and that are compatible.
Magnetic and electromagnetic fields generated near the current-carrying conductors and
permanent magnets in electric machines represent a health danger to persons with heart
pacemakers, metal implants and hearing aids. Persons with a heart pacemaker, metal
implants or hearing aids must consult a doctor before they enter the following areas:
•Areas in which electric equipment and parts are operated
•Areas in which electric equipment with permanent magnets are stored, mounted,
operated or repaired
If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.
EMC stands for Electromagnetic compatibility. It is the ability of electric equipment to operate without
problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere
with any other product or system within its locality. This is a legal requirement for all equipment taken
into service within the European Economic Area (EEA).
Our products are designed with high standards of EMC in mind. Connect the power lines and groundings
along the instructions in this user guide to achieve the required level of EMI protection.
It is the responsibility of the installer to make sure that the equipment or system into which the product is
incorporated complies with the EMC legislation of the country of use. Within the European Union,
equipment into which this product is incorporated must comply with the EMC Directive 2014/30/EU.
Installation safety
Only trained and qualified personnel familiar with the relevant safety requirements can
install the electric device. If the electric device is installed incorrectly it may lead to safety
hazard.
Make sure of correct grounding connections. Do not run the electric device without correctly
attached protective earth conductor. The grounding cable must be sufficient to carry the
maximum supply fault current which is normally limited by the fuses or Miniature Circuit
Breaker (MCB). Suitably rated fuses or MCB should be fitted in the mains supply of the electric
device, by the local legislation and recommendations.
Use only correct (type and value) protective fuses with the high voltage DC-system.
Do not do any work on the electric device control cables when the power is applied to the
electric device or to the external control circuits.
User Guide
EC-LTS1200-410
Safety information
©Danfoss | July 2021 BC355449988603en-000201 | 9

The control input functions of the electric device – for example stop/start must be secured
using independent channel protection in safety critical applications. All applications where
malfunction could cause injury or loss of life must be subject to a risk assessment and improve
control signal protection if needed.
Do not activate the automatic fault reset function on any system, where this may cause a
potentially dangerous situation. Reason for every fault situation should be determined
before resetting the fault.
Make sure that the supply voltage corresponds to the specification of the electric device.
Do not attempt to repair the electric device. In the case of suspected fault or malfunction,
contact Danfoss or Danfoss authorized service center for further assistance.
When you install the electric device, make sure that the cooling system and the used coolant
meet the specifications of the manufacturer. Make sure that the cooling system is in use when
the DC-link is powered.
If the control cabling is installed close with the power cabling, make sure that minimum
separation distance is 100 mm and crossings are at 90 degrees. Make sure that all terminal
connections are tightened correctly by the instructions.
Electric device must not be opened (excluding the connection box lid). Any attempt causes
loss of warranty.
Within the European Union, all machinery in which this product is used must comply with
Directive 98/37/EC, Safety of Machinery. In particular, the machine manufacturer is
responsible for providing a main switch and ensuring the electrical equipment complies with
EN60204-1.
Use correct personal protective equipment when you are near the electric device.
User Guide
EC-LTS1200-410
Safety information
10 | ©Danfoss | July 2021 BC355449988603en-000201

Read the instructions in this user guide before you start to install the electric device.
Operation safety
Do not use the electric device without correctly dimensioned and operating cooling system.
Maximum operation temperature must not be exceeded to avoid permanent damage to the
electrical device.
The requirements of this user guide and other related instructions and standards must be
followed.
Do not touch the electric device during operation. The surface of the electric device can be
hot.
This electric device is intended for professional use as complete equipment or system and as
part of a fixed installation. The electric device uses high voltages and currents, and it has
large amounts of stored electrical energy. Close attention is required to system design and
electrical installation to avoid hazards in either normal operation or in the event of
equipment malfunction.
The electric device can only be used in the applications it is intended for. The rated nominal
values and operational conditions are shown in the rating plate.
User Guide
EC-LTS1200-410
Safety information
©Danfoss | July 2021 BC355449988603en-000201 | 11

The advantages and features of the electric device:
•Extremely compact design – 410 A.
•High enclosure class IP67 – sealed from moisture and dust.
•Ambient temperature -40ºC...105ºC.
•Robust design withstanding high levels of mechanical vibrations and shocks.
•Designed especially for highly cyclical loads typical in heavy mobile work machines.
Main components
1 L1 connection
2 L2 connection
3 L3 connection
4 +LV connection plugged (configurable, see +CG option below)
5 Cooling inlet / outlet connections
6 X2 temperature measurement connector
7 +LV connection cable gland (configurable, see +CG option below)
8 X1 plugged, not in use
9 M8 Mounting points, 6 pcs on the sides and 8 pcs on the bottom
10 Connection box lid
+CG1 option comes with a selection of cable glands and plugs. Typical cable gland configurations are
shown in the Table below.
User Guide
EC-LTS1200-410
Product overview
12 | ©Danfoss | July 2021 BC355449988603en-000201

Typical cable gland configurations for option +CG1
Connections Typical cable gland applications
Connection to DC/DC-
converter (L1, L2, L3)
3x M25 cable glands 3x M25 cable glands 3x M25 cable glands
Low voltage side positive
connection (+LV)
1x M32 cable gland, 2x
M32 plugs
2x M32 cable glands, 1x
M32 plugs
3x M32 cable glands, no
plugs
Intended use of the electric device
The electric device is intended only for professional use. Installation, operation and
maintenance of the electric device is permitted only for trained personnel and professionals.
The electric device is intended for fixed installation, as a part of complete power generation
equipment or system.
Typical applications for the electric device are:
•System component designed to be combined with EC-C1200-450 DCDC-converter, used to transfer
energy between two different voltage levels.
Application example
EC-C1200 DC/DC converter combined with the EC-LTS unit. LV+ and LV- can be connected, for example,
to battery and DC+ and DC- to DC-link. EC-C1200 would then control the battery discharging and
charging.
Not allowed use of the electric device
It is forbidden to use, handle, maintain and storage the electric device in following ways (including but
not limited to):
•Using the electric device for other purposes than defined in the user guide.
•Disregarding the obligation to comply with the user guide, safety signs and rating plate of the
electrical device.
•Using the electric device, making adjustments and maintenance without first reading the user guide.
•Exceeding the designed limits during the operation.
•Using non-original service parts of wrong material causing corrosion problems and mechanical
failures in time.
•Operating and performing maintenance on the electric device without appropriate personal
protective equipment.
•Using the electric device for supporting other structures or indirect movements.
User Guide
EC-LTS1200-410
Product overview
©Danfoss | July 2021 BC355449988603en-000201 | 13

•Causing any kind of impact forces to the electric device (for example hitting or hammering or
dropping objects).
•Operating the electric device with electric connections other than defined in the user guide.
•Operating the electric device with insufficiently tightened connections or cable glands.
•Operating the electric device with power cables routed against the instructions.
•Operating the electric device without properly dimensioned and operating cooling system.
•Accessing the connection box(es) of the electric device, performing maintenance or adjustment
operations without securing that the electricity is disconnected and electric device is discharged as
defined in the user guide.
•Lifting the electric device with additional load attached.
•Using the electric device in potentially explosive environment.
•Allowing dirt or liquid to enter into the electric device or connection box.
•Using cables that can't withstand the maximum current values of the electric device.
•Using dirty cable lugs or broken tools.
•Connecting power cables so that there is less than 10 mm air gap between the cable lug and other
metallic structure (including the braid of the cable).
•Storing the electric device contrary to the guidelines presented in this user guide, for
example, outdoors in wet or dusty conditions.
•Storing the electric device without proper support that prevents overturning and falling.
For product specific and up to date information see product data sheets at https://www.danfoss.com/.
System introduction
Cooling
Cooling system requirements
Cooling system properties Specification
Cooling type Liquid cooling
Coolant type Water or water glycol mixture (glycol max. 50 %)
Coolant temperature -40º…+65 ºC
Coolant flow minimum 10 l/min
Maximum operating pressure 2 bar
Pressure drop 40 mbar with 10 l/min (+25 °C coolant)
See detailed information and specifications from the product data sheets at https://www.danfoss.com/.
Rated values can be found from the rating plate.
Rating plate
Each electric device has a rating plate (also called product label) which can be found on top of the electric
device. The rating plate contains device rating and identification details. The figure below shows an
example of a rating plate. The rating values in the Figure are illustrations only. For the exact information,
see the rating plate on the electric device and product data sheets at https://www.danfoss.com/.
User Guide
EC-LTS1200-410
Product overview
14 | ©Danfoss | July 2021 BC355449988603en-000201

Rating plate example
Rating plate fields
Field Explanation Unit
1 Electric device product family
2 Electric device device full type code including possible options
Serial No. Serial number
n ph Number of phases
U nom Nominal voltage V
U range Voltage range V
f1 Frequency Hz
I nom Nominal current A
P nom Nominal power VA
Manuf. Manufacturing year
Duty Duty class
Cooling Cooling type
TCCoolant temperature °C
QCCoolant flow l/min
IP rating Enclosure class according to IEC60034-5
Mass Total weight of the electric device kg
Tamb Ambient temperature limits °C
Tstorage Storage temperature limits °C
Max. pressure Coolant maximum pressure bar
The rating plate and its values shown here may not all be relevant for every electric device.
Tightening torques
For correct and safe operation, it is essential to use specified tightening torques for the electric device
screws. Tightening torques (screw preloads) used in the electric device are shown in the Table below.
User Guide
EC-LTS1200-410
Product overview
©Danfoss | July 2021 BC355449988603en-000201 | 15

Tightening torque tolerance is +/- 5% of the specified tightening torque.
Tightening torques
Connection Torque
Electric device mounting screws, M8 20 Nm
Connection box lid (power terminal cover) mounting screws 4 Nm
Cable lug mounting screws 15 Nm
Grounding cable mounting screws, M8 20 Nm
Cable gland (tighten from the frame of the gland) 15 Nm
User Guide
EC-LTS1200-410
Product overview
16 | ©Danfoss | July 2021 BC355449988603en-000201

Transportation
Do not apply any excess weight on the electric device during transportation.
See the weight of the electric device from the product data sheets at https://
www.danfoss.com/.
The electric device is shipped in first class condition. Products are inspected and packed correctly to
prevent damage from ordinary handling during the transportation. Transportation conditions shall be in
accordance with the product specification, any kind of shocks must be avoided.
Plug and seal the cabling and cooling connections for transportation.
Receiving and unpacking
Inspect the electric device and the package immediately upon arrival. Ensure that the rating plate data in
the cover letter complies with the purchase order. All external damage in the package or in the electric
device must be photographed and reported to Danfoss immediately.
Lifting
Use correct, adequately dimensioned lifting devices and inspect them before lifting.
Do not apply any excess weight on the electric device when lifting it.
Use correct lifting slings. Use correct position and angle of lifting. The maximum permissible
range of lifting angles is shown in lifting figures.
Make sure that lifting slings are correctly routed so that they do not cause momentum on any
of the signal connectors.
See the rating plate and data sheets for weight information.
Lift the electric device using the correct lifting lugs/eyes only. See the lifting Figures in this
Chapter.
User Guide
EC-LTS1200-410
Transportation and storage
©Danfoss | July 2021 BC355449988603en-000201 | 17

Do not go under a lifted load.
The weight of the electric device is under 25 kg, so lifting it by hand is possible in most cases.
If it is necessary to lift the electric device with a lifting device, install two lifting eyes in the
threaded installation holes and lift from them. Obey the local legislation and
recommendations.
Correct lifting and incorrect lifting
Horizontal lifting
Maximum permissible lifting angles
User Guide
EC-LTS1200-410
Transportation and storage
18 | ©Danfoss | July 2021 BC355449988603en-000201

Horizontal lifting
1. M8 lifting eye, DIN580.
Handling
When turning or lifting the electric device, lift it in the air in order to prevent damage to the
frame or other parts of the electric device.
Although the electric device is designed to operate in harsh and demanding environment, any misuse or
improper handling of the electric device is prohibited to avoid malfunctions later.
Storage
When the device is dismounted and stored and packed for delivery, measure that there is no
voltage and then install short circuit wire to the conductor rails to prevent charge from
building up.
Do not apply any excess weight on the electric device during storage.
Store the electric device always indoors having the storage temperature preferably above -20 ºC and the
relative humidity less than 60 %. Storage conditions should be dry, dust free and vibration free.
Make sure that the cabling and cooling connections are plugged and sealed before storage.
The electric device must not be subjected to any external vibrations during storage to avoid possible
hidden structural damages.
User Guide
EC-LTS1200-410
Transportation and storage
©Danfoss | July 2021 BC355449988603en-000201 | 19

Required tools
Risk of electric shock during electrical installations. Use insulated tools..
Following tools are required to install the electric device:
•Ratchet torque wrench.
•Hex head wrench kit with different metric sizes.
•Socket wrench kit with different metric sizes.
•Cable gland tightening tool. Size according to cable glands.
•Cable skinning knife.
•Crimping tool for cable lugs.
For more detailed information, see appropriate Chapters in this user guide and product data sheets at
https://www.danfoss.com.
Mechanical installation
Allowed mounting position
Do not place the electric device on the ground without proper mounting or protective
structure.
•The electric device must be mounted on a flat, heat- and flame-resistant mounting place (for example
on a bracket).
•The electric device can be mounted in any direction. Mount the electric device permanently
from the mounting points.
•Mounting points are shown in the Figure below.
Location of the mounting points
User Guide
EC-LTS1200-410
Installation
20 | ©Danfoss | July 2021 BC355449988603en-000201