Danfoss EC-C1200-450 User manual

User Guide
Electrical converter
EC-C1200-450
danfoss.com

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1. General information
1.1. Copyright .........................................................................................................................................................................................
1.2. Intended use of the user guide ...............................................................................................................................................
1.3. Product naming convention ....................................................................................................................................................
1.4. Conformity according to standards .......................................................................................................................................
1.5. Warranty ..........................................................................................................................................................................................
1.6. Terms and abbreviations ...........................................................................................................................................................
1.7. Trademarks .....................................................................................................................................................................................
1.8. Responsibility of the manufacturer .......................................................................................................................................
2. Safety information
2.1. General safety statement ..........................................................................................................................................................
2.2. Safety message signal words ...................................................................................................................................................
2.3. Safety symbols ..............................................................................................................................................................................
2.4. Personal protective equipment ............................................................................................................................................
2.5. Safety features .............................................................................................................................................................................
2.6. Electromagnetic compatibility (EMC) .................................................................................................................................
2.7. Installation safety .......................................................................................................................................................................
2.8. Operation safety .........................................................................................................................................................................
3. Product overview
3.1. Intended use of the electric device .....................................................................................................................................
3.2. System introduction .................................................................................................................................................................
3.3. Cooling ..........................................................................................................................................................................................
3.4. Rating plate ..................................................................................................................................................................................
3.5. Tightening torques ....................................................................................................................................................................
4. Transportation and storage
4.1. Transportation ............................................................................................................................................................................
4.2. Receiving and unpacking .......................................................................................................................................................
4.3. Lifting .............................................................................................................................................................................................
4.4. Handling ........................................................................................................................................................................................
4.5. Storage ...........................................................................................................................................................................................
5. Installation
5.1. Required tools .............................................................................................................................................................................
5.2. Mechanical installation ............................................................................................................................................................
5.2.1. Allowed mounting position ...........................................................................................................................................
5.2.2. Installation procedure ......................................................................................................................................................
5.2.3. Cooling connections ........................................................................................................................................................
5.2.4. Recommended coolants .................................................................................................................................................
5.3. Electrical installation .................................................................................................................................................................
5.3.1. Grounding ............................................................................................................................................................................
5.3.2. Cable gland assembly and power line connection ...............................................................................................
5.3.3. Cabling and wiring ............................................................................................................................................................
5.3.4. High voltage connections ..............................................................................................................................................
5.3.5. Low voltage connections ................................................................................................................................................
5.3.6. Connection diagram .........................................................................................................................................................
6. Operation
6.1. Operation conditions ...............................................................................................................................................................
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6.2. Pre-charging ................................................................................................................................................................................
6.3. Condition monitoring during operation ...........................................................................................................................
7. Maintenance
7.1. Cooling system maintenance ................................................................................................................................................
7.2. Regular maintenance ...............................................................................................................................................................
7.3. Cleaning ........................................................................................................................................................................................
8. Dismounting and disposal of the electric device
9. Troubleshooting
10. Aftersales
10.1. Service policy ............................................................................................................................................................................
10.2. Service parts ..............................................................................................................................................................................
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Table of Contents
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Revision Information
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This user guide contains  the installation, operation and maintenance instructions  for the EC-
C1200-450 electrical converter.
Copyright
Danfoss Oy. All rights reserved.
No parts of this user guide  may be reproduced or transmitted in any form or by any means,
electrical or mechanical including photocopying, recording or by an information storage or
retrieval system, without permission in writing from the publisher.
All specications and contents of this user guide  are subject to change without notice.
Intended use of the user guide
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 qualied 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 reect all system features.
Product naming convention
In this user guide, the EC-C1200-450 electric converter  is  referred to as the electric device.
The following naming convention is used to refer to electric device type code and  options:
EC-C1200-450-L+MC/+AFE/+UG/+DC
The rating plate of the electric device has the correct name of that particular electric device. 
Part of the name Explanation
EC Electric Converter
C1200 Product name part 1
450 Product name  part 2
L/S System size
+MC* Motor Control software -option
+AFE* Active Front End software -option
+UG* Microgrid (µgrid) software -option
+DC** DCDC-converter software -option
*Followed  with number that represents the nominal current  (ARMS): 120, 180, 240, 300, 350. These
options are available on the same electric device or alone.
**Followed  with number that represents the nominal current (AAVG): 150, 250, 300, 400. This
option is not available with other options.
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Electric device has option for small systems (S) and large systems (L). Small system option is typical
for vehicle applications and large system option is standard in marine applications because of the
marine regulations. Complete system should be looked when choosing the option as for example
vehicle system with many devices could also need the L-option to keep the isolation resistance or
Y-capacitors at reasonable level. In large and small system options, there are difference in the
isolation measurement resistance, DC-link discharge resistor and Y-capacitor values as shown in
the gure and table below.
Figure 1. S- and L-systems schematics
Table 1. S- and L-system component values
System option Component Value
Small (S)
Resistors R1 and R2 (isolation measurement) 12 M Ω
Resistor R3 (discharge) 3.9 k Ω
Capacitors C1 and C2 (Y-capacitors) 330 nF
Capacitor C3 1 mF
Isolation resistance from DC-link to enclosure 6 M Ω
Large (L)
Resistors R1 and R2 (isolation measurement) 240 M Ω
Resistor R3 (discharge) 39 k Ω
Capacitors C1 and C2 (Y-capacitors) 3.3 nF
Capacitor, C3 1 mF
Isolation resistance from DC-link to enclosure 120 M Ω
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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:
Table 2. Applicable directives
Directives Explanation
Low Voltage Directive
2014/35/EC 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.
Standards
IEC/EN 61800-5-1: 2007 Adjustable speed electrical power drive systems - Part 5-1: Safety
reguirements - Electrical, thermal and energy
EN 13309: 2010 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 compatability
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 rst.
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
modications 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
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Symbol Variable Unit
UDC DC
 link voltage V
Uac AC
 output voltage V
InRated current A
rms
PnRated power kW
fin/out Input / Output frequency Hz
fswitch Switching frequency kHz
Ipeak Overcurrent limit A
Qc Rated coolant liquid ow l/min
Tc Rated coolant liquid input temperature °C
Tamb Rated ambient temperature °C
GND Ground in electrical connections
R Resistance Ω
Trademarks
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss
logotype are trademarks of Danfoss A/S. All rights reserved.
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 qualied 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.
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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 qualied 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.
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Safety symbols
The following safety and information related symbols may exist in this user guide  and on the
electric device.
Danger
This symbol is is identied 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 identied 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 identied by a yellow background, black triangular band, and a black arrowhead symbol. It
indicates dangerous electric voltage that could cause an electric shock to a person.
Burn warning
The symbol is identied 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.
Magnet warning
The symbol is identied by a yellow background, black triangular band, and a black magnet symbol. It
indicates strong magnetic eld that could cause harm to a person or property.
Poison warning.
The symbol is identied 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 user guide.
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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 working with the electric device.  Permanent damage to
the eye could be caused if hot water, glycol or other uids splash.
Use hearing protective equipment when working on the electric device in noisy environment! Hearing injuries could be
caused by too loud noise (noise in excess of 85 dBA).
Use head protective equipment like helmet when mounting or dismounting the electric device! Head injuries could be
caused by object impact.
Use cut resistant gloves when handling and maintaining the electric device! There is a risk of cut injuries.
Use protective footwear when lifting or moving the electric device! Foot injuries could be caused if lifting system or lifting
brackets fail.
Safety features
Protection type Built- in Information
Overcurrent Yes 750 APEAK
Overcurrent Yes 500  Arms
Overvoltage Yes 1050 V DC
Short circuit Yes -
Overspeed (+MC -option only) Yes Adjustable according to controlled motor
Overheat (electric device internal temperature) Yes Sophisticated thermal model that can lower the current if needed
Emergency stop Yes Hardware secured device switch OFF feature
In addition to the electrical protection features, the electric device has  mechanical safety feature, a
connector shield, which prevents direct entry to the power terminals, when the electric device is
powered ON. The connector shield is a sheet metal component, which secures the power terminal
cover and it cannot be released without disconnecting the control signal connector (X1-
connector) rst. When X1-connector is disconnected, it shuts down the electric device and starts
electrical energy discharging process.
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Figure 2. Connector shield (mechanical safety feature)
Electromagnetic compatibility (EMC)
When interfacing other equipment, connect only equipment that are specied as part of the system and that
are  compatible with each other.
Magnetic and electromagnetic elds generated near current-carrying conductors and permanent magnets in electric
devices are 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, do 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).
The products are designed with high standards of EMC in mind. Connect the power lines and
groundings by the instructions in this user guide  to achieve the required level of EMC 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.
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Installation safety
Only trained and qualied 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.
Do not do any ash tests or voltage withstand tests on the electric device. If electrical tests or measurements are required,
do the tests with the electric device disconnected and stored energy discharged.
Disconnect and isolate the electric device before you start  any work on it. High voltages are present at the terminals and
within the inverter. Passive discharging of the DC-link capacitor is done  by the bleeder-resistor. Discharging below 50
Volts is completed within 8 minutes after the power is disconnected. Make sure  that voltage is not present on any inverter
power terminals prior you start any work on it.
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 tted 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.
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.
The electric device  can start at power up if the start- input signal is present.
The STOP function does not remove potentially lethal high voltages. Isolate the electric device and wait for 8 minutes
before you start  any work with  it. Never do any work on the electric device, external devices  or electric cables if  the input
power is connected to the electric device.
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 specication 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  specications of
the manufacturer. Make sure that the cooling system is in use when the DC-link is powered.
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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.
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
Make sure that the cooling system is in use when the DC-link is powered.
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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 xed 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.
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Electric device  with +MC -option
This series of electric devices  is designed especially for controlling the speed and torque of
electrical traction motors.
The advantages and features of the electric device with +MC -option:
Extremely compact structure, weight only 15 kg.
Robust design withstanding high levels of mechanical vibrations and shocks.
High protection class IP67  ensuring operation in extreme conditions.
Wide ambient temperature range from -40 ºC...105 ºC.
Liquid cooling.
Wide allowed coolant temperature range.
Multiple mounting possibilities.
Designed especially for highly cyclical loads typical in heavy mobile work machines.
Controls both induction and permanent magnet motors with or without sensor.
Speed and torque reference motor control.
Generator control mode for DC-link voltage control.
Flexible control interface –CAN, resolver, analog, digital inputs/outputs.
PowerUSER  PC-program for commissioning available.
Various communication protocols, for example  CANopen, SAE J-1939.
Possibility to create customer specic applications with CODESYS (IEC61131-3) software tool.
High performance vector control.
Wide selection of protective safety functions.
Table 3. Motor control characteristics
Controllable
motor types
Synchronous permanent magnet motors
Asynchronous induction motors
Special features to control Danfoss  synchronous reluctance assisted permanent
magnet motors.
Control principle
Rotor ux oriented current vector control
Reference types
Torque reference motor control
Speed reference motor control
Generator control mode for regulating the DC-link voltage
Field weakening
control
Maximizes the eld weakening performance by optimizing the use of inverter
current and torque production capability of the motor.
Working point
optimization
Maximum torque per ampere working point optimization is used to improve
efficiency of the motor.
Electric device  with +AFE, +UG, +MC and +DC  -options
These electric devices are designed for variety of applications:
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Boosting battery voltage to higher DC-link voltage. (+DC -option)
Charging high voltage batteries from higher DC-link voltage. (+DC -option)
Converting alternating current (AC) from electrical generator to direct current (+MC -option)
for energy storage
Active Front End for connecting to AC grid with regenerative power and low harmonic. (+AFE -
option)
Creating standalone microgrid (+UG -option)
The advantages and features of the electric device:
Electric device unit  weight is  15  kg
High enclosure class IP67  – sealed from moisture and dust.
Liquid cooled with plain water or water/glycol mixture, allowed coolant temperature up to
+65ºC
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.
The advantages and features of the EC-LTS  unit* (required for +DC -option):
EC-LTS unit is a separate product, but it is often sold together with the electric device. It weighs
58  kg.
Extremely compact design – 3x 170 A.
High enclosure class IP65 – sealed from moisture and dust.
Liquid cooled with plain water or water/glycol mixture, allowed coolant temperature up to
+65ºC.
Ambient temperature: -40ºC...85ºC.
Robust design withstanding high levels of mechanical vibrations and shocks.
Designed especially for highly cyclical loads typical in heavy mobile work machines.
*Unit sold separately
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Figure 3. Main components (left: EC-LTS unit, right: EC-C)
1 LV1 (EC-LTS) / LV+
2 LV2 (EC-LTS) / LV+
3 LV3 (EC-LTS) / LV+
4 L1 (EC-LTS)
5 L2  (EC-LTS)
6 L3  (EC-LTS)
7 X1-connector  (Low voltage connector for measurement data and control signals)
8 DC+
9 DC- / LV-
10 LV1
11 LV2
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12 LV3
13 X2-connector (maintenance connector)
14 EC-LTS  unit cooling connection bores 2 x  1/2"
15 Electric device cooling connections 2 x 20mm
16 EC-LTS  unit (+DC -option only)
17 EC-C  unit
Connection diagram
Figure 4. Electric device power connection diagram (EC-LTS only for +DC -option)
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  xed installation, as a part of complete power generation equipment or system.
Typical applications for the electric device  are:
System component, functioning as a speed and torque controller for electric motors
System component, functioning as a current converter, converting alternating current (AC)
from electric generator to direct current (DC) for energy storage.
System component, boosting battery voltage to higher DC-Link voltage.
System component, charging HV-Batteries from higher DC-Link voltage.
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 dened 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 rst reading the user
guide.
Exceeding the designed limits during the operation.
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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.
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 dened 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 dened 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 specic and up to date information see product data sheets, http://www.danfoss.com.
System introduction
Danfoss provides electric drivetrains for applications in heavy mobile work machines, marine
vessels and transportation vehicles. The drivetrains include all essential components
for  converting from traditional to hybrid electric (HEV) or electric vehicle (EV) solutions.
This  technology saves fuel and lowers emission and noise levels.
The electrical devices  are an essential part of the electric drivetrain system. Typically they are used
as a speed and torque controller for electric motors and as a current converter, converting
alternating current (AC) from electric generator to direct current (DC) for energy storage.
The electric device is  capable for supplying three-phase alternating current, powering and
controlling electric machines, for example the  EM-PMI  product family electric machines.
If the drivetrain system is equipped with the smart energy storage ES-SC, it can be charged by
using electric device  between the electric machine and the energy storage. System may include
also another electric devices with different software options.
Electric converter  products are designed for controlling the ow of power in heavy-duty, marine
and transportation applications.
EC-C1200-450
3. Product overview
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© Danfoss | Produced By: Danfoss Power Solutions | January 2019 | 19