Danfoss EC-LTS Series User manual

User Guide
Liquid cooled heavy duty  inductance
unit
EC-LTS1200-410
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. Electromagnetic compatibility (EMC) ...................................................................................................................................
2.6. Installation safety .........................................................................................................................................................................
2.7. 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 ................................................................................................................................................
6. Operation
6.1. Operation conditions ...............................................................................................................................................................
6.2. Condition monitoring during operation ...........................................................................................................................
7. Maintenance
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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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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-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 (*). 
Table 1. EC-LTS1200-400 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
classication
*No marine
classication
+CL1 ABS American Bureau of Shipping
+CL2 BV Bureau Veritas
+CL3 DNV GL DNV GL AS
+CL4 LR Lloyd’s Register
+CL5 RINA
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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/EU Electrical equipment means any equipment designed for use with a voltage rating of between 50 and 1000 V for alternating current. 
Standards
IEC/EN 61800-5-1:
2007 Adjustable speed electrical power drive systems - Part 5-1: Safety reguirements - Electrical, thermal and energy
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
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.
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.
The symbol also indicates that the device should be placed and installed so that contact with its potentially
hot surface is not possible.
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.
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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.
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.
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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.
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.
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.
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.
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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.
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
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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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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.
Figure 1. Main components
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1 L1 connection
2 L2 connection
3 L3 connection
4 +LV connection  plugged (congurable, see +CG option below)
5 Cooling inlet / outlet connections
6 X2 temperature measurement connector
7 +LV connection cable gland (congurable, 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
+CG1 option comes with a selection of cable glands and plugs. Typical cable gland congurations
are shown in the Table below.
Table 3. Typical cable gland congurations 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  xed 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.
Figure 2. Application example
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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 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.
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.
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System introduction
Cooling
Table 4. Cooling system requirements
Cooling system properties Specication
Cooling type Liquid cooling
Coolant type Water or water glycol mixture (glycol max. 50 %)
Coolant temperature -40º…+65 ºC
Coolant ow minimum 10 l/min
Maximum operating pressure 2 bar
Pressure drop 40  mbar with 10 l/min  (+25 °C coolant)
See detailed information and specications from the product data sheets, 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 identication details. 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,
http://www.danfoss.com.
Figure 3. Rating plate example
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Table 5. Rating plate elds
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 ow l/min
IP class 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 specied tightening torques for the electric
device screws. Tightening torques (screw preloads) used in the electric device  are shown in the
table  below.
Tightening torque tolerances are: -10%...0% of the specied tightening torque. Exceeding the specied tightening
torque is not allowed.
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Table 6. 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
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Because of the low weight of the electric machine, lifting can be done manually. If necessary, the mounting points can be
used for lifting with correct lifting eyes and lifting equipment.
Transportation
The electric device  is  shipped in rst 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 specication, 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.
Use correct lifting slings. Use correct position and angle of lifting. The maximum permissible range of lifting angles is
shown in lifting gures.
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 lifting gures in this Chapter.
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.
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Figure 4. Correct lifting and incorrect lifting
Horizontal lifting
Figure 5. Maximum permissible lifting angles
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