Danfoss ED3 EC-BDC1200: Liquid Cooled Onboard Charger and Electric Power Take-Off
Features
- Enclosure with high degree of protection from ingress (IP6K9K) – sealed from moisture and dust
- Efficiency up to 96 %
- Liquid cooled with water-glycol mixture
- Ambient temperature range of -40°C and +85°C
- Allowed coolant temperature up to +70°C
- Robust design withstanding high levels of mechanical vibration and shocks
- Support for single and three phase charging at 63 ARMS up to 43.6 kVA
- DC power take-off up to 44 kW
- AC power take-off up to 43.6 kVA
General
The device is an onboard charger designed specifically for the charging of electric and hybrid commercial vehicles and off-highway work machines. It can also be used as an electric power take-off for supplying AC or DC voltage to auxiliary equipment.
Typical Applications
- Onboard charger for high voltage battery of electric vehicle and off-highway machinery
- AC power take-off for single and three phase auxiliary loads, usable during vehicle or machine operation
- DC power take-off for HVAC or heaters, usable during vehicle or machine operation
Software Features
- J1939 compliant Danfoss proprietary CAN interface
- Bidirectional energy flow control
- High performance current and voltage control
- Wide selection of protective functions
Image Description: A rectangular, robust-looking electronic device with multiple connectors on its sides, labeled 'Danfoss'.
Specifications
DC-link connection
| Parameter | Value |
|---|---|
| DC-link voltage range | 500 - 800 VDC |
| Derated DC-link voltage range | 450 - 499 VDC (linear power derating 20 - 100% from 500 VDC values) |
| Maximum charging power | 41.6 kW (see performance curves below) |
AC-In connection
| Parameter | Value |
|---|---|
| AC input voltage | 1-phase 90 - 293 V 3-phase 156 - 507 V Notes: Only in combination with functional 30 mA Type B RCD while charging from TN network with and without neutral. Only in combination with functional IMD while charging from IT network with or without neutral. Charging is prohibited from corner grounded networks. |
| Frequency | 50 Hz ±2 Hz, 60 Hz ±2 Hz |
| Maximum power | 43.6 kVA (see performance curves below) |
| Maximum input current | 63 A per phase |
| Maximum THD (current) | < 4 % |
AC-Out connection (AC ePTO)
| Parameter | Value |
|---|---|
| AC output voltage | 3-phase 380 - 481 V Notes: Single and unbalanced three phase load support. Supply into IT network only in combination with an IMD. Supply into TN network prohibited. |
| Output voltage accuracy | ±2 % |
| Maximum power | 43.6 kVA (see performance curves below) |
| Nominal current | 63 A per phase |
| Maximum peak current | 126 A per phase for 500 ms (see user guide for eFuse functionality) |
| Output frequency | 50 or 60 Hz |
| Maximum THD (voltage) | < 2 % |
DC-Out connection (DC ePTO)
| Parameter | Value |
|---|---|
| DC output voltage | 500 - 850 V ±2 % Notes: Only in combination with an IMD. |
| Output voltage accuracy | ±2 % |
| Maximum output power | 44 kW (see performance curves below) |
| Nominal current | 59 A per phase |
| Maximum peak current | 118 A per phase for 10 ms (see user guide for eFuse functionality) |
Efficiency
| Function | Efficiency |
|---|---|
| Charging | Up to 95.3 % |
| AC electric power take-off | Up to 94.9 % |
| DC electric power take-off | Up to 96.8 % |
Control Voltage Input
| Parameter | Value |
|---|---|
| Voltage range | 8 - 32 VDC |
| Nominal voltage | 1.3 ADC @ 24 VDC |
| Continuous maximum power | Operation: < 33 W Enabled: < 28 W Standby: < 13.5 W Sleep: < 1.1 mW |
Mechanical
| Parameter | Value |
|---|---|
| Dimensions (W x H x L, mm) | 518 x 453 x 166 mm |
| Volume | 35.7 l ±2 % |
| Weight | 45 kg ±1.1 % |
| Main materials | Enclosure: EN AC-43400 (EN AC-AISi10Mg (Fe)) |
| Surface treatment | Passivation |
Cooling
| Parameter | Value |
|---|---|
| Cooling liquid | Water-glycol mixture (nominal 50 %, max. 60 % corrosive inhibitor) (see user guide for more information) |
| Cooling liquid glycol type | Ethylene glycol (see user guide for the approved types) |
| Nominal cooling liquid flow | 10 l/min |
| Maximum continuous pressure | 3 bar |
| Lowest absolute pressure | 1 kPa (for vacuum filling) |
| Coolant volume | 1.75 l ±0.1 l |
| Pressure loss | 126 mbar with 10 l/min (+25°C coolant) |
| Cooling liquid temperature | -40°C...+70°C Note: Coolant temperature may lead to derating of the device (see performance curves below) |
Ambient Conditions
| Parameter | Value |
|---|---|
| Storage temperature | -40°C...+85°C |
| Operating temperature | -40°C...+85°C Note: Ambient operating temperature may lead to derating of the device (see performance curves below) |
| Altitude | max. 3000 m |
| Relative humidity | 93 % |
| Enclosure class | IP6K9K with all external connectors mated IP34 without connectors |
| Mechanical impact | IK08 according to IEC 62262, 60068-2-75:1997 and SFS-EN 62262:2011 |
| Mechanical vibration | ISO 16750-3:2023 Test XVI: Random vibration of large/heavy DUT's, Sprung masses in hybrid/electric commercial vehicle |
| Mechanical shock | ISO 16750-3:2023 4.2.2 Test for devices on rigid points on the body and on the frame |
Connections
| Parameter | Value |
|---|---|
| Coolant connection | M22 x 1.5 internal thread |
| HV cable recommended type | HUBER+SUHNER Radox Elastomer S, screened, single core, automotive cable (FHLR4GC13X) hubersuhner.com |
| HV cable cross section | AC-In, AC-Out – 10 mm² DC-Out - 16 mm² HV Battery - 50 mm² |
| ACIN connector | Amphenol ELR4A04 |
| ACIN mating connector | Amphenol ELP4A04 |
| ACOUT connector | Amphenol ELR4Z04 |
| ACOUT mating connector | Amphenol ELP4Z04 |
| DCOUT connector | Amphenol ELRA2Y03 |
| DCOUT mating connector | Amphenol ELPA2Y16 |
| DC-link connector | Amphenol PL082X-301-10M8 |
| DC-link mating connector | Amphenol straight: PL182X-301-70/50/35 (depending on cable diameter) Amphenol right-angled: PL282X-301-70/50/35 (depending on cable diameter) Note: IEC 60228 Class 5 conductor connectors are also available (see manufacturer documentation). amphenol-industrial.de |
| Signal connector | TE 1534238-1 |
| Signal connector mating connector | TE 1-1534127-1 |
| Signal mating connector pin and seals | Pins: 0.5 - 1.0 mm² TE 1-968855-2 Wire seal: TE 828904-1 Sealing plug for empty cavities: TE 828922-1 Backshell: TE 9-1394050-1 |
| Signal connector pin configuration | See section SIGNAL CONNECTOR PINOUT |
| CAN connections | Non-isolated CAN channel with configurable termination |
| CAN protocol | SAE J-1939 |
Protections
| Protection | Status |
|---|---|
| SW overcurrent trip | Yes |
| SW overvoltage trip | Yes |
| Short circuit protection | Yes |
| High voltage interlock loop | Yes, with monitoring (see user guide for more information) |
| Converter temperature protection | Sophisticated thermal model that can automatically lower the current if needed |
| Converter temperature trip | Yes |
| eFuse | Yes, for AC-In, AC-Out and DC-Out |
Standards and Classifications
| Standard | Description |
|---|---|
| EN 61851-21-1:2017 | Electric vehicle conductive charging system – Part 21-1: Electric vehicle onboard charger EMC requirements for conductive connection to AC/DC supply |
| UN Regulation No. 10 Revision 6 *) | Uniform provisions concerning the approval of vehicles with regards to electromagnetic compatibility. |
*) EMI-filter EC-BDF1200-63 is required to fulfill the UN ECE R10 regulation for charging. AC-out and DC-out fulfill the regulation without EC-BDF1200 filter.
Derating Curves
Charging Power Derating Curves
Charging with 400 VAC 50 Hz Input
This graph illustrates the charging power [kW] as a function of coolant temperature [°C] for different High Voltage (HV) Battery voltages (500V to 800V). At a constant coolant temperature, the charging power generally decreases as the HV Battery voltage increases. As the coolant temperature rises, the charging power output is derated across all HV Battery voltage levels.
Charging with 480 VAC 60 Hz Input
This graph illustrates the charging power [kW] as a function of coolant temperature [°C] for different High Voltage (HV) Battery voltages (500V to 800V). At a constant coolant temperature, the charging power generally decreases as the HV Battery voltage increases. As the coolant temperature rises, the charging power output is derated across all HV Battery voltage levels.
Charging with 380 VAC 60 Hz Input
This graph illustrates the charging power [kW] as a function of coolant temperature [°C] for different High Voltage (HV) Battery voltages (500V to 800V). At a constant coolant temperature, the charging power generally decreases as the HV Battery voltage increases. As the coolant temperature rises, the charging power output is derated across all HV Battery voltage levels.
DC-Out Power Derating Curves
DC-Out power with 650 VDC output
This graph shows the DC-Out power [kW] versus coolant temperature [°C] for various HV Battery voltages (500V to 800V). Power output decreases with increasing coolant temperature. Higher HV Battery voltages tend to result in slightly lower power output at higher temperatures.
DC-Out power with 750 VDC output
This graph shows the DC-Out power [kW] versus coolant temperature [°C] for various HV Battery voltages (500V to 800V). Power output decreases with increasing coolant temperature. Higher HV Battery voltages tend to result in slightly lower power output at higher temperatures.
Charging Current with Single Phase Input
This graph displays the maximum phase current [ARMS] for single-phase AC input as a function of coolant temperature [°C]. It shows two distinct levels: one for AC voltages under 235 VAC and another for AC voltages over 235 VAC. The current remains constant across the depicted temperature range for each voltage level.
DC-Out Power Derating Curves (Continued)
DC-Out power with 850 VDC output
This graph shows the DC-Out power [kW] versus coolant temperature [°C] for various HV Battery voltages (500V to 800V). Power output decreases with increasing coolant temperature. Higher HV Battery voltages tend to result in slightly lower power output at higher temperatures.
AC-Out Power Derating Curves
AC-Out power with 400 VAC 50 Hz output
This graph illustrates the AC-Out power [kW] as a function of coolant temperature [°C] for different High Voltage (HV) Battery voltages (500V to 800V). Power output decreases with increasing coolant temperature. Higher HV Battery voltages tend to result in slightly lower power output at higher temperatures.
AC-Out power with 480 VAC 60 Hz output
This graph illustrates the AC-Out power [kW] as a function of coolant temperature [°C] for different High Voltage (HV) Battery voltages (500V to 800V). Power output decreases with increasing coolant temperature. Higher HV Battery voltages tend to result in slightly lower power output at higher temperatures.
AC ePTO Current with Single Phase Output
This graph displays the maximum phase current [ARMS] for single-phase AC output as a function of coolant temperature [°C]. It shows two distinct levels: one for AC voltages under 235 VAC and another for AC voltages over 235 VAC. The current remains constant across the depicted temperature range for each voltage level.
Pressure Loss vs. Coolant Flow
This graph shows the pressure loss [bar] in the cooling system as a function of the volume flow [l/min] at +25°C coolant temperature. The pressure loss increases non-linearly with increasing coolant flow.
Dimensions
Device Dimensions
Image Description: The diagram shows the physical dimensions of the ED3 EC-BDC1200 unit. It includes front, side, and top views with labels A, B, and C indicating the height, width, and depth respectively.
| Dimension | EC-BDC1200 |
|---|---|
| A | 453 mm |
| B | 518 mm |
| C | 166 mm |
Internal Schematic and Components
Internal Schematic Diagram
Diagram Description: A simplified schematic shows the internal electrical components of the ED3 EC-BDC1200. It includes input stages for AC and DC, a grid filter, DC-link capacitors and resistors, and output stages for AC and DC. Semiconductor switches are also indicated.
Component List
| Component | Description |
|---|---|
| Internal DC bus capacitance C1 | 400 μF |
| Internal DC bus resistance R1 | 250 kΩ |
| AC-In and AC-Out discharge resistance R3, R4, R5, R6, R7, R8 | 100 kΩ |
| AC-In and AC-Out Y-capacitance C8 | 1 μF |
| AC-In X-capacitance C9-C11 | 20 μF |
| DC-link X-capacitance C2 | 240 μF |
| DC-link Y-capacitance C3, C4 | 3.3 nF |
| DC-link discharge resistance R2 | 500 kΩ |
| DC-Out Y-capacitance C6, C7 | 3.3 nF |
| DC-Out X-capacitance C5 | 1 μF |
| DC-Out discharge resistance R9 | 500 kΩ |
| Semiconductor switches S1-S10 | NA |
| Insulation resistance | > 50 MΩ |
Application Example
Image Description: An illustration shows the EC-BDC1200 unit connected between a charging socket or AC connection and an HV Battery (e.g., Webasto battery). An optional EMI filter (EC-BDF1200-63) is also depicted.
Note: UNECE R10 compliance for charging is reached at the component level when EC-BDF1200-63 filter is used. For more information, see EC-BDF1200-63 data sheet.
Signal Connector Pinout
| PIN | Signal name | Description |
|---|---|---|
| 1 | CANH_A | CAN bus A high |
| 2 | CANL_A | CAN bus A low |
| 3 | VIN_P | Positive Power Supply (8-32 V) |
| 4 | CAN ID REF 1 | CAN ID reference 1. Reference pin that can be used to set CAN ID input HIGH. |
| 5 | CAN ID REF 2 | CAN ID reference 2. Reference pin that can be used to set CAN ID input LOW. |
| 6 | VIN_N/GND | Negative Power Supply (0 V) |
| 7 | WAKE_UP | Rising edge enables the device communication but only allows operation mode Charging. Ignored after enable has been received. See ED3 Software manual for shutdown. Active rising edge, Turn ON @> 5.46 V, Turn OFF < 4.52 V. Current draw is 8-11 mA. |
| 8 | HVIL_IN | High voltage internal lock input for DC-link connector. Current between 8-30 mA must be supplier externally to allow charging. 4.7 Ω resistor between HVIL_IN and HVIL_OUT pins. |
| 9 | HVIL_OUT | High voltage internal lock output for DC-link connector. |
| 10 | CAN_A TERM 1 | Termination of CAN bus A, Connect to CANH_A to connect the termination resistor. Can be left unconnected if external termination is used. |
| 11 | CAN_A TERM 2 | Termination of CAN bus A, Connect to CANL_A to connect the termination resistor. Can be left unconnected if external termination is used. |
| 12 | CAN ID 1 | CAN A source address and PGN configuration input 1 Short to supply > 16.07 V 1 = 7.86 - 16.07 V 0 = 4.28 - 7.86 V Open circuit = 4.28 - 2.14 V Short to ground < 2.14 V Input resistance 220 Ω |
| 13 | Reserved | |
| 14 | Reserved | |
| 15 | CAN ID 2 | CAN A source address and PGN configuration input 2 Short to supply > 16.07 V 1 = 7.86 - 16.07 V 0 = 4.28 - 7.86 V Open circuit = 4.28 - 2.14 V Short to ground < 2.14 V Input resistance 220 Ω |
| 16 | Reserved | |
| 17 | Reserved | |
| 18 | CAN ID 3 | CAN A source address and PGN configuration input 3 Short to supply > 16.07 V 1 = 7.86 - 16.07 V 0 = 4.28 - 7.86 V Open circuit = 4.28 - 2.14 V Short to ground < 2.14 V Input resistance 220 Ω |
| 19 | Reserved | |
| 20 | Reserved | |
| 21 | EPTO_ENABLE | Enables the use of AC-out or DC-out. Active High, Turn ON @> 6.26 V, Turn OFF < 4.48 V. Current draw is 8-11 mA. |
High Voltage Pinout
Table 1 Pin configuration of AC-In
| PIN | Signal name | Description |
|---|---|---|
| 1 | L1 | Phase 1 |
| 2 | L2 | Phase 2 |
| 3 | L3 | Phase 3 |
| 4 | N | Neutral |
| A | HVIL_IN | High voltage interlock loop input |
| B | HVIL_OUT | High voltage interlock loop output |
Table 2 Pin configuration of AC-Out
| PIN | Signal name | Description |
|---|---|---|
| 1 | L1 | Phase 1 |
| 2 | L2 | Phase 2 |
| 3 | L3 | Phase 3 |
| 4 | N | Neutral |
| A | HVIL_IN | High voltage interlock loop input |
| B | HVIL_OUT | High voltage interlock loop output |
Table 3 Pin configuration of DC-Out
| PIN | Signal name | Description |
|---|---|---|
| 1 | DCOUT - | DC output negative |
| 2 | DCOUT + | DC output positive |
| A | HVIL_IN | High voltage interlock loop input |
| B | HVIL_OUT | High voltage interlock loop output |
Table 4 Pin configuration of DC-link/TVB
| PIN | Signal name | Description |
|---|---|---|
| A | DC- | DC-link negative |
| B | DC+ | DC-link positive |
Product Code
| Product code | Description |
|---|---|
| EC-BDC1200 | Standard unit |
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed. 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.
