Danfoss EC-C1200-450 Liquid-Cooled Heavy-Duty Converter
Data Sheet
Introduction
The Danfoss EC-C1200-450 is a heavy-duty converter designed for electric or hybrid drive trains in mobile work machines, buses, and marine vessels. It offers versatile functionality, acting as a motor inverter, active front end, microgrid controller, or DC/DC converter, depending on the selected options.
Key Features
- Extremely compact design: converter unit weighs only 14 kg.
- High enclosure class IP6K9K: sealed from moisture and dust.
- Liquid cooling with water-glycol mixture.
- Wide operating ambient temperature range: -40°C to +105°C.
- Allowed coolant temperature up to +65°C.
- Robust design: withstands high levels of mechanical vibrations and shocks.
- Designed for highly cyclical loads typical in heavy mobile work machines.
Software Features
- 2x Isolated CAN ports supporting CANopen and SAE J-1939 protocols.
- Bidirectional energy flow control.
- High performance current and voltage control.
- Interleaved PWM between phases for lower ripple current and voltage.
- Wide selection of protective functions.
- PowerUSER PC-program available for commissioning and diagnostics.
General Information
The device can function as a motor inverter, active front end, create a microgrid, or act as a DC/DC converter, depending on the options selected.
Typical Applications
- Boosting battery voltage to a higher DC-link voltage (+DC option).
- Charging high voltage batteries from a higher DC-link voltage (+DC option).
- Controlling the speed and torque of electrical traction motors (+MC option).
- Converting alternating current (AC) from an electrical generator to direct current (DC) for energy storage (+MC option).
- Active Front End for connecting to an AC grid with regenerative power and low harmonic distortion (+AFE option).
- Microgrid applications (+UG option).
Note: +DC option requires an external inductance unit (see Danfoss EC-LTS data sheets). +AFE and +UG options require an external LCL-filter unit (see Danfoss EC-LCL1200 data sheets).
Specifications
DC Connection (+DC Option)
| Parameter | Value |
|---|---|
| HV-side voltage range | 0-850 VDC |
| HV-side nominal voltage | 750 VDC |
| HV-side nominal current | 350 ADC |
| LV-side typical voltage | 75-750 VDC (maximum transformation ratio between LV and HV voltages is 1:10) |
| LV-side nominal current | See Table 1 |
| Nominal power | See Table 1 (output power is limited by the LV-side voltage and current) |
| Switching frequency | 8 kHz |
DC Connection (+MC/+AFE/+UG Option)
| Parameter | Value |
|---|---|
| DC link voltage range | 0-850 VDC |
| DC link nominal voltage | 750 VDC |
AC Connection (+MC/+AFE/+UG Option)
| Parameter | Value |
|---|---|
| AC output voltage | 0-560 VEFF (UDC = 800 VDC) |
| Maximum power | 300 kW (500 VAC, 350 ARMS) |
| Output frequency | 0...580 Hz (Up to 1000 Hz as option) |
| Switching frequency | 8 kHz |
Control Voltage Input
| Parameter | Value |
|---|---|
| Voltage range | 7-33 VDC |
| Power | 14.4 W |
| Nominal current | 0.6 A @ 24 VDC, 1.2 A @ 12 VDC |
Mechanical
| Parameter | Value |
|---|---|
| Dimensions (W x H x L) | 244 x 109 x 482 mm |
| Weight | 14 kg + -2% (no options) |
| Main materials | Enclosure (including coolant circuit): AlSi12Cu1(Fe) Coolant connections: CuZn39Pb3 CE1 / CE2 option: AlSi12 |
Cooling
| Parameter | Value |
|---|---|
| Cooling liquid | Plain water with appropriate corrosive inhibitor (max. 50% corrosive inhibitor) |
| Cooling liquid mixture | Nominal mixture 50/50 water/glycol (max. 52% glycol allowed with 1% current derating per 1% mixture increase above 50% glycol content) |
| Cooling liquid glycol type | Ethylene glycol (Glysantin G48 recommended) |
| Minimum cooling liquid flow | 10 l/min |
| Maximum continuous pressure | 2 bar |
| Lowest absolute pressure | 1 kPa (for vacuum filling) |
| Coolant volume | 300 cm³ |
| Pressure loss | 100 mbar with 10 l/min (+25°C coolant) |
| Cooling liquid temperature | -40°C...+65°C (with derating 1% / 1°C max. +75°C) |
Ambient Conditions
| Parameter | Value |
|---|---|
| Storage temperature | -40°C...+105°C |
| Operating temperature | -40°C...+105°C (with nominal coolant temp.) |
| Altitude | max. 2000 m |
| Relative humidity | 100 % |
| Enclosure class | IP6K9K, IP67 |
| Mechanical vibration | 10 G ISO 16750-3 Test VII – Commercial vehicle, sprung masses – Table 12 Notes: test duration 8h per each axis (x, y and z axes tested) total spectral acceleration 5.91 GRMS |
| Mechanical shock | 50 G ISO 16750-3 4.2.2 Test for devices on rigid points on the body and on the frame Notes: -acceleration: 500 m/s²; -duration: 6 ms; -number of shocks: 10 per test direction |
Connections
| Parameter | Value |
|---|---|
| Coolant connection | 2 x 20 mm coolant hose connector (see dimension drawing for details) |
| HV cable recommended type | HUBER+SUHNER Radox Elastomer S, screened, single core, automotive cable (FHLR4GC13X) www.hubersuhner.com |
| HV cable cross section | ≤ 70 mm² (Cu) Phase cables up to 120mm² (+CE2 option only) |
| HV cable glands | Pflitsch blueglobe TRI bg 225ms tri (M25 thread) Pflitsch blueglobe TRI bg 232ms tri (M32 thread) (see option list and +CGx options for details) |
| HV cable lug | 35-8, 50-8, 70-8, 95-8, 120-8 |
| Recommended cable lug | 35 mm²: Druseidt with narrow flange 03901 50 mm²: Druseidt with narrow flange 03903 70 mm²: Druseidt with narrow flange 03906 95 mm²: Druseidt with narrow flange 03910 (only compatible for phase cables with +CE2 option) 120 mm²: Druseidt with narrow flange 03914 (only compatible for phase cables with +CE2 option) www.druseidt.de |
| LV connector | 35-pin Tyco electronics AMPSEAL connector www.te.com |
| LV connector type | part no. 776163-1 |
| LV mating connector type | TE 776164-1 |
| LV mating connector pin type | 0.5-1.25 mm²: TE 770854-3 (gold plated) |
| LV connector pin configuration | See section SIGNAL CONNECTOR PINOUT |
| CAN connections | 2x isolated and unterminated CAN channels (see section SIGNAL CONNECTOR PINOUT) |
| CAN protocols | SAE J-1939 CANopen |
| IO/analog output | 5x isolated IO/analog output (see section SIGNAL CONNECTOR PINOUT) |
Control Characteristics
DC/DC Control Characteristics (+DC Option)
| Parameter | Value |
|---|---|
| Converter topology | Bidirectional (Buck or Boost) |
| Control principle | Current control, Voltage control, Power control |
Motor Control Characteristics (+MC Option)
| Parameter | Value |
|---|---|
| Controllable motor types | Synchronous permanent magnet motors, Asynchronous induction motors, Danfoss synchronous reluctance assisted permanent magnet motors (SRPM) |
| Control principle | Rotor flux oriented current vector control |
| Control methods | Torque reference motor control, Speed reference motor control, DC-link voltage control |
| Field weakening control | Maximizes the field 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. |
Protections
| Protection Type | Value / Description |
|---|---|
| HW overcurrent trip | 750 APEAK (reaction time < 15 μs) |
| HW short circuit trip | 2700 APEAK (self-limiting, reaction time < 2 μs) |
| HW overvoltage trip | 1050 VDC |
| SW overcurrent trip | Programmable level |
| SW overvoltage trip | Programmable level |
| Short circuit protection | Yes |
| High-Voltage interlock loop | HV loop on signal connector for external monitoring, HV loop pins are connected on the inverter side. |
| Inverter temperature protection | Sophisticated thermal model that can lower the current if needed. |
| Inverter temperature trip | Yes |
| External temperature measurement | Yes, programmable warning, fault and trip levels. |
Standards and Classifications
- IEC 60664-1 Pollution degree class 2
- IEC 60664-1 Overvoltage category III
- EN 61800-5-1:2007 - Adjustable speed electrical power drive systems - Part 5-1: Safety requirements - Electrical, thermal and energy.
- EN ISO 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 regarding electromagnetic compatibility.
Power and Current Variants
Table 1: Device current and power ratings for +DC option
| Basic product type | Nominal power [kW] | Nominal current [ADC] | Conditions |
|---|---|---|---|
| EC-C1200-450-L+DC150 | 90 | 150 | LV-side voltage 600 VDC, HV-side voltage 750 VDC |
| EC-C1200-450-L+DC250 | 150 | 250 | LV-side voltage 600 VDC, HV-side voltage 750 VDC |
| EC-C1200-450-L+DC300 | 180 | 300 | LV-side voltage 600 VDC, HV-side voltage 750 VDC |
| EC-C1200-450-L+DC400 | 240 | 400 | LV-side voltage 600 VDC, HV-side voltage 750 VDC |
Note: "-S" and "-L" versions have same ratings; see section SMALL/LARGE SYSTEM DIFFERENCES.
Table 2: Device current and power ratings for +MC, +AFE and +UG options
| Basic product type | Nominal power [kVA] | Nominal current [ARMS] | Peak current, time unlimited [ARMS] |
|---|---|---|---|
| EC-C1200-450-L+MC70+AFE70+UG70 | 50 | 70 | 70 |
| EC-C1200-450-L+MC120+AFE120+UG120 | 100 | 120 | 120 |
| EC-C1200-450-L+MC180+AFE180+UG180 | 150 | 180 | 180 |
| EC-C1200-450-L+MC240+AFE240+UG240 | 200 | 240 | 240 |
| EC-C1200-450-L+MC300+AFE300+UG300 | 250 | 300 | 300 |
| EC-C1200-450-L+MC350+AFE350+UG350 | 300 | 350 | 350 |
Note: "-S" and "-L" versions have same ratings; see section SMALL/LARGE SYSTEM DIFFERENCES.
Pressure Loss vs Coolant Flow
Picture 1: Device pressure loss vs coolant flow
This graph illustrates the relationship between coolant volume flow and pressure loss. The X-axis represents Volume Flow in liters per minute (l/min), ranging from 0 to 35. The Y-axis represents Pressure Loss in bar, ranging from 0 to 0.8. The plotted line shows that as the volume flow increases, the pressure loss also increases. At 0 l/min, pressure loss is negligible. At 10 l/min, pressure loss is approximately 0.25 bar. At 20 l/min, it's around 0.5 bar, and at 35 l/min, it reaches approximately 0.75 bar.
Dimensions
Picture 2: Device dimensions shows orthogonal views (front, side, top) of the EC-C1200-450 converter unit, indicating dimensions A, B, and C.
Picture 3: Device dimensions with +CE1 or +CE2 option shows similar orthogonal views, highlighting differences in dimensions when specific connection options are selected.
| Dimension | Lengths for EC-C1200-450 | Lengths for EC-C1200-450 with +CE1 or +CE2 option |
|---|---|---|
| A | 244 mm | 244 mm |
| B | 109 mm | 205 mm |
| C | 482 mm | 479 mm |
Small/Large System Differences
The electric device is available with options for small systems (-S) and large systems (-L). The small system option is typical for vehicle applications, while the large system option is standard in marine applications due to regulations. A complete system assessment is recommended when choosing an option, as vehicle systems with multiple devices might require the -L option for adequate isolation resistance or Y-capacitor levels. Differences in isolation measurement resistance, DC-link discharge resistor, and Y-capacitor values between the large (-L) and small (-S) system options are detailed below.
Picture 4: EC-C1200-450 internal schematic shows a simplified internal circuit diagram of the EC-C1200 converter, including components like resistors (R1, R2, R3), capacitors (C1, C2, C3), and power switches, illustrating the basic topology.
Picture 5: EC-C1200-450 internal schematic and application example when used in combination with external inductance unit EC-LTS shows the internal schematic similar to Picture 4, but also depicts how the EC-C1200 connects to an external EC-LTS unit for DC/DC applications, showing LV connections and output phases L1, L2, L3.
Table 3: S/L-system differences
| Component | Small-system option | Large-system option |
|---|---|---|
| Isolation measurement R1, R2 | 12 MΩ | 240 MΩ |
| Discharge resistor R3 | 3.9 kΩ | 39 kΩ |
| Y-capacitor C1, C2 | 330 nF | 3.3 nF |
| DC-link capacitor C3 | 1 mF | 1 mF |
| Isolation resistance from DC-link to enclosure | 6 MΩ | 120 MΩ |
Devices with +MC, +AFE, or +UG options use the internal schematic shown in Picture 4. Additional equipment like LCL-filters or motors connect to phases L1, L2, and L3. Options +AFE and +UG are not compatible with the -S version. Generally, the -L option is recommended for all applications.
Devices with the +DC option require external inductors, as shown in the application example in Picture 5. LV+ and LV- can connect to a battery, and DC+ and DC- to a higher voltage DC-link. The device manages battery discharging and charging. The +DCE option is recommended when using the device with an external inductance unit.
Connection Options
Picture 6: Connection options of EC-C1200-450 displays various configurations of the converter unit, illustrating different combinations of cable glands and connection extensions like +CG1, +CE2, +DCE, etc.
Table 4: Color coding
| Color | Meaning |
|---|---|
| Gray | Cable glands for phases |
| Red | Cable glands for DC+ |
| Black | Cable glands for DC- |
Parametrizing, Monitoring and Diagnostic of the Device
The PowerUSER monitoring and diagnostics software uses a service connector on the device and a PSSC service cable for connection. The PSSC is an isolated RS485 and shielded cable designed for demanding environments. It is available in 3-meter (PSSC-3M) and 10-meter (PSSC-10M) versions. The service cable is ordered separately.
Table 5: Service cables (ordered separately, needed for parametrizing, monitoring and diagnostics)
| Product code | Cable length | Description |
|---|---|---|
| PSSC-3M | 3 meters | USB to RS485 isolated service cable |
| PSSC-10M | 10 meters | USB to RS485 isolated service cable |
Signal Connector Pinout
Picture 7: Signal connector pinout illustrates the 35-pin connector with detailed pin assignments, signal names, and their respective functions or comments.
| Pin | Signal name | RevR/S/T | Comments |
|---|---|---|---|
| 1 | VIN_P | Positive Power Supply (7-33V) | |
| 2 | POWER_ON | Active High, Turn ON @ >7.4V, Turn OFF @ <5.8V | |
| 3 | #STOP_2 | Active Low, STOP @ < 1.2V, RUN @ > 4.65V Pulling one #STOP down stops the inverter | |
| 4 | RES_EXC_N | Resolver exitation, use twisted pair and shield | |
| 5 | RES_EXC_P | Resolver exitation, use twisted pair and shield | |
| 6 | PT_2 | PT100 or PT1000 temperature sensor input Connect sensor against signal GND | |
| 7 | VP5V_OUT | +5V/200mA output for external sensors. | |
| 8 | CANH_A | Software control CAN bus A, isolated (Functional isolation <100 VDC) | |
| 9 | CANL_A | CAN bus A, isolated (Functional isolation <100 VDC) | |
| 10 | USER_IO_5 | Digital input ('1' @ 3V, '0' @ 2V) (max. 10 mA) | |
| 11 | USER_IO_3 | Digital input ('1' @ 3V, '0' @ 2V) (max. 10 mA) | |
| 12 | USER_IO_1 | Digital input ('1' @ 3V, '0' @ 2V) (max. 10 mA) | |
| 13 | VIN_N | Negative Power Supply (0V) | |
| 14 | SYNC_A | SYNC A for Master/Slave | |
| 15 | GND | Signal GND/PT100 or PT1000 GND | |
| 16 | RES_SIN_N | Resolver input, use twisted pair and shield | |
| 17 | GND | Signal GND/PT100 or PT1000 GND | |
| 18 | PT_1 | PT100 or PT1000 temperature sensor input Connect sensor against signal GND | |
| 19 | LOOP | High Voltage Diagnostic Loop | |
| 20 | GND_CAN_A | GND for CAN bus A | |
| 21 | GND_CAN_B | GND for CAN bus B | |
| 22 | GND_IO | GND for IO, IO is isolated (Functional isolation <100 VDC) | |
| 23 | USER_IO_2 | Digital input ('1' @ 3V, '0' @ 2V) (max. 10 mA) Digital output ('1' = 4.8V, '0' = OV) (max. 10 mA) Digital output open collector (max. 80 mA) Analog input (0-32V) (input impedance ~100 kOhm) | |
| 24 | #STOP_1 | Active Low, STOP @ < 1.2V, RUN @ > 4.65V Pulling one #STOP down stops the inverter | |
| 25 | SYNC_B | SYNC_B for Master/Slave | |
| 26 | RES_COS_N | Resolver input, use twisted pair and shield | |
| 27 | RES_COS_P | Resolver input, use twisted pair and shield | |
| 28 | RES_SIN_P | Resolver input, use twisted pair and shield | |
| 29 | PT_3 | PT100 or PT1000 temperature sensor input Connect sensor against signal GND | |
| 30 | GND | Signal GND/PT100 or PT1000 GND | |
| 31 | LOOP | High Voltage Diagnostic Loop | |
| 32 | CAN_H_B | CAN bus B, isolated (Functional isolation <100 VDC) | |
| 33 | CAN_L_B | CAN bus B, isolated (Functional isolation <100 VDC) | |
| 34 | USER_IO_4 | Digital input ('1' @ 3V, '0' @ 2V) (max. 10 mA) Digital output ('1' = 4.8V, '0' = OV) (max. 10 mA) Digital output open collector (max. 80 mA) Analog input (0-32V) (input impedance ~100 kOhm) | |
| 35 | GND_ENCLOSURE | Enclosure ground |
Product Code and Options
Use the product code including all needed options for ordering. Standard options do not need to be listed in the code as they are selected by default if a non-standard option is not selected. Standard options are indicated by a star (*).
Device with +DC option requires external inductors to work. Separate inductor units can be ordered with product name EC-LTS1200-410 (see EC-LTS1200-410 data sheet for details).
Any combination of control options +MC, +AFE, and +UG is available. Option +DC is only available alone.
Options +AFE and +UG are not compatible with the -S version. Generally, option -L is recommended for all applications.
Table 6: Product code examples
| Product code | Description |
|---|---|
| EC-C1200-450-L-SW11+MC300 | L-version unit for controlling motor with 300 A current limit |
| EC-C1200-450-L-SW11+MC300+CG1 | L-version unit for controlling motor with cable glands and 300 A current limit |
| EC-C1200-450-S-SW11+DC400+DCE | S-version unit for DCDC applications with double DC-connections and 400 ADC current limit |
Table of Options
| Variant | Code | Description | Additional information |
|---|---|---|---|
| System size | -S | Small system | Default EC-C unit for individual or small system installations |
| -L | Large system | EC-C unit for large system installations | |
| Software version | * | Software version 7.x | 7-series software development is in maintenance mode. No new features will be added. Not recommended for new designs |
| -SW11 | Software version 11.x | Software version of the unit is the latest version of 11-series software | |
| Control | +MC70 | Motor control, current limit 70 A | Converter for motor/generator applications |
| +MC120 | Motor control, current limit 120 A | Converter for motor/generator applications | |
| +MC180 | Motor control, current limit 180 A | Converter for motor/generator applications | |
| +MC240 | Motor control, current limit 240 A | Converter for motor/generator applications | |
| +MC300 | Motor control, current limit 300 A | Converter for motor/generator applications | |
| +MC350 | Motor control, current limit 350 A | Converter for motor/generator applications | |
| +AFE70 | Active front end, current limit 70 A | Converter for active front end applications | |
| +AFE120 | Active front end, current limit 120 A | Converter for active front end applications | |
| +AFE180 | Active front end, current limit 180 A | Converter for active front end applications | |
| +AFE240 | Active front end, current limit 240 A | Converter for active front end applications | |
| +AFE300 | Active front end, current limit 300 A | Converter for active front end applications | |
| +AFE350 | Active front end, current limit 350 A | Converter for active front end applications | |
| +UG70 | Microgrid, current limit 70 A | Converter for microgrid applications | |
| +UG120 | Microgrid, current limit 120 A | Converter for microgrid applications | |
| +UG180 | Microgrid, current limit 180 A | Converter for microgrid applications | |
| +UG240 | Microgrid, current limit 240 A | Converter for microgrid applications | |
| +UG300 | Microgrid, current limit 300 A | Converter for microgrid applications | |
| +UG350 | Microgrid, current limit 350 A | Converter for microgrid applications | |
| +DC150 | DCDC control, current limit 150 ADC | Converter for DC/DC applications | |
| +DC250 | DCDC control, current limit 250 ADC | Converter for DC/DC applications | |
| +DC300 | DCDC control, current limit 300 ADC | Converter for DC/DC applications | |
| +DC400 | DCDC control, current limit 400 ADC | Converter for DC/DC applications |
Option List
| Speed option | Communication | Connections | Cable glands | Marine classification | Customer specific |
|---|---|---|---|---|---|
| * Normal speed version (<580 Hz output frequency) | * | * Normal connections | * No cable glands | * No marine classification | * Default unit firmware-wise |
| +HS High speed version (>580 Hz output frequency) | +CO CANopen | +CE1 Connection extension 1 | +CG1 Default M25 cable glands | +CL1 ABS American Bureau of Shipping | +CS Customer specific parameters or application in FW |
| +CO CANopen | +CE2 Connection extension 2 | +CG2 Default M25/M32 cable glands | +CL2 BV Bureau Veritas | ||
| +DCE DC-extension | +CG3 Default M25 cable glands | +CL3 DNV | |||
| +CG4 Default M25 cable glands | +CL4 LR Lloyd's Register | ||||
| +CG5 Default M25/M32 cable glands | +CL5 RINA | ||||
| +CG6 Default M25 cable glands | +CL6 CCS China Classification Society |
* Standard option
NOTE! Products delivered with high speed option (+HS option) are subject to export control as dual-use items when transported outside of European community according to CE 428/2009 regulation.
Legal Disclaimer
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.
