Danfoss EC-C1200-450 Liquid Cooled Heavy Duty Converter
Data Sheet
Features
- Extremely compact design – converter unit only 14 kg
- High enclosure class IP6K9K - sealed from moisture and dust
- Liquid cooled with water-glycol mixture
- Ambient temperature from -40°C to +105°C
- Allowed coolant temperature up to +65°C
- Robust design withstanding high levels of mechanical vibrations and shocks
- Designed especially 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 for commissioning and diagnostics available
General
The device is a heavy-duty converter designed especially for electric or hybrid drive trains for mobile work machines, buses or marine vessels. It can act as motor inverter, active front end, create a microgrid or as a DC/DC-converter depending on the options selected.
Typical Applications
- Boosting battery voltage to higher DC-link voltage (+DC option)
- Charging high voltage batteries from higher DC-link voltage (+DC option)
- Controlling the speed and torque of electrical traction motors (+MC option)
- Converting alternating current (AC) from electrical generator to direct current (DC) for energy storage (+MC option)
- Active Front End for connecting to AC grid with regenerative power and low harmonic (+AFE option)
- Microgrid (+UG option)
+DC option requires an external inductance unit. See Danfoss EC-LTS data sheets for more information. (Contact Danfoss Editron)
+AFE and +UG options require an external LCL-filter unit. See Danfoss EC-LCL1200 data sheets for more information. (Contact Danfoss Editron)
Specifications
DC connection (+DC option)
| 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) |
| HV-side voltage range | 0-850 VDC |
| Switching frequency | 8 kHz |
DC connection (+MC/+AFE/+UG option)
| DC link voltage range | 0-850 VDC |
|---|---|
| DC link nominal voltage | 750 VDC |
AC connection (+MC/+AFE/+UG option)
| 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
| Voltage range | 7-33 VDC |
|---|---|
| Power | 14.4 W |
| Nominal current | 0.6 A @ 24 VDC 1.2 A @ 12 VDC |
Mechanical
| 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
| 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
| 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
HUBER+SUHNER Radox Elastomer S, screened, single core, automotive cable (FHLR4GC13X)www.hubersuhner.com
| Coolant connection | 2 x 20 mm coolant hose connector (see dimension drawing for details) |
|---|---|
| HV cable recommended type | |
| 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 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) |
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 |
"-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 |
"-S" and "-L" versions have same ratings, see section SMALL/LARGE SYSTEM DIFFERENCES.
Pressure Loss vs Coolant Flow
A graph showing pressure loss in bar against volume flow in l/min. The pressure loss increases with volume flow.
Picture 1 Device pressure loss vs coolant flow
Dimensions
Picture 2 Device dimensions
Picture 3 Device dimensions with +CE1 or +CE2 option
| 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 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 differences in the isolation measurement resistance, DC-link discharge resistor and Y-capacitor values as shown in Picture 5 and Table 3.
Picture 4 EC-C1200-450 internal schematic
Picture 5 EC-C1200-450 internal schematic and application example when used in combination with external inductance unit EC-LTS
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 |
Device with +MC, +AFE or +UG option has internal schematic shown in Picture 4. Possible additional equipment like LCL-filter or motor is connected to the phases L1, L2 and L3. Options +AFE and +UG are not compatible with the -S version of the device. Generally, option -L is recommended for all applications.
Device with +DC option requires external inductors to work as seen in application example shown in Picture 5. LV+ and LV- can be connected, for example, to battery and DC+ and DC- to a higher voltage DC-link. Device is in control of the discharging and charging of the battery. +DCE option is recommended when using the device in combination with the external inductance unit.
Different connection options of the electric device are shown below.
Connection Options of EC-C1200-450
Picture 6 Connection options of EC-C1200-450
| Color | Meaning |
|---|---|
| Gray | Cable glands for phases |
| Red | Cable glands for DC+ |
| Black | Cable glands for DC- |
Table 4 Color coding
Parametrizing, Monitoring and Diagnostic of the Device
PowerUSER monitoring and diagnostics software uses service connector on the device and PSSC service cable for connecting to the device. The PSSC is isolated RS485 and shielded cable specially designed for the demanding environments where the inverters are used, and it is available in 3 meter (PSSC-3M) and 10 meter version (PSSC-10M). 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
| Pin number | Signal name | Rev R/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 | |
| 4 | RES_EXC_N | Pulling one #STOP down stops the inverter | |
| 5 | RES_EXC_P | Resolver exitation, use twisted pair and shield | |
| 6 | PT_2 | Resolver exitation, use twisted pair and shield | |
| 7 | VP5V_OUT | PT100 or PT1000 temperature sensor input | |
| 8 | CANH_A | Connect sensor against signal GND | |
| 9 | CANL_A | +5V/200mA output for external sensors. | |
| 10 | USER_IO_5 | Software control | |
| 11 | USER_IO_3 | CAN bus A, isolated (Functional isolation <100 VDC) | |
| 12 | USER_IO_1 | CAN bus A, isolated (Functional isolation <100 VDC) | |
| 13 | VIN_N | Digital input ('1' @ 3V, '0' @ 2V) (max. 10 mA) | |
| 14 | SYNC_A | Digital output ('1' = 4.8V, '0' = OV) (max. 10 mA) | |
| 15 | GND | Digital output open collector (max. 80mA) | |
| 16 | RES_SIN_N | Digital input ('1' @ 3V, '0' @ 2V) (max. 10 mA) | |
| 17 | GND | Digital output ('1' = 4.8V, '0' = OV) (max. 10 mA) | |
| 18 | PT_1 | Digital output open collector (max. 80 mA) | |
| 19 | LOOP | Analog input (0-32V) (input impedance ~100 kOhm) | |
| 20 | GND_CAN_A | Digital input ('1' @ 3V, '0' @ 2V) (max. 10 mA) | |
| 21 | GND_CAN_B | Digital output ('1' = 4.8V, '0' = OV) (max. 10 mA) | |
| 22 | GND_IO | Digital output open collector (max. 80 mA) | |
| 23 | USER_IO_2 | Analog input (0-32V) (input impedance ~100 kOhm) | |
| 24 | #STOP_1 | Negative Power Supply (OV) | |
| 25 | SYNC_B | SYNC A 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 | |
| 30 | GND | Connect sensor against signal GND | |
| 31 | LOOP | High Voltage Diagnostic Loop | |
| 32 | CANH_B | GND for CAN bus A | |
| 33 | CAN_L_B | GND for CAN bus B | |
| 34 | USER_IO_4 | GND for IO, IO is isolated (Functional isolation <100 VDC) | |
| 35 | GND_ENCLOSURE | Enclosure ground |
Product Code and Options
Use 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 unit 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 option -S. 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 7 Option list
| 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 |
Table 7 Option list
| * Standard option | |||
|---|---|---|---|
| Speed option | * | Normal speed version (<580 Hz output frequency) | EC-C with motor/generator control firmware, capable of speeds below 580 Hz |
| +HS | High speed version (>580 Hz output frequency) | EC-C with motor/generator control firmware, capable of speeds up to 1000 Hz | |
| Communication | * | CAN1939 | EC-C with Standard SAE1939-communication |
| +CO | CANopen | EC-C with CANopen-communication | |
| Connections | * | Normal connections | EC-C with default HV connections |
| +CE1 | Connection extension 1 | EC-C with double DC and AC connectivity with connection extension box 1 (double M25 cable gland threads) (Not compatible with +DCE option) | |
| +CE2 | Connection extension 2 | EC-C with M32 cable gland threads on AC connection with connection extension box 2 (choose also +DCE if double DC connection is required) | |
| +DCE | DC-extension | EC-C with double DC-connections: copper bushings for double connection (compatible with +CE2/+CG4/+CG5) | |
| Cable glands | * | No cable glands | EC-C with no cable glands or plugs |
| +CG1 | Default M25 cable glands | EC-C with 5x M25 cable glands and 2x M25 plugs | |
| +CG2 | Default M25/M32 cable glands | EC-C with 2x M25 cable glands, 3xM32 cable glands and 3xM25 plugs (for +CE2 option) | |
| +CG3 | Default M25 cable glands | EC-C with 10x M25 cable glands (for +CE1 option with double DC-link connections) | |
| +CG4 | Default M25 cable glands | EC-C with 7x M25 cable glands (for +DCE option) | |
| +CG5 | Default M25/M32 cable glands | EC-C with 4x M25 cable glands, 3xM32 cable glands and 3xM25 plugs (for combined +CE2 and +DCE options) | |
| +CG6 | Default M25 cable glands | EC-C with 8x M25 cable glands and 2x M25 plugs (for +CE1 option with single DC-link connections) | |
| Marine classification | * | No marine classification | |
| +CL1 | ABS American Bureau of Shipping | ||
| +CL2 | BV Bureau Veritas | ||
| +CL3 | DNV | ||
| +CL4 | LR Lloyd's Register | ||
| +CL5 | RINA | ||
| +CL6 | CCS China Classification Society | ||
| Customer specific | * | Default unit firmware-wise | EC-C with default parameters and application |
| +CS | Customer specific parameters or application in FW | EC-C with separately specified application and/or parameters |
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.
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.
