Danfoss EC-LTS1200-410 User guide
User Guide
Liquid cooled heavy duty inductor unit
EC-LTS1200-410
www.danfoss.com
User Guide
EC-LTS1200-410
Revision history Table of revisions
Date Changed Rev
July 2021 Updated user guide 0201
2 | © Danfoss | July 2021 BC355449988603en-000201
User Guide
EC-LTS1200-410
Contents
General information
Intended use of the user guide................................................................................................................................................... 4
Product naming convention........................................................................................................................................................ 4
Conformity according to standards...........................................................................................................................................4
Warranty.............................................................................................................................................................................................. 5
Terms and abbreviations...............................................................................................................................................................5
Responsibility of the manufacturer........................................................................................................................................... 6
Safety information
General safety statement...............................................................................................................................................................7
Safety message signal words....................................................................................................................................................... 7
Safety symbols...................................................................................................................................................................................7
Personal protective equipment.................................................................................................................................................. 8
Safety features...................................................................................................................................................................................9
Electromagnetic compatibility (EMC)....................................................................................................................................... 9
Installation safety..............................................................................................................................................................................9
Operation safety.............................................................................................................................................................................11
Product overview
Intended use of the electric device......................................................................................................................................... 13
System introduction..................................................................................................................................................................... 14
Cooling...............................................................................................................................................................................................14
Rating plate......................................................................................................................................................................................14
Tightening torques........................................................................................................................................................................15
Transportation and storage
Transportation................................................................................................................................................................................ 17
Receiving and unpacking............................................................................................................................................................17
Lifting................................................................................................................................................................................................. 17
Handling............................................................................................................................................................................................19
Storage...............................................................................................................................................................................................19
Installation
Required tools.................................................................................................................................................................................20
Mechanical installation................................................................................................................................................................20
Allowed mounting position..................................................................................................................................................20
Installation procedure.............................................................................................................................................................21
Cooling connections............................................................................................................................................................... 22
Recommended coolants........................................................................................................................................................22
Electrical installation.....................................................................................................................................................................23
Electrical connections............................................................................................................................................................. 23
Grounding...................................................................................................................................................................................23
Cable gland assembly and power line connection...................................................................................................... 25
Cabling and wiring...................................................................................................................................................................31
High voltage connections..................................................................................................................................................... 32
Low voltage connections.......................................................................................................................................................32
Operation
Operation conditions....................................................................................................................................................................34
Condition monitoring during operation...............................................................................................................................34
Maintenance
Regular maintenance................................................................................................................................................................... 35
Cooling system maintenance....................................................................................................................................................36
Cleaning............................................................................................................................................................................................ 36
Dismounting and disposal of the electric device
Troubleshooting
Aftersales
Service policy...................................................................................................................................................................................40
Service parts.....................................................................................................................................................................................40
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User Guide
EC-LTS1200-410
General information
Intended use of the user guide
Product naming convention
This user guide contains the installation, operation and maintenance instructions for the EC-LTS1200-410
liquid cooled heavy duty inductor unit.
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 qualified 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
reflect all system features.
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 (*).
EC-LTS1200-410 options
Variant Code Description Additional information
Cable glands * No cable glands No cable glands or plugs
Marine classification * No marine classification
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:
+CG1 M25/M32 cable glands 3x M25 cable glands, 3x M32 cable glands and 2x M32 plugs
in delivery
+CL1 ABS American Bureau of Shipping
+CL2 BV Bureau Veritas
+CL3 DNV
+CL4 LR Lloyd’s Register
+CL5 RINA
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User Guide
EC-LTS1200-410
General information
Warranty
Applicable directives and standards
Directives / Standards Explanation
Low Voltage Directive 2014/35/EU Electrical equipment means any equipment designed for use with a voltage
The electromagnetic compatibility
(EMC) Directive 2014/30/EU
IEC/EN 61800-5-1: 2007 Adjustable speed electrical power drive systems - Part 5-1: Safety
EN 13766-1:2018 Construction machinery. Electromagnetic compatibility of machines with
UN Regulation No. 10 Revision 4 and
Revision 5
rating of between 50 and 1000 V for alternating current.
EMC directive ensures that electrical and electronic equipment does not
generate, or is affected by, electromagnetic disturbance.
requirements - Electrical, thermal and energy.
internal electrical power supply.
Uniform provisions concerning the approval of vehicles with regard to
electromagnetic compatibility.
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 first.
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, nonexecution 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 modifications 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
Symbol Variable Unit
U
DC
U
ac
I
n
P
n
f
in/out
f
switch
I
peak
Q
c
T
c
DC link voltage V
AC output voltage V
Rated current A
Rated power kW
Input / Output frequency Hz
Switching frequency kHz
Overcurrent limit A
Rated coolant liquid flow l/min
Rated coolant liquid input
temperature
rms
°C
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User Guide
EC-LTS1200-410
General information
Symbol Variable Unit
T
amb
GND Ground in electrical connections
R Resistance Ω
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 qualified 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.
Rated ambient temperature °C
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EC-LTS1200-410
Safety information
General safety statement
Safety message signal words
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 qualified 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 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 identified 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 identified 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 identified by a yellow background, black triangular band, and a black
arrowhead symbol. It indicates dangerous electrical voltage that could cause an
electric shock to a person.
Burn warning
The symbol is identified 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.
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User Guide
EC-LTS1200-410
Safety information
Magnet warning
The symbol is identified by a yellow background, black triangular band, and a black
magnet symbol. It indicates strong magnetic field that could cause harm to a person
or property.
Poison warning
The symbol is identified 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 manual.
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 you work with the electric
device. Permanent damage to the eye could be caused if bearing grease, melted nitrile rubber
(radial lip seal), glycol or other fluids splash.
Use hearing protective equipment when you work on the electric device. Hearing injuries can
be caused by too loud noise (noise in excess of 85 dBA).
Use head protective equipment like helmet when you lift the electric device! Head injuries can
be caused by object impact.
Use cut resistant gloves when you handle and maintain the electric device. There is a risk of
cut injuries.
Use protective footwear when you lift or move the electric device! Foot injuries could be
caused if lifting system or lifting brackets fail.
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User Guide
EC-LTS1200-410
Safety information
Safety features
Electromagnetic compatibility (EMC)
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).
Our products are designed with high standards of EMC in mind. Connect the power lines and groundings
along the instructions in this user guide to achieve the required level of EMI 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. Within the European Union,
equipment into which this product is incorporated must comply with the EMC Directive 2014/30/EU.
When interfacing other equipment, connect only equipment that are specified as part of the
system and that are compatible.
Magnetic and electromagnetic fields generated near the current-carrying conductors and
permanent magnets in electric machines represent 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, perform a special electromagnetic compatibility (EMC) test on the installation.
Installation safety
Only trained and qualified 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 fitted 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.
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User Guide
EC-LTS1200-410
Safety information
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 specification 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 specifications 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.
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EC-LTS1200-410
Safety information
Operation safety
Read the instructions in this user guide before you start to install the electric device.
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.
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 fixed 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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User Guide
EC-LTS1200-410
Product overview
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.
•
Main components
1 L1 connection
2 L2 connection
3 L3 connection
4 +LV connection plugged (configurable, see +CG option below)
5 Cooling inlet / outlet connections
6 X2 temperature measurement connector
7 +LV connection cable gland (configurable, 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
10 Connection box lid
+CG1 option comes with a selection of cable glands and plugs. Typical cable gland configurations are
shown in the Table below.
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User Guide
EC-LTS1200-410
Product overview
Typical cable gland configurations for option +CG1
Connections Typical cable gland applications
Connection to DC/DCconverter (L1, L2, L3)
Low voltage side positive
connection (+LV)
Intended use of the electric device
3x M25 cable glands 3x M25 cable glands 3x M25 cable glands
1x M32 cable gland, 2x
M32 plugs
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 fixed installation, as a part of complete power generation
equipment or system.
2x M32 cable glands, 1x
M32 plugs
3x M32 cable glands, no
plugs
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.
Application example
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 defined 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 first 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.
•
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