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Danfoss EC-C1200-450, User Manual

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Danfoss EC-C1200-450 User Manual Download Page 30

Figure 11. Location of the mounting points, EC-LTS unit (sold as separate product, needed only with

+DC option)

Selected mounting position must allow the cooling system to work properly. Bleed the air away

from the cooling channels to prevent air pockets.
Make sure that the air vents (2 pcs) are clean and the selected installation place and mounting

direction do not allow water, dust or dirt to block the air vents.

EC-C1200-450

5. Installation

| BC265735231757en-000109

©

Danfoss | Produced By: Danfoss Power Solutions | January 2019 | 29

Summary of Contents for EC-C1200-450

Page 1: ...User Guide Electrical converter EC C1200 450 danfoss com...

Page 2: ...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...

Page 3: ...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 EC C1200 450 Ta...

Page 4: ...Revision Information 9 EC C1200 450 BC265735231757en 000109 Danfoss Produced By Danfoss Power Solutions January 2019 3...

Page 5: ...nstall 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...

Page 6: ...istance DC link discharge resistor and Y capacitor values as shown in the gure and table below Figure 1 S and L systems schematics Table 1 S and L system component values System option Component Value...

Page 7: ...terials 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 m...

Page 8: ...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 op...

Page 9: ...ns 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...

Page 10: ...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 devi...

Page 11: ...if lifting system or lifting brackets fail Safety features Protection type Built in Information Overcurrent Yes 750 APEAK Overcurrent Yes 500 Arms Overvoltage Yes 1050 V DC Short circuit Yes Overspeed...

Page 12: ...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 elect...

Page 13: ...ontrol 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 indep...

Page 14: ...n 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 y...

Page 15: ...s 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 malfunctio...

Page 16: ...tion protocols for example CANopen SAE J 1939 Possibility to create customer speci c applications with CODESYS IEC61131 3 software tool High performance vector control Wide selection of protective saf...

Page 17: ...obust design withstanding high levels of mechanical vibrations and shocks Designed especially for highly cyclical loads typical in heavy mobile work machines The advantages and features of the EC LTS...

Page 18: ...TS LV 3 LV3 EC LTS LV 4 L1 EC LTS 5 L2 EC LTS 6 L3 EC LTS 7 X1 connector Low voltage connector for measurement data and control signals 8 DC 9 DC LV 10 LV1 11 LV2 EC C1200 450 3 Product overview BC265...

Page 19: ...r for electric motors System component functioning as a current converter converting alternating current AC from electric generator to direct current DC for energy storage System component boosting ba...

Page 20: ...raid 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...

Page 21: ...max 50 Coolant temperature 40 65 C 40 40 C for 350 A version Coolant ow minimum 10 l min Nominal operating pressure 2 bar Pressure drop 100 mbar with 10 l min 25 C coolant See detailed information and...

Page 22: ...ct data sheets http www danfoss com Figure 6 Rating plate example Table 5 Rating plate elds Field Explanation Unit 1 Electric device product family 2 Electric device device full type code including po...

Page 23: ...ric device screws Tightening torques screw preloads used in the electric device are shown in the table below Table 6 Tightening torques Connection Torque Electric device mounting screws M8 20 Nm Elect...

Page 24: ...oided 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 dat...

Page 25: ...Figure 7 Correct lifting and incorrect lifting EC C1200 450 4 Transportation and storage 24 Danfoss Produced By Danfoss Power Solutions January 2019 BC265735231757en 000109...

Page 26: ...Horizontal lifting Figure 8 Maximum permissible lifting angles EC C1200 450 4 Transportation and storage BC265735231757en 000109 Danfoss Produced By Danfoss Power Solutions January 2019 25...

Page 27: ...aving the storage temperature preferably above 20 C and the relative humidity less than 60 Storage conditions should be dry dust free and vibration free Make sure that the cabling and cooling connecti...

Page 28: ...oduct data sheets http www danfoss com Mechanical installation Allowed mounting position The electric device must be mounted on a at heat and ame resistant mounting place for example on a bracket The...

Page 29: ...Figure 10 Location of the mounting points EC C1200 450 5 Installation 28 Danfoss Produced By Danfoss Power Solutions January 2019 BC265735231757en 000109...

Page 30: ...tem to work properly Bleed the air away from the cooling channels to prevent air pockets Make sure that the air vents 2 pcs are clean and the selected installation place and mounting direction do not...

Page 31: ...electric device Handle with care Handle the electric device correctly when you install it to the correct mounting position See chapter Handling for more information Do not use excessive force when in...

Page 32: ...ocedure may vary from that shown in this user guide All steps must be included in the procedure although the order of the steps can be di erent Installation procedure 1 Prepare the installation place...

Page 33: ...f the frame of the electric device by direct contact between it and the metal bracket and or from the protective earth contacts The grounding contacts must be paint free See Chapter Grounding 7 Uninst...

Page 34: ...o chapter Electrical installation 10 Install the connection box lid 11 Install the connector shield 12 Connect the X1 connector control signal connector EC C1200 450 5 Installation BC265735231757en 00...

Page 35: ...he electric device Coolant connections 2 x 20mm Coolant connection in EC LTS unit 2 x 1 2 bores It is recommended to x the hose on the coolant connection with a hose clamp or a hose clip after the pro...

Page 36: ...o be used Propylene glycol is relatively safe compound for humans and the environment Electrical installation Before you start the electrical installation make sure that the frame of the electric devi...

Page 37: ...LV2 EC LTS LV 3 LV3 EC LTS LV 4 L1 EC LTS 5 L2 EC LTS 6 L3 EC LTS 7 X1 connector Low voltage connector for measurement data and control signals 8 DC 9 DC LV 10 L1 11 L2 12 L3 13 X2 connector maintena...

Page 38: ...gure 18 Connection diagram Figure 19 Electrical connections with CE2 option and DCE option EC C1200 450 5 Installation BC265735231757en 000109 Danfoss Produced By Danfoss Power Solutions January 2019...

Page 39: ...external 5 DC connection DCE 6 DC connection DCE 7 DC connection DCE 8 DC connection DCE 9 Not in use 10 Not in use 11 Not in use Figure 20 Electrical connections with CE1 option EC C1200 450 5 Insta...

Page 40: ...tion 9 L3 connection 10 L2 connection 11 L1 connection Use all connections when you install an electric machine with CE1 option Using only connections in the connection extension box can cause overhea...

Page 41: ...ment or from any other piece of equipment Ground impedance must be compliant with local industrial safety regulations The protective ground of the unit must be connected to the system ground Ground im...

Page 42: ...ing points Figure 23 Grounding point 1 for EC LTS Safety grounding points and protective earth conductor EC C1200 450 5 Installation BC265735231757en 000109 Danfoss Produced By Danfoss Power Solutions...

Page 43: ...ing voltage before you touch the power terminals All electrical connections must be done according to instructions It is essential to make sure that all terminal connections are installed properly and...

Page 44: ...tsch BlueGlobe series cable glands and H S Radox Elastomer S automotive cables are recommended Cable gland assembly instruction can also be found from P itsch gland catalogue available from http www p...

Page 45: ...en of the cable Figure 26 Cut lenght of the cable sheath 3 Insert the cable to the cable gland with slight turning motion This helps the cable go through the spring inside the cable gland Push the cab...

Page 46: ...the inner sheath shown in Figure below The length D must be equal to the length of the cable lug body Figure 29 Cutting the inner sheath 6 Place the cable inside the cable lug body and crimp the cable...

Page 47: ...power terminal with the correct screw Use spring washer between the cable lug and the connection screw or nut Do not tighten the cable lug screw at this point to ensure tting of the cable gland Make s...

Page 48: ...en the cable lug using the speci ed torque 11 Repeat the procedure to the other cables and connections 12 Close the power terminal cover and install the connector shield 13 Make sure that the power ca...

Page 49: ...ectly If the electric device drives a motor or generator contact Danfoss if the power cable is longer than 15 m For EMC reasons a lter might be needed Install the electric device by the instructions M...

Page 50: ...s are connected to the electric device according to the product speci c operating voltage The electric device is delivered with the power terminal cover mounted To access the power connections remove...

Page 51: ...VDC 75 750 VDC 75 750 VDC 75 750 VDC Nominal current 150 AAVG 250 AAVG 300 AAVG 400 AAVG Nominal power 90 kW 150 kW 200 kW 240 kW Maximum transformation ration between LV and HV voltages is 1 10 Outp...

Page 52: ...nector Low voltage control signal connection includes these functions Power supply of the control system of the electric device Power On O Communication channels CAN Digital In Out Analog In Emergency...

Page 53: ...Detailed and up to date information can be found at manufacturer s web pages Connector assembly according to connector manufacturer instructions for example contact crimping Minimum wiring and connect...

Page 54: ...ut 2 Identical to stop input 1 Both need to be pulled up in order to be able to run A minimal wiring scheme is shown in the gure below The main point is that the POWER_ON input is the one that should...

Page 55: ...ed to the enclosure frame of the converter and can be used to connect cable shields General information Connect VIN_P to the positive power supply and VIN_N to the negative power supply POWER_ON and S...

Page 56: ...sed the device has over current and short circuit protection that stops the device if short circuit or over current is detected Signals for monitoring diagnostics and set up The electric device can be...

Page 57: ...37 Maintenance connector Connection diagram Figure 38 Electric device power connection diagram EC C1200 450 5 Installation 56 Danfoss Produced By Danfoss Power Solutions January 2019 BC265735231757en...

Page 58: ...is damaged please contact local Danfoss representative Pre charging Do the pre charging correctly or the high inrush current may break external electrical components of the electric device The electri...

Page 59: ...ent damage to the electric device If you notice deviations from the normal operation for example high temperatures or noise stop the electric device Find the reason for the deviation and take action t...

Page 60: ...maintenance The cooling system of the electric device requires regular observation and maintenance activities Observe weekly that the cooling system operates correctly and check monthly that there are...

Page 61: ...tion Functioning Cooling system functions as speci ed X Tubing and connection tightness No visible leakage If leaking tighten connections appropriately or replace parts X Ventilation plug Cleanliness...

Page 62: ...discharged Always measure that no voltage is present on the power terminals before you proceed 5 Wait until the temperature of the electric device and cooling liquid has decreased below 40 oC 6 Remove...

Page 63: ...evice overheating Cooling system failure Inspect the cooling system operation and functionality especially possible leaks ow rate and uid temperature Change the cooling ow direction to ush the cooling...

Page 64: ...stored in to Fault history menu After the root cause is de ned and the electric device is inspected and recovered according to instructions the fault can be reset Fault resetting can be done with the...

Page 65: ...ng Figure 40 Service parts with standard connections Table 20 Service parts Position if shown Item order number Quantity Description Type 1 10756 1 Connector shield Mechanical safety feature which pre...

Page 66: ...nnected 2 10348 7 Cable glands P itsch blueglobe TRI bg 225ms tri 3 10988 1 Service connector cap Binder series 713 P N 082616000000 4 X 1 Connection box lid power terminal cover 13231 1 Spacer sleeve...

Page 67: ...ature which prevents opening the connection box if the signal connector is not disconnected 2 10348 10 Cable glands P itsch blueglobe TRI bg 225ms tri 3 10988 1 Service connector cap Binder series 713...

Page 68: ...0988 1 Service connector cap Binder series 713 P N 082616000000 4 X 1 Connection box 5 16871 3 Cable glands P itsch blueglobe TRI bg 232ms tri Use description for ordering Table 24 Accessory spare par...

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