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Summary of Contents for Danfoss ED3
- Page 1 User Guide Electrical converter EC-BDC1200 www.danfoss.com...
- Page 2 Updated sections: Intended use of the electric device, Low voltage connections, Regular 0105 maintenance December 2024 Updated section: Measuring the insulation resistance 0104 October 2024 Updated document (general market) 0103 February 2024 Updated document for P03 hardware revision 0102 September 2022 First edition 0101 © Danfoss | March 2025 BC425854117339en-000105...
- Page 3 High voltage connections..............................36 Low voltage connections...............................37 Operation Operation conditions..................................40 Pre-charging....................................40 Condition monitoring during operation..........................41 Maintenance Regular maintenance................................... 42 Cooling system maintenance..............................43 Cleaning......................................43 Dismounting and disposal of the electric device Troubleshooting Aftersales © Danfoss | March 2025 BC425854117339en-000105 | 3...
- Page 4 User Guide EC-BDC1200 Contents Service policy....................................48 Service parts.....................................48 © Danfoss | March 2025 BC425854117339en-000105...
- Page 5 EC-BDC1200 in vehicle usage In vehicle usage, the electric device requires an external filter when operated as a charger to comply with UN Regulation No. 10. For more information, see the product data sheet. © Danfoss | March 2025 BC425854117339en-000105 | 5...
- Page 6 General information EC-BDC1200 system overview with external filter Warranty 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.
- Page 7 Rated ambient temperature °C 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. •...
- Page 8 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. © Danfoss | March 2025 BC425854117339en-000105...
- Page 9 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. © Danfoss | March 2025 BC425854117339en-000105 | 9...
- Page 10 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. © 10 | Danfoss | March 2025 BC425854117339en-000105...
- Page 11 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.
- Page 12 Read the instructions in this user guide before you start to install the electric device. Operation safety 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. © 12 | Danfoss | March 2025 BC425854117339en-000105...
- Page 13 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. © Danfoss | March 2025 BC425854117339en-000105 | 13...
- Page 14 43.6 kVA • DC power take-off up to 44 kW • AC power take-off up to 43.6 kVA • J1939 compliant Danfoss proprietary CAN interface • Bidirectional energy flow control • High performance current and voltage control •...
- Page 15 HVIL2, HVIL3 and HVIL4 have an internal circuit that feeds the current for the HVIL and monitors the state of the connectors. All of the High voltage connectors have to be mated to allow the device to be operated. © Danfoss | March 2025 BC425854117339en-000105 | 15...
- Page 16 30 mA Type B RCD. When charging from an IT network (with or without neutral), the EC- BDC1200 must be used with a functional IMD. Charging is prohibited from corner grounded networks. © 16 | Danfoss | March 2025 BC425854117339en-000105...
- Page 17 AC ePTO operation on an IT network is permitted only when used with an IMD. Supply to a TN network is prohibited. Allowed use case for AC ePTO in IT network DC ePTO (DC-Out) DC ePTO operation on an IT network is permitted only when used with an IMD. © Danfoss | March 2025 BC425854117339en-000105 | 17...
- Page 18 EC-BDC1200 Product overview Allowed use case for DC ePTO in IT network In case of questions about the allowed use cases, contact Danfoss for more information before using the product. Prohibited use of the electric device It is prohibited to use, handle, maintain and store the electric device in the following ways (including but not limited to): •...
- Page 19 Typically, HEV or EV applications include traction or propulsion system, energy storage and a charging system by using an onboard charger or generator system with combustion engine. Danfoss electric converter products are designed for controlling the flow of power in heavy-duty, marine and transportation applications.
- Page 20 Mass Total weight of the electric device °C Ambient temperature limits °C Storage temperature limits storage Cooling Cooling type Tc (Max) Coolant temperature °C Coolant flow l/min Max. pressure Coolant maximum pressure © 20 | Danfoss | March 2025 BC425854117339en-000105...
- Page 21 24 Nm +/-4 Nm, M8 Coolant connections 48 Nm +/-5 Nm Grounding point 24 Nm +/-4 Nm, M8 Cable bracket 10 Nm +/-1.5 Nm, M6 Mounting points 48 Nm +/- 8 Nm, M10 © Danfoss | March 2025 BC425854117339en-000105 | 21...
- Page 22 Inspect the electric device and the package immediately upon arrival. Ensure that the rating plate data in the cover letter complies with the purchase order. All external damage in the package or in the electric device must be photographed and reported to Danfoss immediately. Lifting Use correct, adequately dimensioned lifting devices and inspect them before lifting.
- Page 23 Transportation and storage Lift the electric device using the correct lifting lugs/eyes only. See the lifting Figures in this Chapter. Do not go under a lifted load. Correct lifting and incorrect lifting © Danfoss | March 2025 BC425854117339en-000105 | 23...
- Page 24 Although the electric device is designed to operate in harsh and demanding environment, any misuse or improper handling of the electric device is prohibited to avoid malfunctions later. Storage When the device is dismounted and stored and packed for delivery, measure that there is no voltage. © 24 | Danfoss | March 2025 BC425854117339en-000105...
- Page 25 Make sure that the cabling and cooling connections are plugged and sealed before storage. Always dry the cooling circuit units before long storage. The electric device must not be subjected to any external vibrations during storage to avoid possible hidden structural damages. © Danfoss | March 2025 BC425854117339en-000105 | 25...
- Page 26 The reference value 50 MΩ has to be exceeded at reference ambient temperature +25°C (measured with 500 V / 1 min insulation resistance test). Contact Danfoss Editron service if the reference value is not exceeded. Measuring the insulation resistance Insulation resistance testers generate lethal voltages.
- Page 27 User Guide EC-BDC1200 Installation Primary circuit and secondary circuit to enclosure The following table lists test conditions and pass criteria for the ED3 onboard charger. Test voltage Test duration Pass criteria 500 V 60 s > 50 MΩ Measurement procedure: 1.
- Page 28 Measure the insulation between the TVB connection (marked in black) and the rest of the connections AC IN, AC OUT and DC OUT (marked in red). Auxiliary circuit to enclosure The following table lists test conditions and pass criteria for the ED3 onboard charger. Test voltage Test duration...
- Page 29 The electric device must be mounted in a way that no other object or structure, which can cause compression, pull, torsion, rotation etc., touches the enclosure of the electric device. In addition, the electric device should not be used to support any other structure of the system. © Danfoss | March 2025 BC425854117339en-000105 | 29...
- Page 30 Note that it is not allowed to install the electric device upside down (the top of the device downward) horizontally. Recommended mounting position Location of the mounting points M10 holes, 3 pcs per side. © 30 | Danfoss | March 2025 BC425854117339en-000105...
- Page 31 26. • Installation procedure 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 different. © Danfoss | March 2025 BC425854117339en-000105 | 31...
- Page 32 When selecting cooling liquid nipples, choose nipples that can resist galvanic corrosion. To prevent damage to the cooling connectors, refer to the documentation of the manufacturer for the correct tightening torque of the cooling liquid nipples. © 32 | Danfoss | March 2025 BC425854117339en-000105...
- Page 33 35. Risk of electric shock is always present when operating high voltage equipment. Before working with the power connections make sure that electricity has been disconnected and the electric device has discharged. © Danfoss | March 2025 BC425854117339en-000105 | 33...
- Page 34 EMC-shielded. Shieldings must be connected to the ground at both ends of the cable or wire. Make sure that the low voltage cable (control signal cable) shield is also grounded from both ends. © 34 | Danfoss | March 2025 BC425854117339en-000105...
- Page 35 If this is not possible, the electric device must be grounded at least from one of the safety grounding points with an appropriate grounding cable. For good functional grounding use wide flat grounding braid. Round grounding wires are adequate for safety grounding but it does not provide very © Danfoss | March 2025 BC425854117339en-000105 | 35...
- Page 36 Check connector manufacturer’s instructions for plugging in, unplugging and locking the connectors. Incorrect procedure can damage the connectors or reduce their lifetime. Do not reverse the TVB and DC Out polarities. Reversing the polarity will result in permanent damage to the device. © 36 | Danfoss | March 2025 BC425854117339en-000105...
- Page 37 Cable type and properties Control signals Shielded multistrand wire For more information, see Signal connector manufacturer specification. Signal connections For information about the assembly of the control signal connectors, see the manufacture's website. © Danfoss | March 2025 BC425854117339en-000105 | 37...
- Page 38 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.
- Page 39 For the ePTO operation with AC-Out or DC-Out also pin 21 is required to enable one of the ePTO outputs. All connections on the signal connector are referenced to ground on pin 6. © Danfoss | March 2025 BC425854117339en-000105 | 39...
- Page 40 Coolant liquid must be water-glycol mixture with glycol content: nominal 50 %, max. 60 %. See chapter Recommended coolants on page 33. If the operation limits are exceeded and the electric device is damaged, please contact local Danfoss representative. Pre-charging DC ePTO pre-charging Do the pre-charging correctly, or the high inrush current may break external electrical components of the electric device.
- Page 41 46 for more information. Monitor the electric device regularly during operation to make sure of reliable operation, to foresee possible upcoming failures and to help to reach the designed lifetime of the product. © Danfoss | March 2025 BC425854117339en-000105 | 41...
- Page 42 Regular maintenance Do not disassemble the electric device. You can do only procedures described in this user guide. For further information contact Danfoss representative. Only trained and qualified personnel that are familiar with the relevant safety requirements can do any maintenance to the electric device.
- Page 43 Weekly Monthly Yearly General Operation Abnormal phenomenon, for example noise or construction heating. If clearly increased, contact Danfoss representative. Mounting Tightness of the screws. Tighten to proper value if necessary. Applies to screws that are presented in this user guide. See Chapter Tightening torques on page 21.
- Page 44 Risk of electric shock if the electric device is cleaned against instructions allowing water to go in to the electric device. Keep the electric device clean. For cleaning, use non-abrasive and non-corrosive cleaning products. Make sure that the detergent can be used for aluminum. © 44 | Danfoss | March 2025 BC425854117339en-000105...
- Page 45 Dispose of the electric device and any of its parts by appropriate means in accordance with local laws and regulations. Electric device must not be opened. Any attempt causes loss of warranty. © Danfoss | March 2025 BC425854117339en-000105 | 45...
- Page 46 Do not try to repair the electric device. In the case of suspected fault or malfunction, contact Danfoss or authorized service center for further assistance. For the reason of general safety and correct operative actions, read the instructions carefully before you start any analysis or work with the electric device.
- Page 47 Broken cooling hose. Replace the cooling hose. Electric device does not Poor powerline contacts Inspect and clean the electrical connections. Replace mating work correctly or the (high voltage) connector if necessary. performance is poor © Danfoss | March 2025 BC425854117339en-000105 | 47...
- Page 48 Aftersales Service policy The electric device has no need for regular maintenance or service parts. Service parts The electric device does not have any customer serviceable parts. Contact Danfoss representative for more information. © 48 | Danfoss | March 2025...
- Page 49 Phone: +86 21 2080 6201 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 subsequent changes being necessary in specifications already agreed.
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