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Installation Guide

CONFIDENTIAL

TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide

Page 23 of 42

2020-11-20

4.5.3 Example installation sequence

The system integrator will define the final electrical connection sequences of the MCU and motor taking the

complete installation into consideration; the sequence for installing the MCU in Section 4.5.3.1 is given as

an example.

4.5.3.1 Suggested installation sequence

Several cables and harnesses are required for the MCU electrical connection. The following steps

summarize the electrical connection sequence of the MCU.

IMPORTANT NOTE

: Disable the high-voltage and auxiliary batteries before handling the product, or

connecting/disconnecting any cable, harness or tube.

Connect the grounding straps, see Section 4.5.4.

Connect the phase cables, see Section 4.5.5.

Connect the motor sensor interface harness, see Section 4.5.6.

Connect the VMU interface harness, see Section 4.5.7.

Connect the high-voltage battery cables, see Section 4.5.8.

Connect the auxiliary battery cables, see Section 4.5.9.

Connect the cooling inlet/outlet hoses, see Section 4.4.

As specified earlier, the final installation sequence should be defined by the integrator according to the

application type. However, for user safety, the grounding strap should always be installed first, and the

product should no longer be handled when the power source is enabled.

Note

: Reverse sequencing is performed when removing the system from the vehicle; remove the grounding

strap last.

4.5.4 Grounding the system

The system must be securely grounded to ensure user safety in case of an insulation fault in the motor

and/or the MCU. An incorrectly grounded connection may result in MCU functionality losses and safety

risks for the user.

IMPORTANT NOTE

: Disable the high-voltage and auxiliary batteries before connecting or disconnecting

the ground.

4.5.4.1 Grounding strap recommendations – MCU

The integrator must consider the possibility of an insulation fault where the high-voltage battery current

would find a path through the grounding strap. The grounding strap or wire must be sized to support the

maximum current of the high-voltage battery for a sufficient time for the high-voltage battery fuse to open.
Refer to Section 4.5.8.2 for the high-voltage battery fuse specification.

4.5.4.2 Connecting the grounding strap – MCU

The grounding strap must be connected to its dedicated connection point (Figure 7) or to one of the

mounting points shown in Figure 3. The type of MCU grounding configuration used may vary according to

the type of vehicle integration.

Note

: To prevent oxidation of the aluminum surfaces and any malfunction of the connection during

operation, we recommend that you sand the contact point on the MCU and apply a layer of conductive

grease on the grounding strap contact surfaces before connecting the strap. The grounding strap wire

length from the MCU grounding point to the vehicle chassis should be as short as possible.

Summary of Contents for CO300-A1

Page 1: ...Installation Guide TG 0057_19 TM4 SUMO HD CO300 A1_A2_A2 5 Installation Guide SUMO HD Product Motor Control Unit MCU Versions CO300 A1 A2 A2 5 ...

Page 2: ... TM4 inc 2013 2020 Page 2 of 42 2020 11 20 Product information Product series TM4 SUMO HD Model numbers CO300 A1 CO300 A2 CO300 A2 5 Document information Reference TG 0057 TM4 CO300 A1_A2_A2 5 Installation Guide Release date 2020 11 20 Version number 19 0 Template information Reference IN 8032_3 ...

Page 3: ...Using separate brackets to support MCU and motor 13 4 2 2 Respecting the physical integrity of the MCU 13 4 2 3 Protecting the casing from external loads 13 4 2 4 Correctly positioning the MCU 13 4 3 Securing the MCU 15 4 4 Installing the cooling system 17 4 4 1 Safety warnings related to handling the cooling agent 17 4 4 2 Parallel configuration 18 4 4 3 Serial configuration 19 4 4 4 Coolant inle...

Page 4: ...Installation Guide Dana TM4 inc 2013 2020 Page 4 of 42 2020 11 20 4 6 Software installation 40 4 6 1 Selecting communication protocol type 40 4 6 2 CAN protocol and TM4 ODIN 40 4 6 3 Embedded software packages 41 4 6 4 Customizing system parameters 42 5 Customer service 42 ...

Page 5: ...pecifications 30 Table 8 HVIL and EmergencyStop Absolute maximum rating 31 Table 9 High voltage battery Recommended fuse sizing 35 Table 10 CO300 model number vs internal common mode capacitor type 35 Table 11 CO300 model number vs capacitor type resistance to chassis 36 Table 12 High voltage battery Pre charge circuit specifications 36 Table 13 Auxiliary battery Steady state and inrush currents 3...

Page 6: ...U 19 Figure 7 Grounding point 24 Figure 8 Phase cable gland locations 25 Figure 9 Motor sensor interface location Base of the MCU 27 Figure 10 Front of connector 28 Figure 11 VMU ECU interface location Underside of the MCU 29 Figure 12 VMU interface harness Plug pinout P770E0160 30 Figure 13 Suggested HVIL EmergencyStop safety circuit INV HP2HV_0309 A 01 06 32 Figure 14 Suggested HVIL EmergencySto...

Page 7: ...he TM4 SUMO HD CO300 MCU 1 2 Scope This technical guide is divided as follows Introduction general information about the product definitions and document reference information Transport and storage conditions guidelines on environmental conditions to be respected during system storage and transport Receiving and unpacking general guidelines on how to safely unpack and inspect the product Installin...

Page 8: ... one safety warning applies to the same procedure they are grouped together in one box and identified with the appropriate safety symbol General Irritant Operational This warning symbol indicates that you are in a potentially hazardous situation that could result in damage to the product or in some situations lead to bodily harm or death Electrical This warning symbol indicates that you are in a p...

Page 9: ...rations and Maintenance Guide 1 5 TG xxxx TM4 SUMO HD System Specifications 1 2 6 Application Note TM4 SUMO Fuse and DC Cable Selection 1 7 SC 6000E 036 Kit 0076 VMU interface connector assembly instructions wire version 1 8 SC 6000E 017 Kit 0014 Right angled MCU connector assembly instructions 1 9 SC 6000E 045 Connector lubricant application instructions 1 10 SC 6004E 007 TM4 Inverter Action Guid...

Page 10: ...ucts must be transported and stored in well ventilated facilities with adequate protections against dust and excessive humidity See Table 2 details of recommended conditions While the products are in the original shipping crates there are no precautions to take against electrostatic discharge ESD however when unpacking and manipulating the products you must avoid touching the connector pins Table ...

Page 11: ...3 2 Inspecting and moving the MCU 1 On receiving the MCU immediately verify that the crate is undamaged if you see signs of damage before signing for the package Inform the person delivering the package Make a note on the way bill and keep a copy Immediately contact TM4 2 On opening the crate perform a quick physical check of the contents Inspect for damaged packaging materials Verify that the MCU...

Page 12: ... guide on how to install the MCU Call TM4 Customer Service if in doubt see Section 5 for contact details 4 1 1 Respecting CSC and MKC markings on interface drawings Before installing the product refer to any CSC and MKC markings on the product interface drawing 11 These markings highlight areas that may potentially impact product safety operation or longevity if proper instructions are not followe...

Page 13: ...stomization before or after installation You must not under any circumstances attempt to modify any part of the MCU as this could cause permanent damage to the MCU and injury to the user This includes any modification that changes the state of the original product such as Drilling holes into the casing Adding and or removing parts including hardware screws and connectors 4 2 3 Protecting the casin...

Page 14: ... Page 14 of 42 2020 11 20 Figure 1 Position of vent on base of MCU casing Figure 2 Position of IGBT coolant overflow holes on base of MCU casing Note In case of any sign of coolant leakage from these points immediately stop operation of the MCU and contact TM4 Customer Service see Section 5 for contact information ...

Page 15: ...TM4 regarding the product must be respected Do not attempt to open or repair this product In case of damaged casing or suspected product malfunction contact TM4 Use only indicated points to secure the MCU See Figure 3 for the locations of the mounting points on the MCU each of the highlighted areas includes 2 or 3 mounting points either under or on the side of the MCU select at least one mounting ...

Page 16: ...00 A1_A2_A2 5 Installation Guide Dana TM4 inc 2013 2020 Page 16 of 42 2020 11 20 Figure 3 Mounting points External view of top and base of the MCU Note Mounting points can also be used as lifting points see the product interface drawing 10 for more information ...

Page 17: ...s or exceeds a pressure of 30 PSI static pressure measured at the entrance of the MCU upstream of the MCU in the circuit Ensure that the pump is adjusted accordingly The cooling agent contains ethylene glycol that is a highly flammable product Ethylene glycol can burn with an invisible flame that can cause serious burns and or other injuries Always handle the cooling agent carefully wearing approp...

Page 18: ...s are supplied by the vehicle integrator and the cooling system setup involves fine tuning and testing at the customer site TM4 has no specific recommendations on how to achieve optimum configuration but coolant liquid pressure must not reach or exceed 30 PSI See the System Specifications 5 for estimated pump requirements Figure 4 Parallel cooling system See the System Specifications 5 for more in...

Page 19: ...30 PSI Figure 5 Serial cooling system See the System Specifications 5 for more information on coolant pressure drops and rate flow management 4 4 4 Coolant inlet outlet specifications Specific hose types should be used to connect the cooling unit to this system Refer to the product interface drawing 11 for coolant inlet outlet specifications the locations of the inlet and outlet are labelled on th...

Page 20: ...tion ASTM D3306 Type III or ASTM D6210 Type III The ethylene glycol must contain some type of active corrosion inhibitors The ethylene glycol must be diluted with de ionized water not distilled water The dilution ratio must be 60 ethylene glycol to 40 de ionized water minimally 50 ethylene glycol to 50 de ionized water Two different types of coolant should not be mixed As the cooling unit cooling ...

Page 21: ...dance with applicable vehicle standards and industry practices Always use appropriate insulation and protection before manipulating the product even when the product is disconnected from a high voltage source ESD sensitive do not touch connector pins or EMI filter The internal electronics are sensitive to electrostatic discharges Risk of electric shock do not open the MCU and or motor Beside the M...

Page 22: ...nsure that cables do not touch or cross over each other Never place cables near sharp edges or on abrasive surfaces Protect cables from damage due to gravel or other environmental factors Allow for enough room for air circulation clearance space for movement and access to cables for maintenance etc When securing cables Ensure that each cable is appropriately supported connector strain relief High ...

Page 23: ...er source is enabled Note Reverse sequencing is performed when removing the system from the vehicle remove the grounding strap last 4 5 4 Grounding the system The system must be securely grounded to ensure user safety in case of an insulation fault in the motor and or the MCU An incorrectly grounded connection may result in MCU functionality losses and safety risks for the user IMPORTANT NOTE Disa...

Page 24: ...43 before insertion One screw is provided for grounding purposes Table 4 Grounding strap installation First end Second end Refer to Figure 7 Vehicle chassis frame or earth ground test bench Note The location of the second end connection point of the grounding strap given here is an example the actual location will depend on the type of application being used by the vehicle integrator 4 5 4 3 Conne...

Page 25: ...preparation before installation For detailed cable end preparation information see the cable end specification document for your installation 7 Note Phase cables can be up to a length of 5 m 4 5 5 2 Installing the phase cable assembly Using the harness you have prepared or purchased from TM4 refer to the product interface drawing 11 and cable harness specification 13 for illustrated installation i...

Page 26: ... Motor MCU Motor MCU A1 1 A1 9 B1 2 B1 8 C1 3 C1 7 A2 4 A2 6 B2 5 B2 5 C2 6 C2 4 A3 7 A3 3 B3 8 B3 2 C3 9 C3 1 Notes 1 If the reversed connection scenario is chosen the PhaseCableReversed parameter must be set to 1 and the DrvParameters Save parameter must be set to 1 For more information refer to the product Operations and Maintenance Guide 4 2 Recommended cable bending radius cable diameter x 8 ...

Page 27: ...o obtain specially designed adaptors from TM4 that allow you to combine a prototype motor with an Alpha version MCU or a prototype MCU with an Alpha version motor Contact TM4 Customer Service for more information see Section 5 for contact details 4 5 6 1 Installing the motor sensor interface harness assembly Before connecting or reconnecting the motor sensor interface harness connector carry out a...

Page 28: ...sor interface pinout information The following information may be required for troubleshooting purposes Table 6 gives the mapping between the pins on the TM4 motor and the TM4 MCU Figure 10 shows the positions of the pins on the connector head Table 6 Motor sensor interface pinout Figure 10 Front of connector TM4 MCU Signal information TM4 motor A Temperature C A B Temperature C B C Temperature B ...

Page 29: ...AN ports The VMU interface is located on the left side of the MCU next to the motor sensor interface Figure 11 and has 14 pins Figure 11 VMU ECU interface location Underside of the MCU As vehicle integrators are able to connect the TM4 SUMO system to the VMU or ECU of their choice the integrator will have the responsibility of fabricating the VMU interface harness using wiring appropriate to the s...

Page 30: ... CAN1H Communication 20 22 High level of differential signal CAN1 C CAN2L Communication 20 22 Low level of differential signal CAN2 D CAN2H Communication 20 22 High level of differential signal CAN2 J HVIL IN HVIL IN 20 22 Hazardous voltage interlock loop signal K HVIL OUT HVIL OUT 20 22 Hazardous voltage interlock loop signal H Emergency stop Output 20 22 Emergency stop Notes 1 Two supply pins E ...

Page 31: ...MPORTANT NOTE Depending on the product model number of the TM4 inverter you are using there are two possible default factory settings either Vaux or Vaux and therefore two possible EmergencyStop scenarios It is the responsibility of the integrator to verify the MCU product model number and then to implement the HVIL and EmergencyStop safety circuit appropriate to that product To implement the nece...

Page 32: ...l is maintained at Vaux Chassis level for a minimum of 10 seconds After this period of time and as long as the MCU is kept enabled IGNITION input at Vaux level this signal will only go at high impedance if the following abnormal condition occurs The MCU is no longer in an Operational state and the high voltage battery current measured by the MCU is beyond established safe limits 30 A to 30 A Note ...

Page 33: ...ignal is maintained at Vaux level for a minimum of 10 seconds After this period of time and as long as the MCU is kept enabled IGNITION input at Vaux level this signal will only go at high impedance if the following abnormal condition occurs The MCU is no longer in an Operational state and the high voltage battery current measured by the MCU is beyond established safe limits 30 A to 30 A Note Once...

Page 34: ...g with your integration 4 5 8 1 Safety instructions related to connecting the high voltage battery Carefully read all safety instructions before connecting the high voltage battery WARNINGS This product generates high voltage that can cause an electric discharge or electrocution resulting in injury or death When installing the product verify that The traction battery high voltage battery is discon...

Page 35: ...ment varies depending on the model of CO300 you are using Table 10 CO300 model number vs internal common mode capacitor type Model number Capacitor INV HP2HV_0309 xx A1 INV HP2HV_0309 03 A2 2 1 μF 20 INV HP2HV_0309 05 A2 5 INV HP2HV_0309 16 A2 5 220 nF 20 To ensure that the reading is precise prior to taking the measurements the DC lug screw must be installed and tightened the lug does not need to...

Page 36: ... 5 INV HP2HV_0309 05 A2 5 645 5 INV HP2HV_0309 06 A1 645 5 INV HP2HV_0309 07 A1 945 5 INV HP2HV_0309 13 A1 645 5 INV HP2HV_0309 14 A1 945 5 INV HP2HV_0309 15 A1 945 5 INV HP2HV_0309 16 A2 5 945 5 The vehicle integrator must add a pre charge mechanism to protect the capacitor bank and limit the pre charge current as specified in Table 12 Table 12 High voltage battery Pre charge circuit specificatio...

Page 37: ...e integrator before installing them in the MCU Refer to the cable end specifications 12 for preparation instructions for both the negative and positive cable ends 4 5 8 7 Installing the high voltage battery cables Before installing the high voltage battery cables refer to the general warnings and safety instructions in Section 4 5 8 1 and in this section WARNING Risk of electrocution The high volt...

Page 38: ...o power the MCU The negative terminal of the battery must be connected to the frame of the vehicle chassis To protect the system against short circuit add a fuse in series with the positive terminal of the auxiliary battery See Table 13 for MCU current information Table 14 for fuse specifications and Figure 17 for the fuse block diagram Table 13 Auxiliary battery Steady state and inrush currents S...

Page 39: ... Guide Dana TM4 inc 2013 2020 Page 39 of 42 2020 11 20 4 5 10 CAN interface The integrator must select impedance according to the desired CAN bus terminations CAN1 is terminated see Figure 18 CAN2 is not terminated see Figure 19 Figure 18 CAN1 terminations Figure 19 CAN2 not terminated ...

Page 40: ...formation 4 6 2 CAN protocol and TM4 ODIN The TM4 CO300HV A MCU uses the CAN protocol to send and receive messages data Although certain aspects of the protocol have default settings at the time of delivery see Table 15 in this version of the software you can reconfigure the CAN baud rate see Section 4 6 2 2 Table 15 TM4 ODIN CAN default configuration values Specifications Units Values Default bau...

Page 41: ...PEED_OPTION in Parameters Drive CanBaudRate in TM4 ODIN 2 Save the new value with the Parameters Command DrvParameters Save command Note The system must be shut down and then restarted for the changes to be effective 3 Before being able to connect the device with TM4 ODIN you need to modify the CAN communication speed in TM4 ODIN Configuration Device Communication for it to match the new value tha...

Page 42: ...he TM4 CO300HV MCU from the list 6 Click on the Apply button 7 From the TM4 ODIN menu select Tools Flash program manager Note A message is displayed asking if you want to save the current workspace before programming another package if you want to keep a copy of the workspace save it as an odn4 file If you do not choose to save the data will be cleared 8 Select the application software from the Ch...

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