DANA TM4 SUMO MD MV Troubleshooting Manual Download Page 1

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SUMO MD MV/HV Powertrain

Troubleshooting Guide

March 2021

Summary of Contents for TM4 SUMO MD MV

Page 1: ...1 SUMO MD MV HV Powertrain SUMO MD MV HV Powertrain Troubleshooting Guide March 2021 ...

Page 2: ...ures creates a high risk of personal injury to the servicing technician CAUTION Failure to follow indicated procedures may cause component damage or malfunction IMPORTANT Highly recommended procedures for proper service of this unit Note Additional service information not covered in the service procedures Tip Helpful removal and installation procedures to aid in the service of this unit This symbo...

Page 3: ...ase of damaged casing or suspected product malfunction contact Dana TM4 Customer Service Use only recommended points to lift and secure the MCU When using straps to lift the MCU ensure they do not touch or put pressure on any part of the product exterior surface connectors and or cables Do not attach the motor to the MCU using a shared support or bracket Do not apply any external load to the casin...

Page 4: ...cooling agent breathing in high concentrations of ethylene glycol can cause nausea In case of contact with eyes and skin rinse with water and consult a doctor In case of ingestion seek medical help immediately The cooling agent is under pressure when heated removing the cap when the coolant is hot can cause serious burns and or other injuries Wait until the coolant reaches an ambient temperature b...

Page 5: ...rotected EEPROM memory section 89 TT16 Invalid Hardware or Software 91 TT17 Inconsistence between Control Logic and IGBT 93 TT18 High power battery voltage lower voltage limit 95 TT19 High Power Battery Voltage Maximum 99 TT20 IGBT Temperature Sensor reading over the limit 105 TT21 Temperature Sensor reading over the limit107 TT22 EMI Temperature measurement over limit 109 TT23 Motor Coil Temperat...

Page 6: ...al Signal Processor ECU Electronic Control Unit EMF ElectroMotive Force ESD ElectroStatic Discharge EV Electrical Vehicle GΩ Giga Ohm unit GDD TM4 ODIN Gathered Diagnostic Data sub program h hour unit HVIL Hazardous Voltage Interlock Loop HS High Side kW kiloWatt unit kΩ KiloOhm unit mA Milliampere unit L Liter unit L h Liter per hour unit MΩ Mega Ohm unit MCU Motor Control Unit Nm Newton meter un...

Page 7: ...g and stopping the system o Applying a mechanical torque o Safely shutting down the system o Verifying operational status Hazardous Voltage Interlock Loop HVIL The Hazardous Voltage Interlock Loop HVIL internal loop is closed resulting in a short circuit between its two input pins The HVIL signal is used to open the high voltage battery contactor when its internal loop is opened during product mai...

Page 8: ...Mishandling of this product may damage the product and or cause injury or death Do not attempt to open or repair this product In case of damaged casing or suspected product malfunction contact Dana TM4 Use only recommended points to lift and secure the system When manipulating and or installing this product you must NOT Modify any part of the MCU Apply any external load to the casing of the MCU Ap...

Page 9: ...9 General Information Dana TM4 Motor and MCU Components This is an example Dana TM4 Motor Dana TM4 MCU ...

Page 10: ...t 0 6mADC 8 VDC 1 2mADC 32 VDC Maximum System Efficiency 95 3 CAN interface version 2 0b Motor Control Unit Short Circuit Protection Yes Motor Control Unit Over Current Protection Yes System Specification Characteristics Designed Measured Maximum Mechanical Output Power 250 kW 265 kW for 47 seconds Maximum Mechanical Output Torque 2645 Nm 2761 Nm for 30 seconds Maximum Mechanical Output Torque at ...

Page 11: ...igh side Output 20 16 Generic high side output 200mA 8 Vaux Power 20 16 Positive power wire of the MCU Must be connected to the auxiliary battery using fuse type 9 CAN1L Communication 20 16 Low level of differential signal CAN1 10 CAN2H Communication 20 16 High level of differential signal CAN2 11 5V SENSOR Analog supply 20 16 12 PWM2_OUT Low side output 20 16 Generic Low side Output 1A can be use...

Page 12: ...differential signal CAN2 E Vaux Power 20 22 Positive power wire of the MCU Must be connected to the auxiliary battery using fuse type F Vaux Power 20 22 Positive power wire of the MCU Must be connected to the auxiliary battery using fuse type G Ignition Input 20 22 Enable signal to the Motor Control Unit H Emergency stop Output 20 22 Emergency stop J HVIL_IN HVIL IN 20 22 Hazardous voltage interlo...

Page 13: ...tion points on the MCU and the motor to the vehicle chassis frame The vehicle chassis connection points for the MCU and motor grounding straps should ideally be the same point or the same vehicle chassis frame side Conductive grease should be used on each of the contact points to ensure reliable and durable grounding connections The resistance between the grounding points and the chassis must be t...

Page 14: ...Power cables are required between the MCU and the motor to connect each phase An example of a product with a view of the phase cable connection points is shown below Phase Cable Identification Straight Terminal Phase Cable Identification 90 degrees ...

Page 15: ...ors MCU Type 1 MCU Type 2 Signal name TM4 Motor Type 1 TM4 Motor Type 2 A 1 Temperature C A F3 B 9 Temperature C B F2 C 16 Temperature B C A3 D 2 Temperature B D A2 E 10 Temperature A E A4 F 17 Temperature A F B4 J 3 R1_OUT N A1 T 11 R2_OUT P B1 L 18 COS S1 L C1 M 4 COS S3 M D1 N 12 SIN S2 J E1 P 19 SIN S4 T F1 H 5 HVIL_TO_MOTOR H F4 R 13 1 Wire OUT R C2 S 20 1 Wire GROUND S C3 K 6 HVIL_FROM_MOTOR...

Page 16: ...16 General Information Motor connector head Identification Dana TM4 MCU A3 Type 2 Dana TM4 Motor Type 2 Dana TM4 MCU A1 A2 Type 1 Dana TM4 motor Type 1 ...

Page 17: ... vehicle chassis Auxiliary Battery Fuse To protect the system against short circuit a fuse is connected in series with the positive terminal of the auxiliary battery Specifications Units Values 12 V Values 24 V Maximum MCU steady state current A 4 5 3 Maximum MCU inrush current A 10 10 Maximum MCU quiescent current mA 1 1 5 Note Refer to the Installation guide for further details ...

Page 18: ...re develop by ex TM4 E Motor type ex MO340 F Motor size ex 240 G Software family letter ex A H Software version Major minor delivery and change list ex 3 6 1 95366 As an example here is a typical software package file name MCU_INVHP2HV_0206_TM4_MO340_240_A_V3 6 1 95366Pkg exe File Name Description Embedded Software Package Executable MCU_INV ABCDEFGH Pkg exe See note on software PACKAGE naming Emb...

Page 19: ...n the vehicle and connected to the MCU and the motor to dissipate the excess heat The motor and the MCU are linked to the cooling system by a fan pump coolant tank and radiator configuration There are two possible configurations for the cooling system the parallel configuration and serial configuration Parallel Configuration Serial Configuration MCU example with coolant inlet and outlet indication...

Page 20: ...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 hose and cooling agent are not supplied by Dana TM4 the vehicle integrator has full responsibi...

Page 21: ...t 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 voltage cables secured no more than 10 cm from the connectors Low voltage cables secured no more than 30 cm from the conne...

Page 22: ...use and DC Cable Selection published on the Knowledge base section of the Dana TM4 extranet site for proper fuse selection The chart below is an example of the specifications available Other system can be used with different wire size Notes 1 The wire size or wire wall material can be adapted to fit required use 2 Depending on the location of the wires a wire tubing orange split loom can be used t...

Page 23: ...with DB9 connector VMU interface connector Vaux input Ignition enable CAN termination resistor PC With TM4 ODIN installed USB port DB9 connector 2 CAN L 7 CAN H CAN GND Grounding straps Cooling source pump and radiator Cooling in Cooling out Cooling in Cooling out Cooling in Cooling out Vehicle chassis USB to CAN interface connector NC CAN interface channel X Phase cables Motor sensor harness Lege...

Page 24: ...ows 7 8 with limited access Software extraction zip 7zip WinRar Note Windows XP and lower version are no longer supported Any of the supported CAN interfaces below o Kvaser USB cable interfaces o PEAK System PCAN USB PCAN PCIe and PCAN USB Pro interfaces o Vector Vector XL Interface family for example CANcaseXL CANboardXL CANcardXLe and CANcardLe and the VN16XX series are all supported by TM4 ODIN...

Page 25: ...sed to check Continuity Effective Ground connection Broken wires Open circuits Shorted circuits Incorrect voltage level high voltage battery or Vaux Megohmmeter This device is used to measure the insulation of high voltage equipment or installation that may present a safety hazard in the event of a fault The measurement is performed by generating a high DC voltage with a specific current magnitude...

Page 26: ...e CAN interface to the CAN port of the Dana TM4 product Then connect the CAN interface to your computer You may need an adaptor depending on the CAN interface CAN box used The specific characteristics for the implementation of the CAN buses are described in the technical documentation for the Dana TM4 product you are using Note CAN protocol supports parallel connections It is possible to use a CAN...

Page 27: ...the GDD files 1 Power on the unit with the appropriate Auxiliary Vehicle Battery Vaux supply 2 Turn the ignition ON for the MCU to be enabled 3 Open Odin Server 1 and establish connection to the MCU The Process description is in Appendix 4 Retrieve GDD Files and User Parameters 4 Make sure that at the bottom left of the Odin screen Device Connected is displayed in green text 5 In Odin Server 1 in ...

Page 28: ...own menu select GDD or click the icon in the tool bar Note GDD is also available and can be invoked if a CAN trace is required 8 Click on and browse to the folder where the zip file is created 9 Click on the Start button to begin the process Note If GDD was selected a new window opens to begin the CAN trace recording 10 On the new window click on the Start button CAN trace recording start ...

Page 29: ... the Abort button on the second window to stop the process Once the data has been gathered the Email Data button on the first window becomes available It generates an email with the zip Cancel can be selected to avoid sending an email with the data right away SysFile ID File 1 After retrieving the GDD zip file extract the file SysFile csv ...

Page 30: ...e ID Event Description Brief description of the SysFile ID Event Data This data gives precision about the cause of event Time Amount of time before the Event Code occurs starting from each unit power up DTC ID Not used Purposed Actions Not used 1 2 3 4 5 6 7 1 2 3 4 5 6 7 ...

Page 31: ...leshooting Tree that refer to a specific diagnostic tree Table of SysFile ID The following table of the SysFile ID provides the in formation of the diagnostic type the code description and the related Troubleshooting Tree see the section Appendix 1 Table of SysFile ID Erreur Source du renvoi introuvable in the Appendix section Table of Troubleshooting Tree The table of Troubleshooting Tree provide...

Page 32: ...0507 37 0x0320 11 0x320E 31 0x0508 37 0x0321 05 0x320F 23 0x0509 37 0x0322 05 0x3210 32 0x050A 37 0x0323 05 0x3211 32 0x050D 37 0x0324 05 0x3212 13 0x0325 05 0x3301 16 0x0326 05 0x3303 33 0x0504 12 0x3307 14 0x1000 15 0x3400 05 0x1003 16 0x3401 05 0x1100 15 0x3402 05 0x1200 15 0x3403 05 0x120A 13 0x3404 05 0x1300 02 0x3405 24 0x2200 05 0x3406 05 0x2209 14 0x3407 05 0x3100 17 0x3408 05 0x3101 17 0x...

Page 33: ...A service code is set by a specific fault condition and may be cleared by switching the ignition off and then on It s possible to clear an error message only to have it display again when the fault condition reoccurs To make sure an issue is fixed be sure to run the system through the same operating modes that caused the issue and verify that the service code does not reappear Electrical faults ar...

Page 34: ...s used in multiple Troubleshooting Trees TT SysFile ID Service Codes SysFile IDs SysFile IDs are shown by software ODIN They describe an error warning or information message related to the unit System Mode SysFile ID Condition Possible Causes Functional state of the unit when the Condition dysfunctional event occurs List of the Service Code SysFile ID related to the Troubleshooting Tree TT Details...

Page 35: ... related to the unit involved Sub tree Indicates a sub tree present in this document Process Actions Indicates any process or action to do Assistance Process Indicates a process we describe an assistance action Ex Call Dana TM4 for help Question Decision Choice Indicates a decision point between two or more paths in the tree Document Indicates the document to refer for a dedicated action ...

Page 36: ...e gets written in the unit EEPROM memory upon a shutdown sequence If the Vaux power 12 V or 24 V is removed before the MCU is in ReadyToPowerOff state via CAN the SysFile section could possibly get corrupted and will be cleared on the next power ON Note Refer to the Dana TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerat...

Page 37: ...37 Service Codes ...

Page 38: ...cur upon writing while power Vaux is removed Note SysFile event log only shows one Info System power up Note Refer to the TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the tr...

Page 39: ...39 Service Codes ...

Page 40: ...ed equipment to diagnose this fault This can be also that the Vaux Fuse about to open or more resistive The MCU itself may be defective Note Refer to the TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment an...

Page 41: ...n VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 VMU ECU Interface Type 1 VMU ECU interface harness Plug Pinout Type1 Connector Front Type 2 Wire Insertion Side Back Type 2 Connector Front Type 1 Wire Insertion Side Back Type 1 ...

Page 42: ...42 Service Codes Connector type 2 pinout Connector type 1 pinout ...

Page 43: ...43 Service Codes ...

Page 44: ...44 Service Codes ...

Page 45: ...45 Service Codes ...

Page 46: ...uide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Re...

Page 47: ...VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 VMU ECU Interface Type 1 VMU ECU interface harness Plug Pinout Type1 Connector Front Type 2 Wire Insertion Side Back Type 2 Connector Front Type 1 Wire Insertion Side Back Type 1 ...

Page 48: ...48 Service Codes Connector type 2 pinout Connector type 1 pinout ...

Page 49: ...49 Service Codes ...

Page 50: ...50 Service Codes ...

Page 51: ... machine then the measurements may be different and refer to your machine specification Note Refer to the TM4 motor installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting tree...

Page 52: ...52 Service Codes Machine internal resistance measurement table ...

Page 53: ...53 Service Codes Connector Head Identification TM4 Motor connector Type 1 TM4 Motor connector Type 2 ...

Page 54: ...54 Service Codes ...

Page 55: ...55 Service Codes ...

Page 56: ...56 Service Codes ...

Page 57: ...sm is activated to maintain the DC bus under the high voltage maximum limit At the time the motor phases are short circuited through the MCU power modules the battery current will temporarily exceed the threshold limit upon failure and raise this SysFile ID error This error can therefore be ignored following the 0x3113 warning TT26 Back EMF Motor reduction mechanism activated phases are short circ...

Page 58: ...58 Service Codes ...

Page 59: ...f the same 3 phase systems keeping the system in operation If ever a fault occurs on another internal phase current sensor the system will go into fault reporting other error types Note Refer to the TT03 SysFile ID 0x0313 entry for the Vaux too low Event for Vaux Verification and corrective actions refer to steps in that TT03 tree that comes after voltage measurement To correctly diagnose the faul...

Page 60: ...VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 VMU ECU Interface Type 1 VMU ECU interface harness Plug Pinout Type1 Connector Front Type 2 Wire Insertion Side Back Type 2 Connector Front Type 1 Wire Insertion Side Back Type 1 ...

Page 61: ...61 Service Codes Connector type 2 pinout Connector type 1 pinout ...

Page 62: ...62 Service Codes ...

Page 63: ...63 Service Codes ...

Page 64: ...opening the HVIL loop from the HVIL input of the MCU To fix this fault refer to the troubleshooting guide of the other system 3 The connectors that connect the HVIL circuit to the MCU are somehow defective In this case the VMU ECU connectors must be disconnected from the MCU and repaired 4 The MCU itself is defective It should be disconnected and replaced Note Refer to the TM4 Product installation...

Page 65: ...65 Service Codes Connector Head Identification VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 Connector Front Type 2 Wire Insertion Side Back Type 2 ...

Page 66: ...66 Service Codes Connector type 2 pinout ...

Page 67: ...67 Service Codes ...

Page 68: ...68 Service Codes ...

Page 69: ...s opening the HVIL loop from the HVIL output of the MCU To fix this fault refer to the troubleshooting guide of the other system 3 The connectors that connect the HVIL circuit to the MCU are somehow defective In this case the system must be turned OFF and the connectors must be repaired 4 The MCU itself is defective and must be replaced Note Refer to the TM4 Product installation guide for more det...

Page 70: ...70 Service Codes Connector Head Identification VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 Connector Front Type 2 Wire Insertion Side Back Type 2 ...

Page 71: ...71 Service Codes Connector type 2 pinout ...

Page 72: ...72 Service Codes ...

Page 73: ...73 Service Codes ...

Page 74: ...st be turned OFF and then the cables must be locked by the locking mechanism engaged on both sides MCU and motor 4 The motor is defective 5 The MCU is defective Note Refer to the TM4 Product Operation and maintenance guide for more details Note Refer to the TM4 MCU installation guide for more details on installation and deinstallation procedure including safety warning considerations Note Refer to...

Page 75: ...75 Service Codes ...

Page 76: ...76 Service Codes ...

Page 77: ...77 Service Codes ...

Page 78: ...set them according to the needs and the limits set by the Operations and Maintenance Guide 2 There is a problem with the HVIL power source that is connected to the HVIL line This problem is external to the Motor Control Unit MCU refer to HVIL source Troubleshooting Guide 3 The MCU is defective The system must be turned OFF and the MCU removed and replaced Note Refer to the TM4 Product Operation an...

Page 79: ...VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 VMU ECU Interface Type 1 VMU ECU interface harness Plug Pinout Type1 Connector Front Type 2 Wire Insertion Side Back Type 2 Connector Front Type 1 Wire Insertion Side Back Type 1 ...

Page 80: ...80 Service Codes ...

Page 81: ...81 Service Codes ...

Page 82: ...ion from Dana TM4 extranet The correct software version must be flashed to the MCU The user must access the Dana TM4 Extranet to determine which software versions are compatible with the particular MCU 4 The MCU is defective because the factory setting may be wrong In this case the MCU must be replaced To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for ...

Page 83: ...83 Service Codes ...

Page 84: ...84 Service Codes ...

Page 85: ...and replaced Note Refer to the TM4 motor installation guide for more details on installation and deinstallation procedure including safety warning considerations Note Refer to the TM4 Product installation guide MCU and motor for more details on installation regarding the motor sensor connection between the MCU and the motor To correctly diagnose the faulty system connect the Diagnostic Tool see Di...

Page 86: ...86 Service Codes ...

Page 87: ... Update Software for the procedure to do this 3 The motor itself may be defective Note Refer to the TM4 motor installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting procedure ...

Page 88: ...88 Service Codes ...

Page 89: ...CU installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnosti...

Page 90: ...90 Service Codes ...

Page 91: ...CU must be turned OFF and be disconnected and replaced Note Refer to the MCU installation guide for more details on installation and deinstallation procedure including safety warning considerations Note Replace the MCU with a MCU corresponding to the MCU subfolder specified on the Dana TM4 extranet site To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for...

Page 92: ...92 Service Codes ...

Page 93: ...ation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System ...

Page 94: ...94 Service Codes ...

Page 95: ... installation guide for more details on installation and deinstallation procedure including safety warning considerations Note List of potential external causes Another defective system on the DC bus causing electrical overloads Defective Battery Management System or Battery Interface Module Defective battery contactor causing intermittent contact Defective controller VMU ECU Higher than normal Hi...

Page 96: ...96 Service Codes ...

Page 97: ...97 Service Codes ...

Page 98: ...98 Service Codes ...

Page 99: ...te There are resonance within the DC lines or the regeneration torque causes increase in voltage because of battery resistance or the motor resolver is making a voltage ripple Note Regarding contact intermittence to MCU if the contactor contacts or any other contacts in the battery chain from contactor to MCU are intermittent while the MCU is in operational state it could make the DC bus to fluctu...

Page 100: ...veform if the MCU goes in faulty state it will capture a BlackBox upon the reported error s The BlackBox can then be consulted via ODIN tool to see if the angle waveform saw tooth is straight on each rising and falling edges See below examples of waveform ...

Page 101: ...101 Service Codes ...

Page 102: ...102 Service Codes ...

Page 103: ...103 Service Codes ...

Page 104: ...104 Service Codes ...

Page 105: ...cuit Note The flow of the cooling liquid is too low to cool the motor Refer to the cooling system troubleshooting Guide Note The temperature of the liquid temperature is too high to cool the motor The system must turn Ignition off and the coolant mixture must be replaced Note The mixture of the cooling liquid was done badly which does not let the coolant cool the motor Replace the mixture of cooli...

Page 106: ...106 Service Codes ...

Page 107: ...f the cooling liquid is too low to cool the motor Refer to the cooling system troubleshooting Guide Note The temperature of the liquid temperature is too high to cool the motor The system must be turned off and the coolant mixture must be replaced Note The mixture of the cooling liquid was done badly which does not let the coolant cool the motor Replace the mixture of cooling liquid Refer to the c...

Page 108: ...108 Service Codes ...

Page 109: ...oling liquid is too low to cool the motor Refer to the cooling system troubleshooting Guide Note The temperature of the liquid temperature is too high to cool the motor The system must turn Ignition off and the coolant mixture must be replaced Refer to the cooling system Service Manual Note The mixture of the cooling liquid was done badly which does not let the coolant cool the motor Replace the m...

Page 110: ...110 Service Codes ...

Page 111: ...rcuit The air must be let out of the cooling circuit Note The flow of the cooling liquid is too low to cool the motor Refer to the cooling system troubleshooting Guide Note The temperature of the liquid temperature is too high to cool the motor The system must turn Ignition off and the coolant mixture must be replaced Refer to the cooling system Service Manual Note The mixture of the cooling liqui...

Page 112: ...112 Service Codes ...

Page 113: ...ture of the liquid temperature is too high to cool the motor The system must turn Ignition off and the coolant mixture must be replaced Refer to the cooling system Service Manual Note The mixture of the cooling liquid was done badly which does not let the coolant cool the motor Replace the mixture of cooling liquid Refer to the cooling system Service Manual To correctly diagnose the faulty system ...

Page 114: ...114 Service Codes ...

Page 115: ...ve To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics Related Process The TT25 call the following process Appendix 6 Update Software System Mode Referred by SysFile ID Cond...

Page 116: ...116 Service Codes ...

Page 117: ...n the DC bus under the high voltage maximum limit until the motor speed is reduced under the unsafe speed At the time the motor phases are short circuited it is normal that the phase currents and potentially the input DC current will temporarily exceed the limits and raise these errors type Other error s must be investigated Note Refer to the Application note High Speed fault Management Document T...

Page 118: ...118 Service Codes ...

Page 119: ...the motor speed is beyond the unsafe speed the motor phases will be short circuited by the control to maintain DC bus under the high voltage limit until the motor speed is reduced below the unsafe speed At the time the motor phases are short circuited it is normal that the phase currents and potentially the input DC current will temporarily exceed the limits and raise these errors type Note Refer ...

Page 120: ...120 Service Codes ...

Page 121: ...urrent Note Refer to the MCU installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guid...

Page 122: ...122 Service Codes ...

Page 123: ... might be not enough defluxing current at high speed and this error will be raised Note Refer to the TM4 ODIN technical guide for more information Note Refer to the TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test e...

Page 124: ...124 Service Codes ...

Page 125: ...125 Service Codes References ...

Page 126: ...allation guide for more details on installation and deinstallation procedure including safety warning considerations Note Refer to the Dana TM4 product s MCU installation guide s for more details on installation and deinstallation procedure including safety warning considerations Note If the MCU goes in failure it will capture a BlackBox upon the high voltage battery reached the high limit error T...

Page 127: ...veform if the MCU goes in faulty state it will capture a BlackBox upon the reported error s The BlackBox can then be consulted via ODIN tool to see if the angle waveform saw tooth is straight on each rising and falling edges See below examples of waveform ...

Page 128: ...128 Service Codes ...

Page 129: ...129 Service Codes ...

Page 130: ...130 Service Codes ...

Page 131: ...131 Service Codes ...

Page 132: ...132 Service Codes ...

Page 133: ...y another equipment can potentially trigger the fault Software upgrade might solve the issue providing more filtering to the detection Note Refer to the Dana TM4 Product installation guides for more details on installation and deinstallation procedure including safety warning considerations Note Refer to the TM4 Product Interface drawing for more details on torque requirement Note on the phase cab...

Page 134: ...134 Service Codes ...

Page 135: ...135 Service Codes ...

Page 136: ...136 Service Codes ...

Page 137: ...137 Service Codes ...

Page 138: ...138 Service Codes ...

Page 139: ...ximum speed fault will therefore trigger when the speed forward or backward reach the parameter setting forward or backward Note Refer to the Operation and Maintenance guide for more details on the speed parameters settings Note Refer to the System Specification document for more details on Overspeed range limit Note on maximum speed reached It is possible to reach maximum speed limit regardless o...

Page 140: ...veform if the MCU goes in faulty state it will capture a BlackBox upon the reported error s The BlackBox can then be consulted via ODIN tool to see if the angle waveform saw tooth is straight on each rising and falling edges See below examples of waveform ...

Page 141: ...141 Service Codes ...

Page 142: ...142 Service Codes ...

Page 143: ...ise if this error is listed at time 0 00 second this event will put the MCU in error Note regarding this type of error If the software is the latest version as published on the Dana TM4 extranet site and this error is listed at 0 00 second after the Info System power up event this indicates that there is an issue with the software To correctly diagnose the faulty system connect the Diagnostic Tool...

Page 144: ...144 Service Codes ...

Page 145: ...nt as published on the Dana TM4 extranet site To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Referred by SysFile ID Condition Possible Causes Operational 0x...

Page 146: ...146 Service Codes ...

Page 147: ...on a CAN bus there should be a termination resistor of 120 ohms between the CAN lines high and low at one end of the CAN bus and another termination resistor of 120 ohms between the CAN lines at the other end of the CAN bus This makes a resultant end termination of 60 ohms Note Refer to the MCU installation guide for more details on installation and deinstallation procedure including safety warnin...

Page 148: ...148 Service Codes Connector type 1 and type 2 pinouts Expected resistance measurement between CAN ports ...

Page 149: ...149 Service Codes ...

Page 150: ...150 Service Codes ...

Page 151: ...cuited to be raised while the motor speed was greater than the threshold of that warning The ECU VMU controller could have registered a fault at its level and shutdown the MCU In that case the source of the problem must be investigated at the ECU VMU controller level Note Refer to the Application Note High speed fault management document To correctly diagnose the faulty system connect the Diagnost...

Page 152: ...152 Service Codes ...

Page 153: ...gered from a lower level error type To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Referred by SysFile ID Condition Possible Causes Operational 0x0506 0x050...

Page 154: ...154 Service Codes ...

Page 155: ...nector a pin might tend to move toward inside the related system For connector not Amphenol connector pull gently the pin until the locking mechanism engaged Note Refer to the TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations Note Refer to the TM4 Product installation guide for more details on product connector pino...

Page 156: ...156 Service Codes ...

Page 157: ... TM4 Product installation guide for more details on cooling agent mixture Note On cooling agent Wrong cooling agent can create dust rust in the cooling circuit To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the procedure of troubleshooting tree below See Safety Warnings and Troubleshooting Tips sections for...

Page 158: ...158 Service Codes ...

Page 159: ...159 Service Codes ...

Page 160: ...ated phase 7 8 or 9 07 0x031D Error Board 0x1D HVIL voltage input fault 08 0x031E Error Board 0x1E HVIL voltage output fault 09 0x031F Error Board 0x2F HVIL internal fault 10 0x0320 Error Board 0x20 HVIL over current 11 0x0321 Warning Board 0x21 motor temperature sensor A1 was shorted to Vaux 05 0x0322 Warning Board 0x22 motor temperature sensor A1 was disconnected or shorted to Vaux 05 0x0323 War...

Page 161: ...0C High power battery voltage reached the high limit H W detection 19 0x310D Error Motor Control Inverter 0x0D Temperature too high 20 0x310E Error Motor Control Inverter 0x0E Temperature too high 20 0x310F Error Motor Control Inverter 0x0F Temperature too high 21 0x3110 Error Motor Control Inverter 0x10 Temperature too high 21 0x3111 Error Motor Control Inverter 0x11 Invalid command 25 0x3112 Err...

Page 162: ...hed its limit in forward direction 32 0x3211 Error Motor Control Machine 0x11 Speed reached its limit in backward direction 32 0x3212 Error Motor Control Machine 0x12 Invalid motor phase 13 0x3301 Error Application in Safe Mode 16 0x3303 Error Application 0x03 33 0x3307 Warning Invalid Motor Hardware Version 14 0x3400 Warning Resolver 1 Parity error 05 0x3401 Warning Resolver 2 Abnormal signals 05...

Page 163: ...4 0x400D Warning ComClient 0x0D Safety check delta too high between CommandMode 34 0x400E Warning ComClient 0x0E Safety check delta too high between SpeedCommand 34 0x400F Warning ComClient 0x0F Safety check delta too high between TorqueCommand 34 0x4010 Warning ComClient 0x10 The library cannot decode the received data 34 0x4011 Warning ComClient 0x11 A message received had the wrong DLC 34 0x401...

Page 164: ... Deactivation timed out This event indicates that a timeout occurred while going in the deactivation process 36 0x0506 Error Sequencer 0x06 Motor control in wrong state 37 0x0507 Error Sequencer 0x07 Activation failed 37 0x0508 Error Sequencer 0x08 Activation timed out 37 0x0509 Error Sequencer 0x09 Motor control in wrong state 37 0x050A Error Sequencer 0x0A Motor control in wrong state 37 0x050D ...

Page 165: ...e Auxiliary vehicle battery Vaux 12V or 24V powered OFF before the MCU Ready To Power OFF CAN status on a shutdown sequence 2 Defective MCU 03 0x0313 1 DCDC not regulating auxiliary DC voltage correctly 2 High auxiliary load being activated causing voltage drop 3 The auxiliary vehicle battery does not operate correctly 4 Intermittent or bad Vaux connection at the MCU 5 Vaux Fuse about to open or m...

Page 166: ...efective MCU 2 0x050B error occurred at the same time that may lead to an error at the VCU ECU level 3 Another SysFile occurred at the same time 4 Defective MCU 07 0x031A 0x031B 0x031C 1 If the 0x0313 SysFile occurred the same time this can be the main cause 2 Defective DCDC system 3 Defective auxiliary batteries 4 Defective MCU 08 0x031D 1 MCU HVIL parameters were not correctly configured 2 Anoth...

Page 167: ... connected to the MCU 2 Wrong software flashed to the MCU 3 Defective MCU Potential wrong factory settings 13 0x120A 0x3212 1 Third party motor not calibrated 2 Defective motor 14 0x3307 0x2209 1 Wrong motor type connected to the MCU 2 Wrong software flashed to the MCU 3 Defective Motor 15 0x1000 0x1100 0x1200 1 Defective MCU 16 0x1003 0x3301 1 Wrong software flashed to the MCU unit not compatible...

Page 168: ...rature too high 4 Wrong cooling agent mixture used can create dust rust in the cooling circuit 5 Phase cable are damaged 6 Wrong torque applied to one or many phase lugs 7 Wrong phase cable crimping 8 Defective MCU 21 0x310F 0x3110 1 Air in the cooling circuit 2 Cooling liquid flow too low or nil cooling pump issue 3 Cooling liquid temperature too high 4 Wrong cooling agent mixture used can create...

Page 169: ...3 Intermittent or bad Vaux connection at the MCU 4 Vaux Fuse about to open or more resistive 5 An external error was caused by VMU ECU 6 Defective MCU 28 0x3203 0x3207 0x320B 1 The auxiliary vehicle battery not operating correctly 2 Intermittent or bad Vaux connection at the MCU 3 Vaux Fuse about to open or more resistive 4 Defective MCU 29 0x320C 1 MCU temperature too high for the motor speed ver...

Page 170: ...er power up 2 MCU software error 34 0x4001 0x4002 0x4003 0x4004 0x4005 0x4006 0x4007 0x4008 0x4009 0x400A 0x400B 0x400C 0x400D 0x400E 0x400F 0x4010 0x4011 1 Verify MCU CAN protocol document for protocol requirements 35 0x4013 0x4014 0x4015 0x4703 1 Verify MCU CAN protocol document for protocol requirements controller issue 2 Defective CAN connection Cable or harness 3 Defective CAN network 4 Defec...

Page 171: ...d wait until it comes back to 0 by itself 8 Follow recommended power off and power on cycle to ensure that the unit has properly saved All EEPROM sections The new parameters will take effect in the MCU control only on the next power ON 9 It is possible to save all the parameters under Drive subfolder in one file that could be used to upload in another MCU First delete the Motor subfolder since thi...

Page 172: ...tom left of the Odin screen Device Connected is displayed in green text 4 In Odin Server 1 in the Diagnostic dropdown menu select GDD and then click the Note This will allow you to select the location of where the Motor Control Unit GDD Gathered Diagnostic Data File will be saved Note If you didn t succeed to retrieve the GDD Files and user parameters notify to Dana TM4 and continue further down t...

Page 173: ...sh connection to the ACDC controller of the unit 6 Make sure that at the bottom left of the Odin screen the message Device Connected shows up green 7 In Odin Server 1 in the Package Files dropdown menu select Workspaces and then UserInterface odn4 ...

Page 174: ... ODIN load the following page 9 Make sure you are connected to the product using TM4 ODIN by checking that the bottom left of the Odin screen Device Connected is displayed in green text 10 In the Diagnostic dropdown menu select GDD ...

Page 175: ...175 Appendix 11 Wait until TM4 ODIN load the following page 12 On the Parameters Tab right click the select Export Values To File ...

Page 176: ...er pressure Full comprehension of the cooling system is mandatory Necessary precautions should be observed to avoid injuries 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 appropriate safety clothing and eyeglasses The ...

Page 177: ...on 7 Make sure that the ignition key is set to OFF and wait until Device disconnected in yellow is shown in the ODIN status bar From a previous power ON this could take up to 10 seconds maximum 8 From the TM4 ODIN menu select Configuration 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...

Page 178: ... these capacitors if they are connected to a high voltage DC bus Always measure the voltage between the high voltage DC bus and the chassis using appropriate protection and insulation before manipulating the product This product uses differential mode capacitors between the positive high voltage DC bus and the negative high voltage DC bus Even when the product is disconnected from the high voltage...

Page 179: ... disconnected from a high voltage source Operations 1 Remove the mechanical fixation from the charger 2 Remove the charger from the vehicle with precaution Install the new unit Safety precaution Mishandling of this product may damage the product and or cause injury or death Do not attempt to open the charger for repairs in case of damaged casing or suspected product malfunction contact TM4 If usin...

Page 180: ...om vibrations and impacts and is able to withstand maritime conditions during transportation TM4 products must be transported in well ventilated facilities with adequate protections against dust and excessive humidity Note The replacement unit comes with all necessary caps and protectors It will arrive in fully equipped transports box While the products are in the original shipping crates there ar...

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Page 182: ...ite at http www dana com AllapplicationsmustbeapprovedbytheApplicationEngineeringDepartment Specificationsand ordesignaresubjecttochangewithoutnoticeorobligation Printed in USA Dana TM4 inc 135 Joseph Armand Bombardier 25 Boucherville Québec J4B 8P1 Canada www dana com TM4 ...

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