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Danfoss ED-DT318B, Installation And Operation Manual

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Installation and Operation Guide 
ED-DT318B 
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission 

 

BC353060341319en-000101 

Revision D 

© Danfoss | November 2020 | 159 

Status Signal 

Time period 

before 

reacting 

Typical Vehicle Controller Unit (VCU) Expected 

Action 

Recommended Service Action 

Slow Upshift 

Section 7.3.2.7

 

Immediate 

Check engine light 

Power-cycle PowerPhase®DT2 system. 

Visual inspection of air lines. 

Replace transmission air solenoid. 

Replace transmission gear switch sensors. 

Replace transmission speed sensor. 

Send data log to Danfoss Power Solutions for 
analysis. 

Slow Downshift 

Section

 

7.3.2.8

 

Immediate 

Check engine light 

Power-cycle PowerPhase®DT2 system. 

Visual inspection of air lines. 

Replace transmission air solenoid. 

Replace transmission gear switch sensors. 

Replace transmission speed sensor. 

Send data log to Danfoss Power Solutions for 
analysis. 

Shift Disabled 

Section

 

7.3.2.9

 

Immediate 

Check engine light 

Power-cycle PowerPhase®DT2 system. 

Visual inspection of air lines. 

Replace transmission air solenoid. 

Replace transmission gear switch sensors. 

Replace transmission speed sensor. 

Send data log to Danfoss Power Solutions for 
analysis. 

Summary of Contents for ED-DT318B

Page 1: ...URL www danfoss com Installation and Operation Guide ED DT318B Drive Train Systems with Traction Control Converter and Machine with 2 Speed Transmission Revision D Classified as Business...

Page 2: ...e TCU to MCU Interface Cable 16 2 2 7 Applying Voltage 16 2 3 Installing the Motor 2 Speed Transmission 16 2 3 1 Connection of the driveline to the transmission output flange 16 2 3 2 Mounting the Mot...

Page 3: ...7 1 1 Abbreviations 56 7 1 2 Boolean Values 57 7 1 3 Hexadecimal Values 57 7 2 VCU to TCU Command Messages 58 7 2 1 TCU Command Message 1 58 7 2 2 TCU Command Message 2 64 7 3 TCU to VCU Status messa...

Page 4: ...er Controller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 iii Classified as Business 10 1 Vehicle responses to Danfoss Power Solutions CAN Status Messa...

Page 5: ...nd motor 33 Figure 3 4 Exploded View of the Controller Connections 34 Figure 3 5 Signal Cable Connection Insertion 36 Figure 3 6 Signal Cable Connection Tightening 36 Figure 3 7 Signal Cable Connectio...

Page 6: ...2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 v Classified as Business Figure 8 21 Event Dialog Box 148 Figure 8 22 Mark Event Log with Today s Date dialog box 151 Figu...

Page 7: ...of a Danfoss Power Solutions Motor Diagnostic Software Installation 124 Table 8 2 Status Bar Communication Messages 125 Table 8 3 Front Panel Group Descriptions 126 Table 8 4 Status Group Problems 12...

Page 8: ...ement Added allowable tolerances on Max Sink and Max Source Currents Added limits to 24 V power supply for proper operation of the solenoid Added notes to Upshift Failed and Downshift Failed stating t...

Page 9: ...processor DSP controller referenced in this manual as the Motor Control Unit MCU the controller or the inverter depending on the functionality being discussed This manual covers installation and oper...

Page 10: ...gs for the PowerPhase DT2 system are available by contacting Danfoss Power Solutions This manual is organized as follows 1 Section 1 is a general introduction to the PowerPhase DT2 system Section 2 co...

Page 11: ...board located within the inverter 1 1 3 Safety Information The procedures described in this guide are highly technical and involve high voltage equipment which rotates at thousands of rpm Accidents i...

Page 12: ...high voltage and bolts for cover The Motor Transmission TCU with a ship kit containing mating connectors with pins hardware for fabricating cable between the drivetrain interface connector connector 3...

Page 13: ...s part of the motor Danfoss Power Solutions supplies the Phase Cable The cable length is defined as part of the purchase order 2 meters if not otherwise specified E Signal Cable Danfoss Power Solution...

Page 14: ...aintain direction of travel at or below the speed limit The vehicle designer is responsible for providing the 24 V low voltage power for both the Traction Control Unit TCU and Motor Control Unit MCU D...

Page 15: ...customer is responsible for the termination to the battery system and for ensuring proper termination of the shielding is achieved WARNING Ensure that the motor shaft will remain unobstructed during...

Page 16: ...r housings and sealing interfaces are not stressed during installation or operation 2 2 4 Preparing the Coolant Loop for MCU and Motor Danfoss Power Solutions requires that the controller be the first...

Page 17: ...ge is applied The 24 V power must remain on and TCU Enable must remain true as long as high voltage is applied If at any time either of these conditions is not met while the vehicle is in motion the h...

Page 18: ...p The fastener thread engagement for bell housing mounting holes is 18mm minimum and 24mm maximum The torque specification for bell housing mounting holes is 80 105 Nm WARNING The fastener thread enga...

Page 19: ...ol Inverter Controller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 18 Classified as Business Figure 2 2 Right Side attachment points for bell housing t...

Page 20: ...lator is Hutchison 22003 11 12 or 13 and should be sized based on customer requirements The customer should contact Hutchinson Inc directly at 1 508 417 7000 to discuss specific vehicle application re...

Page 21: ...angular orientation of the coolant fittings can be changed by loosening the nut on the coolant fitting rotating it to the desired angle and tightening the nut to the torque specification on the ICD d...

Page 22: ...ated if these procedures are closely followed Maintain oil level Inspect regularly Follow maintenance interval recommendations below Use the brand recommended by the vehicle manufacturer 2 4 1 3 Maint...

Page 23: ...il Level Before checking the oil level or refilling ensure vehicle is on level ground Make sure that the oil is level with the filler opening Draining Oil Drain transmission while oil is warm To drain...

Page 24: ...n during towing 2 4 2 Transmission Oil cooler The vehicle manufacturer is responsible for providing the hardware and connections to the transmission for cooling the transmission oil to ensure the oil...

Page 25: ...ision D Danfoss November 2020 24 Classified as Business The port locations on the transmission are shown in Figure 2 8 and Figure 2 9 Figure 2 8 Eaton Transmission Lubricant Ports Figure 2 9 Lubricant...

Page 26: ...o air cooler Typical transmission application o 27 C 80 F ambient o 121 C 250 F oil o 77 C 170 F temperature differential o Actual application capacity is 1 7 x graph Drastic changes in oil flow have...

Page 27: ...ion in cool air May overcool transmission in cold weather Requires longer hoses Sensitive to vehicle speed Requires installation evaluation lubrication check Note Eaton OEM part 18025 oil to air coole...

Page 28: ...es an air supply for shifting The requirements for the air supply to the transmission are Operating pressure range at transmission to be within 7 5 bar to 8 3 bar Minimum is 7 bar to support High Low...

Page 29: ...uce the level of electromagnetic emissions and compatibility issues from the drive system once the ED DT318B system is installed into a vehicle They include but are not limited to the following sugges...

Page 30: ...tion on the user interface connector CAN_COM to the same source as the CAN signal using the CAN shield or a separate ground connection The CAN circuits within the Danfoss Power Solutions controller ar...

Page 31: ...ER Ensure that the 24 V battery input is not connected before making any connections 3 1 Power Cables Before connecting any cable to the controller remove the terminal housing cover Figure 3 1 and Fig...

Page 32: ...tion DANGER Do not connect either the positive or negative high voltage bus to the chassis motor cases or controller Catastrophic damage will occur Provide sufficient insulation on all power terminals...

Page 33: ...the holes in the controller terminals Tighten to the indicated torque in the ICD drawing At rated peak power of the ED DT318B system at the nominal voltage both stated in the specific product specific...

Page 34: ...em the MCU to TCU cable is provided and has a breakout on the TCU end with a two pin TE Deutsch connector for the user HVIL connection The mating connector is provided in the ship kit Danfoss Power So...

Page 35: ...o rubbing and abrasion of the outer insulation The customer is responsible for securing the cables to avoid insulation damage In addition it is recommended that the Phase and DC cables be routed such...

Page 36: ...occur 3 3 Signal Cable The signal cable cable E in Figure 1 1 is the small shielded cable with a 17 pin Amphenol M23 style connector Some of the wires in this cable are used for the rotor position sig...

Page 37: ...Connection Insertion 2 Screw knurled connection nut clockwise At about 3 turns some resistance will be felt This is the nut coming into contact with the sealing O ring The connector is not fully seat...

Page 38: ...r at one end and a 10 pin connector at the other The customer is responsible for insuring that the cable is firmly connected from the inverter s Deutsch connector Connector 1 in Figure 1 1 to the 10 p...

Page 39: ...e controller Note that the kit Danfoss Power Solutions part 98010 022 supplied with the PowerPhase DT2 system provides terminals Danfoss Power Solutions part 15010 083 and wire seals Danfoss Power Sol...

Page 40: ...16040 020 14020 019 3 VCU VCU CAN Leg B 98010 022 15010 084 16040 020 14020 019 4 Common to pin 1 VCU CAN Leg B 98010 022 15010 084 16040 020 14020 019 5 Common to pin 2 VCU CAN Leg B Shield 98010 022...

Page 41: ...ision D Danfoss November 2020 40 Classified as Business Pin Assignment Kit Terminal Wire Seal Wire Pin Signal Source FEPS 98010 021 15010 093 16040 025 18 AWG 15 TCU Programing Vbatt TCU 98010 020 150...

Page 42: ...ystems with Traction Control Inverter Controller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 41 Classified as Business Figure 3 10 Danfoss Power Soluti...

Page 43: ...ve Train Systems with Traction Control Inverter Controller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 42 Classified as Business Figure 3 11 Drivetrain...

Page 44: ...ata The MCU configuration is updated via the RS232 port documented below Danfoss Power Solutions provides one TCU to MCU CAN bus termination resistor which is located within the body of the Danfoss Po...

Page 45: ...of the Diagnostic Connector Therefore the Connector should be positioned inside the vehicle s cabin in a location that will provide easy access while the vehicle is in motion but will not interfere w...

Page 46: ...Guide ED DT318B Drive Train Systems with Traction Control Inverter Controller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 45 Classified as Business Fig...

Page 47: ...d cooling system The recommended liquid cooling setup is shown in Figure 4 1 below Figure 4 1 Recommended Liquid Cooling Setup 4 1 Coolant Loop Requirements CAUTION The coolant should never run in par...

Page 48: ...rement Specification Coolant Type 50 50 water to glycol Maximum Inlet Coolant Temperature full performance 60 C Minimum Coolant Flow Rate 10 liters per minute LPM Coolant volume for the controller and...

Page 49: ...elow Figure 5 1 Block Diagram of Electric Vehicle Drive System The customer must supply the Vehicle Control Module Typically it performs the following functions Monitors the accelerator brake pedal an...

Page 50: ...ion some applications have mandated limits to the acceleration experienced by vehicle riders Danfoss Power Solutions Acceleration Limit feature attempts to control the acceleration of the electric mot...

Page 51: ...voltage or over motor speed The Danfoss Power Solutions Motor Diagnostic Software see Section 8 shows the limitations acting on the torque whenever they are below 100 The limitations can take away sig...

Page 52: ...calibration 51 51 Motor Leg current Over Current 51 51 Invalid Sensor voltage 52 52 Apparent Rotor Movement 52 52 Error with leg current sensors 53 53 Current Transducer Fault 53 53 1 If the Allow Br...

Page 53: ...The mode releases control within 128 milliseconds if conditions indicate that the battery is still connected This condition is reported through the Diagnostic Software described in Section 8 of this m...

Page 54: ...rror signals contained in TCU Status Message 2 Section 7 3 2 and TCU Status Message 3 Section 7 3 3 TCU Status Message 4 Section 7 3 4 TCU Status Message 5 Section 7 3 5 TCU Status Message 6 Section 7...

Page 55: ...ermination resistor should be connected between VCU CAN Leg B and VCU CAN Leg B If the user does not wish to place the MCU at the end of the daisy chain both sets of signal pins should be used The use...

Page 56: ...s the RS232 serial bus is routed to the 16 pin User Interface connector Connector 3 in Figure 1 1 via the TCU to MCU Interface Cable Cable C in Figure 1 1 The customer is responsible for the wiring fr...

Page 57: ...exceed 4800 rpm and may be lower depending on the limits of the selected MCU system The TCU will have total control of torque and MCU speed during High Low and Low High gear shifts Control will be ret...

Page 58: ...cant bit lsn least significant nibble msn most significant nibble lsB least significant byte msB most significant byte rrss receiver CAN address rr sender CAN address ss for PDU1 message gess message...

Page 59: ...r116 From VCU To TCU Msg Rate 50ms 64 63 62 61 60 59 58 57 TCU CAN Message Error TCU CAN Active TCU CAN Watchdog Timeout VCU Watchdog Counter 1 56 55 54 53 52 51 50 49 TCU Enable Transmission Mode 48...

Page 60: ...has received the last 3 commands from the VCU within 150 of the normally allotted time and in each of the messages the Watchdog Counter is in sequence and they were immediately followed by the sequen...

Page 61: ...r_1 lsb 57 msb 60 Offset 0 Scale Factor 1 Min Value 0 Max Value 15 Units Rolling Count Description The Watchdog count is used to detect missed message and to detect issues with VCU messaging procedure...

Page 62: ...irected Mode of operation 0 Neutral Transmission is decoupled from the drive train and the motor is disabled 1 Reverse The transmission does not have an explicit reverse gear Reverse is achieved by pl...

Page 63: ...n to the driveshaft When the Transmission Mode is Neutral this value will be treated as if it is 0 When the Transmission Mode is Reverse Forward Low Forward High or Forward Automatic this is the maxim...

Page 64: ...In all modes when this value exceeds the Maximum Allowed Drive Torque it will be treated as if it were that value Likewise if it exceeds Maximum Allowed Regen Torque it will be treated as if it were t...

Page 65: ...08FFgess16 11 bit xrr116 From VCU To TCU Msg Rate 50ms 64 63 62 61 60 59 58 57 VCU Watchdog Counter 2 56 55 54 53 52 51 50 49 Acceleration Limit msB 48 47 46 45 44 43 42 41 Acceleration Limit lsB 40 3...

Page 66: ...east three successive Traction Control Parameters Command messages in which the Watchdog Count conforms to the requirement the TCU will report Traction Control Parameters Command Watchdog Timeout and...

Page 67: ...s Note4 To avoid perturbations due to fluctuating limits the command to the MCU will only be updated at a 1s interval 7 2 2 4 Max Sink Current dbc ref TCUCmd2_MaxSinkCurrent lsb 25 msb 32 Offset 0 Sca...

Page 68: ...d Transmission BC353060341319en 000101 Revision D Danfoss November 2020 67 Classified as Business Min Value 16384 Max Value 16383 Units rpm Description The rotational speed of the driveshaft If the Dr...

Page 69: ...Msg Rate 50ms 64 63 62 61 60 59 58 57 MCU System Type TCU Watchdog Counter 56 55 54 53 52 51 50 49 TCU System Type msB 48 47 46 45 44 43 42 41 TCU System Type lsB 40 39 38 37 36 35 34 33 TCU System Ty...

Page 70: ...otor 6 Undefined 7 EM PMI318B T360 465V PowerPhase HD 251 HD2 3 turn varnished motor 8 15 Undefined 7 3 1 2 Watchdog Counter dbc ref TCUStat1_TCUWatchdogCounter lsb 57 msb 60 Offset 0 Scale Factor 1 M...

Page 71: ...for the VCUs configuration 7 3 1 4 TCU System Type Revision dbc ref TCUStat1_TCUSystemTypeRev lsb 33 msb 40 Offset 0 Scale Factor 1 Min Value 0 Max Value 255 Units Enumeration Description The value of...

Page 72: ...dbc ref TCUStat1_TCUSubVersion lsb 17 msb 20 Offset 0 Scale Factor 1 Min Value 1 Max Value 15 Units Integer Description TCU Code Sub Version Number 7 3 1 8 MCU Major Version dbc ref TCUStat1_MCUMajorV...

Page 73: ...troller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 72 Classified as Business 7 3 1 10 MCU Sub Version dbc ref TCUStat1_MCUSubVersion lsb 1 msb 4 Offse...

Page 74: ...ownshift In Progress 56 55 54 53 52 51 50 49 Upshift Failed Downshift Failed Slow Upshift Slow Downshift Shift Disabled Max Shift Speed Delta Exceeded Air Pressure Out of Range Forced Gear Engage Torq...

Page 75: ...BC Phase Order MCU System Disabled In Motion MCU CAN Limits Active MCU Forced Voltage Control 7 3 2 1 Current Transmission Mode dbc ref TCUStat2_CurrentTransmissionMode lsb 61 msb 64 Offset 0 Scale Fa...

Page 76: ...TCUStat2_UpshiftInProgress lsb 58 msb 58 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Description True Gear shift to High gear is in progress False Gear shift to High gear is not in p...

Page 77: ...This flag can only reset on Power Cycle Note 4 The system will hold the current gear once it has encountered an upshift fail Limp Home Mode irrespective of the commanded transmission mode 7 3 2 6 Dow...

Page 78: ...1 Units Boolean Description True The previous shift to Low gear required an excessive amount of time False The previous attempted shift to Low gear was accomplished in a normal amount of time 7 3 2 9...

Page 79: ...t reliably detect the direction of travel therefore it cannot reliably match the transmission output speed and with sufficient accuracy to successfully change gears 7 3 2 11 Air Pressure Out of Range...

Page 80: ...scription True There is a significant mismatch between the Motor Speed reported by the MCU and the Transmission Output Speed reported by the Transmission Speed Sensor False The difference between the...

Page 81: ...NActive lsb 46 msb 46 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Description True Normal communication has been established between the TCU and the MCU False TCU is unable to commun...

Page 82: ...s from the VCU in which the VCU Watchdog Counter 1 is out of sequence The TCU has not received a TCU Command Message 1 messages from the VCU in 150 of the normally allotted time False The MCU has rece...

Page 83: ...m the VCU in 150 of the normally allotted time False The MCU has received the last 3 commands from the VCU within 150 of the normally allotted time and in each of the messages the VCU Watchdog Counter...

Page 84: ...set 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Description True The transmission lubricant temperature has exceeded 120 C for 30 minutes in the last hour or the transmission lubricant temp...

Page 85: ...nits Boolean Description True The TCU detected either an open or a short in the transmission lubricant temperature sensor False The transmission lubricant temperature sensor is working properly 7 3 2...

Page 86: ...he MCU Rotor temperature sensor False The MCU Rotor temperature sensor is working properly 7 3 2 29 MCU Regen Type Error dbc ref TCUStat2_MCURegenTypeError lsb 32 msb 32 Offset 0 Scale Factor 1 Min Va...

Page 87: ...switches have shut down to protect the operator and the Danfoss Power Solutions controller During startup the switches will not be turned on until High Voltage reaches a minimum value The switches wi...

Page 88: ...nt measurement occurred Bad rotor temperature occurred In these cases a power cycle is required to clear the error Note When this situation occurs the TCU will shift to Neutral 7 3 2 32 MCU Invalid Po...

Page 89: ...nsor False The MCU has not detected any errors in the leg current sensor This situation may be transitory or persistent If this situation is persistent the MCU is unable to determine the motor s posit...

Page 90: ...value for 30 seconds It then allows normal torque until the stall conditions are met again The probability of encountering this situation is greatly reduced by configuring the MCU to use a low PWM fre...

Page 91: ...Factor 1 Min Value 0 Max Value 1 Units Boolean Description True The MCU is using unfiltered speed values False The MCU is using filtered speed values The MCU derives speed from motor position signals...

Page 92: ...c ref TCUStat2_MCUCurrentTripFaultIleg_Ibus lsb 6 msb 6 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Description True A Current Trip Fault condition has been detected by the MCU False...

Page 93: ...d is detected while the Enable bit in the Control Parameters signal of the UniversalCommand Message is not set This implies that the motor is being spun by an external force 7 3 2 44 MCU CAN Limits Ac...

Page 94: ...ied as Business Description True MCU is in Forced Voltage Control Mode False MCU is not in Forced Voltage Control Mode The MCU will only operate in in Forced Voltage Control Mode when a dangerous over...

Page 95: ...e MCU Limp Home Mode History MCU ADC Calibration Problem MCU ADC Calibration Problem History 56 55 54 53 52 51 50 49 MCU Over Voltage Alarm MCU Over Voltage Alarm History MCU Over Speed Alarm MCU Over...

Page 96: ...ing MCU inverter faults are power switch protection events Too much heat or too much current can damage the switches so the MCU protects them and sets this bit while it is doing so Too much heat norma...

Page 97: ...ime MCU power was cycled False MCU Inverter Fault has not been set to True at any point since the last time MCU power was cycled 7 3 3 4 MCU Inverter Fault Latched History dbc ref TCUStat3_MCUInverter...

Page 98: ...200F EM PMI318B User Manual for more details 7 3 3 6 MCU Limp Home Mode History dbc ref TCUStat3_MCULimpHomeModeHistory lsb 59 msb 59 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Desc...

Page 99: ...Alarm dbc ref TCUStat3_MCUOverVoltageAlarm lsb 56 msb 56 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Description True The High Voltage DC bus voltage is greater than the high voltage...

Page 100: ...tor speed is less than the high speed alarm threshold This indicates that the motor speed has exceeded maximum forward or reverse speed limit by at least 300 rpm The MCU does not allow motoring torque...

Page 101: ...e and limiting the available regeneration torque 7 3 3 14 MCU Over Voltage Warning History dbc ref TCUStat3_MCUOverVoltageWarningHistory lsb 51 msb 51 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 U...

Page 102: ...the last time MCU power was cycled 7 3 3 17 MCU Inverter Over Temperature dbc ref TCUStat3_MCUInverterOverTemperature lsb 48 msb 48 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Descri...

Page 103: ...ing limits False The motor s stator temperature is within normal operating limits When this condition occurs the MCU attempts to lower the maximum torque the system can produce until it reaches a poin...

Page 104: ...mpts to lower the maximum torque the system can produce until it reaches a point at which the temperature no longer exceeds the limit The MCU will then produce as much torque as it can while keeping t...

Page 105: ...Stat3_MCUUnderVoltageWarningHistory lsb 41 msb 41 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Description True MCU Under Voltage Warning has been set to True at some point since the...

Page 106: ...r was cycled False MCU Over Phase Advance has not been set to True at any point since the last time MCU power was cycled 7 3 3 27 MCU Over Bus Current dbc ref TCUStat3_MCUOverBusCurrent lsb 38 msb 38...

Page 107: ...olean Description True The motor phase currents are exceeding their normal operating parameters False The motor phase currents are within their normal operating parameters 7 3 3 30 MCU Over Leg Curren...

Page 108: ...tEnabledHistory lsb 33 msb 33 Offset 0 Scale Factor 1 Min Value 0 Max Value 1 Units Boolean Description True MCU Not Enabled has been set to True at some point since the last time MCU power was cycled...

Page 109: ...rection of travel is the opposite of the commanded direction of travel i e if the commanded direction of travel is forward a negative value indicates that the vehicle is moving in the reverse directio...

Page 110: ...the Status Message 3 The VCU will detect whether or not the message is received and will react as appropriate 64 63 62 61 60 59 58 57 Max Drive Torque Allowed msB 56 55 54 53 52 51 50 49 Max Drive To...

Page 111: ...dbc ref TCUStat4_MaxRegenTorqueAllowed lsb 33 msb 48 Offset 0 Scale Factor 0 1 Min Value 0 Max Value 6425 6 Units Nm Description This is the maximum regen torque the system is capable of delivering to...

Page 112: ...ntroller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 111 Classified as Business Note 1 This value will not exceed Max Drive Torque Allowed or the Max R...

Page 113: ...ly following the transmission of the Status Message 4 The VCU will detect whether or not the message is received and will react as appropriate 64 63 62 61 60 59 58 57 TCU Requested Torque msB 56 55 54...

Page 114: ...the system is in high or low gear and will be decoupled from those values while a gear shift is in progress 7 3 5 2 MCU Desired Torque dbc ref TCUStat5_MCUDesiredTorque lsb 33 msb 48 Offset 0 signed...

Page 115: ...esired Torque but it will be calculated based on the amount of current being consumed or produced by the motor Note 3 This is the value reported by the MCU and is not corrected for the gear ratio 7 3...

Page 116: ...tely following the transmission of the Status Message 5 The VCU will detect whether or not the message is received and will react as appropriate 64 63 62 61 60 59 58 57 MCU Acceleration Limit msB 56 5...

Page 117: ...main in effect and will be reflected in this value Note this value is the acceleration limit seen at the transmission output Therefore the limit reported by the MCU will be divided by 3 529 when in lo...

Page 118: ...Offset 0 Scale Factor 1 Min Value 0 Max Value 32128 Units A Description The absolute value of the peak currents passing through the motor s phase leads the large cables between the inverter and the mo...

Page 119: ...lowing the transmission of the Status Message 6 The VCU will detect whether or not the message is received and will react as appropriate 64 63 62 61 60 59 58 57 MCU Stall Safety Percentage 56 55 54 53...

Page 120: ...Manual for more details 7 3 7 2 TCU Lubricant Temperature dbc ref TCUStat7_TCULubricantTemperature lsb 49 msb 56 Offset 40 Scale Factor 1 Min Value 40 Max Value 210 Units C Description The temperature...

Page 121: ...or stator Note The MCU will limit motor torque to keep this temperature within acceptable limits 7 3 7 5 MCU Rotor Temperature dbc ref TCUStat7_MCURotorTemperature lsb 25 msb 32 Offset 40 Scale Factor...

Page 122: ...ransmission BC353060341319en 000101 Revision D Danfoss November 2020 121 Classified as Business 7 3 7 7 MCU Max Sink Current dbc ref TCUStat7_MCUMaxSinkCurrent lsb 9 msb 16 Offset 0 Scale Factor 5 Min...

Page 123: ...or Diagnostic Software Danfoss Power Solutions provides diagnostic software with our systems This software runs on Microsoft Windows XP and later and provides an environment to monitor and record the...

Page 124: ...60341319en 000101 Revision D Danfoss November 2020 123 Classified as Business Figure 8 2 Menu Bar Figure 8 3 General Group Figure 8 4 Data Logging Control Figure 8 5 Status Group Figure 8 6 Physical G...

Page 125: ...c file for the PowerPhase DT2 system The default configuration is for PDU1 29bit headers and Little Endian 8 2 Starting the Software After launching the Danfoss Power Solutions Motor Diagnostic Softwa...

Page 126: ...in the Status Bar Figure 8 13 When errors occur the software provides additional information through message boxes or other dialog boxes For example if the software encounters a device that uses an o...

Page 127: ...tion These activities do not disturb the normal operation of the Danfoss Power Solutions controller as it manages its electric motor You can connect the diagnostic software to a Danfoss Power Solution...

Page 128: ...le in real time at second or multiple second rates The software can log data at these slow rates indefinitely Details on logging are located in Section 8 4 Data Acquisition Data Acquisition Figure 8 9...

Page 129: ...GHT EEROM failed The persistent memory on board the controller has failed or is not programmed The controller cannot operate Bad System Configuration The system configuration information in the persis...

Page 130: ...mposes limitations on its output during this condition Note that on average the currents in the legs can be large but sum to 0 Bad A B C Switch es The controller has detected a problem on one or more...

Page 131: ...e CANbus Manual for further details IBus CT Fault ILeg CT Fault The measurement sensors are untrustworthy and the system cannot operate Limp Home happening Indicates that the inverter has detected a c...

Page 132: ...event has occurred in the last 15 seconds No CANbus communication The controller is in CANbus control but no CANbus communication has yet been detected The controller is disabled CANbus limit acting...

Page 133: ...tch will close when the internal and external voltage measurements close to within 25V of each other System Halt The system is not operational Voltage must rise to the minimum battery level before the...

Page 134: ...or more details Allow PWMs at Stop Normally the pulse width modulation PWM the Danfoss Power Solutions controller uses to control its motor is not present when zero torque is requested and the motor i...

Page 135: ...is a shortcut to setting the name portion of a logging filename Normally this name is set in the logging Set Up but it is sometimes more convenient to change the filename without going into the Set Up...

Page 136: ...e Enter the number of rows you want in each logging file The diagnostic software will open a new file incremented name when this number of rows has been stored into a logging file In general Data Logg...

Page 137: ...er build date and the file storage date time Index An incrementing line number starting from zero SysErr History This displays the controller s System Error History This is the on going history of the...

Page 138: ...e Danfoss Power Solutions motor The maximum acceleration rate can be controlled by the Stall Percentage The stall percentage value counts up from 0 to 100 as the motor approaches stall conditions When...

Page 139: ...after applying safeties and limits to the requested value Desired Speed RPM This is the speed that the controller aims to maintain in revolutions per minute If the controller is not in speed control...

Page 140: ...n 0 value when power switches are not active RegenSwitchOpen If there is a Regen Switch in the system this would indicate that it is open with a 1 Position Noise Level Rate of noise on the position si...

Page 141: ...s Power Solutions controller The amount of time is dependent on the baud rate and whether Data Logging is also occurring If your connection speed is 115200 baud and you are not logging then a download...

Page 142: ...convenient to be able to change the filename without going into the Set Up dialog box Set Up This button is the equivalent of the menu choice Actions Daq Configuration Edit Settings It brings up the...

Page 143: ...he controller s control mode torque or speed changes through the CANbus Desired Torque becomes dynamic A trigger occurs when a significant change in desired torque is detected Desired Torque becomes s...

Page 144: ...below trigger level percentage A percentage level is set and the trigger occurs when the limit acting on the regeneration torque is below that level Regen switch changes A trigger occurs when the sta...

Page 145: ...AQ triggers and automatically uploads the DAQ event capture buffer on trigger completion the CSV file is automatically generated You can specify the directory it is placed in and you can specify a nam...

Page 146: ...B Drive Train Systems with Traction Control Inverter Controller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 145 Classified as Business Figure 8 19 DAQ...

Page 147: ...lide bar to indicate how much of the data you want before the trigger event and how much after it Load from Config File This button is the equivalent of the menu choice Actions Daq Configuration Load...

Page 148: ...te when running at 115200 baud rate Once the file is finished the Show File button becomes available Clicking on it starts your spreadsheet program opening the file last written by DAQ If the data poi...

Page 149: ...le number of motor revolutions have occurred This can be thought of as a mileage counter when the number of revolutions equates to a distance Figure 8 21 Event Dialog Box Table 8 13 Possible Entries i...

Page 150: ...oblems Over mechanical danger speed Under mechanical danger speed Over speed occurred Over speed problem OFF These events mark when speed problems have occurred Over Inverter Voltage ON Over Inverter...

Page 151: ...use the vehicle controller is powered off and is no longer communicating but the motor controller has not yet been powered off Torque matching problem The controller found that it was unable to contro...

Page 152: ...ed The bus current sensor value is not consistent with the expected value for existing operating conditions The word ONCE in an event log entry indicates that the event was logged the first time that...

Page 153: ...acturer install vibration isolators on the controller to ensure that vibration levels of the controller are not in excess of the specifications tested throughout the vehicle s life It is the responsib...

Page 154: ...sition feedback cable Coolant ports and hoses All covers in place sealed and screws torqued to manufacturing specifications 9 1 1 1 Acceptance Criteria After each axis test the unit will be returned t...

Page 155: ...irection of engine cylinder hole axis when products are installed at engine parallel direction of the vertical direction of vehicles when product is installed at other parts Drive motors and drive mot...

Page 156: ...to the Danfoss Power Solutions CAN Status and Error signals contained in TCU Status Message 2 Section 7 3 2 and TCU Status Message 3 Section 7 3 3 TCU Status Message 4 Section 7 3 4 TCU Status Message...

Page 157: ...ge 1 is followed messages TCU Status Message 2 7 before the next TCU Status Message 1 is received Note An occasional dropped message may occur without affecting the system If dropouts are frequent or...

Page 158: ...Minor Version Section 7 3 1 6 X Nothing informational only X TCU Sub Version Section 7 3 1 7 X Nothing informational only X MCU Major Version Section 7 3 1 8 X Nothing informational only X MCU Minor...

Page 159: ...ence X Upshift Failed Section 7 3 2 5 Immediate Check engine light Power cycle PowerPhase DT2 system Visual inspection of air lines Replace transmission air solenoid Replace transmission gear switch s...

Page 160: ...smission gear switch sensors Replace transmission speed sensor Send data log to Danfoss Power Solutions for analysis Slow Downshift Section 7 3 2 8 Immediate Check engine light Power cycle PowerPhase...

Page 161: ...e light Verify air pressure minimum Visual inspection of air lines Forced Gear Engagement Torque Section 7 3 2 12 X Nothing will only be seen when Air Pressure Out of Range is set Verify air pressure...

Page 162: ...ng MCU Watchdog Error Section 7 3 2 17 Immediate Check engine light Note 1 Will be accompanied by loss of power Note 2 Contact Danfoss Power Solutions to investigate possible hardware issue Verify the...

Page 163: ...er Note 2 Check integrity of the CAN Bus connection between the VCU and the TCU Verify the MCU CAN settings Check the integrity of the CAN Bus between the TCU and MCU Replace the TCU to MCU CAN Bus wi...

Page 164: ...ght Note 1 Extended use of the system in this condition risks damage to the MCU Note 2 Contact Danfoss Power Solutions to investigate possible hardware issue X MCU Stator Temperature Read Error Sectio...

Page 165: ...r Solutions MCU Invalid Power Supply Section 7 3 2 32 Long System inoperable Record data and contact Danfoss Power Solutions MCU Bad Switch Section 7 3 2 33 Long Check engine light Record data and con...

Page 166: ...ing typical occurrence X MCU Using Raw Speed Section 7 3 2 39 X Nothing typical occurrence X MCU Acceleration Limited Section 7 3 2 40 X Nothing typical occurrence X MCU Current Transducer Fault Ileg...

Page 167: ...Phase DT2 system Record data and contact Danfoss Power Solutions MCU Inverter Fault History Section 7 3 3 2 Immediate Check engine light Power cycle PowerPhase DT2 system Record data and contact Danfo...

Page 168: ...k engine light Note 1 Regen switch will open and shifting will be disabled Note 2 Check for battery fuse blown battery contactor opened or high voltage battery problem Verify DC bus operation Record d...

Page 169: ...peed limit MCU Over Speed Warning History Section 7 3 3 16 X Nothing latched indication that MCU Over Speed Warning has occurred Provided for trouble shooting X MCU Inverter Over Temp Section 7 3 3 17...

Page 170: ...hooting Verify coolant circuit MCU Under Voltage Warning Section 7 3 3 23 X Customer dependent under customer s limit Verify DC Bus operation MCU Under Voltage Warning History Section 7 3 3 24 X Nothi...

Page 171: ...ly dynamic situation X MCU Over Leg Current History Section 7 3 3 30 X Nothing latched indication that MCU Over Leg Current has occurred Provided for trouble shooting X MCU Not Enabled Section 7 3 3 3...

Page 172: ...t Regen torque requested by the VCU will be limited to this value X VCU Torque Requested Section 7 3 4 3 X Customer dependent this is torque that the system will attempt to deliver at the output of th...

Page 173: ...3 6 2 X Customer dependent this is voltage that the MCU is either sinking in drive or sourcing in regen It may be used as a feedback signal to check compliance with the Battery Control Unit Voltage r...

Page 174: ...as this temperature approaches 120 C The TCU will limit the torque allowed if this temperature exceed 120 C and will cease torque production if this temperature reaches 125 C Note Extended operation...

Page 175: ...Current Section 7 3 7 6 X Nothing this value is set as the result of changes in the Max Source Current Section 7 2 2 3 Note The max value of this signal is defined by the MCU X MCU Max Sink Current Se...

Page 176: ...roller and Motor with 2 Speed Transmission BC353060341319en 000101 Revision D Danfoss November 2020 175 Table 10 2 Error Response Delay Time Length of time period before reacting Typical Vehicle Contr...

Page 177: ...al science which studies the unintentional generation propagation and reception of electrical magnetic energy with reference to the unwanted effects EMI that such energy may induce Fault A partial or...

Page 178: ...f a force or system of forces tending to cause rotation 11 1 Abbreviations CCW Counterclockwise CW Clockwise CSV A spreadsheet using the comma separated values format DAQ Data Acquisition ESD Electros...

Page 179: ...cable and DC cable are necessary for safe operation Do not swap motor windings to reverse direction Section 1 1 4 DANGER Exposure to high voltage can cause shock burns and even death Technicians with...

Page 180: ...when the vehicle vibration levels at the controller mounting location are in excess of typical automotive or commercial vehicle levels Section 2 2 3 CAUTION The customer must route and secure the Phas...

Page 181: ...operly loaded WARNING A separate ground wire must connect the motor case to the controller housing High Voltage lines positive or negative must not be tied to the chassis or the motor and controller i...

Page 182: ...locations will increase the resistance of the connection and may result in melting of the overmolding DANGER Failure to orient the power lug connections correctly can cause short to chassis DANGER Do...

Page 183: ...IBLE Cycling either of these signals will cause the inverter CPU to shut down and restart which may result in unpredictable current surges DANGER Your system may be configured for rotation when input...

Page 184: ...he vehicle While towing the vehicle the drive wheels MUST NOT ROTATE or damage will result when the motor system is not operational If needed the drive shaft should be disconnected from the transmissi...

Page 185: ......

Page 186: ...available as samples prototype or similar type identification whether charged for or not may only be used for evaluation purposes may not be resold or be made part of Customer s products for resale UR...

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