ELECTRIC POWER TRAIN TRACTION MOTOR SYSTEM SECTION I MS CONTENTS PRECAUTION PRECAUTIONS ....sss Precaution for Technicians Using Medical Electric....4 Point to Be Checked Before Starting Maintenance Work 4 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN- SIONER™ 4 Precaution for Procedure without Cow! Top Cover....6 High Voltage Precautions 6 Precautions for Removing Battery Terminal 8 General Precautions 8 PREPARATION ......ssssessssssssssseeseessnnnnereesensn 9 PREPARATION ssssssssnsntentnsniensensnsenin 9 Special Service Tool - son Commercial Service Tools .... one SYSTEM DESCRIPTION ......csccsssssssssseeeeseeel DESCRIPTION ...... a Description . vol Specifications (Traction Motor)... 1 Location of Traction Motor Model Number and Se- rial Number Stamps . eo COMPONENT PARTS .. Component Parts Location... st Traction Motor Inverter . fone 13 Traction Motor sen . 13 High Voltage Waring Label nal STRUCTURE AND OPERATION Structural Drawing Operation Description SYSTEM .. TRACTION MOTOR INVERTER : System De- scription 7 TRACTION MOTOR INVERTER : Fail-safe 7 TRACTION MOTOR INVERTER : Protection Control 19 MOTOR POWER CONTROL wnsninssnnnt® MOTOR POWER CONTROL : System Descrip- tion 19 MOTOR POWER CONTROL persis Princ le saennnn st MOTOR REGENERATION CONTROL .. MOTOR REGENERATION CONTROL : System Description 19 MOTOR REGENERATION CONTROL : Operat- ing Principle 20 DIAGNOSIS SYSTEM M (TRACTION MOTOR INVERTER) DIAGNOSIS DESCRIPTION DIAGNOSIS DESCRIPTION ystem Description DIAGNOSIS DESCRIPTION : DTC and Freeze Frame Data DIAGNOSIS DESCRIPTION : Counter System ....21 CONSULT Function 2 ECU DIAGNOSIS INFORMATION TRACTION MOTOR INVERTER . Reference Value Failsafe Protection Control DTC Inspection Priority Chart DTC Index WIRING DIAGRAM TRACTION MOTOR INVERTER 17 TRACTION MOTOR INVERTER .. Wiring Diagram Revision: June 2014 TMS-1 2015 Leaf NAMBASIC INSPECTION DIAGNOSIS AND REPAIR WORK FLOW Work Flow Question sheet RESOLVER WRITE Description Work Procedure DTCICIRCUIT DIAGNOSIS .. POA1B DRIVE MOTOR A CONTROL MOD- ULE DTC Logie Diagnosis Procedure POA2C DRIVE MOTOR A TEMP SENSOR ...... DTC Logie Diagnosis Procedure Component inspection (Traction Motor Tempera- ture Sensor) POA2D DRIVE MOTOR A TEMP SENSOR....... DTC Logie Diagnosis Procedure Component inspection (Traction Motor Tempera- ture Sensor) POA2F DRIVE MOTOR A OVER TEMPERA- TURE 38 36 36 a Pe 41 2 2 2 a 4 “4 “4 45 DTC Logie 8 Diagnosis Procedure 48 Component inspection (Traction Motor Tempera- ture Sensor) 48 Component inspection (Traction Motor Stator Coil) 48 POA3F DRIVE MOTOR A POSITION SEN- SOR DTC Logie Diagnosis Procedure Component inspection (Traction Motor Resolver). POA44 DRIVE MOTOR A OVER SPEED .. DTC Logie Diagnosis Procedure Component inspection (Traction Motor Resolver). POA78 DRIVE MOTOR A INVERTER DTC Logie Diagnosis Procedure POA8D 14VOLT POWER VOLTAGE DTC Logie Diagnosis Procedure POBES D-MOTOR A PHASE U CURRENT SEN .. DTC Logie Diagnosis Procedure Revision: June 2014 POBE6 D-MOTOR A PHASE U CURRENT SEN .. 59 DTC Logic . 2.69) Diagnosis Procedure 69 POBE9 D-MOTOR A PHASE V CURRENT SEN .. DTC Logic Diagnosis Procedure . 60 POBEA D-MOTOR A PHASE V CURRENT DTC Logie et Diagnosis Procedure et POC79 DRIVE MOTOR A INVERTER VOLT- AGE DTC Logic Diagnosis Procedure 62 P318E CAN ERROR vssssssstnnenintnnennsane DTC Logic . Diagnosis Procedure P3193 CAN ERROR DTC Logic . Diagnosis Procedure P3197 CAN ERROR DTC Logic Diagnosis Procedure P3199 CAN ERROR DTC Logic Diagnosis Procedure P319E CAN ERROR DTC Logic . Diagnosis Procedure P31A2 CAN ERROR DTC Logic . Diagnosis Procedure P31A4 CAN ERROR DTC Logic Diagnosis Procedure P31A9 CAN ERROR DTC Logic Diagnosis Procedure P31AD CAN ERROR sess DTC Logic Diagnosis Procedure . P3240 DRIVE MOTOR A INVERTER CRNT CONT ... DTC Logic Diagnosis Procedure 68 2 IS-2 2015 Leaf NAMP3241 DRIVE MOTOR A INVERTER CRNT CONT... 76 DTC Logic . 276 Diagnosis Procedure . 276 P3242 D-MOTOR A PHASE U CURRENT SEN .. 18 DTC Logic . . TB Diagnosis Procedure — ve TB P3243 D-MOTOR A PHASE V CURRENT DTC Logic 79 Diagnosis Procedure 79 P3244 DRIVE MOTOR A INVERTER DTC Logic Diagnosis Procedure P3245 DRIVE MOTOR A INVERTER DTC Logic Diagnosis Procedure P3247 DRIVE MOTOR A INVERTER ... A DTC Logie 83 Diagnosis Procedure 83 P3249 DRIVE MOTOR A INVERTER .rssoss84 DTC Logic 84 Diagnosis Procedure a4 P324A DRIVE MOTOR A INVERTER VOLT- AGE 85 DTC Logie 85 Diagnosis Procedure 85 P324D DRIVE MOTOR A INVERTER IGBT DTC Logic 87 Diagnosis Procedure . 87 ‘Component Inspection (Traction Motor Stator Cail) . fev . 88 P3252 DRIVE MOTOR A INVERTER IGBT .......90 DTC Logic 0 90 Diagnosis Procedure se ene P325A CAN ERROR . DTC Logic Diagnosis Procedure Revision: June 2014 TMS-3 P325B DRIVE MOTOR A INVERTER .... DTC Logie Diagnosis Procedure P325C DRIVE MOTOR A POSITION ...ssssonen93 DTC Logie 93 Diagnosis Procedure 93 P325D DRIVE MOTOR A POSITION DTC Logie Diagnosis Procedure P325E DRIVE MOTOR A POSITION DTC Logie Diagnosis Procedure P325F DRIVE MOTOR A POSITION DTC Logie Diagnosis Procedure U1000 CAN COMM CIRCUIT wsesssssnseutanenen9T Description o7 DTC Logie or Diagnosis Procedure 97 TRACTION MOTOR INSULATION RESIS- TANCE CHECK Component inspection 98 TRACTION MOTOR INVERTER INSULA- TION RESISTANCE CHECK ... Component Inspection SYMPTOM DIAGNOSIS ELECTROMAGNETIC SOUND IS AUDIBLE . DESCRIPTION REMOVAL AND INSTALLATION TRACTION MOTOR INVERTER . Exploded View Removal and Installation Inspection and Adjustment UNIT REMOVAL AND INSTALLATION .. TRACTION MOTOR Exploded View Removal and Installation Inspection and Adjustment 100 100 102 102 102 103, 103 103 103 107 109 109 109 109 113 2015 Leaf NAMPRECAUTIONS < PRECAUTION > PRECAUTION PRECAUTIONS Precaution for Technicians Using Medical Electric woe coven OPERATION PROHIBITION WARNING: + Parts with strong magnet is used in this vehicle. + Technicians using a medical electric device such as pacemaker must never perform operation on the Vehicle, as magnetic field can affect the device function by approaching to such parts. NORMAL CHARGE PRECAUTION WARNING: a technician uses a medical electric device such as an implantable cardiac pacemaker or an implantable cardioverter defibrillator, the possible effects on the devices must be checked with the device manufacturer before starting the charge operation. + As radiated electromagnetic wave generated by PDM (Power Delivery Module) at normal charge operation may affect medical electric devices, a technician using a medical electric device such as implantable cardiac pacemaker or an implantable cardioverter defibrillator must not approach motor room [PDM (Power Delivery Module)] at the hood-opened condition during normal charge operation. PRECAUTION AT TELEMATICS SYSTEM OPERATION WARNING: + If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), avoid the device implanted part from approaching within approximately 220 mm (8.66 In) from Inte- rior/exterior antenna. + The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or the implantable cardioverter defibrillator (ICD), when using the service, etc. + If'a technician uses other medical electric devices than implantable cardiac pacemaker or implant- able cardioverter defibrillator (ICD), the electromagnetic wave of TCU might affect the function of the device. The possible effects on the devices must be checked with the device manufacturer before TCU use. PRECAUTION AT INTELLIGENT KEY SYSTEM OPERATION WARNING: + If'a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), avoid the device implanted part from approaching within approximately 220 mm (8.66 in) from inte- rlor/exterior antenna. + The electromagnetic wave of Intelligent Key might affect the function of the implantable cardiac pacemaker or the implantable cardioverter defibrillator (ICD), at door operation, at each request switch operation, or at engine starting. + Ifa technician uses other medical electric devices than implantable cardiac pacemaker or implant- able cardioverter defibrillator (ICD), the electromagnetic wave of Intelligent Key might affect the function of the device. The possible effects on the devices must be checked with the device manu- facturer before Intelligent Key use. Point to Be Checked Before Starting Maintenance Work neo comcooraes The high voltage system may starts automatically. It is required to check that the timer air conditioner and timer charge (during EVSE connection) are not set before starting maintenance work. NOTE: If the timer air conditioner or timer charge (during EVSE connection) is set, the high voltage system starts automatically even when the power switch is in OFF state. Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ves The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER’, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision, This system includes seat belt switch inputs and dual stage front air bag modules. The SRS Revision: June 2014 TMS-4 2015 Leaf NAMPRECAUTIONS < PRECAUTION > system uses the Seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SR and SB section of this Service Man- ual WARNING: * To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSANJINFINITI dealer. + Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal [il injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SR section. + Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har- ness connectors. PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS WARNING: + When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni- tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. + When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the battery and wait at least three minutes before performing any service. Precaution for Procedure without Cowl Top Cover ‘When performing the procedure after removing cow! top cover, cover the lower end of windshield with urethane, ete to prevent damage to windshield High Voltage Precautions DANGER: Avsince nyona venicies and electric vehicles contain a high voltage battery, there Is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance. WARNING: + Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- ing inspection or maintenance of high voltage system harnesses and parts. + The removed service plug must always be carried in a pocket of the responsible worker or placed in the tool box during the procedure to prevent the plug from being connected by mistake. + Be sure to wear insulated protective equipment before beginning work on the high voltage system. + Never allow workers other than the responsible person to touch the vehicle containing high voltage parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- lating sheet except when using them. CAUTION: Never bring the vehicle into the READY status instructed in the Ser the service plug removed unless otherwise Manual. A malfunction may occur if this is not observed. HIGH VOLTAGE HARNESS AND EQUIPMENT IDENTIFICATION Revision: June 2014 TMS-5 2015 Leaf NAMPRECAUTIONS < PRECAUTION > ‘All the high voltage hamesses and connectors are orange. The Lion battery and other high voltage devices include an orange high voltage label. Never touch these harnesses and high Voltage parts. HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS Immediately insulate disconnected high voltage connectors and terminals with insulating tape. REGULATIONS ON WORKERS WITH MEDICAL ELECTRONICS WARNING: The vehicle contains parts that contain powerful magnets. If a person who is wearing a heart pace- maker or other medical device is close to these parts, the medical device may be affected by the mag- nets. Such persons must not perform work on the vehicle. PROHIBITED ITEMS TO CARRY DURING THE WORK Hybrid vehicles and electric vehicles contain parts with high voltage and intense magnetic force. Never carry metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage parts. If this is not observed, the metal products may create a risk of short circuit and the magnetic recording media may lose their magnetic recording, POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT” Revision: June 2014 TMS-6 2015 Leaf NAMPRECAUTIONS VOLTAGE. DO NOT TOUGH* on the vehicle under repair/inspection to call attention to other < PRECAUTION > Indicate "HIGH . roBueyo ul UOSded iHONOL LON OG “SS3YHDOUd NI YIVdSy ASVLIOA HDIH ‘YSDNVG DANGER: HIGH VOLTAGE REPAIR IN PROGRESS. DO NOT TOUCH! Person in charge: Copy this page and put it after folding on the roof of the vehicle in service. TMS-7PRECAUTIONS < PRECAUTION > Precautions for Removing Battery Terminal + When removing the 12V battery terminal, turn OFF the power switch and wait at least 5 minutes. NOTE: ECU may be active for several minutes after the power switch is tuned OFF. If the battery terminal is removed before ECU stops, then a DTC detection error or ECU data corruption may occur. + Always disconnect the battery terminal within 60 minutes after turing OFF the power switch. Even when the power switch is OFF, the 12V battery automatic charge control may automatically start after a lapse of 60 minutes from power switch OFF. + Disconnect 12V battery terminal according to the following steps. WORK PROCEDURE 1. Check that EVSE is not connected, NOTE: If EVSE Is connected, the air conditioning system may be automatically activated by the timer A/C func- tion. 2. Turn the power switch OFF — ON — OFF. Get out of the vehicle. Close all doors (including back door). 3. Check that the charge status indicator lamp does not blink and wait for § minutes or more. NOTE: If the battery is removed within 5 minutes after the power switch is turned OFF, plural DTCs may be detected 4, Remove 12V battery terminal within 60 minutes after turning the power switch OFF > ON — OFF. CAUTION: * After all doors (including back door) are closed, if a door (including back door) is opened before battery terminals are disconnected, start over from Step 1. + After turning the power switch OFF, if “Remote A/C” is activated by user operation, stop the air conditioner and start over from Step 1. NOTE: Once the power switch is turned ON > OFF, the 12V battery automatic charge control does not start for approximately 4 hour. + For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON the power switch, NOTE: Ifthe power switch is turned ON with any one of the terminals of main battery and sub battery disconnected, then DTC may be detected. + After installing the 12V battery, always check "Self Diagnosis Result” of all ECUs and erase DTC. NOTE: The removal of 12V battery may cause a DTC detection error. General Precautions CAUTION: If the traction motor inverter or traction motor was replaced, be sure to perform writing of the traction motor resolver offset. Refer to TMS-39, "Description". Take care when handling the traction motor inverter so that dust, dirt, and other substances do not enter into the inside from the opening. Revision: June 2014 TMS-8 2015 Leaf NAMPREPARATION < PREPARATION > PREPARATION PREPARATION Special Service Tool ‘The actual shape ofthe tools may ifr from those lustrated here ‘Tool number Description E (TechMate No.) Tool name Kv99712300 (251050) Guide pin Removing and instaing traction mator in- verter ao 3 pinsiset — a ‘8: 106 mm (4.47 in) (1 pin)/96 mm (3.78 In) pins) Commercial Service Tools asmacnsce eine Toot name Description Insulated gloves Removing and instaling high votlage ‘components [Guaranteed insulation pertormance for 000v73008 Leather gloves + Removing and installing high vottage components + Protect insulated gloves [Use leather gloves that can fasten the wrist ght) Insulated safely shoes Safety glasses Removing and intaling high voltage ‘components + Removing and inialing high voltage components + To protect eye from the spatter on the ‘Work fo elect ine (aNsi 87.1) TMS-9 Revision: June 2014 2015 Leaf NAMPREPARATION < PREPARATION > Tool name Desorption Face shied + Removing and installing high vollage ‘components, + To protec face rom the spatter on the Work to electric ine Insulated helmet Removing and Insiallg high valiage components Insulation reaisiance tester (Mutt tester) ‘Measuring nsulaion resistance, vakage and resistance Revision: June 2014 TMS-10 2015 Leaf NAMDESCRIPTION < SYSTEM DESCRIPTION > SYSTEM DESCRIPTION DESCRIPTION Description + The traction motor contains a compact, lightweight, high output, high efficiency “Interior Permanent Magnet ‘Synchronous Motor (IPMSM)" + The traction motor inverter is @ device which converts DC power from the Li-ion battery to AC power, and (ii drives the traction motor. Because the AC power frequency and voltage can be varied when the DC power is converted to AC power. it provides control performance with a high degree of freedom, Specifications (Traction Motor) Max torque 254Nm Max output BO KW Max speed 10,500 rpm ‘Cooling system Water cooling type Location of Traction Motor Model Number and Serial Number Stamps Revision: June 2014 TMS-11 2015 Leaf NAM< SYSTEM DESCRIPTION > COMPONENT PARTS COMPONENT PARTS Component Parts Location Motor room Ne. Tem Funcion vom a Transmits mainly the folowing signals to VOM via EV eystem OAN, Motor speed signal Motor torque limit signal Motor aischarge status signal High votage power supply preparation completion signal Input high voltage signal Receives mainly the following signals from VCM via EV system CAN, Target motor torque signal Pulse signal OFF signal High voltage power supply status signal System cut of signal Vibration contro switching signal ‘Motor charge preparation request signal Motor cischarge request signal Regenerative torque command signal Shift postion signal Refer to EVC-19, “Component Parts Location” for detailed instalation location. Refer to EVC-18, "VCMF for detals Electric sin control module “The electric shih control module is built into the VCM. Receives mainly the following signal from electric shit control module via EV system CAN, Shift postion signal Refer to TM-83, “Electric Shift Control Module" for details. Revision: June 2014 TMS-12 2015 Leaf NAMCOMPONENT PARTS < SYSTEM DESCRIPTION > Ta Tem Function @ | Tacion motor verter TMS-18, “Traction Motor invari @ | Traction motor TMS-13, "Traction Motor Traction Motor Inverter NOTE: Control of the traction motor and control of EV system CAN communications with other control modules is actually performed by the motor controller. However, because the motor controller is installed inside the trac tion motor inverter, the motor controller is here referred to as the traction motor inverter. + The traction motor inverter is composed of the motor controller, driver, smoothing condenser, 2 current sen- sors, and power module. + The traction motor inverter controls the traction motor based on the target motor torque signal transmitted by EV system CAN from the VCM + Traction motor inverter drives traction motor accurately based on resolver detection signal and current sen- sor detection signal. + The traction motor inverter performs charging judgment for the high voltage circuit and also discharges the voltage inside the circuit. + The traction motor inverter performs vibration control in order to improve accelerator response and provide good acceleration while driving, MOTOR CONTROLLER + The motor controller receives the rotor rotation angle from the traction motor resolver and the traction motor current value from the current sensor, and creates the pulse signal for driving the IGBT (Insulated Gate Bipo- lar Transistor). + The motor controller detects the traction motor temperature by means of the traction motor temperature sen- sor, and limits the output torque (protection control) according to the level of heat in the traction motor DRIVER ‘The driver converts the pulse signal (12 V) from the motor controller to a high voltage signal (300 V) and drives the IGBT. POWER MODULE + The power module is composed of 6 power semiconductor IGBTs. + An IGBT is a semiconductor switch that is capable of switching ON/OFF at high speed. + An IGBT uses the IGBT drive signal from the driver to perform switching, converting the Li-ion battery DC power to AC power and supplying AC power to the traction motor. SMOOTHING CONDENSER The smoothing condenser controls the voltage ripple which occurs as a result of GBT switching. CURRENT SENSOR Current sensors are located in Phase U and V, respectively. These sensors detect a current supplied to the drive motor and feed back a current value to the motor controller. The current sensors have two builtin sen- sors. A.current of Phase W is calculated according to the values of Phase U and V. DISCHARGE RESISTER ‘The discharge resistor discharges the high voltage in case the traction motor inverter is unable to discharge the remaining high voltage in the high voltage circuit due to a malfunction. Traction Motor row cinnent9 + The traction motor contains an “Interior Permanent Magnet Synchronous Motor (IPMSM)". A permanent magnet is embedded inside the rotor core, and the rotating magnetic field generated by the stator coil is used to generate rotational torque. Revision: June 2014 TMS-13 2015 Leaf NAMCOMPONENT PARTS < SYSTEM DESCRIPTION > +The traction motor is able to generate torque even when the vehi- cle is stopped, and outputs maximum drive torque when the vehi- cle starts moving in order to provide good initial acceleration’ g ° ole speed TRACTION MOTOR RESOLVER, The traction motor resolver is located coaxially with the traction motor, and detects the rotor rotation angle, The rotation angle is sent to the motor controller. CAUTION: If the traction motor inverter or traction motor is replaced, be sure to perform writing of the traction motor resolver offset. Refer to TMS-39, “Description”. TRACTION MOTOR TEMPERATURE SENSOR The traction motor temperature sensor detects the temperature of the stator inside the traction motor, and ‘sends that temperature information to the motor controller. High Voltage Warning Label lneno snomeoneane ‘When replacing component parts make sure to affix the label in the original position. The label @ is affixed to the right side of traction motor. o Vehicle front « Direction ofthe label Revision: June 2014 TMS-14 2015 Leaf NAMSTRUCTURE AND OPERATION < SYSTEM DESCRIPTION > STRUCTURE AND OPERATION Structural Drawing MOTOR MECHANISM (DIAGRAM) @ Satoroore @ cal @ shat @ Rotorcore @® Permanent magnet Operation Description OPERATION PRINCIPLE ait (Poranet mapret) ksh Sonne + When S-phase AC Current is applied To The slater col a rolaling magnetic Weld Ts generated. This rotating magnetic field pulls on the permanent magnet inside the rotor core, generating rotational torque that is syn= Revision: June 2014 TMS-15 2015 Leaf NAMSTRUCTURE AND OPERATION < SYSTEM DESCRIPTION > chronized with the rotating magnetic field. The generated torque is approximately proportional to the current, and the rotating speed depends on the frequency of the 3-phase current. + In order to generate optimal rotor rotation, judgments regarding the position (angle) of the permanent mag- inet within the rotor core and the timing of current application to the coil are necessary. For this purpose, the traction motor resolver and current sensor are used in order to continually detect the rotating position of the rotor and control the timing of current application to the coil. Revision: June 2014 TMS-16 2015 Leaf NAMSYSTEM < SYSTEM DESCRIPTION > SYSTEM TRACTION MOTOR INVERTER TRACTION MOTOR INVERTER : System Description + The traction motor inverter controls the traction motor based on the target motor torque signal transmitted by EV system CAN from the VCM. + Traction motor inverter converts DC power from Li-ion battery to AC power, and drives traction motor acou- AR rately based on resolver detection signal and current sensor detection signal + At deceleration, traction motor is used as generator. It converts kinetic energy generated by rotary motion of tires (AC power) to electric energy (DC power) and charges Li-ion battery, + If malfunction is detected, the system enters fail-safe mode. Refer to TMS-25. "Fail-safe" SYSTEM DIAGRAM Traction motor ive os =e verehiane |e Be | can ser “ace = ny ad “a2 ‘Pre sive sana raster mot TaV bation =. Cen} Motor controter Em: CAN comneaten oe > sec gal TRACTION MOTOR INVERTER : Fail-safe DIE ‘Vehicle behavior ‘Any ofthe following statuses is observed + No impact to vehicie behavior POMIB + Stops drive contol of traction motor + Stops crive contol of traction motor, and requires system main relay OFF to VOM + Limits the maximum torque of traction motor to 40% or less PoAZc Limits the maximum torque of traction motor to 40% or less PoAQD LUits the maximum torque of traction motor to 40% or less POAQF ‘Stops drive contro of traction motor POASE ‘Stops drive control of traction motor POM ‘ops drive control of traction motor Revision: June 2014 TMS-17 2015 Leaf NAMSYSTEM < SYSTEM DESCRIPTION > Dre Vehicle behavior OATS ‘Stops drive control of traction motor OAD ‘Stops ive control of raction motor, and requires system main relay OFF to VOM OBES ‘Stops arive control of action motor OBES ‘Stops drive contol of traction motor OBES ‘Stops arive contol of traction motor POBEA ‘Stops crive control of traction motor PooT9 ‘Stops ive control of traction meter Either ofthe folowing statuses is observes. Patge + No impact to vehicle behavior + Stops drive control of traction motor P3198 No impact to vehicle behavior Ether ofthe folowing statuses Is observes. P3197 + Slops drive control of traction motor + Limits the maximum torque of traction motor to OY Either ofthe folowing statuses Is observed. P3199 + No impact to vehicle behavior + Stops drive contol of traction motor Ste No impact to vehicle behavior Ether ofthe folowing statuses Is observes. pata + Stops drive control of traction motor + Limits the maximum torque of traction motor to 09% Ether ofthe folowing statuses Is observes. Pata + No impact to vehicle behavior + Stops drive control of traction motor PatAa ‘No impact to vehicle Behavior Either ofthe folowing satuses Is observed. P3iaD + Stops drive contol of traction motor + Limits the maximum torque of traction motor to O96 P3240 ‘Stops rive control of traction motor Pa2at ‘Stops drive control of traction motor P3242 ‘Stops rive control of traction moter P3243 “Stops arive control of traction mater P3248 No impact to vehicle behavior P3245 ‘No impact to vehicle behavior P3247 ‘Stops ative control of traction mater P3249 ‘Stops rive control of traction motor, and requires system main relay OFF to VCM PS24A, ‘Stops ative control of traction mater P3240 ‘Stops rive control of traction meter P3252 No impact to vehicle behavior Pa25A, No impact to vehicle behavior P3256 No impact to vehicle behavior P3260 No impact to vehicle behavior P3260 Limits the maximum torque of tration motor to 40% or less PS25E No impact to vehicle behavior PS25F ‘No impact to vehicle behavior U1000 No impact to vehicle behavior Revision: June 2014 TMS-18 2015 Leaf NAMSYSTEM < SYSTEM DESCRIPTION > TRACTION MOTOR INVERTER : Protection Control When temperature of traction motor inverter or traction motor components rises, the traction motor inverter temporarily enters a protective control state in order to protect the system. It automatically returns to the nor- mal status if the safety is secured. Condition Conor ‘Normal retum condition “Traction motor output torque is Traction motors overheated Iraction motor temperature. ed aecorang 101M | Tracyon motor tempera ops Ic5T ign tempers seenwnen (SET switingequncy edie «attempt rps traction motor speeds extremely low | T2cton motor electromagnetic noise increases, *- acto motor speed increases “Traction motor output torque is limited according to the IGBT temperature. MOTOR POWER CONTROL MOTOR POWER CONTROL : System Description IGBT is overneates IGBT temperature arops ‘The traction motor inverter applies AC power to the traction motor according to the target motor torque signal calculated by VCM in order to generate drive force. MOTOR POWER CONTROL : Operating Principle Flow of energy (4) mm (3) mms 2) (1) @ @ @ m “The AC power from the traction motor inverter is = converted to magnetic en- The traction motor inverter (1G The ave torque trom the 1C power from the ‘aston motors oupulas | egy andaetating nog theoC power fomibelion” || fetecon hot nve kinetic energy, nei eld is created in on n ‘order to generate orive battery 0. AC power " torque. MOTOR REGENERATION CONTROL MOTOR REGENERATION CONTROL : System Description During deceleration, the traction motor inverter drives the traction motor to function as a generator based on the regenerative torque command signal sent via EV system CAN fram the VCM, converting the kinetic torque generated by rotation of the tires into electrical energy. The converted electrical energy charges the Li-ion bat- tery. Revision: June 2014 TMS-19 2015 Leaf NAMSYSTEM < SYSTEM DESCRIPTION > The regenerative torque that is generated when the traction motor is driven as a generator can be used as braking force, acting similar to engine braking and reducing the burden on the service brakes. MOTOR REGENERATION CONTROL : Operating Principle Flow of energy a Lion ay | _——==> (3) > (4) a @ o @ The kinetic energy generat- ‘The traction motor inverter ‘The DC power regeneral- ed by oiation ofthe tres | =| Rotation ofthe traction mo. = | (IGBT) switches in oder to | = edb the traction motor in- ‘operates the traction motor | | tor generates AC power, Convertthe AC powerfromthe | | verter used to charge a8 generator traction motor to DC power. the Liion batter, Revision: June 2014 TMS-20 2015 Leaf NAMDIAGNOSIS SYSTEM (TRACTION MOTOR INVERTER) < SYSTEM DESCRIPTION > DIAGNOSIS SYSTEM (TRACTION MOTOR INVERTER) DIAGNOSIS DESCRIPTION DIAGNOSIS DESCRIPTION : System Description This is an on-board trouble diagnosis system which automatically detects malfunction, Detected malfunction is memorized in ECU as DTC. Diagnosis information can be confirmed using CONSULT. DIAGNOSIS DESCRIPTION : DTC and Freeze Frame Data NOTE: Operate the power switch from OFF to ON, This operation is defined as 4 trip. + DTC (POA1B, POABD, POC7S, etc.) is specified by SAE J2012/ISO 15031-6. + Traction motor inverter memorizes DTC and freeze frame data when malfunction is detected. + Traction motor inverter can memorize plural DTCs but only 1 set of freeze frame data. + Freeze frame data is not updated even if a different DTC is detected in another trip. The first memorized data is kept as freeze frame data + The procedure to erase DTC from traction motor inverter memory is described in “How to Erase DTC”. Refer to TMS-21, "CONSULT Function", DIAGNOSIS DESCRIPTION : Counter System Counter system counts up at every operation of power switch from OFF to ON under condition that the same malfunction is not detected. On the other hand, if the same DTC as memorized one is detected again, the count is reset and the counter system counts up again from *0" CONSULT Function APPLICATION ITEM Tem Function ‘AIDTG Reading | Display all DTCs or diagnostic tems that all EGUs are recording and judging ‘Work Support This mode enables a technician to adjust some devices faster and more accurately. Seif Diagnostic Results Reitieve DTC from ECU and display dlagnostic tems, Data Monitor Monitor the inpuitoutput signal ofthe contol unit in realtime. ‘CAN Diagnosis This mode displays a network diagnosis result about CAN by diagram. ‘CAN Diagnosis Support Monitor | It monitors the status of GAN communication ECU Identification Display the ECU identitcation number (part number et) of the selected system. WORK SUPPORT Tem Deserpton RESOLVER WRITE Performs writing of action motor resolver offset. Resets output iit history of traction motor and traction motor inverter. NOTE: CLEAR OUTPUT LIMIT REASON Resets “OUTPUT LIMIT MOTOR TEMP” and “OUTPUT LIMIT INV TEMP" values of data monitor. SELF DIAGNOSTIC RESULTS Display item List Refer to TMS-28, "DTC Index" How to Read DTC DTC is displayed on “Self Diagnostic results” of CONSULT. When DTC is currently detected, “CRNT” is displayed. If*PAST" is displayed, it shows a malfunction occurred in the past.The trip number of drive without malfunction of concemed DTC can be confirmed with “IGN counter’ inside “FFD”. Revision: June 2014 TMS-21 2015 Leaf NAMDIAGNOSIS SYSTEM (TRACTION MOTOR INVERTER) < SYSTEM DESCRIPTION > How to Erase DTC NOTE: If the power switch is kept ON after repair operation, operate the power switch to OFF. Operate the power switch to ON again after waiting at least 10 seconds, 1, Touch “MOTOR CONTROL" of CONSULT. 2. Touch “Self Diagnostic Resutt” 3, Touch “Erase”, (DTC memorized in electric traction motor inverter is erased.) IGN Counter IGN counter is displayed in “FFD”. It displays the number of operations of power switch from OFF to ON after DTC recovery to normal. + If maifunction (DTC) is currently detected, “0” is displayed. + The displayed number counts up at each operation of power switch from OFF to ON after recovery to nor- mal, such as 1 2—> 3..38 —> 39. + When the number reaches to 40, DTC is erased. NOTE: The counter display of “40” cannot be checked, FREEZE FRAME DATA (FFD) The following vehicle status is recorded when DTC is detected and is displayed on CONSULT. Tionifored tem (Uni Remarks DIE Displays the DTO which caused FFD memory 12V POWER VOLTAGE ()| Displays 12V battery power voltage input to traction motor inverter (CODE IN INVERTER Displays the trouble code inside traction motor inverter RESOLVER OFFSET VALUES (Istana Displays 1st and 2nd symbo's of action motor resolver offset value writen in 2n¢ symbols) traction moter inverter DIAGNOSIS START HISTORY 1 Displays DTC detection mode Is started DIAGNOSIS START HISTORY 2 DPA REQUEST Displays the request status of DPA TORQUE LIMIT RATE 1 (@5)] Displays the motoring torque limit rate TORQUE LIMIT RATE 2 (3) Displays the regeneration torque limit rate MOTOR TEMPERATURE (C oF -F)| Displays the temperature of traction motor MAX MOTOR TEMPERATURE (6 or -F)) Displays the highest temperature of traction motor detected INV INPUT HIGH VOLTAGE (V)] Displays high voltage input to traction motor inverter (COMMAND TORQUE (Nm)| Displays the torque command value from VCMI via EV system CAN INSIDE COMMAND TORQUE (Nm)| Displays the torque command value in motor controler MOTOR SPEED (@pm)| Displays the action motor speed MOTOR d CURRENT ()| Displays the detected value of current (@-axis) of traction motor MOTOR q CURRENT (A)| Displays the detected valve of current (q-axs) of traction motor U PHASE CURRENT (A)| Displays the U-phase current detected value \VPHASE CURRENT (A)| Displays the V-phase current detected value PHASE ANGLE (eq) | Displays the turning angle postion of rotor ‘SEQUENCE MODE Displays the sequence number in motor controller CARRIER FREQUENCY Displays the camer frequency IGBT HIGH TEMP DETECT Displays the status of high temperature detection of IGT HIGH VOLTAGE SUPPLY Displays the high voltage supply status from VOM via EV system CAN VOLTAGE (S1-83) (V)| Displays the $1-83 of resolver detected voliage VOLTAGE (S2-84) (V)| Displays the 52-54 of resolver detected voltage ERRORLEVEL ERROR LEVEL 2 Displays the diagnosis fag of resolver IC ERROR LEVELS Revision: June 2014 TMS-22 2015 Leaf NAMDIAGNOSIS SYSTEM (TRACTION MOTOR INVERTER) < SYSTEM DESCRIPTION > ‘Monitored em (Unit) Remarks ERROR CODE? ERROR CODE 2 RESOLVER VOLTAGE '5V POWER SUPPLY ‘3V POWER SUPPLY “ “ w Displays the diagnosis results of resolver IC Displays the power supply voltag Displays the SV control power supply voltage Displays the 3V control power supply voltage DATA MONITOR NOTE: ‘The following table includes information (items) inapplicable to this vehicle. For information (items) applica- bleto this vehicle, refer to CONSULT display items. ‘Monitored em (Unity Remarks MOTOR TEMPERATURE (CCor*F) Displays the temperature of traction motor 12V POWER VOLTAGE (W)_ Displays 12V battery power voltage input to traction motor inverter INV INPUT HIGH VOLTAGE ()_ Displays high voltage input to traction motor inverter ‘COMMAND TORQUE (Nm) | Displays the torque command value from VOM via EV system CAN MOTOR SPEED (tpm)_ Displays the traction motor speed SEQUENCE MODE Displays the sequence number in motor controller OUTPUT LIMIT MOTOR TEMP OUTPUT LIMIT INV TEMP + Displays presence of output limit due to traction motor temperature increase after last deletion of output limit history + Values can be reset using “CLEAR OUTPUT LIMIT REASON of work sup- port + Displays presence of output limit due to temperature increase inside traction ‘motor Inverter afer last deletion of eutput imi history + Values can be reset using “CLEAR OUTPUT LIMIT REASON of work sup- port CARRIER FREQUENCY HIGH VOLTAGE SUPPLY CHARGE RELAY READY REQ SHIFT POSITION (VCM) Displays the carrier Fequency Displays the high vattage supply status fram VOM via EV system CAN Displays the state of charge judgment start request of high volage circuit Displays the shift postion from VM via EV system CAN Revision: June 2014 TMS-23 2015 Leaf NAMTRACTION MOTOR INVERTER < ECU DIAGNOSIS INFORMATION > ECU DIAGNOSIS INFORMATION TRACTION MOTOR INVERTER Reference Value CONSULT DATA MONITOR STANDARD VALUE, NOTE: The following table includes information (items) inapplicable to this vehicle. to this vehicle, refer to CONSULT display items. For information (items) applicable ‘Menor Rem ‘Ganation Value / Status (APO) READY (stop the vehicie) “Almost same as coolant temperature af ter temperature saturation, [approxl= mately within 10°C (50°F) of coovant MOTOR TEMPERATURE temperature) The value changes along with accelera- During ing toneveersion 12V POWER VOLTAGE Power switch ON 9-16 INV INPUT HIGH VOLTAGE READY (siop the vehicle) and during diving 240-403 COMMAND TORQUE uring ering “The value changes along with accelera- READY (stop the vehicie) MOTOR SPEED During enving ‘SEQUENCE MODE READY (stop the vehicle) tloniaeceleraton Ompm ‘The value changes along with accelera- tion/deceleration, 1 ‘When the vehicle has history of output limit ‘When output limit is reset When the vehicle has history of output iit (OUTPUT LIMIT MOTOR TEMP (OUTPUT LIMIT INV TEMP ‘When output limit is reset CARRIER FREQUENCY READY (stp the venice) HIGH VOLTAGE SUPPLY READY (stop the vehicle) CHARGE RELAY READY REQ READY (stop the vehicle) P poston SHIFT POSITION (voM) READY (stop the vehicle) — D postion Yes None Yes None 5K SUPPLY ON Oza TERMINAL LAYOUT PHYSICAL VALUES CAUTION: Revision: June 2014 TMS-24 2015 Leaf NAMTRACTION MOTOR INVERTER < ECU DIAGNOSIS INFORMATION > * Check them with vehicle side harness connector, removing traction motor inverter connector. Never touch terminals of traction motor inverter side connector at this operation. + If power switch is pushed ON with traction motor inverter connector removed, other control modules might detect malfunction of traction motor inverter. TemminalNa: ua Desc cnaton vate oe) + - ‘Signal name. input) i. Output 14 Teveystem input wo | vasemoan Output - - ‘5 ip )—_| Bvsystem CANL Output _ - "8 Tacomas lat) Powe oth OFF - 8) | TadanRoercsier | npg | Power eno 20-380 a a 1) | Tasman apa | over owh OFF ssa 2&1 acinar ese . 21 | TasonroteSe |_| rover schOFF 0-350 42 curd POWTON overs |__| POWER ON a6 (Ls) ply Power switch OFF ov itn 50% longer cae gran Bo 45 #4 Taconmotrtenpen. , 5 eS | tee wee rowrencort | | $s z. Motor temp. °C (F) Goma BVEaoy Foner papers . 8 | wana) movers on oe @ orard) on ano ov 48 Ground) 12V battery power sup- - Power switch ON 9-16V 6 mo ‘© , $2 crema uo pois ov Fail-safe nse oe Tao Any og ses oad Motos elie eho pone |S Soptve ctl on eter «Soper ona of ace mo andres sytem many OFF VOM «Eke He nrtacun eatin sO ree PORIC nse macnum tev o octonmts res PRD) Lins ems con mtr 4% rier PORE | Specie conte racon mor PORE | Seve conte acon rar Revision: June 2014 TMS-25 2015 Leaf NAMTRACTION MOTOR INVERTER < ECU DIAGNOSIS INFORMATION > Dre Vehicle behavior POA ‘Stops drive control of traction motor POATE ‘Stops drive control of traction moter OAD ‘Stops crive control of racton motor, and requires system main relay OFF to VOM OBES ‘Stops drive contol of traction motor OBES ‘Stops arive contol of traction motor OBES ‘Stops drive contol of traction motor POBEA ‘Stops rive control of traction meter PocTs ‘Stops drive control of traction motor Ether ofthe folowing statuses Is observes. Pate + No impact to venicle behavior + Slops drive control of traction motor P3198 No impact to vehice behavior Either ofthe folowing statuses is observed. P3197 + Stops drive contol of traction motor + Limits the maximum torque of traction motor to O¥% Either ofthe folowing statuses Is observed. P3199 = No impact to venicle benavior + Slops drive control of traction motor PSt9e No impact to vehicie behavior Either ofthe foloing statuses is observed Pata + Siops drive control of traction motor + Limits the maximum torque of traction motor to 0% Either ofthe folowing statuses is observed. Pata + No impact to venicle benavior + Stops drive control of traction motor Stag No impact to vehicle behavior Either ofthe folowing statuses Is observes. P3iAD + Slops drive control of traction motor + Limits the maximum torque of traction motor to 0% P3240 ‘Stops drive control of traction motor P3241 ‘Stops rive control of traction moter Pa242 “Stops arive control of traction mater P3243 ‘Stops crive control of traction moter 324s No impact to vehicle behavior P3245 No impact to vehicle behavior P3247 ‘Stops rive control of traction meter P3249 ‘Stops crive control of traction motor, and requires system main relay OFF to VOM PS24A, ‘Stops rive control of traction meter Pa24D ‘Stops drive control of traction motor P3282 No impact to vehicle behavior PS25A, No impact to vehicle behavior P3286 No impact to vehicle behavior Pa25c No impact to vehicie behavior P3260 Limits the maximum torque of traction motor to 40% or less PS25E No impact to vehicle behavior POF No impact to vehicle behavior ui000 No impact to vehicle behavior Revision: June 2014 TMS-26 2015 Leaf NAMTRACTION MOTOR INVERTER < ECU DIAGNOSIS INFORMATION > Protection Control When temperature of traction motor inverter or traction motor components rises, the traction motor inverter temporarily enters a protective control state in order to protect the system. It automatically returns to the nor- mal status if the safety is secured. Condition Conor ‘Normal retum condition “Traction motor output torque is Iraction motor temperature. IGBT switching frequency is reduced . vnperature ox NOTE: IGBT temperature drops Traction motor electromagnetic noise increases. | * Traction motor speed Increases “Traction motor output torque is limited according to the IGBT temperature. Traction motors overheated led according 101M | Tracton motor temperature drops IGBT high temperatures seen when lraction motor speed is extremely low IGBT is overneates IGBT temperature arops DTC Inspection Priority Chart —— Ifsome DTCs are displayed at the same time, perform inspections one by one based on the priority as per the- following list. Prioiy Detected items (OTC) Reference 7 POA&D 14VOLT POWER VOLTAGE INST Revision: June 2014 TMS-27 2015 Leaf NAMTRACTION MOTOR INVERTER < ECU DIAGNOSIS INFORMATION > Priority Detected tems (OTC) Reference ‘POAZG DRIVE MOTOR A TEMP SENSOR TMSaz POA2D DRIVE MOTOR A TEMP SENSOR TMs44 POA2F DRIVE MOTOR A OVER TEMPERATURE TMS-46 POASF DRIVE MOTOR A POSITION SENSOR TMs-50 POA# DRIVE MOTOR A OVER SPEED IMS-53 POA78 DRIVE MOTOR A INVERTER TMS-56 POG79 DRIVE MOTOR A INVERTER VOLTAGE Tus-62 PS18E CAN ERROR TMS-64 P3193 CAN ERROR TMS-65 P3197 CAN ERROR TMS-66 P3199 CAN ERROR IMss7 PS19E CAN ERROR TMS-68 P31A2 CAN ERROR Tus-69 Pa1A4 CAN ERROR TMS.70 PS1A9 CAN ERROR Tus71 2 P31AD GAN ERROR TMS72 P3241 DRIVE MOTOR A INVERTER CRNT CONT TMS-76 P3244 DRIVE MOTOR A INVERTER Tus.20 P3245 DRIVE MOTOR A INVERTER TMS-82 P3247 DRIVE MOTOR A INVERTER TMS.83 P3249 DRIVE MOTOR A INVERTER TMS P324A DRIVE MOTOR A INVERTER VOLTAGE TMS-85 P324D DRIVE MOTOR A INVERTER IGBT TMS-87 P9252 DRIVE MOTOR A INVERTER IGBT Tus-90 PS25A CAN ERROR IMS-1 P9258 DRIVE MOTOR A INVERTER Tus-82 P325C DRIVE MOTOR A POSITION Tuss3 P325D DRIVE MOTOR A POSITION TMS-94 PS26E DRIVE MOTOR A POSITION TMS-95 PS25F DRIVE MOTOR A POSITION TMS-26 U1000 CAN COMM CIRCUTT Iss? ‘POAT DRIVE MOTOR A CONTROL MODULE TMS POBES O-MOTOR A PHASE U CURRENT SEN TMS-58 POBEG D-MOTOR A PHASE U CURRENT SEN TMs.69 3 POBE9 O-MOTOR A PHASE V CURRENT SEN Tus-60 POBEA D-MOTOR A PHASE V GURRENT SEN Tus-61 P3242 D-MOTOR A PHASE U CURRENT SEN 2 TMS-78 P3428 D-MOTOR A PHASE V CURRENT SEN 2 Ius79 4 P3240 DRIVE MOTOR A INVERTER CRNT CONT IMS-73 DTC Index NOTE: Ifsome DTCs are displayed at the same time, perform inspections one by one based on the priority as per the following list. Refer to TMS-27, "DTC Inspection Priority Chart’ Revision: June 2014 TMS-28 2015 Leaf NAMTRACTION MOTOR INVERTER < ECU DIAGNOSIS INFORMATION > pre" z ors (CONSULT steen tes Evejsemwamingiamp| Reference POAT DRIVE MOTOR A CONTROL MODULE ‘Gan muminate TMS Poaac DRIVE MOTOR A TEMP SENSOR = IMS-42 PoA2D DRIVE MOTOR A TEMP SENSOR = ust POA DRIVE MOTOR A OVER TEMPERATURE ON IMS46 OAS DRIVE MOTOR A POSITION SENSOR ON Tus.60 POAes DRIVE MOTOR A OVER SPEED ON TMS.53 POATE DRIVE MOTOR A INVERTER ON TMS56 PoAD 44VOLT POWER VOLTAGE ON TMS.S7 OBES: D-MOTOR A PHASE U CURRENT SEN ON TMs58 OBES D-MOTOR A PHASE U CURRENT SEN ON TMS59 OBES D-MOTOR A PHASE V CURRENT SEN ON TMS60 POBEA D-MOTOR A PHASE V CURRENT SEN ON Tusst PocTs DRIVE MOTOR A INVERTER VOLTAGE ON TMS-62 PStge ‘CAN ERROR Can ilurinate Tust P3188 (CAN ERROR = IMS5 P3te7 CAN ERROR Can iluminate TMS-66 P3199 ‘CAN ERROR Can lluminate TMS6T PS18E CAN ERROR = TMS.68 PatA2 CAN ERROR Can iluminate TMS69 PIA CAN ERROR Can iluminate TMS.70 P3TA9 ‘CAN ERROR = IMS P3iaD ‘CAN ERROR Can iluminate IMS72 P3240 DRIVE MOTOR A INVERTER GRNT CONT ON usa Pa2at DRIVE MOTOR A INVERTER CRNT CONT ON IMS6 P3242 D-MOTOR A PHASE U CURRENT SEN 2 ON TMs.78 P3243 D-MOTOR A PHASE V CURRENT SEN2 ON TMS.79 Pa24d DRIVE MOTOR A INVERTER — TMS80 P3248 DRIVE MOTOR A INVERTER = TMS.82 P3247 DRIVE MOTOR A INVERTER ON TMS83 P3249 DRIVE MOTOR A INVERTER ON TMS PS24A DRIVE MOTOR A INVERTER VOLTAGE ON TMS85 P3240 DRIVE MOTOR A INVERTER IGBT ON IMSST P3282 DRIVE MOTOR A INVERTER IGT = TMS-90 Pa25A, ‘CAN ERROR = IMSS1 P3256 DRIVE MOTORA INVERTER = IMSS2 P3250 DRIVE MOTOR A POSITION ON TMS.93 S250 DRIVE MOTOR A POSITION = TMS-98 PS25E DRIVE MOTOR A POSITION = TMS.95 PS25F DRIVE MOTOR A POSITION = TMS-26 U1000 ‘CAN COMM CIRCUIT = IMS9T "These numbers are prescribed by SAE J2012150 15037. Revision: June 2014 TMS-29 2015 Leaf NAMTRACTION MOTOR INVERTER < WIRING DIAGRAM > WIRING DIAGRAM TRACTION MOTOR INVERTER, Wiring Diagram scons roars 8 g i i Es| é : : z al| | Peo J a id : = 2 g ke r ro} | Zz . i 3 8 2D ° ! g Ll L_} & Revision: June 2014 TMS-30 2015 Leaf NAMTRACTION MOTOR INVERTER < WIRING DIAGRAM > BR = Tw = e La nn 00 882009) > ~ 0 “Jan Or sun | wen 88.409) , exro[ es zen] on 909.009] = 7] « = + |e of} a aumviawis iM | on eum uy eu int op eau " vera [SN essvo4| mts | ut feneuuso| Bi B “aa FD EBT] Sa 6 SAD] ‘BOREBOLOENNGD ANIOr [ewe 1000) "Bali OL Be | SEN 058.109) oan] on enon ren] “on 950009] SHOLOSNNOO W3LSAS HOLOW NOILOVEL 2015 Leaf NAM TMS-31 Revision: June 2014729 pao] faven 000.09] ‘ay maeaeg| TRACTION MOTOR INVERTER Vz Tae Re] fauen 058.09] ‘en mBaa09| < WIRING DIAGRAM > 2015 Leaf NAM TMS-32 Revision: June 2014= Se = Ts wants [ith awry cewunee [pn wean TRACTION MOTOR INVERTER E a) a = Tis a = stor a 78 a cronies [itt [ov emme s Bl Fi WO¥Ta] "99 o2Ue5] WOFTA| "RO 1HeNAD| Sm [a0 0052005] Far OL au wen mpowe9| "BOL gem [ Sue OEE] "Bai OL Bu uEN 0S] aon 00009) tal ewropawo| soia] en sepewe0) < WIRING DIAGRAM > 2015 Leaf NAM TMS-33 Revision: June 2014TRACTION MOTOR INVERTER < WIRING DIAGRAM > ans Haas HSMOa ual iva ac ‘ONS gaiis wamoa ‘Aiiiva het BOSS aunlvasana Pernice TOSS aunlvasana OLS NOUVEL yao NO WaMos HVONSLEAS AS TENVO FIISAS A ey eu one, Gaus Sanioeye OLS NOUO VL um eats El alalsfala| s |s/als SOV TE] OS MAID) {BOLO NOMLoWL | uEN TPEHAAD Sia we ‘anos HOLS NOUV a 789 mP=HN5] ig] ow IR=UC) suey ewig on robo] on june aware NoLon Novi, leur owen ‘ev i09weo) 2015 Leaf NAM TMS-34 Revision: June 2014TRACTION MOTOR INVERTER < WIRING DIAGRAM > = | = o | # = on = 8 eueyets |, 2M [eeu cuaeds — |,,YMJ on mawes| ou eg on ews | ae sowvuo [609 SBsuIe] stale [J [=] aonvuo [2965 maw] — oqa0 [909 pou] aa ssaarao want ade [oun is OTR NONLSW umn 30300 oLon HOt sua cise.29 “ivf ew809 TH] ewiaes09| sin] eumPea09) : o[™ = ofa” WOR [= = o> a : oe TERWO A Tp = Ts euevieos | ett [oven cuen ts |, lon aus xs pant owes nuevos | eHow nits | lh Jon waa rusts | pi ease JowvuO | 599 SPaNE] = a Sim [35 a=] Sm [a0 0052005] uOLORNSUSVEL [suey oneweo [REELIVG NOrT [SHEN 1H HN09| ‘Bann 1 su Sven ono) Zin] oN paw 2a) en 955we9| eo) 2015 Leaf NAM TMS-35 Revision: June 2014DIAGNOSIS AND REPAIR WORK FLOW < BASIC INSPECTION > BASIC INSPECTION DIAGNOSIS AND REPAIR WORK FLOW Work Flow neseormceneeeet 1 .OBTAIN INFORMATION ABOUT SYMPTOM Refer to IMS-37, “Question sheet” and interview the customer to obtain the malfunction information (condi- tions and environment when the malfunction occurred) as much as possible when the customer brings in the vehicle. >> GOTO2 2..CHECK DTC IN VOM 7. Gheck DTC in VOM. 2. Check related service bulletins for information. Ate any DTCs detected? YES >> Check the DTC, Refer to EVC-103, "DTC Index". NO >>GOTO3. 3.CHECK DTC IN TRACTION MOTOR INVERTER 7 Before checking the malfunction, check whether any DTC exists, 2, IFDTC exists, perform the following operations. + Record the DTC and freeze frame data. (Print out the data using CONSULT and affix them to the Work Order Sheet.) - Erase DTCs - Check the relationship between the cause that is clarified with DTC and the maifunction information described by the customer. 3. Check the information of related service bulletins and others also. Do malfunction information and DTC exist? Maifunction information and DTC exists, >>GO TO 4. Matfunction information exists, but no DTC. >>GO TO 5. No malfunction information, but DTC exists. >>GO TO 6. 4. REPRODUCE MALFUNCTION SYMPTOM. Check any malfunction described by a customer, except those with DTC on the vehicle. Also investigate whether the symptom is a fail-safe or normal operation. Refer to TMS-25, "Fail-safe". When a malfunction symptom is reproduced, the question sheet is effective. Refer to TMS-37, “Question sheet". Verify the relationship between the symptom and the conditions in which the malfunction described by the cus- tomer occurs. >>GOTO6 ‘5.REPRODUCE MALFUNCTION SYMPTOM Check the malfunction described by the customer on the vehicle. Also investigate whether the symptom is @ normal operation. Refer to TMS-27, "Protection Control" When a malfunction symptom is reproduced, the question sheet is effective. Refer to TMS-37. “Question Venfy the relationship between the symptom and the conditions in which the matfunction described by the cus- tomer occurs, >> GOTOS, 6 PERFORM “DTC CONFIRMATION PROCEDURE” Perform “DTC CONFIRMATION PROCEDURE” of the appropriate DTG to check if DTC is detected again. Refer to TMS-27, "DIC inspection Priority Chart" when multiple DTCs are detected, and then determine the order for performing the diagnosis. Revision: June 2014 TMS-36 2015 Leaf NAMDIAGNOSIS AND REPAIR WORK FLOW < BASIC INSPECTION > NOTE: If no DTC is detected, refer to the freeze frame data, ny DTK 2 YES >>GOTO7. NO >> Check according to GI-53, "Intermittent Incident”, 7.REPAIR OR REPLACE THE MALFUNCTIONING PARTS Repair or replace the detected malfunctioning parts Reconnect parts or connector after repairing or replacing, and then erase DTC if necessary. >>GOTOS. 8.FINAL CHECK Perform “DTC CONFIRMATION PROCEDURE” again fo make sure that the repair is correclly performed Check that malfunctions are not reproduced when obtaining the malfunction information from the customer, referring to the symptom inspection result in step 4 or 5. Is DTC or malfunction symptom reproduced? YES >>GOTO2, NO >> Before delivering the vehicle to the customer, make sure that DTC is erased Question sheet DESCRIPTION By understanding those conditions properly, a quick and exact diag- inosis can be achieved. In general, customers have their own criteria for a problem. There- KEY POINTS fore, it is important to understand the symptom and status well enough by asking the customer about the conceins carefully. in | WHAT .... Vehicle & engine model order to systemize all the information for the diagnosis, prepare the | WHEN .... Date, Frequencies 9 ystemze al mfr te WHERE.” Rosd conctions question sheet referring to the question points. How ‘Operating conditions, Weather cordon, ‘Symptoms WORKSHEET SAMPLE Guo Gasonernane | HN Tete MIMS Incident Date VIN Tae Year in Soe Tans ieage ine Smears oes nto READY GeV asiemvamingmpieon Foye atone ‘aviseriea WSR? EVbato® —e-Shaa——_ccearnoe EBNon ng? Poor acetaon* Poort? Rai ris" es rt Ge sober “app erin et Detaled syrom Cranage Feueey CiAlbetne Once OSonatines (tines adayy CLO eater ‘conditions| DNot affected Revision: June 2014 TMS-37 2015 Leaf NAMDIAGNOSIS AND REPAIR WORK FLOW < BASIC INSPECTION > ‘Question Sheet Weather Temp, Humiaity Road conditions ‘Shift postion Driving conaitions ‘Moments when mak function disappears ‘tner Gir Sate ORenng Gag Ore i av ami = ace) ow ENGR avi) O Midge lloilo. Getafeced Ciniom Freeway GOF'nad(Up/Oomm) ORE Fairs Whe ung (Le) Bump Sone Nets Ppoaton GRpeaon —GWyosion—GDpeaion Boson aEComode neta CPonorevic ON-+ OFF ELPOWrSNOFF-> ON OLREADY oe wie) Gwniecn Ce geos. UM woe OLLIE oo paten apne ence) cam Sonia 2 We eas Bote vende speed] tM) Asap 78) 1D Battery Ievel (Low / Middle / High) Disappears with select oper Disappears while ativing Stor Disappears when stopped ‘D Disappears when power switch is pushed OFF Dother "DIDIsappears wnen baltery carge's 1 Dees nat disappear stopped PP Revision: June 2014 TMS-38 2015 Leaf NAMRESOLVER WRITE < BASIC INSPECTION > RESOLVER WRITE Description neocon I the work listed below was performed, it is necessary to perform writing of the traction motor resolver offset to the traction motor inverter. + Replacement of traction motor + Replacement of traction motor inverter + Replacement of traction motor and traction motor inverter a Location of traction motor resolver offset stamp NOTE: Because the traction motor resolver offset stamp is located on the lower side of the traction motor, it is neces- sary to remove the under cover in order to check it. Work Procedure aeomacnsre eased CAUTION: If the traction motor inverter was replaced, then the EV system warning lamp illuminates when the power switch Is turned ON, and DTC “P325C" is detected. Therefore after writing of the traction motor resolver offset Is completed, verify that the EV system warning lamp has turned off and erase DTC “P325C". 1 .cHECK BEFORE PERFORMING WRITING OF THE TRACTION MOTOR RESOLVER OFFSET Check the replaced paris, Which parts were replaced? Traction motor>>GO TO 2. Traction motor inverter>>GO TO 3. Traction motor and traction motor inverter>>GO TO 3. 2..wRITING OF THE TRACTION MOTOR RESOLVER OFFSET @With CONSULT 4. Power switch ON. 2. Select “Work Support” in “MOTOR CONTROL’. 3. Select "RESOLVER WRITE”, 4. Enter the traction motor resolver offset. 5. Touch "WRITE" ts “Writing is complete’displayed? YES >>1. Power switch OFF. 2. Power switch ON and wait 2 seconds or more. 3. Confirm the value is changed according to the correction value input. Revision: June 2014 TMS-39 2015 Leaf NAMRESOLVER WRITE < BASIC INSPECTION > 4. Power switch OFF to complete the work NO >> Perform again STEP 2 3.WRITING OF THE TRACTION MOTOR RESOLVER OFFSET with CONSULT Power switch ON. NOTE: EV system warning lamp tums on. Select "Work Support” in ‘MOTOR CONTROL" Select “RESOLVER WRITE” Enter the traction motor resolver offset Touch “WRITE” |s “Writing is complete’displayed? YES >>GOTO4 NO >> Perform again STEP 3. 4. STEPS AFTER WRITING OF THE TRACTION MOTOR RESOLVER OFFSET @with CONSULT 7. Power switch OFF. Power switch ON and wait 2 seconds or more. Verify that the EV system warning lamp is off Select “Work Support” in “MOTOR CONTROL" Select “RESOLVER WRITE" Confirm the value is changed according to the correction value input. Perform “Self Diagnostic Results” in “MOTOR CONTROL" Erase the DTC "P325C” Power switch OFF. >> END Revision: June 2014 TMS-40 2015 Leaf NAMPOA1B DRIVE MOTOR A CONTROL MODULE < DTCICIRCUIT DIAGNOSIS > DTC/CIRCUIT DIAGNOSIS POA1B DRIVE MOTOR A CONTROL MODULE DTC Logic svsosnnsn ore CONSULT sarean tems (alse vingase toner Malfunction detected condition Possible cause poaip | ORIVEMOTORACONTROL MODULE | Amalfunction is detected in the traction (Drive Motor “A Control Module) ‘ator inverter (motor controller) DTC CONFIRMATION PROCEDURE 1 .PRECONDITIONING IDTC CONFIRMATION PROCEDURE” has been previously conducted, always power switch OFF and wait at least 10 seconds before conducting the next test. DTC DETECTION LOGIC ‘Traction motor inverter >> GOTO 2. 2..cHECK DTC DETECTION @with CONSULT 7. Power switch ON and wait for 10 seconds or more. 2. Check DTC. Is *POA1B" detected? YES >> Go to TMS-41, "Diagnosis Procedure”. NO-1 >> To check malfunction symptom before repair: Refer to GI-53, "Intermittent Incident”, NO-2. >> Confirmation after repair: INSPECTION END Diagnosis Procedure 1 .REPLACE TRACTION MOTOR INVERTER Replace the traction motor inverter. Refer to IMS-103, "Removal and Installation”. >> END Revision: June 2014 TMS-41 2015 Leaf NAMPOA2C DRIVE MOTOR A TEMP SENSOR < DTCICIRCUIT DIAGNOSIS > POA2C DRIVE MOTOR A TEMP SENSOR: DTC Logie sevosewnrer DTC DETECTION LOGIC “CONSULT sereen terms pre (Trouble diagnosis content) Maifunction detected condition Possible causes ~ Harness or connectors ‘Traction mator temperature sensor sig- | _ (Each circuits open or shorted.) nal interruption for 2 seconds or more + Traction motor + Traction motor Inverter DRIVE MOTOR A TEMP SENSOR POAZC | (Drive Motor ‘A’ Temperature Sen- ser Ciroult Low) DTC CONFIRMATION PROCEDURE 1 PRECONDITIONING IFDTC CONFIRMATION PROCEDURE" has been previously conducted, always power switch OFF and wait at least 10 seconds before conducting the next test. >> GOTO2 2..CHECK DTC DETECTION @with CONSULT 7. Power switch ON and wait for 10 seconds or more. 2. Check DTC. Is "POAZC" detected? YES >> Go to IMS-42, "Diagnosis Procedure”, NO-1 >> To check malfunction symptom before repair: Refer to GI-53. "Intermittent Incident”. NO-2 >> Confirmation after repair: INSPECTION END Diagnosis Procedure soso 1 .cHECK TRACTION MOTOR INVERTER HARNESS CONNECTOR 1 Power switch OFF 2. Check the connection conditions of the traction motor inverter harness connector Is the inspection result normal? YES >>GOTO2 NO >> Repair or replace damaged parts 2..CHECK TRACTION MOTOR HARNESS CONNECTOR heck the connection conditions of the action motor hamess connector, s the inspeotion result normal? YES >>GOTO3 NO >> Repair or replace damaged parts 3. CHECK TRACTION MOTOR TEMPERATURE SENSOR CIRCUIT 7. Disconnect the traction motor inverter ames connector 2. Check the resistance between traction motor inverter vehicle side harness connector terminals and ground. “Tradion mator verter Grouna Resistance Connector Terminal a Fi3 Ground 200 ka oF more 5 Isthe inspection result normal? YES >>GOTO4 Revision: June 2014 TMS-42 2015 Leaf NAM