TG-0084 - 16 TM4 CO150-A2 Installation Guide

Installation Guide
Motor Control Unit (MCU)

Version: CO150-A2
TG-0084_16 TM4 CO150-A2 Installation Guide

Installation Guide
Product information
Product name: TM4 CO150-A2
Model numbers: CO150-MV-A2
CO150-HV-A2
Document information
Reference: TG-0084 TM4 CO150-A2 Installation Guide
Release date: 2020-04-15
Version number: 16.0
Template information
Reference: IN-8032_3
CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

© Dana TM4 inc., 2013-2020 Page 2 of 45
Installation Guide
Table of contents
1 Introduction ........................................................................................................................ 7
1.1 Purpose ..................................................................................................................... 7
1.2 Scope......................................................................................................................... 7
1.3 What’s new ................................................................................................................ 7
1.4 Disclaimer .................................................................................................................. 7
1.5 Safety instructions ...................................................................................................... 8
1.5.1 Format and location of safety warnings in this guide ........................................... 8
1.6 Definitions, acronyms and abbreviations .................................................................... 9
1.7 References................................................................................................................. 9
2 Transport and storage conditions ..................................................................................... 10
3 Receiving and unpacking the MCU .................................................................................. 11
3.1 Safety warnings related to handling the MCU........................................................... 11
3.2 Inspecting and moving the MCU .............................................................................. 11
4 Installing the MCU in the vehicle ...................................................................................... 12
4.1 Planning to install the MCU ...................................................................................... 12
4.1.1 Respecting CSC and MKC markings on interface drawings .............................. 12
4.2 Preventing damage to the MCU ............................................................................... 12
4.2.1 Using separate brackets to support MCU and motor ......................................... 13
4.2.2 Respecting the physical integrity of the MCU .................................................... 13
4.2.3 Protecting the casing from external loads .......................................................... 13
4.2.4 Correctly positioning the MCU ........................................................................... 13
4.3 Securing the MCU .................................................................................................... 15
4.4 Installing the cooling system .................................................................................... 16
4.4.1 Safety warnings related to handling the cooling agent ....................................... 16
4.4.2 Serial configuration ........................................................................................... 17
4.4.3 Parallel configuration ......................................................................................... 17
4.4.4 Coolant inlet/outlet specifications ...................................................................... 18
4.4.5 Coolant specifications ....................................................................................... 18
4.5 Electrical installation................................................................................................. 20
4.5.1 Safety instructions related to electrical installation ............................................. 20
4.5.2 General information for installing and handling cables/harnesses ..................... 21
4.5.3 Example installation sequence .......................................................................... 22
4.5.4 Grounding the system ....................................................................................... 22
4.5.4.1 Grounding strap recommendations – MCU .................................................... 22
4.5.4.2 Connecting the grounding strap – MCU ......................................................... 22
4.5.4.3 Connecting the grounding strap – Chassis..................................................... 23
4.5.5 Connecting the phase cables ............................................................................ 24
4.5.5.1 Preparing the phase cable assembly ............................................................. 24
4.5.5.2 Installing the phase cables on the MCU ......................................................... 24
4.5.5.3 Installing the phase cable assembly on the motor .......................................... 26
4.5.6 Connecting the motor sensor interface harness ................................................ 26
4.5.6.1 Preparing the motor sensor interface harness ............................................... 26
4.5.6.2 Installing the motor sensor interface harness assembly ................................. 30

Installation Guide
4.5.7 Connecting the VMU interface harness ............................................................. 31

4.5.7.1 Preparing the VMU/ECU interface harness .................................................... 31
4.5.7.2 HVIL and EmergencyStop signals ................................................................. 33
4.5.7.2.1 Suggested HVIL and EmergencyStop safety circuit ................................. 34
4.5.7.3 Installing the VMU interface harness assembly .............................................. 34
4.5.8 Connecting the high-voltage battery .................................................................. 35
4.5.8.1 Safety instructions related to connecting the high-voltage battery .................. 35
4.5.8.2 High-voltage battery short-circuit protection ................................................... 35
4.5.8.3 Internal common mode capacitors ................................................................. 36
4.5.8.4 High-voltage battery pre-charge circuit .......................................................... 36
4.5.8.5 High-voltage battery cable assembly specifications ....................................... 37
4.5.8.6 Calculating high-voltage cable length............................................................. 37
4.5.8.7 Preparing the high-voltage battery cables ...................................................... 37
4.5.8.8 Installing the high-voltage battery cable assembly ......................................... 38
4.5.9 Auxiliary battery................................................................................................. 39
4.5.10 CAN interface .................................................................................................... 40
4.6 Software installation ................................................................................................. 41
4.6.1 CAN protocol and TM4 ODIN ............................................................................ 41
4.6.1.1 Reconfiguring CAN bus base addresses ....................................................... 41
4.6.1.2 Reconnecting with TM4 ODIN using modified addresses............................... 42
4.6.1.3 Reconfiguring the CAN bus baud rate............................................................ 43
4.6.1.4 Finding available TM4 devices using CAN ..................................................... 43
4.6.1.5 Recovering modified base addresses after loss of communication ................ 44
4.6.2 Embedded software packages .......................................................................... 44
4.6.2.1 Verifying the version of the embedded software ............................................ 44
4.6.2.2 Updating the embedded software .................................................................. 45
4.6.3 Customizing system parameters ....................................................................... 45
5 Customer service ............................................................................................................. 45

Installation Guide
List of tables
Table 1 Related document references ............................................................................. 9
Table 2 Recommended transport and storage conditions .............................................. 10
Table 3 Grounding strap installation ............................................................................... 23
Table 4 Lapp cable glands – Recommended tool........................................................... 24
Table 5 Phase cable installation mapping ...................................................................... 26
Table 6 Motor sensor interface pinout – TM4 motor ....................................................... 28
Table 7 Motor sensor interface – Plug pinout – REMY HVH250-115 motor.................... 29
Table 8 Motor sensor interface – Plug pinout – GKN-EVO AF-140-4 motor ................... 30
Table 9 VMU/ECU interface harness – Plug pinout specifications.................................. 32
Table 10 HVIL and EmergencyStop – Absolute maximum rating ..................................... 34
Table 11 High-voltage battery – Recommended fuse sizing............................................. 35
Table 12 High-voltage battery – Pre-charge circuit specifications .................................... 36
Table 13 High-voltage battery – Recommended cable specifications ............................... 37
Table 14 Lapp cable glands – recommended tools .......................................................... 37
Table 15 Auxiliary battery – Steady state and inrush currents .......................................... 39
Table 16 Auxiliary battery – Fuse specifications ............................................................... 39
Table 17 TM4 ODIN CAN default configuration values .................................................... 41
Table 18 CAN MCU interface (CAN 1) base ranges......................................................... 42
Table 19 CAN MCU interface (CAN 2) base ranges......................................................... 42
Table 20 Embedded software package content ............................................................... 44

Installation Guide
List of figures
Figure 1 Vent and IGBT coolant overflow hole on base of MCU casing........................... 14
Figure 2 Mounting points ................................................................................................. 15
Figure 3 Cooling system – Serial configuration ............................................................... 17
Figure 4 Cooling system – Independent configuration ..................................................... 17
Figure 5 Coolant inlet/outlet locations on the MCU .......................................................... 18
Figure 6 Grounding point................................................................................................. 23
Figure 7 Phase cable gland locations .............................................................................. 25
Figure 8 Motor sensor interface location – Base of MCU................................................. 27
Figure 9 Motor sensor interface pin information – TM4 motors ........................................ 28
Figure 10 Front of connector ............................................................................................. 28
Figure 11 Wire insertion side............................................................................................. 28
Figure 12 VMU interface location – Base of the MCU ....................................................... 31
Figure 13 VMU interface harness – Plug pinout – P770E0160 .......................................... 32
Figure 14 Suggested HVIL and EmergencyStop safety circuit .......................................... 34
Figure 15 MCU high-voltage impedance sensor circuit ..................................................... 36
Figure 16 Auxiliary battery – Fuse block diagram .............................................................. 39
Figure 17 CAN1 terminations ............................................................................................ 40
Figure 18 CAN2 – not terminated ...................................................................................... 40
Figure 19 Device Communication Configuration ............................................................... 43

Installation Guide
1 Introduction
The TM4 CO150-A2 Motor Control Unit (MCU) has been designed for electric and hybrid vehicle
applications. This MCU utilizes the latest technology of automotive grade insulated-gate bipolar transistors
(IGBT) coupled with TM4 Reflex™ driving technology to deliver the industry’s highest specific power and
current densities. It is embedded with advanced control algorithms for optimal power module usage and
efficiency.
1.1 Purpose
This technical guide contains important information on how to install the TM4 CO150-A2 MCU.
1.2 Scope
This technical guide is organised as follows:
• Introduction – general information about the product, definitions and document reference information.
• Transport and storage conditions - guidelines on environmental conditions to be respected during
system storage and transport.
• Receiving and unpacking – general guidelines on how to safely unpack and inspect the product.
• Installing the MCU in the vehicle – how to safely install the product.
• Customer service – TM4 customer service contact details.
1.3 What’s new

This document has been updated as follows:
• Modified the Suggested HVIL and Emergency Stop safety diagram to add the DC cover switch, see
Figure 14.
• Modified information on CAN base addresses and parameter names, see Section 4.6.1.
• Added information on finding available TM4 devices using CAN, see Section 4.6.1.4.
• Modified embedded software package information, see Section 4.6.2.
1.4 Disclaimer
All installation instructions, limits and warnings given in the technical documentation supplied by Dana TM4
must be respected in order to ensure that the system runs optimally and is not at risk of damage by misuse.
Operating the system outside of the established limits constitutes misuse and may invalidate any warranty.

Installation Guide
1.5 Safety instructions

This product must be installed and manipulated by qualified personnel who are fully aware of the types of
hazards involved in working with electrical circuitry and are familiar with standard practices for preventing
accidents. The vehicle integrator is responsible for ensuring that proper training is given to all those who
use this system in order to avoid physical, electrical and operational hazards.
1.5.1 Format and location of safety warnings in this guide

Each warning in this guide follows the same format and includes the reason for the potential hazard and
how to avoid it:
WARNING Reason for the warning – explanation of the potential hazard.

How to avoid the hazard.
Note: When more than one safety warning applies to the same procedure, they are grouped together in
one box and identified with the appropriate safety symbol:
General/Irritant/Operational: This warning symbol indicates that you are in a potentially hazardous
situation that could result in damage to the product or in some situations lead to bodily harm or death.
Electrical: This warning symbol indicates that you are in a potentially hazardous situation that is
electrical in nature and could result in damage to the product or in some situations lead to bodily harm or
death.
To remind you of the potential hazards involved, appropriate safety warnings are located throughout this
guide in procedures that if performed incorrectly may harm you or damage the product.

Installation Guide
1.6 Definitions, acronyms and abbreviations
Auxiliary battery Standard 12 V or 24 V vehicle battery

AWG American Wire Gauge
CAN Controller Area Network (communication protocol)
HVIL Hazardous Voltage Interlock Loop
MCU Motor Control Unit
PTD/PTS Optional down-angled or straight phase terminal boxes on MCU
TM4 ODIN TM4 diagnostic software
VMU Vehicle Management Unit
1.7 References
All system and product documentation is available in the Documentation section of the TM4 Extranet.
Requests to open an account can be made online via https://extranet.tm4.com.
Table 1 Related document references
Reference Title/Description Note
[1] IN-8013e MCU CAN Protocol vx.x Specifications 1, 2
[2] TG-0001 TM4 ODIN v4 Technical Guide 1
[3] TG-xxxx Operations and Maintenance Guide 1, 2
[4] TG-xxxx System Specifications 1, 2
[5] Application Note TM4 SUMO fuse and DC Cable selection 1
[6] INT3-xxxx Interface drawing 1, 2
[7] WE-xxxx Cable end specifications – phase cables 1, 2
[8] WE-xxxx Cable end specifications – HV battery cables 1, 2
[9] WH-xxxx Cable harness specifications specific to your system 1, 2
[10] SC-6000E-014 Kit-0011 Right-angled VMU connector assembly instructions 1
[11] SC-6000E-012 Kit-0012 Straight VMU connector assembly instructions 1
[12] SC-6000E-017 Kit-0014 Right-angled MCU connector assembly instructions 1
[13] SC-6000E-045 Connector lubricant application instructions 1
[14] SC-6004E-007 TM4 Inverter Action Guide 1
[15] TM4 Extranet https://extranet.tm4.com -
Notes:
1. Refer to the latest published version of documentation and/or software package on the TM4 Extranet site.
2. Documentation specific to your system is available on the TM4 Extranet.

Installation Guide
2 Transport and storage conditions

This section describes the conditions that must be adhered to when either transporting or storing Dana TM4
products in order to ensure optimum performance once installed in a vehicle.
On leaving Dana TM4 facilities, the product is void of all coolant and all connectors are covered. The
packaging is designed to protect the content against damage from vibrations and impacts and is able to
withstand maritime conditions during transportation.
Dana TM4 products must be transported and stored in well-ventilated facilities with adequate protections
against dust and excessive humidity. See Table 2 details of recommended conditions.
While the products are in the original shipping crates, there are no precautions to take against electrostatic
discharge (ESD); however, when unpacking and manipulating the products, you must avoid touching the
connector pins.
Table 2 Recommended transport and storage conditions
Condition Information
Max. ambient temperature +85 C
Min. ambient temperature -40 C
Max. relative humidity 85%
Min. relative humidity 5%
Condensation Not permitted
Precipitation Not permitted
Icing Not permitted
Direct exposure to sunlight Not permitted
Max. storage period 6 months
Note: Refer to the ISO-16750-4 standard for information related to ambient temperature values.

Installation Guide
3 Receiving and unpacking the MCU

The TM4 MCU was carefully inspected and tested before being packed at our facilities; however, we
recommend that you carry out a full visual inspection when unpacking as it is possible that the crate and
contents might become damaged during the shipping process.
3.1 Safety warnings related to handling the MCU

Read these general safety warnings before handling the product.
WARNING Mishandling of this product may damage the product and/or cause injury or death.
• All limitations and specifications communicated by TM4 regarding the product must be respected.
• Do not attempt to open this product for repair; in case of damaged casing or suspected product
malfunction, contact TM4 Customer Service.
• When using straps to lift the MCU, ensure they do not touch or put pressure on the connectors, and/or
cables.
• Use only recommended points to secure the MCU.
3.2 Inspecting and moving the MCU

1 On receiving the MCU, immediately verify that the crate is undamaged; if you see signs of damage,
before signing for the package:
• Inform the person responsible for delivery;
• Make a note on the waybill and keep a copy;
• Immediately contact TM4.
2 On opening the crate, perform a quick physical check of the contents:
• Inspect for damaged packaging materials.
• Verify that the MCU has remained in place in the crate during shipping.
• Verify the contents of the crate against the list of delivered goods on the packing slip (a copy of
which is located inside the crate).
3 Carefully lift the MCU out of the crate using the lifting points indicated on the product interface
drawing [6].
4 Remove all packaging materials before carrying out a full visual inspection of the MCU to ensure that
it is entirely to your satisfaction:
• Inspect the MCU for cracks, scratches, broken parts, etc.
• Verify that there are no loose external parts on the MCU.
Note: If the packaging and/or the product are damaged, take photographs of the damage, save all
packaging materials and immediately notify the carrier as well as Customer Service at TM4; see Section 5
for contact information.

Installation Guide
4 Installing the MCU in the vehicle

The following sections describe how to install the MCU in a vehicle. The final installation sequence should
be defined by the integrator according to the type of application.
Read these general safety warnings before installing the MCU.
• Do not attempt to open the MCU for repairs; in case of damaged casing or suspected product
malfunction, contact TM4.
• Use only recommended points to lift and secure the MCU.
• If using chains or other lifting tools, ensure they do not touch or put pressure on any part of the
product exterior (surface, connectors, and/or cables).
4.1 Planning to install the MCU

• Ensure that everyone coming into contact with the MCU has received full training and has read all the
safety warnings in this guide.
• Follow all instructions in this guide on how to install the MCU.
• Call TM4 Customer Service if in doubt (see Section 5 for contact details).
4.1.1 Respecting CSC and MKC markings on interface drawings

Before installing the product, refer to any CSC and MKC markings on the product interface drawing [6].
These markings highlight areas that may potentially impact product safety, operation or longevity if proper
instructions are not followed:
• CSC is used to indicate Critical/Safety Characteristics with specific instructions that must be followed in
order to avoid potentially dangerous, hazardous or non-regulatory situations.
• MKC is used to indicate Major Key Characteristics with specific instructions that must be followed in
order to avoid major inconvenience to the user. Items marked with MKC do not, however, represent a
hazard in terms of operational safety.
4.2 Preventing damage to the MCU

These subsections give information on how to prevent damage to the MCU.
WARNING Mishandling of this MCU may damage the product and/or cause injury or death.
When manipulating this product:
• Ensure that the MCU and the motor are attached to separate supports or brackets.
• Do not modify any part of the MCU.
• Do not apply any external load to the casing of the MCU.

Installation Guide
4.2.1 Using separate brackets to support MCU and motor

The MCU must not be attached to the motor using the same support or bracket.
The MCU must be decoupled from the motor as the MCU and the motor were designed to resist to different
vibration profiles. The MCU could be permanently damaged if exposed to the vibration profile of the motor.
The MCU must be installed on its own support which is attached to the frame of the vehicle.
Note: It is the responsibility of the system integrator to design the MCU support brackets and vibration
damping mechanism in order to ensure that the vibration profile of the MCU does not exceed the limitations
referred to in the Product or System Specifications [4].
4.2.2 Respecting the physical integrity of the MCU

The MCU is a sealed unit requiring no physical customization before or after installation. You must not
under any circumstances attempt to modify any part of the MCU as this could cause permanent damage to
the MCU and injury to the user. This includes any modification that changes the state of the original
product, such as:
• Drilling holes into the casing.
• Adding and/or removing parts including hardware, screws, and connectors.
Note: The side panel of the MCU can be removed in order to install the high-voltage battery cables; see
Section 4.5.8.8.
4.2.3 Protecting the casing from external loads

The MCU casing was not designed to bear weight from external loads such as:
• Components sitting on top of the MCU.
• Components suspended from the bottom of the MCU.
• Components attached to the sides of the MCU.
4.2.4 Correctly positioning the MCU

The MCU can be installed in a variety of positions, but we do not recommend that it is installed in an
inverted (upside down) position as there is a risk of water accumulation that may cause product damage.
Ensure that any warning labels on the product remain visible at all times and are not removed or obscured
by cables or accessories. Also take care to avoid obstructing the vent and IGBT coolant emergency
overflow hole on the MCU casing, see Figure 1.

Installation Guide
Figure 1 Vent and IGBT coolant overflow hole on base of MCU casing
Note: In case of any sign of coolant leakage; immediately stop operation of the MCU and contact TM4
Customer Service, see Section 5 for contact information.

Installation Guide
4.3 Securing the MCU

In order to properly install the MCU, it should be securely fixed into the vehicle with the load evenly
distributed using at least one of the mounting points on each corner of the base or top of the casing. See
Figure 2 for the locations of the mounting points on the MCU; and the product interface drawing [6] for exact
specifications.
• All limitations and specifications communicated by TM4 regarding the product must be respected.
• Do not attempt to open or repair this product. In case of damaged casing or suspected product
malfunction, contact TM4.
• Use only indicated points to secure the MCU.
Figure 2 Mounting points

Installation Guide
Notes:
1. Prepare the zinc-coated bolt with Loctite 242 or 243 before insertion.
2. Each of the grey highlighted areas shown in Figure 2 includes 2 or 3 mounting points either under or on the side of
the MCU. Use a minimum of 1 mandatory mounting point per highlighted area to ensure that the load is equally
distributed.
3. If using one of the mounting points as ground, prepare the surfaces as described in the note in Section 4.5.4.2.
4. Mounting points can also be used as lifting points; see the product interface drawing [6] for more information.
4.4 Installing the cooling system

As power is delivered to the wheels, temperatures of the various components within the motor and the
MCU rise. Therefore, a cooling unit/radiator must be installed in the vehicle and connected to the MCU and
the motor to dissipate the excess heat.
The following two configurations are recommended:
• Serial configuration
• Parallel configuration
Note: TM4 does not supply any cooling equipment or accessories.
4.4.1 Safety warnings related to handling the cooling agent

Read all safety warnings associated with handling the cooling agent before working with the cooling
system.
WARNINGS Regardless of the cooling system used, the MCU can be irreparably damaged and may become
unstable if the coolant liquid pressure reaches or exceeds a pressure of 30 PSI (static pressure
measured at the entrance of the MCU, upstream of the MCU in the circuit).
Ensure that the pump is adjusted accordingly.
The cooling agent contains ethylene glycol that is a highly flammable product. Ethylene glycol can
burn with an invisible flame that can cause serious burns and/or other injuries.
Always handle the cooling agent carefully wearing appropriate safety clothing and eyeglasses.
The cooling agent can irritate the skin, the eyes and the mucous membranes.
• Always work in a well-ventilated area when handling the cooling agent; breathing in high
concentrations of ethylene glycol can cause nausea.
• In case of contact with eyes and skin, rinse with water and consult a doctor.
• In case of ingestion, seek medical help immediately.
The cooling agent is under pressure when heated; removing the cap when the coolant is hot can
cause serious burns and/or other injuries.
Wait until the coolant reaches an ambient temperature before removing the cap.
All potential dangers of handling cooling agents cannot be listed here.
Consult manufacturer warnings and recommendations for safe handling of the cooling agent.

Installation Guide
4.4.2 Serial configuration

When there is only one cooling unit/radiator installed in the vehicle, a serial configuration is used to supply
the cooling agent to both MCU and motor using the same flow of coolant. In a serial configuration, the
coolant coming from the cooling unit must first go through the MCU and then through the motor before
returning to the cooling unit as shown in Figure 3.
Note: Coolant liquid pressure must not reach or exceed 30 PSI.
Figure 3 Cooling system – Serial configuration
4.4.3 Parallel configuration

An alternative is to set up two parallel flows of cooling agent; this configuration involves the MCU and motor
being cooled in parallel.
As the cooling units are supplied by the vehicle integrator and the cooling system setup involves fine-tuning
and testing at the customer site, TM4 has no specific recommendations on how to achieve optimal
configuration but coolant liquid pressure must not reach or exceed 30 PSI.
Figure 4 Cooling system – Independent configuration

Installation Guide
4.4.4 Coolant inlet/outlet specifications

Specific hose types should be used to connect the cooling unit to the system. Refer to the product interface
drawing [6] for inlet/outlet pipe specifications.
See the Product or System Specifications [4] for more information on coolant pressure drops and rate flow
management.
Figure 5 Coolant inlet/outlet locations on the MCU
Note: The coolant inlet and outlet are clearly marked on the casing.
4.4.5 Coolant specifications

WARNING The internal mechanisms of the MCU may be prematurely damaged if not protected from corrosion
by use of an automotive antifreeze product in the coolant liquid.
Refer to the recommended best practices in this section.
Regardless of the cooling system used, the MCU can be irreparably damaged and may become
highly unstable if the coolant liquid pressure reaches or exceeds a pressure of 30 PSI (static
pressure measured at the entrance of the MCU, upstream of the MCU in the circuit).
Ensure that the pump is adjusted accordingly.
To prevent corrosion problems in cooling systems, here are the recommended best practices.
• The cooling circuit must be rinsed with de-ionized water each time before filling.
• The ethylene glycol must respect the standard corresponding to its application (ASTM D3306 Type III
or ASTM D6210 Type III).
• The ethylene glycol must contain some type of active corrosion inhibitors.
• The ethylene glycol must be diluted with de-ionized water (not distilled water).
• The dilution ratio must be 60% ethylene glycol to 40% de-ionized water (minimally 50% ethylene glycol
to 50% de-ionized water).
• Two different types of coolant should not be mixed.

Installation Guide
As the cooling unit, cooling hose and cooling agent are not supplied by TM4, the vehicle integrator has full
responsibility for following specifications and operating methods given by the manufacturers of each of
these parts.
In order to meet TM4 specifications and to obtain maximum system performance, the temperature of the
coolant should never exceed 55 C (or the maximum temperature according to the Product or System
Specifications [4]). Above this temperature, the system can degrade the output torque to protect its internal
components from overheating.
When using either the serial (see Figure 3) or parallel cooling configuration, (see Figure 4), there can be
associated drops in pressure that have to be managed; see the Product or System Specifications [4] for
more information.

Installation Guide
4.5 Electrical installation

This section describes the procedures in order to safely undertake the electrical installation of the MCU.
Although the final installation sequence will be decided by the system integrator, there are two suggested
installation sequences given in Section 4.5.2.
Note: It is imperative that you are aware of the safety risks involved in this type of electrical installation;
before you start, refer to Section 4.5.1.
4.5.1 Safety instructions related to electrical installation

Carefully read all safety instructions before making any electrical connections in the system.
WARNINGS This product generates high voltage that can cause an electric discharge or electrocution
resulting in injury or death.
When installing/handling the product, verify that:
• The traction battery (high-voltage battery) is disabled.
• The auxiliary battery (12 V/24 V battery) is disabled.
Incorrect assembly or an incorrect electrical connection during assembly of this product can
cause electrocution and/or fire.
The assembly and connections must conform to the instructions included in this Technical Guide.
Care must be taken when manipulating electrical equipment.
This product must be installed by qualified and authorized personnel in accordance with applicable
vehicle standards and industry practices. Always use appropriate insulation and protection before
manipulating the product even when the product is disconnected from a high-voltage source.
ESD sensitive – do not touch connector pins.
The internal electronics are sensitive to electrostatic discharges.
Risk of electric shock – do not open the MCU.
Beside the MCU high-voltage panel, the electrical installation of the system does not require the MCU
and/or the motor to be opened or disassembled.
Risk of electric shock – capacitor stores hazardous energy.
Wait 10 minutes after disconnecting all sources of supply prior to removing cables and/or servicing to
ensure that internal TM4 CO150 MCU capacitors are discharged.
This product uses common mode capacitors between the high-voltage DC bus and the chassis.
Some apparatuses can cause dangerous frame current to pass through these capacitors if they
are connected to a high-voltage DC bus.
Always measure the voltage between the high-voltage DC bus and the chassis using appropriate
protection and insulation before manipulating the product.
This product uses differential mode capacitors between the positive high-voltage DC bus (+) and
the negative high-voltage DC bus (-). Even when the product is disconnected from the high-
voltage source, these capacitors can hold a voltage high enough to cause an electric discharge
or death.
Always measure the voltage between the positive high-voltage DC bus (+) and the negative high-voltage
DC bus (-) using appropriate protection and insulation before manipulating the product.

Installation Guide
4.5.2 General information for installing and handling cables/harnesses

During installation and connection of cables and harnesses follow these recommendations:
User security:
• Ensure that each cable is clearly identified for specific usage to prevent errors during installation and
operation that may damage the system or cause injury to the user.
• Ensure that, once installed, cables do not obscure any warning labels on the product.
When installing:
• Ensure cable bending radius of x5 of the cable diameter or greater. A correctly installed cable should
be smooth with no creases or signs of strain that might eventually compromise cable integrity.
• Ensure that cables do not touch or cross over each other.
• Never place cables near sharp edges or on abrasive surfaces.
• Protect cables from damage due to gravel or other environmental factors.
• Allow for enough room for air circulation, clearance space for movement and access to cables for
maintenance etc.
When securing cables:
• Ensure that each cable is appropriately supported (connector strain relief):
• High-voltage cables – secured no more than 10 cm from the connector heads on the casing.
• Low-voltage cables – secured no more than 30 cm from the connector heads on the casing.
• To restrict movement and vibration in longer cables, a maximum of 3 cables should be fastened
together in parallel every 40 cm or less; do not gather cables in a tight bundle.
• Ensure that the brackets/fasteners used to support/secure the cables do not compromise cable
integrity.
• Never apply perpendicular loads on the connectors/cables when using cable fasteners as this could
compromise ingress protection (i.e. IP6K9K).

Installation Guide
4.5.3 Example installation sequence

The system integrator will define the final electrical connection sequences of the MCU and motor taking the
complete installation into consideration; this sequence for installing the MCU is given as an example.
Several cables and harnesses are required for the MCU electrical connection. The following steps
summarize the electrical connection sequence of the MCU.
IMPORTANT NOTE: Disable the high-voltage and auxiliary batteries before handling the product, or
connecting/disconnecting any cable, harness or tube.
1 Connect the grounding straps, see Section 4.5.4.
2 Connect the phase cables, see Section 4.5.5.2.
3 Connect the motor sensor interface harness, see Section 4.5.6.
4 Connect the VMU interface harness, see Section 4.5.7.
5 Connect the cooling inlet/outlet hoses, see Section 4.4.
6 Connect the high-voltage battery cables, see Section 4.5.8.
7 Connect the auxiliary battery cables, see Section 4.5.9.
As specified earlier, the final installation sequence should be defined by the integrator according to the
application type. However, for user safety, the grounding strap should always be installed first and the
product must not be handled when the power source is enabled.
Note: Reverse sequencing is performed when removing the system from the vehicle; remove the grounding
strap last.
4.5.4 Grounding the system

The system must be securely grounded to ensure user safety in case of an insulation fault in the motor
and/or the MCU. An incorrectly grounded connection may result in MCU functionality losses and safety
risks for the user.
4.5.4.1 Grounding strap recommendations – MCU

The integrator must consider the possibility of an insulation fault where the high-voltage battery current
would find a path through the grounding strap. The grounding strap or wire must be sized to support the
maximum current of the high-voltage battery for a sufficient time for the high-voltage battery fuse to open.
Refer to Section 4.5.8.2 for the high-voltage battery fuse specification.
4.5.4.2 Connecting the grounding strap – MCU

The grounding strap must be connected to its dedicated connection point (Figure 6) or to one of the
mounting points shown in Figure 2 (see the product interface drawing [6] for more detailed information).
The type of MCU grounding configuration used may vary according to type of vehicle integration.
Note: To prevent oxidation of the aluminum surfaces and any malfunction of the connection during
operation, we recommend that you sand the contact point on the MCU and apply a layer of conductive
grease on the grounding strap contact surfaces before connecting the strap.

Installation Guide
Refer to the product interface drawing [6] for ground point/screw specifications.
Figure 6 Grounding point
Note: The zinc-coated bolt provided by TM4 must be prepared with Loctite 242 or 243 before insertion. One screw is
provided by TM4 for grounding purposes.
Table 3 Grounding strap installation
First end Second end
Refer to Figure 6 Vehicle chassis (frame) or earth ground (test bench)
Note: The location of the second end connection point of the grounding strap given here is an example; the actual
location will depend on the type of application being used by the vehicle integrator.
4.5.4.3 Connecting the grounding strap – Chassis

In the case where the grounding strap is to be connected to the vehicle chassis, prepare the chassis by
removing the paint from the contact area, then sand and apply a layer of conductive grease before
connecting the strap.
It is important to note that when integrating the system, both the motor and MCU must be grounded in the
same place on the chassis, or at least on the same connected frame before checking that the resistance
between the chassis and another metallic part of the vehicle is less than 0.1 Ohm.

Installation Guide
4.5.5 Connecting the phase cables

Carefully read all safety instructions related to electrical installation in Section 4.5.1 before connecting the
phase cables and general information for installing cables and harnesses in Section 4.5.2 before continuing
with your integration.
Table 4 Lapp cable glands – Recommended tool
Item Mfg Mfg P/N TM4 # Qty
Torque ratchet set – Skinmatic® Lapp Group 61610000 n/a 1
Quick Set 1
Notes: Torque wrench recommended, but not supplied by TM4; see the manufacturer’s site for more information:
http://lapplimited.lappgroup.com/products/online-catalogue/cable-glands/skinmatic-mounting-tools/skinmatic-metric-
mounting-tools/skinmatic-quick-set-1.html.
4.5.5.1 Preparing the phase cable assembly

The integrator can choose to purchase phase cables ready for installation, or prepare the cables in-house;
see the cable drawing [7] for a step-by-step procedure of how to prepare the cables.
Note: Phase cables can be up to a length of 5 m.
4.5.5.2 Installing the phase cables on the MCU

Refer to Section 4.5.1 for safety instructions and Section 4.5.2 for recommendations before installing the
phase cable connections.
Using the harness you have prepared, modified, or purchased from TM4, refer to the product interface
drawing [6] and cable harness drawing [8] for illustrated cable installation information.

Installation Guide
Figure 7 Phase cable gland locations
Note: The screws required for this installation procedure are not installed on the product at time of delivery;
you will find them in small bags in the shipping crate.
Important note: The maximum recommended torque given in these instructions is for final cable
installation; if you insert the socket head screws without the lugs, hand tighten the screws lightly to prevent
damage to the product.

Installation Guide
4.5.5.3 Installing the phase cable assembly on the motor

Power cables are required between the MCU and the motor to connect each phase; cables of a pre-
determined length are attached to the MCU by TM4 and must then be connected to the motor by the
customer.
To provide greater flexibility when integrating the system into the vehicle and to prevent the cables from
touching or crossing over each other when connecting the motor to the MCU, we recommend two possible
phase cable configurations: standard and reversed. See Table 5 for both standard and reversed mappings.
Both the motor and the MCU have numbers/letters engraved on the casing to help you with the installation.
• Standard: Cables connected with logical letter/number sequence (1-A; 2-B; 3-C).
• Reversed: Cables connected with reversed letter/number sequence (1-C; 2-B; 3-A.).
Table 5 Phase cable installation mapping
Standard Reversed
MCU Motor MCU Motor
1 A 1 C
2 B 2 B
3 C 3 A
Notes
1. If the reversed connection scenario is chosen, the PhaseCableReversed parameter must be set to 1, and the
DrvParameters.Save parameter must be set to 1. For more information, refer to the Operations and Maintenance
Guide for your system.
2. Recommended bending radius = diameter x 5.
Important: When installing the phase cables onto the motor, it is the responsibility of the integrator to
ensure that the shield connection is undamaged, tested and properly connected to the motor chassis. If
incorrectly connected, this could cause irreparable damage to the MCU.
4.5.6 Connecting the motor sensor interface harness

Note: Carefully read all safety instructions related to electrical installation (Section 4.5.1) and general
information for installing cables and harnesses in Section 4.5.2 before continuing with your integration.
A motor sensor interface harness is required between the MCU and the motor.
If the TM4 CO150 MCU is to be used in a system with a motor from TM4, order a motor sensor interface
harness of a pre-determined length to be delivered with the system, contact Customer Service for available
lengths and part numbers.
When integrating the TM4 MCU with a non-TM4 motor, the cable should be assembled using the parts
delivered in Kit-0014. See Section 4.5.6.1 for more information.
4.5.6.1 Preparing the motor sensor interface harness

Note: The actions in this section are to be performed only when integrating the TM4 MCU with a non-TM4
motor.
The motor sensor interface is located on the left side of the MCU next to the VMU interface (Figure 8) and
has 19 pins.
As vehicle integrators are able to connect the TM4 MCU to the motor of their choice, the integrator will have
the responsibility of fabricating the motor sensor interface harness using wiring appropriate to the specific

Installation Guide
installation environment. TM4, therefore, does not deliver a motor sensor harness with the system; only the
plug and contacts listed and described in the Kit documentation [12] are included.
For all motors, see Figure 10 and Figure 11 for the plug pinout information, then:
• For all TM4 motors, use the plug pinout specifications given in Table 6 and Figure 9.
• For the REMY HVH250-115 motor, use the plug pinout specifications given in Table 7 and refer to the
documentation for Kit-0014 [12] for full assembly instructions.
• For the GKN-EVO AF-140-4 motor, use the plug pinout specifications given in Table 8 and refer to the
documentation for Kit-0014 [12] for full assembly instructions.
Once the cable is prepared, connect it to the MCU; see Section 4.5.6.2.
Figure 8 Motor sensor interface location – Base of MCU

Installation Guide
Figure 9 Motor sensor interface pin information – TM4 motors
Table 6 Motor sensor interface pinout – TM4 motor Figure 10 Front of connector
MCU Resolver TM4
motor
A Temperature C- A
B Temperature C+ B
C Temperature B- C
D Temperature B+ D
E Temperature A- E
F Temperature A+ F
G Not to be connected G
H HVIL+ H
J Resolver Excitation+ (R1) N
K HVIL- K
L COS+ (S1) L Figure 11 Wire insertion side
M COS- (S3) M
N SIN+ (S2) J
P SIN- (S4) T
R 1 Wire+ R
S 1 Wire- S
T Resolver Excitation- (R2) P
U GND U
V Chassis V
Note: Asymmetrical signal connections highlighted in Table 6.

Installation Guide
Table 7 Motor sensor interface – Plug pinout – REMY HVH250-115 motor

TM4 MCU pin # REMY signal Motor HVH250-115 pin #
See Kit-0014 [12] D388999/26FD15SN
A Temperature C- -
B Temperature C+ -
C Temperature B- -
D Temperature B+ -
E Temperature A- 9
F Temperature A+ 18
G Reserved -
H HVIL+ 4
J Resolver Excitation+ (R1) 10
K HVIL- 13
L COS+ (S1) 12
M COS- (S3) 3
N SIN+ (S2) 11
P SIN- (S4) 2
R Not to be connected -
S Not to be connected -
T Resolver Excitation- (R2) 1
U GND -
V Chassis/Shield 5
Notes:
1 In case of conflict between pinout information given here and in manufacturer documentation; pinout
information given by the manufacturer should be considered the official version.
2 By default, the system is set to read two temperature sensors, if a system requires only one
temperature sensor to be read, set the NbMotorTempSensor parameter to 1 or an error will be
returned at system start-up.

Installation Guide
Table 8 Motor sensor interface – Plug pinout – GKN-EVO AF-140-4 motor

TM4 MCU pin # GKN-EVO signal Motor AF-140-4 pin #
See Kit-0014 [12] IMC26-2212S
A Temperature C- -
B Temperature C+ -
C Temperature B- 10
D Temperature B+ 9
E Temperature A- 7
F Temperature A+ 8
G Reserved -
H HVIL+ -
J Resolver Excitation+ (R1) 1
K HVIL- -
L COS+ (S1) 3
M COS- (S3) 4
N SIN+ (S2) 5
P SIN- (S4) 6
R Not to be connected -
S Not to be connected -
T Resolver Excitation- (R2) 2
U N/C -
V Chassis/Shield 12
Note: In case of conflict between pinout information given here and in manufacturer documentation; pinout information
given by the manufacturer should be considered the official version.
4.5.6.2 Installing the motor sensor interface harness assembly

Before connecting or reconnecting the motor sensor interface harness connector, carry out a visual
inspection to ensure that the pins on both connectors of the harness are undamaged and that there is no
dirt or debris that might interfere with the contacts. Then, in order to protect the electrical contacts against
the surrounding environment, apply a contact lubricant (Electrolube CG60, NyoGel 760G or equivalent) to
the connector heads following the instructions provided by TM4 [13].
Note: Although the signal connectors are fully watertight when correctly installed, we strongly recommend
that you help direct water away from the connector heads by creating a drip loop with the cable in your
installation.
Using the motor sensor harness delivered with your TM4 system, or the harness you have prepared for use
with a non-TM4 motor, connect the cable to the MCU using its dedicated mating location (Figure 8).
To install the motor sensor harness on the MCU, turn the connector head until the pins are aligned with the
pinholes on the motor sensor interface. The connector head will lock when the pins are aligned: do not use
force to insert the connector head.
Note: Carefully read all safety instructions related to electrical installation (Section 4.3.1) before connecting
the motor sensor interface harness.

Installation Guide
4.5.7 Connecting the VMU interface harness

Carefully read all safety instructions related to electrical installation (Section 4.5.1) and general information
for installing cables and harnesses in Section 4.5.2 before continuing with your integration.
4.5.7.1 Preparing the VMU/ECU interface harness

A VMU or client ECU interface harness is required between the MCU and the Vehicle Management Unit
(VMU). The VMU interface harness contains all required signals to interface the MCU with the VMU
including the enable signal and the CAN ports.
As vehicle integrators are able to connect the TM4 MOTIVE™ system to the VMU or ECU of their choice,
the integrator will have the responsibility of fabricating the VMU interface harness using wiring appropriate
to the specific installation environment. TM4, therefore, does not deliver a VMU harness with the system;
only the plug and contacts listed and described in the kit documentation [10]/[11] are included.
Note: Although the signal connectors are fully watertight when correctly installed, we strongly recommend
that you help direct water away from the connector heads by creating a drip loop with the cable in your
installation. Also, before connecting or reconnecting VCU harness connector, carry out a visual inspection
to ensure that the pins on both connectors of the harness are undamaged and that there is no dirt or debris
that might interfere with the contacts.
The VMU interface is located on the left side of the MCU next to the motor sensor interface (Figure 12) and
has 12 pins. Use the plug pinout specifications given in Table 9 and Figure 13 and refer to the
documentation for Kit-0011 [10] or Kit-0012 [11] for full assembly instructions. Once the cable is prepared,
connect it to the MCU, see Section 4.5.7.3.
Figure 12 VMU interface location – Base of the MCU

Installation Guide
Figure 13 VMU interface harness – Plug pinout – P770E0160
Connector (front) Wire insertion side (back)
Note: The plug on the MCU has been uniquely keyed to prevent the harness from being incorrectly
connected.
Table 9 VMU/ECU interface harness – Plug pinout specifications
Pin Signal names Types AWG Descriptions
E V AUX + Power 20-22 Positive power wire of the MCU. Must be
connected to the auxiliary battery using the
F 20-22 fuse type recommended in Table 16.
L V AUX - (Chassis) Reference 20-22 Must be connected to the vehicle chassis
(frame/auxiliary battery -).
M 20-22
G IGNITION Input 20-22 Enable signal to activate the MCU.
A CAN1L Communication 20-22 Low level of differential signal CAN1.
B CAN1H Communication 20-22 High level of differential signal CAN1.
C CAN2L Communication 20-22 Low level of differential signal CAN2.
D CAN2H Communication 20-22 High level of differential signal CAN2.
J HVIL HVIL IN 20-22 Hazardous voltage interlock loop.
K HVIL HVIL OUT 20-22 Hazardous voltage interlock loop.
H Emergency stop Output 20-22 Emergency stop.
Notes:
• While designing the VMU/ECU interface harness, plan a connector or a mechanism to connect the
diagnostic tool (TM4 ODIN) to CAN1 and/or CAN2 (CAN2 is not used in all versions of the system).
See Section 4.5.10 for termination information.
• Ensure that the connector heads respect the IP6K9K ratings to prevent water infiltrating into the
system.
• There are no recommended wire colours.

Installation Guide
4.5.7.2 HVIL and EmergencyStop signals

The system will draw power and recharge the high-voltage battery based on the torque request and will
limit the maximum charge/discharge currents as specified using the associated CAN protocol message.
However, in case of hazardous behaviour or maintenance of the traction system, two hardware signals
should be connected for safety purposes: HVIL and EmergencyStop.
When the system is fully installed and connected, the HVIL internal loop is closed therefore resulting in a
short circuit between its two input pins. The HVIL signal is used to open the high-voltage battery contactor
when its internal loop is opened during product maintenance or repair (e.g. removal of MCU cover or
disconnection of motor sensor cable) thereby protecting the user.
The Emergency Stop signal is driven by a software algorithm.
When the MCU is disabled (IGNITION input at Vaux- (Chassis)), this signal is at high impedance.
On boot-up from the time the MCU is enabled (IGNITION input at Vaux+ level); this signal is maintained at
Vaux- (Chassis) level for a minimum of 10 seconds.
After this period of time and as long as the MCU is kept enabled (IGNITION input at Vaux+ level), this
signal will only go at high impedance if the following abnormal condition occurs:
• The MCU is no longer in an Operational state and the high-voltage battery current measured by the
MCU is beyond established safe limits (-30 A to +30 A).
Note: Once the signal has changed state, the high-voltage contactor to the MCU must be opened and
the MCU disabled to prevent injury to the user and/or damage to the components.
See Figure 14 for the suggested HVIL and EmergencyStop safety circuit to implement the necessary safety
feature.

Installation Guide
4.5.7.2.1 Suggested HVIL and EmergencyStop safety circuit

Disclaimer: Note that if you choose not to implement this circuit, TM4 is not responsible for any effects of
hazardous behaviour or system malfunction during maintenance or due to a situation requiring an
emergency stop.
Figure 14 Suggested HVIL and EmergencyStop safety circuit
Table 10 HVIL and EmergencyStop – Absolute maximum rating

Specifications Units Values
Imax – HVIL steady state A 2
EmergencyStop steady state mA 250
EmergencyStop inrush current A 7
4.5.7.3 Installing the VMU interface harness assembly

Use the plug pinout specifications given in Table 9 and Figure 13 and in Kit-0012 assembly instructions [11]
to fabricate the appropriate VMU harness for your installation and then connect the VMU interface cable to
the MCU using its dedicated mating location (Figure 12).
Before connecting or reconnecting the VMU interface harness connector, carry out a visual inspection to
ensure that the pins on both connectors of the harness are undamaged. Then, in order to protect the
electrical contacts against the surrounding environment, apply a contact lubricant (Electrolube CG60,
NyoGel 760G or equivalent) to the connector heads following the instructions provided by TM4 [13].
To install the harness on the MCU, turn the connector head until the pins are aligned with the pinholes on
the VMU interface. The connector head will lock when the pins are aligned: do not use force to insert the
connector head.

Installation Guide
4.5.8 Connecting the high-voltage battery

This section describes how to safely assemble, protect and connect the high-voltage battery to the MCU.
Note: It is imperative that you are aware of the safety risks involved in connecting a high-voltage battery to
the system; before you start; refer to Section 4.5.8.1 for safety instructions and Section 4.5.2 for general
information on installing cables and harnesses before continuing with your integration.
4.5.8.1 Safety instructions related to connecting the high-voltage battery

Carefully read all safety instructions before connecting the high-voltage battery.
WARNINGS This product generates high voltage that can cause an electric discharge or electrocution
resulting in injury or death.
When installing the product, verify that:
• The traction battery (high-voltage battery) is disconnected.
• The auxiliary battery (12 V/24 V battery) is disconnected.
The high-voltage cables MUST be shielded.
The external cables used for high voltage must be orange and shielded; the high voltage and level of
current delivered by this product can be lethal.
Failure to shield the high-voltage cables will result in non-compliance with EMI regulatory requirements.
Care must be taken when manipulating electrical equipment.
This product must be installed by qualified and authorized personnel in accordance with applicable
vehicle standards and industry practices. Always use appropriate insulation and protection before
manipulating the product even when the product is disconnected from a high-voltage source.
This product uses differential mode capacitors between the positive high-voltage DC bus (+) and
the negative high-voltage DC bus (-) and common mode capacitors between the high-voltage DC
bus and the chassis. Even when the product is disconnected from the high-voltage source, these
capacitors can hold a voltage high enough to cause an electric discharge or death.
It is important to ensure that no voltage is present on the high-voltage battery wires between both
polarities and from each polarity to chassis before manipulation.
Before opening the access panel, wait 10 minutes to ensure that internal MCU capacitors are discharged.
After that delay, the access panel can be opened and the MCU high-voltage battery inputs can be
measured between both polarities and from each polarity to chassis to ensure that no voltage is present.
4.5.8.2 High-voltage battery short-circuit protection

The system requires a fuse on the HV DC bus. Proper fuse sizing is necessary in order to protect against
reverse polarity and short-circuit. TM4 recommends installing the following fuse:
Table 11 High-voltage battery – Recommended fuse sizing
Specifications Units CO150 CO150HV
Voltage rating V 450 750
Current A 600 400
See the TM4 application note on SUMO Fuse and DC Cable Selection [5] for more information.

Installation Guide
4.5.8.3 Internal common mode capacitors

There are 2 common mode capacitors installed internally in the MCU. In order to verify that these
components are functioning correctly, measure the value from Vbatt+ to chassis or Vbatt- to chassis; this
measurement should be 2.2 μF ± 20%. To ensure that the reading is precise, prior to taking the
measurements, the DC lug screw must be installed and tightened; the lug does not need to be installed.
Note: The value given above is for reference purposes only; no action is required by the integrator.
4.5.8.4 High-voltage battery pre-charge circuit

The system requires the protection of a pre-charge circuit without which the system start-up sequence will
fail and the MCU may be permanently damaged. This pre-charge mechanism will protect the system from
component stress during each power-up thereby reducing the risk of damage to system components and
promoting component reliability.
In the system, the high-voltage battery input shows a capacitive charge of about 500 μF for the CO150 and
315 μF for the CO150-HV. The vehicle integrator must add a pre-charge mechanism to protect the
capacitor bank and limit the pre-charge current as specified in Table 12.
Table 12 High-voltage battery – Pre-charge circuit specifications
Specifications Units Values Notes
Pre-charge current limit A 25
Figure 15 MCU high-voltage impedance sensor circuit

Installation Guide
4.5.8.5 High-voltage battery cable assembly specifications

The high-voltage battery must be connected to the MCU using specific cable assemblies. Refer to Table 13
for the recommended cable specifications.
WARNING The high-voltage cables MUST be shielded.

The external cables used for high voltage must be orange and shielded; the high voltage and level of
current delivered by this product can be lethal.
Failure to shield the high-voltage cables will result in non-compliance with EMI regulatory requirements.
Table 13 High-voltage battery – Recommended cable specifications

Specifications Units Values Notes
Wire size AWG 1/0 1
Material - Under-hood contaminant resistant 1, 2
Voltage V 1000
Continuous current rating A 300 3
Temperature rating °C 150
Colour - Orange 4
Shielded - Yes – Mandatory 5
Notes:
1. The wire size or wire wall material can be adapted to fit required use.
2. Depending on the location of the wires, a wire tubing (orange split loom) can be used to prevent abrasion or other
effects that could damage the wires.
3. Based on a temperature of 85 °C.
4. The colour orange is recommended for safety purposes when handling high-voltage levels.
5. The external cables used for DC high voltage must be orange and shielded.
Table 14 Lapp cable glands – recommended tools
Item Mfg Mfg P/N TM4 # Qty Notes
Skinmatic Quick Set 1 Lapp Group 61610000 n/a 1 1
Skinmatic Torque Wrench – Lapp Group 61610013 n/a 1 1
Skinmatic DMG 5-25 Nm
4.5.8.6 Calculating high-voltage cable length

While calculating the length of cable required for the high-voltage battery cable installation, the integrator
must allow for the length of the crimped cable that is installed inside the MCU. This is calculated from
where the cable enters the MCU to the end of the wire installed inside the crimped lug, see the cable
harness drawing [9] for exact measurements.
Note: When operating the system in a test environment using a DC source, the high-voltage battery
cable should be at least 3 m in length, inclusive of the cable inside the MCU. This is to avoid problems of
resonance between the low output impedance sources, the low inductance of a shorter cable and the
internal capacity of the MCU.
When using a high-voltage battery, whether in a test environment or installed in a bus, there is no
minimum cable length requirement.
4.5.8.7 Preparing the high-voltage battery cables

The high-voltage battery cables must be prepared by the integrator before installing them in the MCU; see
the cable drawing [8] for preparation instructions.

Installation Guide
4.5.8.8 Installing the high-voltage battery cable assembly

Refer to Section 4.5.8.1 and this section for safety instructions before installing the high-voltage battery
connections.
WARNING Risk of electrocution.

The high-voltage power source must not be connected until the installation is completed and the plugs are
firmly attached.
WARNING Overtightening the screws/plugs may damage the product.

• The maximum recommended torque given in the product interface drawing is for final cable
installation; if you insert the screws without the lugs, hand-tighten the screws lightly to prevent
damage to the product).
• We recommend that you protect or cushion the end of the tool used to tighten the plugs to prevent
scratching the casing.
Using the harness you have prepared or purchased from TM4, refer to the product interface drawing [6] and
cable harness specification [9] for illustrated installation information.
Note: The screws and washers required for this installation procedure are not installed on the product at
time of delivery; you will find them in small bags packaged in the crate with the product.

Installation Guide
4.5.9 Auxiliary battery

Carefully read all safety instructions related to electrical installation (Section 4.5.1) before connecting the
auxiliary battery.
The auxiliary battery is required to power the MCU. The negative terminal of the battery must be connected
to the frame of the vehicle (chassis).
To protect the system against short circuit, add a fuse in series with the positive terminal of the auxiliary
battery. See Table 15 for MCU current information; Table 16 for fuse specifications and Figure 16 for the
fuse block diagram.
Table 15 Auxiliary battery – Steady state and inrush currents
Specifications Units Values Values Notes
(12 V) (24 V)
Maximum MCU steady state current A 4.5 3 1, 2
Maximum MCU inrush current A < 10 < 10 1
Maximum MCU quiescent current mA <1 < 1.5 1
Note:
1. Typical values are given at 25 C.
2. Vehicle at maximum speed.
Table 16 Auxiliary battery – Fuse specifications
(12 V/24 V)
Current rating A 10
Fuse type - Fast-acting
Figure 16 Auxiliary battery – Fuse block diagram

Installation Guide
4.5.10 CAN interface

The integrator must select impedance according to the desired CAN bus terminations:
• CAN1 is terminated, see Figure 17.
• CAN2 is not terminated, see Figure 18.
Figure 17 CAN1 terminations
Figure 18 CAN2 – not terminated

Installation Guide
4.6 Software installation

All software-related installation and diagnostics are performed using TM4 ODIN, a Windows application
developed by TM4, and a computer equipped to connect to the TM4 CO150 MCU CAN port. For more
information on how to install TM4 ODIN and set up the CAN connection, see the TM4 ODIN Technical
Guide [2].
Note: Dana TM4 is not responsible for any damage to the system caused by misuse or modification of the
application code.
This section gives more information on how to connect to TM4 ODIN, and how to modify CAN speed and
base addresses, if required.
4.6.1 CAN protocol and TM4 ODIN

The TM4 CO150 MCU uses the CAN protocol to send and receive messages/data. Although certain
aspects of the protocol have default settings at the time of delivery (see Table 17), these can be
reconfigured using TM4 ODIN to accommodate the specifics of your integration.
Table 17 TM4 ODIN CAN default configuration values
Default baud rate kb/sec 500
Default base address CAN1 -- 0x660 (1632)
Default base address CAN2 -- 0x680 (1664)
Default base range -- See Table 18 (CAN1) & Table 19 (CAN2)
For more information on reconfiguring the CAN speed and addresses, see the following sections:
• Reconfiguring CAN bus base addresses, Section 4.6.1.1.
• Reconfiguring the CAN bus baud rate, Section 4.6.1.3.
4.6.1.1 Reconfiguring CAN bus base addresses

Although it is recommended to use the default CAN base addresses whenever possible, there are certain
cases in which the CAN IDs might be in conflict with other CAN modules during vehicle integration. In these
cases, it is possible to configure the base addresses for high and low priority messages and TM4 ODIN
messages.
Note: When multiple MCUs are connected to the same CAN bus, the message base addresses must have
a unique configuration for each MCU connected on the CAN bus.
To change the base addresses:
1 Modify the values of the following parameters in the TM4 ODIN GUI:
•
Parameters:Drive:CANConfig:HighPrioBaseAddress
Default value: 0x0040 (64)
• Parameters:Drive:CANConfig:LowPrioBaseAddress
• Parameters:Drive:CANConfig: OdinCan1BaseAddress
• Parameters:Drive:CANConfig: OdinCan2BaseAddress
2 Save the new values with the "Parameters:.Command:DrvParameters.Save" command.
Note: The system must be shut down and then restarted for the changes to be effective.

Installation Guide
Refer to Table 18 and Table 19 for the default base ranges used in the current application.
Table 18 CAN MCU interface (CAN 1) base ranges
Base Address ID Related messages Base range Default base
length range
Can1BaseAddr1 MCU messages (High priority) 8 0x0040-
(CtrlCanPortNumber = 1) 0x0047
Can1BaseAddr2 MCU messages (Low priority) 16 0x0440-
(CtrlCanPortNumber = 1) 0x044F
Can1BaseAddr3 TM4 diagnostic tool messages 32 0x0660-
(TM4 ODIN) 0x067F
Can1BaseAddr4 Customer specific messages 8 0x0450-
(CAN extension pack) 0x0457
Can1BaseAddr5 Diagnostic messages 2 0x712
(UDS when EnableUds = 1 and 0x71A
UdsCanPort = 1)
Table 19 CAN MCU interface (CAN 2) base ranges
Base Address ID Related messages Base range Default base
length range
Can2BaseAddr1 MCU messages (High priority) 8 0x0040-
(CtrlCanPortNumber = 2) 0x0047
Can2BaseAddr2 MCU messages (Low priority) 16 0x0440-
(CtrlCanPortNumber = 2) 0x044F
Can2BaseAddr3 TM4 diagnostic tool messages 32 0x0680-
(TM4 ODIN) 0x069F
Can2BaseAddr4 Customer specific messages 8 0x0450-
(CAN extension pack) 0x0457
Can2BaseAddr5 Diagnostic messages 2 0x712
(UDS when EnableUds = 1 and 0x71A
UdsCanPort = 2)
4.6.1.2 Reconnecting with TM4 ODIN using modified addresses

TM4 ODIN is configured to connect with the default addresses given in Table 17. To connect with TM4
ODIN using the modified base addresses, you must reconfigure the base address in the Device
Communication window (Configuration/Device Communication), see the TM4 ODIN v4 Technical
Guide [2] for more information.
Note: If you modify the CAN base address of the VMU or MCU you need to modify the IDs of the message
addresses recorded in the CAN database (TM4_MCU_CAN_PROTOCOL_V4.1.dbc) to match your new
configuration.

Installation Guide
4.6.1.3 Reconfiguring the CAN bus baud rate

The CAN bus baud rate can be configured at the following speeds: 125 kb, 250 kb, 500 kb and 1 Mb. The
default CAN baud rate is 500 kb.
Before reconfiguring the speed, ensure that your software versions are as follows:
• Bootloader: v1.6.1.56671 or later.
• TM4 ODIN: v4.12.0.x or later.
Note: Earlier versions do not support baud rate configuration.
1 To change baud rate, select the desired SPEED_OPTION in "Parameters:Drive:CanBaudRate" in
TM4 ODIN.
2 Save the new value with the "Parameters:.Command:DrvParameters.Save" command.
Note: The system must be shut down and then restarted for the changes to be effective.
3 To connect with TM4 ODIN, you need to change the CAN communication speed in TM4 ODIN
(Configuration/Device Communication).
4.6.1.4 Finding available TM4 devices using CAN

See the section on Device communication configuration in the TM4 ODIN Guide [2] for information on how
to use CAN to find available TM4 devices.
Once connected to the CO150-A2, the available device will be displayed in the Devices Found part of the
Device Communication Configuration window.
Figure 19 Device Communication Configuration

Installation Guide
4.6.1.5 Recovering modified base addresses after loss of communication

If after modifying the base addresses you lose communication with TM4 ODIN and can no longer
remember the new TM4 ODIN base address configuration, you can verify the CAN bus message as
follows:
1 At MCU power on, with TM4 ODIN closed, the MCU will send a message (DLC = 4) with an ID equal
to OdinCan1BaseAddress + 1 if you are connected to CAN1 or OdinCan2BaseAddress + 1 if you are
connected to CAN2.
2 Use these base addresses to configure TM4 ODIN and reconnect to the device to change the
configuration again.
3 In the CAN protocol, verify the CAN base address and interpret the following base addresses; each
CAN base address is mapped to the following parameter names:
• Can1BaseAddr1 / Can2BaseAddr1 = HighPrioBaseAddress
• Can1BaseAddr2 / Can2BaseAddr2 = LowPrioBaseAddress
• Can1BaseAddr3 / Can2BaseAddr3 = OdinCan1BaseAddress / OdinCan2BaseAddress
4.6.2 Embedded software packages

The software installation package provided to the customer is an executable self extractor file that will
automatically copy the package content in a TM4 ODIN folder. The package contains several files that can
be accessed using TM4 ODIN. The package content may vary depending on the system. Table 20 gives a
list of the most common files.
Table 20 Embedded software package content
File Name Description
Embedded MCU_INVHP2LV_0103_A2_*_v*_*_*_*_Pkg.exe Self extractor file
software package
executable
CAN protocol TM4_MCU_CAN_PROTOCOL_V4_*_HP_0x40_LP_0x440.dbc Database
database files TM4_MCU_J1939_protocol_V1_*.dbc describing the CAN
protocols format
supported by the
software
Error code list MCU_*_Error_Codes_and_Corrective_Action.html Event code list with
descriptions
Release notes TM4_Release_Notes.htm or Description of the
MCU_*_ Release_Notes.htm changes for every
version of the
software
Basic TM4 ODIN UserInterface.odn4 Basic file used in
workspace TM4 ODIN to see
software variables
Note: TM4 product software package names may be subject to change.
4.6.2.1 Verifying the version of the embedded software

Verify that the currently programmed software version is up to date with the latest released application
software by connecting to the embedded application with TM4 ODIN; the name of the embedded
application and the version of the current application are displayed in the status bar. Ensure that the version
of the software corresponds to the latest version available on the TM4 Extranet site [15].

Installation Guide
4.6.2.2 Updating the embedded software

If the version you are currently using requires an update, the application software can be programmed
using TM4 ODIN as follows:
1 Install the desired embedded software package as described in the TM4 ODIN Technical Guide [2].
2 Turn the ignition key to OFF and wait until the system shuts down (about 10 s).
3 Start ODIN4 using the ODIN 4 Server 1 shortcut.
4 From the TM4 ODIN menu, select Configuration/Device communication.
5 Using the scrolling menu, select the appropriate name for the TM4 CO150-A2 MCU from the list.
6 Click on the Apply button.
7 From the TM4 ODIN menu, select Tools/Flash program manager.
Note: A message is displayed asking if you want to save the current workspace before programming
another package; if you want to keep a copy of the workspace, save it as an .odn4 file. If you do not
choose to save, the data will be cleared.
8 Select the application software from the Choose program list.
9 Click Start; wait a few seconds until the start button name change to Stop.
10 Turn the ignition key to ON and wait for the software update to complete.
11 Once completed, TM4 ODIN disconnects from the server and will display a window to confirm the
success of the package update.
12 Click the OK button to reconnect to the TM4 ODIN server.
13 At this point, the Basic TM4 ODIN file (UserInterface.odn4) can be opened from the TM4 ODIN menu
File/Open to view customer TM4 CO150-A2 MCU parameters.
Contact TM4 Customer Service if you require help programming the system using TM4 ODIN. For
customer service contact details, see Section 5.
4.6.3 Customizing system parameters

Refer to the Operations and Maintenance Guide [3] for system parameter information.
5 Customer service
For further technical assistance, please contact TM4 Customer Service:
Email: tm4customersupport@dana.com


TG-0084 - 16 TM4 CO150-A2 Installation Guide

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Installation Guide

Motor Control Unit (MCU)

TG-0084_16 TM4 CO150-A2 Installation Guide

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.5.7 Connecting the VMU interface harness ............................................................. 31

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

1.3 What’s new

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

1.5 Safety instructions

1.5.1 Format and location of safety warnings in this guide

WARNING Reason for the warning – explanation of the potential hazard.

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

1.6 Definitions, acronyms and abbreviations

Auxiliary battery Standard 12 V or 24 V vehicle battery

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

2 Transport and storage conditions

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

3 Receiving and unpacking the MCU

3.1 Safety warnings related to handling the MCU

3.2 Inspecting and moving the MCU

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4 Installing the MCU in the vehicle

4.1 Planning to install the MCU

4.1.1 Respecting CSC and MKC markings on interface drawings

4.2 Preventing damage to the MCU

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.2.1 Using separate brackets to support MCU and motor

4.2.2 Respecting the physical integrity of the MCU

4.2.3 Protecting the casing from external loads

4.2.4 Correctly positioning the MCU

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.3 Securing the MCU

Figure 2 Mounting points

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.4 Installing the cooling system

4.4.1 Safety warnings related to handling the cooling agent

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.4.2 Serial configuration

4.4.3 Parallel configuration

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.4.4 Coolant inlet/outlet specifications

4.4.5 Coolant specifications

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.5 Electrical installation

4.5.1 Safety instructions related to electrical installation

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.5.2 General information for installing and handling cables/harnesses

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.5.3 Example installation sequence

4.5.4 Grounding the system

4.5.4.1 Grounding strap recommendations – MCU

4.5.4.2 Connecting the grounding strap – MCU

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.5.4.3 Connecting the grounding strap – Chassis

CONFIDENTIAL TG-0084_16 TM4 CO150-A2 Installation Guide

4.5.5 Connecting the phase cables

4.5.5.1 Preparing the phase cable assembly

4.5.5.2 Installing the phase cables on the MCU