DANA TM4 SUMO MD MV User manual

Installation Guide
TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
SUMO HD
Product: Motor Control Unit (MCU)
Versions: CO300-A1/A2/A2.5

Installation Guide
CONFIDENTIAL
TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
Page 2 of 42
2020-11-20
Product information
Product series:
TM4 SUMO™ HD
Model numbers:
CO300-A1
CO300-A2
CO300-A2.5
Document information
Reference:
TG-0057 TM4 CO300-A1_A2_A2.5 Installation Guide
Release date:
2020-11-20
Version number:
19.0
Template information
Reference:
IN-8032_3

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Table of contents
1Introduction ........................................................................................................................ 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 .................................................................... 8
1.7 References................................................................................................................. 9
2Transport and storage conditions ..................................................................................... 10
3Receiving and unpacking the MCU .................................................................................. 11
3.1 Safety warnings related to handling the MCU........................................................... 11
3.2 Inspecting and moving the MCU .............................................................................. 11
4Installing 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 .................................................................................... 17
4.4.1 Safety warnings related to handling the cooling agent....................................... 17
4.4.2 Parallel configuration......................................................................................... 18
4.4.3 Serial configuration ........................................................................................... 19
4.4.4 Coolant inlet/outlet specifications ...................................................................... 19
4.4.5 Coolant specifications ....................................................................................... 20
4.5 Electrical installation................................................................................................. 21
4.5.1 Safety instructions related to electrical installation............................................. 21
4.5.2 General information for installing and handling cables/harnesses ..................... 22
4.5.3 Example installation sequence .......................................................................... 23
4.5.4 Grounding the system ....................................................................................... 23
4.5.5 Phase cables .................................................................................................... 25
4.5.6 Motor sensor interface harness ......................................................................... 27
4.5.7 Connecting the VMU interface harness ............................................................. 29
4.5.8 Connecting the high-voltage battery .................................................................. 34
4.5.9 Connecting the auxiliary battery to the MCU ..................................................... 38
4.5.10 CAN interface.................................................................................................... 39

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4.6 Software installation ................................................................................................. 40
4.6.1 Selecting communication protocol type ............................................................. 40
4.6.2 CAN protocol and TM4 ODIN............................................................................ 40
4.6.3 Embedded software packages .......................................................................... 41
4.6.4 Customizing system parameters ....................................................................... 42
5Customer service ............................................................................................................. 42

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List of tables
Table 1 Related document references ............................................................................. 9
Table 2 Recommended transport and storage conditions .............................................. 10
Table 3 Grounding – Strap size...................................................................................... 24
Table 4 Grounding strap installation............................................................................... 24
Table 5 Phase cable installation mapping ...................................................................... 26
Table 6 Motor sensor interface pinout ............................................................................ 28
Table 7 VMU/ECU interface harness – Plug pinout specifications.................................. 30
Table 8 HVIL and EmergencyStop – Absolute maximum rating ..................................... 31
Table 9 High-voltage battery – Recommended fuse sizing............................................. 35
Table 10 CO300 model number vs internal common mode capacitor type....................... 35
Table 11 CO300 model number vs capacitor type/resistance to chassis.......................... 36
Table 12 High-voltage battery – Pre-charge circuit specifications .................................... 36
Table 13 Auxiliary battery – Steady state and inrush currents.......................................... 38
Table 14 Auxiliary battery – Fuse specifications............................................................... 38
Table 15 TM4 ODIN CAN default configuration values .................................................... 40
Table 16 CAN MCU interface (CAN 1) base ranges......................................................... 40
Table 17 CAN diagnostic interface (CAN 2) base ranges................................................. 41
Table 18 Embedded software package files..................................................................... 41

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List of figures
Figure 1 Position of vent on base of MCU casing............................................................ 14
Figure 2 Position of IGBT coolant overflow holes on base of MCU casing ...................... 14
Figure 3 Mounting points – External view of top and base of the MCU............................ 16
Figure 4 Parallel cooling system...................................................................................... 18
Figure 5 Serial cooling system ........................................................................................ 19
Figure 6 Coolant inlet/outlet locations on the MCU.......................................................... 19
Figure 7 Grounding point................................................................................................. 24
Figure 8 Phase cable gland locations.............................................................................. 25
Figure 9 Motor sensor interface location – Base of the MCU........................................... 27
Figure 10 Front of connector ............................................................................................. 28
Figure 11 VMU/ECU interface location – Underside of the MCU ....................................... 29
Figure 12 VMU interface harness – Plug pinout – P770E0160.......................................... 30
Figure 13 Suggested HVIL/EmergencyStop safety circuit –
INV-HP2HV_0309-A-01 & -06 ........................................................................... 32
Figure 14 Suggested HVIL/EmergencyStop safety circuit –
all models except -A-01 & -06............................................................................ 33
Figure 15 MCU high-voltage impedance sensor circuit ..................................................... 36
Figure 16 High-voltage battery – Cable gland location ...................................................... 38
Figure 17 Auxiliary battery – Fuse block diagram.............................................................. 38
Figure 18 CAN1 terminations ............................................................................................ 39
Figure 19 CAN2 – not terminated...................................................................................... 39

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1 Introduction
The TM4 SUMO™ HD CO300 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™ driver 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.
WARNING Prototype X and ALPHA version components cannot be combined.
Do not pair –X and –A versions of components in your integration.
1.1 Purpose
This technical guide contains important information on how to install the TM4 SUMO™ HD CO300 MCU.
1.2 Scope
This technical guide is divided as follows:
•Introduction – general information about the product, definitions and document reference information.
•Transport and storage conditions – guidelines on environmental conditions to be respected during
system storage and transport.
•Receiving and unpacking – general guidelines on how to safely unpack and inspect the product.
•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 guide has been modified as follows:
•Clarification of information on the fuse used to protect the VAUX supply, see Table 7.
1.4 Disclaimer
All installation instructions, limits and warnings given in the technical documentation supplied by 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.

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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.
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).
DC Direct Current.
HVIL Hazardous Voltage Interlock Loop.
MCU Motor Control Unit.
TM4 ODIN TM4 diagnostic software.
VMU Vehicle Management Unit.

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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
Note
[1]
IN-8013e
MCU CAN Protocol vx.x Specifications
1, 2
[2]
TG-0001
TM4 ODIN v4 Technical Guide
1
[3]
TG-0058
TM4 LSM280A-A1 Installation Guide
1
[4]
TG-0059
TM4 SUMO HD Operations and Maintenance Guide
1
[5]
TG-xxxx
TM4 SUMO HD System Specifications
1, 2
[6]
Application Note
TM4 SUMO Fuse and DC Cable Selection
1
[7]
SC-6000E-036
Kit-0076 VMU interface connector assembly instructions wire version
1
[8]
SC-6000E-017
Kit-0014 Right-angled MCU connector assembly instructions
1
[9]
SC-6000E-045
Connector lubricant application instructions
1
[10]
SC-6004E-007
TM4 Inverter Action Guide
1
[11]
INT3-xxxx
Interface drawings.
1, 2
[12]
WE-xxxx
Cable end specifications
1, 2
[13]
WH-xxxx
Cable harness specifications
1, 2
[14]
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.

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2 Transport and storage conditions
This section describes the conditions that must be adhered to when either transporting or storing TM4
products in order to ensure optimum performance once installed in a vehicle.
On leaving 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.
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.

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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
1On receiving the MCU, immediately verify that the crate is undamaged; if you see signs of damage,
before signing for the package:
•Inform the person delivering the package;
•Make a note on the way bill and keep a copy;
•Immediately contact TM4.
2On 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).
3Carefully lift the MCU out of the crate using straps (this will require 2 people) or using the lifting points
indicated on the product interface drawing [10].
4Remove 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 TM4 contact information.

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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 CO300HV MCU.
WARNING Mishandling of this product may damage the product and/or cause injury or death.
•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 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 [11].
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.

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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 System Specifications [5].
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.
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
inverse (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 (see Figure 1) and IGBT coolant
emergency overflow holes (see Figure 2) on the MCU casing.

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

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4.3 Securing the MCU
In order to properly install the MCU, it should be securely fixed into the vehicle using four (4) of the eleven
(11) available mounting points to evenly distribute the load.
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 or repair this product. In case of damaged casing or suspected product
malfunction, contact TM4.
•Use only indicated points to secure the MCU.
See Figure 3 for the locations of the mounting points on the MCU; each of the highlighted areas includes 2
or 3 mounting points either under or on the side of the MCU; select at least one mounting point in each
zone (numbered 1-4) regardless of installation position in order to stabilize the unit. Refer to the product
interface drawing [10] for exact specifications of mounting holes and screws.
Note: Prepare the zinc-coated bolt with Loctite 242 or 243 before insertion.

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Figure 3 Mounting points – External view of top and base of the MCU
Note: Mounting points can also be used as lifting points, see the product interface drawing [10] for more
information.

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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.
A parallel cooling system is recommended for the TM4 SUMO™ HD system, but information is also given
on a possible serial cooling configuration, see Section 4.4.3.
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.
WARNINGSRegardless 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 eye-glasses.
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.

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4.4.2 Parallel configuration
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 optimum
configuration but coolant liquid pressure must not reach or exceed 30 PSI.
See the System Specifications [5] for estimated pump requirements.
Figure 4 Parallel cooling system
See the System Specifications [5] for more information on coolant pressure drops and rate flow
management.

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4.4.3 Serial configuration
Although it is recommended that you use a parallel cooling configuration, a serial cooling configuration can
also be used in your integration, see Figure 5.
Note: Coolant liquid pressure must not reach or exceed 30 PSI.
Figure 5 Serial cooling system
See the System Specifications [5] for more information on coolant pressure drops and rate flow
management.
4.4.4 Coolant inlet/outlet specifications
Specific hose types should be used to connect the cooling unit to this system. Refer to the product interface
drawing [11] for coolant inlet/outlet specifications; the locations of the inlet and outlet are labelled on the
MCU casing (Figure 6).
See the System Specifications [5] for more information on coolant pressure drops and flow rate
management.
Figure 6 Coolant inlet/outlet locations on the MCU

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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.
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 not exceed 65 °C (or the maximum temperature according to the Specifications associated
with your system [5]. Above this temperature, the system can degrade the output torque to protect its
internal components from overheating.
When using either the parallel (see Figure 4) or serial cooling configuration (see Figure 5), there can be
associated drops in pressure that have to be managed; see the System Specifications [5] for coolant
specifications.