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

Installation Guide
CONFIDENTIAL
TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
Page 3 of 42
2020-11-20
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

Installation Guide
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TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
Page 4 of 42
2020-11-20
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

Installation Guide
CONFIDENTIAL
TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
Page 5 of 42
2020-11-20
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

Installation Guide
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TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
Page 6 of 42
2020-11-20
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

Installation Guide
CONFIDENTIAL
TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
Page 7 of 42
2020-11-20
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.

Installation Guide
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TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
Page 8 of 42
2020-11-20
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.

Installation Guide
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TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
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2020-11-20
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.

Installation Guide
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TG-0057_19 TM4 SUMO HD CO300-A1_A2_A2.5 Installation Guide
© Dana TM4 inc., 2013-2020
Page 10 of 42
2020-11-20
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.