Danfoss ED-DT318B Operating instructions

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

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | i
Classified as Business
Table of Contents
Table of Contents ...............................................................................................................................................................................................i
List of Figures .....................................................................................................................................................................................................iv
List of Tables.......................................................................................................................................................................................................vi
1Introduction ...........................................................................................................................................................................................8
1.1 About this Guide ..................................................................................................................................................................................9
1.1.1 Conventions ...........................................................................................................................................................................................9
1.1.2 Control Units.......................................................................................................................................................................................10
1.1.3 Safety Information ............................................................................................................................................................................ 10
1.1.4 High Voltage Safety Information ................................................................................................................................................10
1.2 Packaging and Disassembly .........................................................................................................................................................11
1.3 The following items are included in the packaging: ...........................................................................................................11
1.4 System Overview...............................................................................................................................................................................11
1.4.1 Vehicle Control Unit.........................................................................................................................................................................13
2Installation ...........................................................................................................................................................................................14
2.1 Avoiding Installation Problems ...................................................................................................................................................14
2.2 Installing the MCU/Controller ......................................................................................................................................................14
2.2.1 General Notes.....................................................................................................................................................................................14
2.2.2 Vibration Considerations ...............................................................................................................................................................15
2.2.3 Cable Routing.....................................................................................................................................................................................15
2.2.4 Preparing the Coolant Loop for MCU and Motor .................................................................................................................15
2.2.5 Routing the Signal Cable................................................................................................................................................................15
2.2.6 Routing the TCU to MCU Interface Cable ................................................................................................................................16
2.2.7 Applying Voltage...............................................................................................................................................................................16
2.3 Installing the Motor & 2 Speed Transmission.........................................................................................................................16
2.3.1 Connection of the driveline to the transmission output flange .....................................................................................16
2.3.2 Mounting the Motor/Transmission into the vehicle ........................................................................................................... 17
2.3.3 Overall Clearance Recommendation.........................................................................................................................................19
2.3.4 Motor Coolant Connections..........................................................................................................................................................20
2.4 Transmission Initial set-up and requirements .......................................................................................................................20
2.4.1 Transmission oil/fluid ......................................................................................................................................................................20
2.4.2Transmission Oil cooler................................................................................................................................................................... 23
2.4.3 Eaton recommended coolers.......................................................................................................................................................25
2.4.4 Air supply to the transmission .....................................................................................................................................................27
2.5 Electro-Magnetic Interference and Compatibility................................................................................................................ 28
2.5.1 CAN and RS232 Shielding..............................................................................................................................................................29
3Electrical Connections.....................................................................................................................................................................30
3.1 Power Cables ......................................................................................................................................................................................30
3.1.1 Phase Cables (3 Phase AC cables)...............................................................................................................................................31
3.1.2 DC Cables .............................................................................................................................................................................................32
3.1.3 High Voltage Interlock Connection............................................................................................................................................32
3.1.4 Termination Cover Installation ....................................................................................................................................................34
3.1.5Phase Cable and DC Cable Routing and Air Flow Requirement..................................................................................... 34
3.2 Grounding Requirements ..............................................................................................................................................................35
3.3 Signal Cable.........................................................................................................................................................................................35
3.4 TCU to MCU Interface Cable .........................................................................................................................................................37
3.5 Drivetrain Interface Connector....................................................................................................................................................37
3.6 DT2 Diagnostic Connector ............................................................................................................................................................43
4Liquid Cooling MCU and Motor...................................................................................................................................................46
4.1Coolant Loop Requirements......................................................................................................................................................... 46

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | ii
Classified as Business
4.2 Flow Rate vs. Pressure Drop..........................................................................................................................................................47
5Electric Vehicle System Operation..............................................................................................................................................48
5.1 Electric Vehicle System Overview...............................................................................................................................................48
5.2 Valid Control Modes via CAN........................................................................................................................................................49
5.2.1 Special Features.................................................................................................................................................................................49
5.2.2 Acceleration Control........................................................................................................................................................................49
5.3 Safety Features...................................................................................................................................................................................50
5.3.1 Limits......................................................................................................................................................................................................50
5.3.2 Forced Voltage Control...................................................................................................................................................................52
5.3.3 Stall .........................................................................................................................................................................................................52
5.3.4 Forced Open Loop............................................................................................................................................................................52
5.3.5 Software Watchdog Timer.............................................................................................................................................................52
5.4 Vehicle responses to Danfoss Power Solutions CAN Status Messages........................................................................ 53
6Communications ...............................................................................................................................................................................54
6.1 VCU to TCU CAN Communications ............................................................................................................................................54
6.2 TCU to MCU CAN monitor .............................................................................................................................................................54
6.3 RS232 Communications .................................................................................................................................................................55
6.4 DT2 Diagnostic Connector ............................................................................................................................................................55
7VCU to TCU CAN Bus........................................................................................................................................................................56
7.1 CAN Messages....................................................................................................................................................................................56
7.1.1 Abbreviations .....................................................................................................................................................................................56
7.1.2 Boolean Values...................................................................................................................................................................................57
7.1.3 Hexadecimal Values .........................................................................................................................................................................57
7.2 VCU to TCU Command Messages...............................................................................................................................................58
7.2.1 TCU Command Message 1.............................................................................................................................................................58
7.2.2 TCU Command Message 2.............................................................................................................................................................64
7.3 TCU to VCU Status messages........................................................................................................................................................68
7.3.1 TCU Status Message 1 .....................................................................................................................................................................68
7.3.2 TCU Status Message 2 .....................................................................................................................................................................73
7.3.3 TCU Status Message 3 .....................................................................................................................................................................94
7.3.4 TCU Status Message 4 ...................................................................................................................................................................109
7.3.5 TCU Status Message 5 ...................................................................................................................................................................112
7.3.6 TCU Status Message 6 ...................................................................................................................................................................115
7.3.7 TCU Status Message 7 ...................................................................................................................................................................118
8Motor Diagnostic Software .........................................................................................................................................................122
8.1 Setting Up the Software ...............................................................................................................................................................124
8.2 Starting the Software.....................................................................................................................................................................124
8.2.1 Status Bar............................................................................................................................................................................................125
8.3 Diagnostic Software Operation .................................................................................................................................................126
8.3.1 Measurement Update Speed......................................................................................................................................................127
8.3.2 Status Group .....................................................................................................................................................................................128
8.3.3 Menu Bar and Toolbar...................................................................................................................................................................132
8.4 Logging Data ....................................................................................................................................................................................133
8.4.1 Logging Set Up ................................................................................................................................................................................134
8.5 Data Acquisition ..............................................................................................................................................................................140
8.5.1 DAQ Set Up........................................................................................................................................................................................144
8.5.2 DAQ Set Up Example .....................................................................................................................................................................146
8.6 Event Log............................................................................................................................................................................................147
9Appendix A: Vibration Testing ...................................................................................................................................................152
9.1 Controller Vibration Testing .......................................................................................................................................................152
9.1.1 SAE J1455 Vibration Test..............................................................................................................................................................152
9.1.2 GB/T 18488.1-2015 Vibration Test............................................................................................................................................153
10 Appendix B: Vehicle responses to Danfoss Power Solutions’ CAN Status Messages ...........................................155

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | iii
Classified as Business
10.1 Vehicle responses to Danfoss Power Solutions’ CAN Status Messages.....................................................................155
11 Appendix C: Glossary.....................................................................................................................................................................176
11.1 Abbreviations ...................................................................................................................................................................................177
12 Appendix D: Safety Notices.........................................................................................................................................................178

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | iv
Classified as Business
List of Figures
Figure 1.1: Block Diagram of the Total System ...................................................................................................................................12
Figure 2.1: Left Side – attachment points for bell housing & transmission mounting brackets. ....................................17
Figure 2.2: Right Side – attachment points for bell housing & transmission mounting brackets. .................................18
Figure 2.3: Approved location of vibration isolators........................................................................................................................18
Figure 2.4: Mounting angle limits............................................................................................................................................................19
Figure 2.5: Direction of rotation in forward..........................................................................................................................................20
Figure 2.6: Proper lubricant level .............................................................................................................................................................21
Figure 2.7: Transmission lubricant drain ...............................................................................................................................................22
Figure 2.8: Eaton Transmission Lubricant Ports .................................................................................................................................24
Figure 2.9: Lubricant Drain Port................................................................................................................................................................24
Figure 2.10: Eaton 18025 oil to air cooler..............................................................................................................................................25
Figure 2.11: Eaton 18025 cooler heat transfer based on 38° C (100° F) temperature differential ..................................25
Figure 2.12: Eaton 5586750 oil to water heat exchanger ...............................................................................................................26
Figure 2.13: Eaton 5586750 heat exchanger heat transfer ............................................................................................................26
Figure 2.14: Pneumatic system .................................................................................................................................................................28
Figure 3.1: Controller Phase Connection...............................................................................................................................................31
Figure 3.2: Controller Connections..........................................................................................................................................................31
Figure 3.3: HVIL daisy chain routing thrugh the controller and motor.....................................................................................33
Figure 3.4 Exploded View of the Controller Connections ..............................................................................................................34
Figure 3.5: Signal Cable Connection – Insertion ................................................................................................................................36
Figure 3.6: Signal Cable Connection – Tightening............................................................................................................................36
Figure 3.7: Signal Cable Connection – Final Torque.........................................................................................................................36
Figure 3.8: Connector Bracket ...................................................................................................................................................................37
Figure 3.9: Drivetrain Interface Connector (connector 3)...............................................................................................................39
Figure 3.10: Danfoss Power Solutions Specification for 2 lead twisted pair shielded wire...............................................41
Figure 3.11: Drivetrain Interface Connector terminals and wire seals.......................................................................................42
Figure 3.12: Allowed VCU to TCU CAN Bus Configurations ...........................................................................................................43
Figure 3.13: TCU to MCU CAN bus ...........................................................................................................................................................45
Figure 4.1: Recommended Liquid Cooling Setup..............................................................................................................................46
Figure 5.1: Block Diagram of Electric Vehicle Drive System...........................................................................................................48
Figure 8.1: Danfoss Power Solutions Motor Diagnostic Software Front Panel.................................................................... 122
Figure 8.2: Menu Bar................................................................................................................................................................................... 123
Figure 8.3: General Group........................................................................................................................................................................ 123
Figure 8.4: Data Logging Control.......................................................................................................................................................... 123
Figure 8.5: Status Group ........................................................................................................................................................................... 123
Figure 8.6: Physical Group........................................................................................................................................................................ 123
Figure 8.7: Control Group......................................................................................................................................................................... 123
Figure 8.8: Electrical Group...................................................................................................................................................................... 123
Figure 8.9: Data Acquisition (DAQ) Control ...................................................................................................................................... 123
Figure 8.10: Critical Group ....................................................................................................................................................................... 123
Figure 8.11: Status Bar ............................................................................................................................................................................... 123
Figure 8.12: Choose COM Port Dialog Box ........................................................................................................................................ 124
Figure 8.13: Status Bar ............................................................................................................................................................................... 125
Figure 8.14: Status Group......................................................................................................................................................................... 128
Figure 8.15: Menu Bar and Toolbar ...................................................................................................................................................... 132
Figure 8.16: Front Panel Components of Logging ......................................................................................................................... 134
Figure 8.17: Logging Set Up Dialog Box............................................................................................................................................. 135
Figure 8.18: Front Panel Components of DAQ................................................................................................................................. 141
Figure 8.19: DAQ Setup............................................................................................................................................................................. 145
Figure 8.20: DAQ Trigger Thresholds................................................................................................................................................... 145

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | v
Classified as Business
Figure 8.21: Event Dialog Box................................................................................................................................................................. 148
Figure 8.22 Mark Event Log with Today’s Date dialog box......................................................................................................... 151
Figure 9.1: Controller Axis Orientation................................................................................................................................................ 152
Figure 9.2: SAE J1455 PSD Bobtail vertical Mid frame, Heavy-duty Truck Profile............................................................... 153

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | vi
Classified as Business
List of Tables
Table 1.1: ED-DT318B systems ................................................................................................................................................................... 8
Table 3.1: Drivetrain Interface Connector (connector 3) pinout..................................................................................................39
Table 3.2: RS232 Communications pinout............................................................................................................................................44
Table 3.3: DT2 Diagnostic Connector (Connector 4) pinout..........................................................................................................44
Table 4.1: Liquid Cooling System Requirements................................................................................................................................47
Table 5.1: Potential Limitations.................................................................................................................................................................50
Table 8.1: Components of a Danfoss Power Solutions Motor Diagnostic Software Installation.................................. 124
Table 8.2: Status Bar Communication Messages............................................................................................................................. 125
Table 8.3: Front Panel Group Descriptions........................................................................................................................................ 126
Table 8.4: Status Group Problems......................................................................................................................................................... 128
Table 8.5: Menu and Toolbar Descriptions........................................................................................................................................ 132
Table 8.6: Front Panel Logging Group Components..................................................................................................................... 134
Table 8.7: Logging Set Up Components............................................................................................................................................. 135
Table 8.8: Logging and DAQ Measurement Columns................................................................................................................... 136
Table 8.9: DAQ Configuration Menu.................................................................................................................................................... 140
Table 8.10: Front Panel DAQ Group Components.......................................................................................................................... 141
Table 8.11: DAQ Trigger Descriptions ................................................................................................................................................. 142
Table 8.12: DAQ Set Up Components.................................................................................................................................................. 146
Table 8.13: Possible Entries in Event Log ........................................................................................................................................... 148
Table 9.1: Severe Grade of Frequency Sweep Vibration Test..................................................................................................... 154
Table 10.1: System Status Signals ......................................................................................................................................................... 156
Table 10.2: Error Response Delay Time............................................................................................................................................... 175

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | vii
Classified as Business
Revision Date Author Information
A 2018/12/19 Jesse C. Loggins Initial Release
B 2019/04/16 Jesse C. Loggins Increased minimum air pressure to implement shift
Added note to Air Pressure Out Of Range to reflect the
minimum air pressure requirement
Added allowable tolerances on Max Sink and Max Source
Currents Added limits to 24 V power supply for proper
operation of the solenoid
Added notes to Upshift Failed and Downshift Failed stating
the updated logic
Added notes in Section 7.1, 7.2.1.6 and 7.3.6.1 to reflect
reverse operation in High gear
Added note to MCU CAN Active to reflect the observed
discrepancy
Ensured a consistent 10A Fuse requirement throughout the
Manual
C 2019/12/07 Jesse C. Loggins Decreased minimum air pressure requirement to implement
shift
Added Factory Diagnostic Message under TCU Status
Message 2
D 2020/09/01 Jesse C. Loggins Update to reflect change of ownership to Danfoss

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 8
Classified as Business
1Introduction
Thank you for your purchase of a Danfoss Power Solutions™ PowerPhase®DT2 Drive Train System Motor and
Controller package. Notify Danfoss Power Solutions immediately if any damage has occurred during shipment.
PLEASE READ THIS ENTIRE MANUAL BEFORE APPLYING VOLTAGE TO THE SYSTEM.
This manual applies to any Drivetrain found in Table 1.1.
Table 1.1: ED-DT318B systems
Editron Product Model Description Code Description Former UQM Designation
ED-DT / EDITRON SUB SOLUTIONS (Electric drivetrain system with transmission)
ED-DT318B-PT2370E-360 ED-DT Drivetrain Sub Solution DT2 HD 220(+)
ED-DT318B-PT3050-600 ED-DT Drivetrain Sub Solution DT2 HD 250
ED-DT318B-PT3050E-600 ED-DT Drivetrain Sub Solution DT2 HD 250(+)
This state-of-the-art system is specifically designed for high performance drive applications. The shipped
package consists of 2 parts:
•A high performance, liquid cooled, Brushless Permanent Magnet (PM) motor attached to a two speed
pneumatically controlled transmission and a system level control processor referenced in this manual as
the Transmission Control Unit or TCU.
•A high-power, liquid-cooled inverter with a full-featured digital signal processor (DSP) controller
referenced in this manual as the Motor Control Unit (MCU), the controller or the inverter depending on
the functionality being discussed.
This manual covers installation and operation of the PowerPhase®DT2 System. The system is ready to use,
powerful, lightweight, rugged, reliable, and designed based upon Danfoss Power Solutions’ years of experience
developing and manufacturing motors and controllers for electric drive systems.
This manual also provides an overview of the CAN interface of a Danfoss Power Solutions Motor Control Unit
(MCU) coupled to an Eaton 2 speed transmission with a Transmission Control Unit (TCU). It includes details of the
CAN message layout and addressing schemes for command, feedback, and status messages.
The system provides many features required to develop a customized, high performance drive application. The
system is capable of fully regenerative, four-quadrant, bi-directional torque-controlled operation.
The PowerPhase®DT2 system has been validated as a propulsion system. For applications other than propulsion
systems, please contact Danfoss Power Solutions to determine if the PowerPhase®DT2 system is capable of
operation in your desired application.
This guide gives a broad description of the motor, transmission, and controller package. We highly recommend
that you read through these instructions to familiarize yourself with the operation and installation of the
package before you begin installation. Please feel free to contact Danfoss Power Solutions if you have any
questions regarding installation, application, or service.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 9
Classified as Business
DANGER
Dangerous voltages, currents, and energy levels exist in this product. Exercise extreme
caution in the application of this equipment. Only qualified individuals should attempt
to install, set-up, and operate this equipment.
DANGER
Incorrect motor and controller wiring can cause catastrophic failure. Proper connection
of motor cables, signal cable, and DC cable are necessary for safe operation. Do not
swap motor windings to reverse direction.
1.1 About this Guide
This installation guide provides instructions and guidelines for mounting, starting, testing, and operating your
PowerPhase®DT2 system. These instructions are intended for an experienced audience with a high level of
relevant knowledge.
This manual utilizes textual explanations, diagrams, photographs, computer-aided design (CAD) renderings, and
interface control drawings (ICDs) to guide the user through installation and operation. The latest ICD drawings
for the PowerPhase®DT2 system are available by contacting Danfoss Power Solutions.
This manual is organized as follows: (1)
•Section 1is a general introduction to the PowerPhase® DT2 system
•Section 2covers installation of the PowerPhase® DT2 system
•Section 3covers electrical connections
•Section 4covers cooling requirements for the motor and the inverter
•Section 5discusses vehicle operation considerations
•Section 6describes the hardware and protocols involved in system communications
•Section 7contains the definitions of the CANbus message between the VCU and the TCU
•Section 8describes the diagnostic software used to monitor the MCU
•Section 9describes vibration test results
•Section 10 contains suggested response to status/error conditions.
•Section 11 contains a glossary of terms used in this document.
•Section 12 repeats all the safety notices contained within this document
1.1.1 Conventions
The inverter/controller/Motor Control Unit assembly may be referred to as the ‘controller’, the ‘inverter’ or
the ‘MCU’ depending on the specific functionality being discussed.
You, the customer and reader of this manual, are referred to as ‘the user.’
The Signal Cable (Cable E in Figure 1.1) may be referred to as motor position or temperature cable.
Clickable links to other sections in the manual, such as figures or appendices, are red.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 10
Classified as Business
1.1.2 Control Units
This manual makes extensive references to three control units with different areas of responsibility. These units
are:
VCU: Vehicle Control Unit – The customer supplied unit which has overall control to the vehicle. The VCU
sends commands to and receives status from the TCU
TCU: Transmission Control Unit – The vendor supplied unit which controls the amount of torque supplied to
the vehicle’s drivetrain. The TCU receives commands from and reports status to the VCU. In turn, the
TCU uses the commands from the VCU to control the MCU.
MCU: Motor Control Unit – The vendor supplied unit which controls the vehicle’s motor. The MCU receives
commands from and reports status to the TCU. The MCU uses the commands from the TCU to control
speed of the motor, the electricity to drive the motor and the electricity generated by the motor. The
term MCU refers specifically to the DSP processor board located within the inverter.
1.1.3 Safety Information
The procedures described in this guide are highly technical and involve high voltage equipment which rotates at
thousands of rpm. Accidents involving this equipment could result in severe injury or death. Please read and
understand the entire guide before beginning to install the motor or controller.
The following notices signal possible hazardous situations or other important information:
DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious
injury.
WARNING Indicates a hazardous situation that, if not avoided, could result in death or serious
injury, or catastrophic damage to the equipment.
CAUTION Indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury or damage to the equipment.
NOTICE Emphasizes important information or advice.
1.1.4 High Voltage Safety Information
DANGER
Exposure to high voltage can cause shock, burns, and even death.
Technicians with special training and knowledge are required to service the high
voltage components in the vehicle.
High voltage components are identified by labels. Do not remove, open, take apart, or
modify these components.
High voltage cable or wiring has an orange covering. Do not probe, tamper with, cut,
or modify high voltage cable or wiring.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 11
Classified as Business
1.2 Packaging and Disassembly
The standard packaging for the PowerPhase®DT2 system will consist of the MCU/controller/inverter, the Drive
Train (the motor and transmission), and the associated cables, connectors and pins. The total weight of the
controller is 37 kg and motor/transmission is 176 kg.
WARNING
Both the motor/transmission and controller are very heavy! Be careful while removing
the products from packaging to avoid dropping the components and potentially
damaging the products.
1.3 The following items are included in the packaging:
•The Controller/Inverter/MCU with a ship kit containing bolts for high voltage and bolts for cover.
•The Motor/Transmission/TCU with a ship kit containing mating connectors with pins/hardware for
fabricating cable between the drivetrain interface connector (connector 3 in Figure 1.1) and the Vehicle
Control Unit.
•The TCU to MCU Interface Cable (item C in Figure 1.1).
•The Signal Cable (item E in Figure 1.1).
•DC Cable (item F in Figure 1.1).
•The ship kit will also contain the connector housings and pins/hardware to fabricate cable between the
Drivetrain Interface Connector (connector 3 in Figure 1.1) and DT2 Diagnostic Connector (connector 4 in
Figure 1.1). Note: The customer is responsible for supplying the cabling between the VCU, the DT2
Diagnostic Connector, and the Drivetrain Interface Connector.
1.4 System Overview
The PowerPhase®DT2 system converts the High Voltage DC battery voltage into torque as an output from the
transmission, and converts vehicle inertia as torque input to the transmission to electricity to charge the High
Voltage DC battery. The system overview block diagram is shown below.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 12
Classified as Business
Figure 1.1: Block Diagram of the Total System
A. Motor & 2 speed transmission — Installation of the Motor & 2 speed transmission is defined in
this user/installation manual.
B. Motor Controller (MCU) — Installation of the Controller is defined in this user/installation
manual.
C. TCU to MCU Interface Cable — Danfoss Power Solutions supplies this Interface Cable. The
cable length is defined as part of the purchase order (2.5 meters if not otherwise specified).
D. Phase Cable — Included as part of the motor. Danfoss Power Solutions supplies the Phase Cable.
The cable length is defined as part of the purchase order (2 meters if not otherwise specified).
E. Signal Cable —Danfoss Power Solutions supplies this Position Cable. The cable length is defined
as part of the purchase order (2.6 meters if not otherwise specified).
F. High Voltage DC Cable — See the documented ICD drawing. The cable length is defined as
part of the purchase order (2 meters if not otherwise specified).
G. Ground Strap – Customer builds using 4 gage or larger wire. Braided ground strap wire is
recommended.
H. Drivetrain Control Cables– Customer builds. The customer is responsible for all components
including proper termination of CAN buses. The customer is responsible to ensure proper wire
crimps are performed to the terminals.
1. 12-pin Deutsch connector – Connects the MCU to the TCU via the TCU to MCU interface
Connector

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 13
Classified as Business
2. 10-pin MCU Interface connector – Connects the TCU to the MCU via the TCU to MCU interface
Connector
3. 16-pin User Interface connector – Connects the TCU to the VCU and provides access to the
TCU to MCU CAN bus and the MCU’s RS232 port.
4. Diagnostic Connector – Customer responsibility. Provides configuration and troubleshooting
access to the TCU and MCU.
1.4.1 Vehicle Control Unit
The Danfoss Power Solutions system requires a vehicle level controller with the following expectations:
•PowerPhase® DT2 systems are designed to act as torque slaves within the vehicle system which receive
torque, speed limit, and direction of travel commands from a vehicle level controller and react with
appropriate torque to maintain direction of travel at or below the speed limit.
•The vehicle designer is responsible for providing the 24 V low voltage power for both the Traction
Control Unit (TCU) and Motor Control Unit (MCU). Danfoss Power Solutions recommends that the VCU
control the voltage supplied to the TCU & MCU. The current requirement for low voltage is 10 amps and
the voltage supply line should be appropriately fused.
•The VCU is the system that takes various vehicle inputs (e.g., accelerator, brake pedals, and PRNDL),
determines the desired action for the Danfoss Power Solutions system, and communicates the desired
commands to the TCU.
•The vehicle control module must include hardware and software to ensure that accurate commands are
issued to the TCU.
•It is the user’s responsibility to determine and control the Danfoss Power Solutions system properly.
•The user is responsible for integrating the Danfoss Power Solutions system into the vehicle and must
implement any regulatory requirements to ensure compliance.
•All vehicle level feedback and safety features are the responsibility of the vehicle system and NOT the
Danfoss Power Solutions system.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 14
Classified as Business
2Installation
This section provides information on mounting the drivetrain and controller in your vehicle. The installation
process for the Danfoss Power Solutions system is fairly straightforward but requires planning and caution to
avoid potential injury and/or damage to you or the equipment.
2.1 Avoiding Installation Problems
Please be aware of the following potential installation issues, which will cause damage or non-operational
equipment:
WARNING Do not modify, or cut and re-solder, the Position cable length. If you need an alternate
length, contact Danfoss Power Solutions.
WARNING Do not modify, or cut and re-solder, the Phase cable length. If you need an alternate
length, contact Danfoss Power Solutions.
WARNING
The DC cable length can be shortened if necessary. The customer is responsible for
the termination to the battery system and for ensuring proper termination of the
shielding is achieved.
WARNING Ensure that the motor shaft will remain unobstructed during acceleration.
WARNING Do not open the controller or motor housings.
CAUTION Ensure that there is sufficient liquid cooling and flow rate of coolant.
2.2 Installing the MCU/Controller
This section describes the guidelines for installing the controller for optimum performance and maximum life.
Mounting dimensions of the liquid-cooled controller are shown in ICD drawing.
2.2.1 General Notes
The controller may be mounted in any orientation. Danfoss Power Solutions advises that the cable entry points
are NOT located on the top of the assembly, to avoid fluids wicking into the controller via the signal cable or user
interface cable. Secure the controller using four M10 bolts (user supplied), thru the mounting holes at the
corners of the case. The mounting points should be flat within 0.25 mm. The user is responsible for determining
the correct torque to apply to the M10 bolts. Controller is not to be mounted to the Motor Transmission
Assembly or support structure for the Motor Transmission Assembly.

Installation and Operation Guide
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Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
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2.2.2 Vibration Considerations
The controller is to be mounted to the vehicle frame that is supported by the suspension system of the vehicle.
CAUTION
Vibration isolators at the mounting points of the controller are required when the
vehicle vibration levels at the controller mounting location are in excess of typical
automotive or commercial vehicle levels.
Danfoss Power Solutions has qualified the controller to the vibration levels stated in Appendix A: Vibration
Testing. It is the responsibility of the integrator or vehicle manufacturer to determine the vibration levels in the
application and when necessary, specify, install and maintain the vibration isolators.
2.2.3 Cable Routing
Route the cables in a way that avoids unnecessary binding and premature wear. Do not locate connections in
close proximity to any surface or connector that could short the motor leads.
CAUTION
The customer must route and secure the Phase Cables, DC Cable, Signal Cable, and
TCU to MCU Interface Cable and Drivetrain Control Cables in such a manner as to
ensure that connector housings and sealing interfaces are not stressed during
installation or operation.
2.2.4 Preparing the Coolant Loop for MCU and Motor
Danfoss Power Solutions requires that the controller be the first component in the coolant loop. The controller
coolant ports function as either inlet or outlet. The performance of the system is not impacted by which
controller coolant port is used for inlet or outlet. The temperature of the coolant going to the controller must not
exceed 60°C to achieve full performance (reference the flow rates in ICD).
The coolant fittings on the controller are intended for a 20mm hose. The coolant must have a minimum flow of
10 LPM.
If the customer elects to use the Eaton 5586750 heat exchanger (oil to water) to cool the transmission lubrication
fluid, the coolant supply to the cooler must Not be in line with the inverter or the motor.
CAUTION Never allow the controller to operate unless the coolant is flowing at a minimum flow
rate of 10 LPM.
There is no restriction on the maximum coolant flow. However, the system is designed for a maximum operating
pressure of 30 PSI.
2.2.5 Routing the Signal Cable
The Signal Cable (cable E in Figure 1.1) contains information about the position of the rotor, and the
temperatures of the motor’s rotor and stator. The controller depends on that information to properly control the
motor. The data integrity of the Signal Cable is necessary for optimum operation and care must be taken to
ensure the reliability of these signals.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 16
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Please exercise care with the routing of this cables to prevent them from being scraped, damaged, cut, shorted,
unplugged, or disturbed by high voltage noise fields. Do not route these cables near any DC power cables or the
motor phase cables.
2.2.6 Routing the TCU to MCU Interface Cable
The TCU to MCU Interface Cable (cable C in Figure 1.1) provides 24 V power to the MCU, CAN signals from the
TCU, and RS232 com signals from the Diagnostic Software (Section 8). As with the Signal Cable, insuring data
integrity is required for optimum performance.
Please exercise care with the routing of this cables to prevent them from being scraped, damaged, cut, shorted,
unplugged, or disturbed by high voltage noise fields. Do not route this cable near any DC power cables or the
motor phase cables.
Note: When specifying a non-standard length for this cable, consideration must be given to the approximately
0.6 m distance from the face of the motor (the point of attachment for the Signal Cable) to the TCU mounting
bracket (the attachment point for the TCU to MCU Interface Cable).
2.2.7 Applying Voltage
For safe operation of the PowerPhase®DT2 system, the TCU must have the 24 V system powered up and the TCU
Enable (Section 7.2.1.5) and the MCU CAN Active (Section 7.3.2.15) signals must be set to true (1) before high
voltage is applied. The 24 V power must remain on and TCU Enable must remain true as long as high voltage is
applied.
If at any time either of these conditions is not met while the vehicle is in motion, the high voltage should be
disconnected from the inverter and the vehicle should be brought to a complete stop before high voltage is
reapplied to the inverter. Failure to do so may result in uncontrolled surges in high voltage which may damage
the high voltage battery, the high voltage battery control unit or the inverter itself.
CAUTION For proper solenoid operation, the 24 V supply must be no lower than 20.4 V and no
higher than 28.8 V.
2.3 Installing the Motor & 2 Speed Transmission
The interface dimensions and tolerances of the PowerPhase®DT2 system can be found on the ICD drawing. Please
discuss any other methods with Danfoss Power Solutions Engineering before implementing.
2.3.1 Connection of the driveline to the transmission output flange
The output flange (mounts to transmission) is XS type, ISO 8667 cross serrated. The functional limiting torque of
the output flange is 14 kNm. The mating driveline flange mounts to output flange and is part of driveline
assembly. It is an XS type flange and shall comply with ISO 12667 requirements for cross serrated flanges. The
mounting fasteners used to join the output flange to the driveline flange will be supplied by customer and sized
according to driveline requirements. Driveline assembly must conform to a balance quality grade of G16 as per
ISO 1940-1-2003.
WARNING
Axial loading of the transmission output flange induced by the coupling system can
result in premature transmission failure. Users of the system MUST ensure the output
flange is not improperly loaded.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 17
Classified as Business
2.3.2 Mounting the Motor/Transmission into the vehicle
The customer is responsible for the design of motor / transmission mounting brackets. Refer to Figure 2.1 (left
side) and Figure 2.2 (right side) for attachment points for bell housing (motor) mounting brackets. Mounting
holes for bell housing mounting brackets are M12x1.75 X 24mm deep. The fastener thread engagement for bell
housing mounting holes is 18mm (minimum) and 24mm (maximum). The torque specification for bell housing
mounting holes is 80 – 105 Nm.
WARNING The fastener thread engagement for bell housing mounting holes must not exceed
24mm.
The transmission housing mounting brackets will be attached to the transmission at the locations specified in
Figure 2.1 and Figure 2.2. The customer is responsible for replacing existing fasteners with fasteners of
comparable strength and of correct length to ensure full thread engagement of the M10x1.5 nut with the
addition of their mounting brackets. The torque specification for M10x1.5 nuts is 60-70 Nm.
Figure 2.1: Left Side – attachment points for bell housing & transmission mounting brackets.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 18
Classified as Business
Figure 2.2: Right Side – attachment points for bell housing & transmission mounting brackets.
Figure 2.3: Approved location of vibration isolators.

Installation and Operation Guide
ED-DT318B
Drive Train Systems with Traction Control, Inverter/Controller, and Motor with 2 Speed Transmission
BC353060341319en-000101 Revision D © Danfoss | November 2020 | 19
Classified as Business
If the fastener securing the wire harness to the transmission (at topmost transmission mounting point in Figure
2.2) is disrupted and used for a mounting bracket attachment point, it is the customer’s responsibility to fasten
the wire harness to the transmission in the same position as the original wire harness mounting scheme. The
wire harness must be secured to alleviate any potential of rubbing on transmission housing and respective
components, if this requirement is disregarded damage to harness may occur.
Each mounting bracket (4X) should incorporate an adequately sized vibration isolator.
The minimum distance from the isolator to the centerline of the transmission output shaft is 200mm; refer to
Figure 2.3 for recommended location of isolators. The Danfoss Power Solutions recommended isolator is
Hutchison 22003, 11, 12 or 13 and should be sized based on customer requirements. The customer should
contact Hutchinson, Inc. directly at 1-508-417-7000 to discuss specific vehicle application requirements.
WARNING The motor housing is not a structural member and is not intended to bear structural
loads.
WARNING
Exercise care when mounting the motor and transmission to ensure that moving
parts are not constrained and proper clearances are observed. All drive mechanisms
mounted to the transmission shaft must be properly secured.
WARNING
Loads on the motor shaft induced by the coupling system can result in premature
motor failure. Users of the motor MUST ensure the motor shaft is not improperly
loaded.
WARNING
A separate ground wire must connect the motor case to the controller housing. High
Voltage lines (positive or negative) must not be tied to the chassis, or the motor and
controller/inverter cases. Please see Section 3.2 for more information on grounding
requirements.
2.3.3 Overall Clearance Recommendation
•At least 19mm required clearance for powertrain package with surrounding structure
•Transmission shall be angled between 3 and 9.75 Degrees downward from level ground.
Figure 2.4: Mounting angle limits