User Manual

Dana TM4 Compact Display

Compact Display Manual Revision 01 NetGain Motors, Inc. Page 1 of 17

 Table of Contents
Compact Display Capabilities .................................................................................................................................................. 3
Compact Display Specifications .............................................................................................................................................. 4
Compact Display Pinout .......................................................................................................................................................... 5
Compact Display Female Mating Plug................................................................................................................................. 5
Diagnostic Mode and Display Keys ......................................................................................................................................... 6
Fault Code Guide ..................................................................................................................................................................... 8
Additional Support ............................................................................................................................................................ 13
Settings.................................................................................................................................................................................. 14
Overview ........................................................................................................................................................................... 14
Display’s Speedometer Settings........................................................................................................................................ 14
Operating Profile Selection Settings ................................................................................................................................. 15
Indicator Style Settings ..................................................................................................................................................... 16
Notes ..................................................................................................................................................................................... 17

Figure 1. Compact Display Engineering Drawing .................................................................................................................... 4

Figure 2. Compact Display Male Connector ............................................................................................................................ 5
Figure 3. Compact Display Female Connector ........................................................................................................................ 5
Figure 4. Diagnostic Code Level Priority List ........................................................................................................................... 6
Figure 5. Diagnostic Code Level Priority List ........................................................................................................................... 7
Figure 6. Diagnostic Code Level Priority List ........................................................................................................................... 8
Figure 7. Diagnostic Code List ............................................................................................................................................... 13
Figure 8. Configure – Traction – Global – Control Mode....................................................................................................... 14
Figure 9. Configure – System – Operating Profiles................................................................................................................ 15
Figure 10. Configure – System – Displays ............................................................................................................................. 16

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 Compact Display Capabilities
The SME Compact Display is an optional add-on component for any HyPer-Drive X1 or HyPer-Drive
X144 controller/Inverter. The immediate EV capabilities of the Compact Display include:

• Display vehicle speed in MPH or KM/H. This is a calculated value determined by tire diameter and up
to two gear ratios.

• Display active fault code of highest priority.

• Indicate main battery pack state of charge.

• Indicate de-rating due to Motor or Inverter over-temperature.

• Cycle between 3 operating profiles with push button (E/S/H) switch. Must be assigned in clone file.

• Not available in 2BD Firmware: View parameter values and states in “Diagnostic Mode”. Pressing
ENTER and DOWN keys together for 2 seconds will enter the display’s Diagnostic mode.

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 Compact Display Specifications

Figure 1. Compact Display Engineering Drawing

Figure 1 Compact Display Engineering Drawing

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 Compact Display Pinout

Figure 2. Compact Display Male Connector

Figure 2 Compact Display Male Connector

Compact Display Female Mating Plug

4 1
Add-On for HyPer 9 IS:
Econoseal .070 MK-II 8 POS
Plug Part# 2822393-1 or 174982-2
Pin Part# 171662-1 or 171630-1
Locking Plate Part Part# 174983
8 5

Compact Display - 8 Position Connector

Pin Name Position
8 +12V Out K1-10
7 I/O Ground K1-12
6 Not Connected N/A
5 LIN-BUS K1-15
4 Digital Input 1 TBD
3 Digital Input 2 TBD
2 Digital Input 3 TBD
1 Digital Input 4 TBD
Figure 3. Compact Display Female Connector

Figure 3 Compact Display Female Connector

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 Diagnostic Mode and Display Keys
Diagnostic Code Lists
# Variable Names Unit # Variable Names Unit
1 Key switch voltage dV 19 Digital Input 9 Logic state 0/1
2 DC Bus Current dA 20 Drive Out 1 % if used
3 Capacitors Voltage dA 21 Drive Out 2 % if used
4 5V Supply mV 22 Drive Out 3 % if used
5 12V Supply mV 23 Drive Out 4 % if used
mV Logic state 0/1
Analog Input 1 Voltage 24 Digital Out 1
- % duty cycle
mV Logic state 0/1
7 Analog Input 2 Voltage 25 Digital Out 2
- % duty cycle
8 Analog Input 3 Voltage mV 26 Motor - Encoder channels mV
9 Analog Input 4 Voltage mV 27 Motor - Speed Ref RPM
10 Analog Input 5 Voltage mV 28 Motor - Speed RPM
11 Digital Input 1 Logic state 0/1 29 Motor - Throttle request %
12 Digital Input 2 Logic state 0/1 30 Motor - Torque %
13 Digital Input 3 Logic state 0/1 31 Motor - Temperature °C
14 Digital Input 4 Logic state 0/1 32 Motor - Cutback Temperature °C
15 Digital Input 5 Logic state 0/1 33 Inverter - Current dArms
16 Digital Input 6 Logic state 0/1 34 Inverter - Modulation depth %
17 Digital Input 7 Logic state 0/1 35 Inverter - Temperature °C
18 Digital Input 8 Logic state 0/1 36 Inverter-Cutback Temperature °C

Figure 4. Diagnostic Code List

Figure 4 Diagnostic Code Level Priority List

The table below explains the interaction of the user and the display keys.
Key Function Description
This function is active only in case of Operating Profile changeable by display.

Pressing only the ESH Key for 1s, the Operating Profile will change as described below.

ESH • Profile 1 -> Profile 2

• Profile 2 -> Profile 3
• Profile 3 -> Profile 1

The ESH Key must be steady pressed, otherwise the Operating Profile will not change.

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 • If the display is in Diagnostic State, by pressing the UP key the user can scroll the
diagnostics list of variables.
• This function is active only in case of traction speed limiting settable by display.
UP/TURTLE
Pressing only the UP/TURTLE key for 200ms, the traction speed will be limited to the
value desired.

• If the display is in Diagnostic State, by pressing the ENTER key the display will return
ENTER to its previous state (before entering Diagnostic one).

• If the display is in Diagnostic State, by pressing the DOWN key the user can scroll the
diagnostics list of variables.
• If it is enabled the function for trip reset by display and the display is visualizing the trip
distance, pressing DOWN key for 5s the trip value will be reset.
• If the display isn't in Diagnostic state, pressing the DOWN key the display will enter
DOWN into its scrolling state.

The display will exit from the scrolling state only if the system goes on fault. Otherwise,
once entered in this state, the user pressing UP/TURTLE and DOWN keys can
visualized cyclically the system time, the system distance, the key-on time and the trip
distance.

Pressing ENTER and DOWN keys together for 2s, the display will enter in Diagnostic mode.

In this situation, basic system information such as inputs, outputs, motor/controller temperatures
ENTER & DOWN are visualized to monitor these values through COMPACT display.

In Diagnostic state, variable list is scrolled through by pressing UP/TURTLE and DOWN keys.
To exit from Diagnostic state, the user must press only the ENTER key.

Figure 5. Display Key Interaction

Figure 5 Diagnostic Code Level Priority List

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 Fault Code Guide
The HyPer-Drive X1™ may indicate Fault Codes ranging from al no.1 to al no.107. If the controller is in a
fault condition, the Fault Code can be retrieved through your Compact Display, CANBUS Communication, or
through any version of the SmartView Software. A list of each code and its level is provided below. For further
information on these codes, please refer to the Diagnose tier of SmartView’s Help section, and click on any
Fault name for a troubleshooting guide.

• Level: anomalous working conditions are indicated by different alarm levels, classified as follows,
depending on their effects on the system:

Level Priority Action Icon

• Main Contactor: Opened
• Motors: Disabled
Blocking 1 (THE HIGHEST)
• Outputs: Disabled

• Main Contactor: Closed

• Motors: Stopped
Stopping 2
• Outputs: Enabled

• Main Contactor: Closed

• Motors: Limited
Limiting 3
• Outputs: Enabled

• Main Contactor: Closed

• Motors: Enabled
Warning 4 (THE LOWEST)
• Outputs: Enabled

• Main Contactor: Closed

• Motors: Enabled
Ready No Faults
• Outputs: Enabled

Figure 6. Fault Code Level Priority List

Figure 6 Diagnostic Code Level Priority List

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 Code Fault Set Condition Level
Key-switch voltage or capacitors voltage is above the maximum
1 Over Voltage Blocking
level allowed for the controller.
Key-switch voltage or capacitors voltage is below the minimum
2 Under Voltage Blocking
level allowed for the Controller.
Key-switch voltage is above the maximum level defined by the
3 User Over Voltage Blocking
user via related parameter.
Key-switch voltage is below the minimum level defined by the
4 User Under Voltage Blocking
user via related parameter.
5 Inverter 1 Over Current Inverter 1 phase current exceeded its current limit. Blocking
6 Inverter 2 Over Current Inverter 2 phase current exceeded its current limit. Blocking
7 Not Assigned - -
Inverter 1 Over
8 Inverter 1 power module temperature is above +100°C. Blocking
Temperature
Inverter 2 Over
9 Inverter 2 power module temperature is above +100°C. Blocking
Temperature
Inverter 1 High
10 Inverter 1 power module temperature is above +80°C. Limiting
Temperature
Inverter 2 High
11 Inverter 2 power module temperature is above +80°C. Limiting
Temperature
Inverter 1 Under
12 Inverter 1 power module temperature is below -40°C. Blocking
Temperature
Inverter 2 Under
13 Inverter 2 power module temperature is below -40°C. Blocking
Temperature
Inverter 1 Current
14 Current sensor of Inverter 1 measures an invalid offset at key on. Blocking
Sensor Fault
Inverter 2 Current
15 Current sensor of Inverter 2 measures an invalid offset at key on. Blocking
Sensor Fault
16 Not Assigned - -
Inverter 1 Temp Sensor Difference between Inverter 1 and microprocessor temperature
17 Stopping
Fault greater than 70°C.
Inverter 2 Temp Sensor Difference between Inverter 2 and microprocessor temperature
18 Stopping
Fault greater than 70°C.
Motor 1 Over Motor 1 temperature is above the Motor 1 Over Temperature
19 Stopping
Temperature defined by the user via related parameter.
Motor 2 Over Motor 2 temperature is above the Motor 2 Over Temperature
20 Stopping
Temperature defined by the user via related parameter.
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 Motor 1 High Motor 1 temperature is above the motor Start Cutback
21 Limiting
Temperature Temperature defined by the user via related parameter.
Motor 2 High Motor 2 temperature is above the motor Start Cutback
22 Limiting
Temperature Temperature defined by the user via related parameter.
Motor 1 Temp Sensor
23 Motor 1 temperature sensor value is out of permitted range. Limiting
Fault
Motor 2 Temp Sensor
24 Motor 2 temperature sensor value is out of permitted range. Limiting
Fault
Key-switch Voltage or Capacitors Voltage is above the
25 High Voltage Controller Starting Cutback Voltage defined by the user via Limiting
related parameter.
Key-switch Voltage or Capacitors Voltage is below the
26 Low Voltage Controller Starting Cutback Voltage defined by the user via Limiting
related parameter.
Microprocessor Over
27 Microprocessor temperature is above 125°C. Blocking
Temperature
28 +5V Supply Failure +5V supply is outside the +5V ± 10% range. Blocking
29 +12V Supply Failure +12V supply is outside the +12V ± 10% range. Blocking
Sin/Cos inputs values are above/below the fault thresholds or
30 Encoder 1 Fault Blocking
spin sensor offset is not right.
31 Encoder 2 Fault Sin/Cos inputs values are above/below the fault thresholds. Blocking
Driver Output 1
32 Driver Output 1 is either opened or short-circuited. Blocking
Open/Short
Driver Output 2
33 Driver Output 2 is either opened or short-circuited. Blocking
Open/Short
Driver Output 3
34 Driver Output 3 is either opened or short-circuited. Blocking
Open/Short
Digital Output 1
35 Digital Output 1 is either opened or short-circuited. Blocking
Open/Short
Digital Output 2
36 Digital Output 2 is either opened or short-circuited. Blocking
Open/Short
37 EEPROM Failure Error during read/write operation in EEPROM memory. Blocking
38 EEPROM Corrupted Memory CRC doesn't match. Blocking
Driver Output 4
39 Driver Output 4 is either opened or short-circuited. Blocking
Open/Short
Pre-charge of internal line capacitors is too fast or capacitors
40 PreCharge Circuit Fault Blocking
voltage is fixed to zero during precharge.

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 Pre-charge phase fails to charge capacitors till the voltage level
41 PreCharge Failed Blocking
of key input.
Before closing the line contactor, internal capacitors are loaded
42 Main Contactor Welded Blocking
for short time and voltage doesn't go down.
Main Contactor Did Not The difference between key switch and capacitors voltage is too
43 Blocking
Close high after the contactor has been powered.
44 Interlock Disabled Interlock input is not active and line contactor is open. Stopping
Static Return to Off One or more traction inputs are active at the key on, after an
45 Warning
Traction Emergency stop or a controlled stop procedure.
Static Return to Off One or more hydraulic/pump inputs are active at the key on after
46 Warning
Hydraulic a controlled stop procedure.
47 Traction Throttle Fault A fault condition of traction throttle is detected. Stopping
48 Hydraulic Throttle Fault A fault condition of hydraulic/pump throttle is detected. Stopping
49 Brake Throttle Fault A fault condition of brake throttle is detected. Stopping
50 Service Time Expired Service Timer has expired. Warning
Low Battery State of Battery state of charge estimated is lower than minimum value
51 Limiting
Charge defined by the user via related parameter.
52 Wrong Parameter Parameter setting is out of the permitted range. Blocking
53 Restart Required Changed a parameter setting. Blocking
54 Can Bus Off Bus Off condition detected. Stopping
55 Can Open Circuit Messages no longer received. Stopping
Can Bad Wiring or Short Can bus synchronization phase failed or bus off condition
56 Blocking
Circuit detected.
57 Not Assigned - -
58 Not Assigned - -
59 Not Assigned - -
60 Not Assigned - -
61 Not Assigned - -
At least one Heartbeat hasn't been received during the startup of
62 Net Timeout Heartbeat Stopping
the network or after the synchronization phase.
63 Net RPDO Timeout At least one PDO hasn't been received. Stopping
Main Contactor Close Pre-charge timer has expired before the master sends the power
64 Blocking
Command Timeout ready request.
Blocking Request From
65 Fault Request is received from Master. Blocking
Master

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 Not
66 Not Assigned -
Assigned
67 Net Startup Timeout The node hasn't been able to synchronize itself to the network. Blocking
68 Net External Failure At least one Node has become not operational. Stopping
Net Mains Manager The Main Contactor Manager has executed a wrong powering
69 Blocking
Wrong Sequence procedure.
Net Mains Manager
70 DC Bus Voltage will not increase after discharging phase. Blocking
Precharge Too Slow
Net Mains Manager
71 The main contactor doesn't close. Blocking
Closing Too Slow
Net Mains Manager At least one fault has occurred on Main Contactor Manager
72 Blocking
Powering Alarm Controller.
At least one node of the network could be wrong configured or
73 CO Synchro Failed Blocking
switched off.
At least one node of the network could be wrong configured or
74 CO Synchro Lost Stopping
switched off during operation.
Stopped For System Node is stopped because another node has a stopping/blocking
75 Stopping
Fault fault condition.
Node is blocked because another node has a stopping/blocking
76 Blocked for System Fault Blocking
fault condition.
77 BMS Wall Charge The TAU Node sets a blocking fault. Blocking
78 BMS Stop The TAU Node sets a stopping fault Stopping
79 BMS Fault The TAU Node sets a blocking fault. Blocking
The TAU Node limits its current to the required value from
80 BMS Limiting Limiting
BMS.
81 Steering Sensor Fault A fault condition of steering sensor is detected. Limiting
CAN Protocol Run Time
82 Wrong Request for Driver Outputs Limiting
Error
83 Programming Required Controller Firmware Programming Blocking
84 DigInputs Overvoltage Digital Input Supply has reached dangerous value Blocking
Inverter Model Not
85 Inverter model is not supported by the firmware. Blocking
Supported
97 Commission In Progress Spin sensor commission is in progress Warning
98 Commission End Success Spin sensor commission end successfully Stopping
99 Commission End Errors Spin sensor commission end with errors Stopping
100 Internal Software Fault 1 Internal Error. Blocking
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 101 Internal Software Fault 2 Internal Error. Warning
102 Internal Software Fault 3 Internal Error. Warning
Internal Hardware Fault
103 Internal Error. Blocking
1
Internal Hardware Fault
104 Internal Error. Blocking
2
Internal Hardware Fault
105 Internal Error. Blocking
3
Internal Hardware Fault
106 Internal Error. Blocking
4
107 Internal Software Fault 4 Internal Error. Blocking

Figure 7. Fault Code List

Figure 7 Diagnostic Code List

Additional Support

If you need additional support to solve Fault Codes signaled by the firmware or strange behaviors of the
vehicle, please contact your Authorized Dealer.

In order to make the collection of information faster, you must provide them:

1. Product Code of the Controller.

2. Clone file of the Controller.
3. Screenshots of the About Page in the Main Menu.
4. Screenshots of the Active Faults Tab in DIAGNOSE
5. Screenshots of the Faults History Tab in DIAGNOSE
6. Screenshots of the Time/Distance Tab in MONITOR

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 Settings
Overview

Setting modifications for the Compact Display are handled in SmartView OEM version that is supplied
to all Authorized Dealers. If you need to modify any of the following parameters, please send your controller’s
current Clone File to your Dealer, along with the list of requested value/setting changes. Below is a list of
possible Compact Display settings.

Display’s Speedometer Settings

Vehicle Mph or Km/h is represented on the Compact Display. Vehicle Speed is calculated using the Tire
Diameter and up to two Gear Ratios. A Digital Input can be assigned and wired to the 2nd Gear sensor for
Second Gear speed calculation.

Figure 8. Configure – Traction – Global – Control Mode

Figure 8. Configure – Traction – Global – Control Mode

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Operating Profile Selection Settings

The HyPer-Drive X1 and X144 offer the use of 3 different performance Operating Profiles. These
profiles can be cycled through using the Compact Display’s (E/S/H) Button, or Digital Inputs.

For HyPer 9 Motor Serial#’s H9000105 and below, Clone files are assigned to select Operating Profile
by Compact Display. All other HyPer Motor Serial#’s are currently assigned to select Operating Profile by
Switches/Digital Inputs. Follow directions in Dealer Programming Overview paragraph for changes to your
Clone file. (We will soon have a download-able clone file option for this change)

Figure 9. Configure – System – Operating Profiles

Figure 9. Configure – System – Operating Profiles

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Indicator Style Settings

The Compact Display provides a list of system condition indicators. The style of these indicators can be
set can be modified on the SmartView OEM Display tab.

Figure 10. Configure – System – Displays

Figure 10. Configure – System – Displays

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 Notes
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