五合一集成控制器

5-in-1 Integrated Control Unit

孙亚东
Sun Yadong

郑州宇通集团有限公司
Yutong Group Co., Ltd.
课程编号： YTTC–05351
20221114 Course No.: YTTC–05351
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GLOBAL TRAINING 1
课程内容 Course Contents

• 1 技术参数
1 Technical Parameters
• 2 功能介绍
2 Function Introduction
• 3 组成结构
3 Structural Composition
• 4 工作原理
4 Working Principle
• 5 专用工具
5. Special Tools
• 6 系统维护
6 System Maintenance
• 7 故障问题及操作步骤
7 Faults and Operation Steps
• 8 系统调试
8 System Debugging

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GLOBAL TRAINING 2
1 、技术参数 Technical
Parameters
1.1 型号说明
1.1 Model description

图像对象
Image object

标识 产品系列 标识 定制机客户代号
Mark Product series Mark Customized machine
customer code

标识 系列名 标识 辅助供电类型
Mark Series name Mark Auxiliary power supply type
第三代铝压铸外壳
The third generation aluminum
die-cast housing
DC/DC+ 高压仓 + 辅助单元 +TM
DC/DC+high-voltage
compartment+ auxiliary 标识 冷却方式
unit+TM Mark Cooling mode
标识 额定电压 液体冷却
Mark Rated voltage Liquid cooling
直流 610v 输入
DC 610v input

标识 驱动器容量 标识 行业线
Mark Drive capacity Mark Industry line
客车
Bus

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GLOBAL TRAINING 3
1 、技术参数 Technical
1.2 主要技术参数
Parameters
1.2 Main technical parameters
TM
额定输入电压
614.4VDC
Rated input voltage
电压范围
200VDC-750VDC
Voltage range
全功率电压范围
480VDC-700VDC
Voltage range of full power
降功率电压范围
200VDC-480VDC
Voltage range of power reduction
额定电流 380A （单路输出）
Rated current 380 A (single-circuit output)
峰值电流 760A/1min （双 / 双路输出）
Peak current 760 A/1min (double/double-circuit output)
额定输出功率
286kW
Rated output power
峰值输出功率
640kW
Peak output power
最高载频
6KHz
Maximum carrier frequency

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GLOBAL TRAINING 4
1 、技术参数 Technical
Parameters
1.2 主要技术参数
1.2 Main technical parameters

EPS/ACM

EPS ACM

额定输入电压
614.4VDC
Rated input voltage

额定输出电流
16A 16A
Rated output current

最高载频 6KHz
6KHz
Maximum carrier frequency

最高控制器效率
≥97% ≥97%
Maximum controller efficiency

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GLOBAL TRAINING 5
1 、技术参数 Technical
Parameters
1.3 主要技术参数
1.3 Main technical parameters
DCDC

DC/DC 电源
DC/DC power supply

输入电压范围
200-750VDC
Input voltage range

满载输出电压范围
400-750VDC
Full-load output voltage range

额定输出电压
27.8VDC
Rated output voltage

额定输出电流
162A
Rated output current

输出峰值电流 175A( 持续输出 6min)

Output peak current 175 A (Continuously output 6min)

额定输出功率
4.5kW
Rated output power

峰值输出功率
5kW/6min
Peak output power

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GLOBAL TRAINING 6
 2 、功能介绍 Function Introduction
2.1 主要功能
2.1 Main function

电机控制器包括主电机控制器、高压配电、 DC/DC 电源模块、助力转向控制器、空压机控制器。

系统总成
The motor control unit includes main motor controller, high voltage distributor, DC/DC power supply module, power steering controller and
System assembly
air compressor controller.
输入电压范围（ DC ）
0~750V
Input voltage range (DC)
外径 25mm ，内径 >=18mm ；流量为 30L/min 时流阻为≤ 40kPa ；流量为≥ 30L/min ，进水口温度≤ 65℃ ，控制器可安全工作；流量为≥ 25L/min ，进水口温度≤ 55℃ ，控制器可安
全工作。
水冷要求
Outer diameter: 25 mm, inner diameter >= 18 mm. When the flow mass is 30 L/min, flow resistance ≤ 40 kPa. When the flow mass is ≥ 30
Water cooling requirement
L/min and inlet water temperature ≤ 65℃, the controller works safely. When the flow mass is ≥ 25 L/min and inlet water temperature ≤
55℃, the controller works safely.
电机控制器带电电路与地（外壳）之间的绝缘电阻在环境温度 40℃ 和相对湿度为 95% 时，在 1000V 测试电压下不小于 5MΩ 。
绝缘性能
When the ambient temperature is 40°C and the relative humidity is 95%, the insulation resistance between live circuit of the motor
Insulation performance
controller and the ground (housing) is not less than 5 MΩ under the test voltage of 1,000 V.

B 级电压部件所用塑料材料（包含线束、电子器件外壳塑料材料、密封胶条、防水胶塞等）的阻燃性能应符合 GB/T 2408-2008 《塑 》规

直
垂
和
法
平
水
定
测
的
能
性
烧
燃
料烧HB 级，垂直燃烧 V-0 级。 B 级电压电缆防护用热收缩的温度等级应不低于
燃
平
水
的
定
125℃ ，热收缩的性能应符合 QC/T 29106-2014 《》 B 的要求。
防火安全要求 For Grade B voltage components, the flame retardant properties of the plastic materials used (including wiring harness, plastic material of
Fire prevention safety the electronic device housing, sealing strip, waterproof plug, etc.) should meet HB level for horizontal combustion and V-0 level for vertical
requirements combustion specified in GB/T 2408-2008 Plastics - determination of burning characteristics - horizontal and vertical test. The temperature
level of heat shrinkage for Grade B voltage cable protection should not be below 125°C. The thermal shrinkage performance should meet
the requirements of Appendix B in QC/T 29106-2014 Technical Specification of Automobile Wire Harness.

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GLOBAL TRAINING 7
 2 、功能介绍 Function Introduction
2.1 主要功能
2.1 Main function

电机控制器采用具有 360 度屏蔽的锁紧头（包括电池正、负， DC/DC 正、负， TM U 、 V 、 W 输出、电空调）。

锁紧头
The motor controller adopts locking heads with 360-degree shielding function (including battery positive and negative, DC/DC positive and
Locking head
negative, TM U, V, W outputs, electric A/C).

CAN 通讯收发器需进行隔离处理；通过 CAN 总线实现 Bootloader 功能或者其它方式烧录，为程序升级提供便利， CAN 通讯一路，其接口设计为 2 路， 2 路 CAN 在收发器前合为一路，并匹配 120Ω 终端电
阻。
CAN 通信
CAN communication transceivers should be isolated. Via CAN bus, Bootloader function or burning in other ways can be realized, providing
CAN communication
convenience for the program upgrade. Port of CAN communication channel-I is designed as two. Two channels of CAN are combined into
one in front of the transceiver and match the 120 Ω terminal resistance.

安全接地 电机控制器中能触及的可导电部分与外壳接地点处的电阻≤ 0.1Ω 。

Safety grounding The resistance between the conductive part that can be reached on the motor controller and the ground point of the housing is ≤ 0.1 Ω.
噪音 电机控制器的工作噪音≤ 60dB 。
Noise Motor controller operating noise ≤ 60 dB.

满足电机峰值转矩 / 功率需求，峰值条件下至少能持续工作 1 分钟；若水温高，导致模块 NTC 温度超过降功率点时，驱动器会提前降功率，过载时间将不足 1min 。

过载能力 Meet motor peak torque/power requirements. At least 1 minute continuous operation under peak conditions. If the temperature of the
Overload capability module NTC exceeds the power drop point due to high water temperature, the drive will reduce the power in advance, so the overload time
will be less than 1 minute.

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GLOBAL TRAINING 8
 2 、功能介绍 Function Introduction
2.1 主要功能
2.1 Main function
电机电角度偏差≤ ±3° 条件下，电机控制器应能容错运行，不发生逐波限流、过流故障。
电角度
When the motor electrical degree deviation is ≤±3°, the motor controller should keep operating in spite of having experienced deviation
Electrical degree
without cycle-by-cycle and overcurrent fault.
控制器最高效率
Controller maximum ≥98 ％
efficiency
在整车制动时，驱动电机及其控制器工作于发电状态并向储能系统充电，发电时的开路电压与动力电池特性匹配，回馈电压及功率根据整车控制器要求确定。
制动能量回馈 When the vehicle is braking, the traction motor and its controller work in power generation status and charge the energy storage system.
Braking energy feedback The open circuit voltage during power generation matches the characteristics of the traction battery. Feedback voltage and power
depend on the vehicle control unit.
接触器粘连检测
具有粘连检测和报警功能，并通过 CAN 通讯上报。
Contactor adhesion
It has adhesion inspection and warning function, and reports via CAN communication.
inspection
使能信号 24V 高有效，要求 DC/DC 使能信号在 12~32V( 范围内可正常启动与工作，且为高有效模式 ) 。
控制功能
The enable signal 24V high is valid. The required DC/DC enable signal is within 12 to 32 V (In this range, it can start and work normally,
Control function
and it is in high valid mode).
对高压、低压、控制信号的上电顺序无要求， DC/DC 、空压机、转向电机等均应正常工作，不至故障保护或损坏。
上电顺序
There is no requirement on the power-on sequence for high voltage, low voltage and control signals. The DC/DC, air compressor and
Power-on sequence
steering motor should work normally without fault protection or damage.

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GLOBAL TRAINING 9
 2 、功能介绍 Function Introduction
2.1 主要功能
2.1 Main function
由于车辆高压系统在电源到负载前端安装有手动开关，在生产和调试过程中会有短时频繁通断的情况发生，所以要求 DCDC\ 转向控制器 \ 空压机本身在控制信号给定及正常工作有输出情况下，可接受 1 分钟内连续通断 5
短时高压通断次数要求 次的冲击，而不至故障或损坏。
Requirements of on-off For the vehicle high-voltage system, a manual switch is installed at the front end of the power supply to the load. During production and
times under high voltage commissioning, it could be frequently on-off in a short period of time. Therefore, it is required that the DCDC\ steering controller \ air
during short time compressor can endure 5 continuous on-off shocks without fault or damage within 1 minute when the control signal is given and when
there is normal operation output.
海拔
5500 米及以下满功率输出 Full power output (5,500 m and below).
Altitude
在 -40℃~+55℃ 环境温度下电机控制器输出应满足电机系统设计峰值特性， +55℃~+85℃ 环境温度下电机控制器应能按规定要求（电机控制器温度降额要求）正常工作。
温度 At ambient temperature of -40℃ to +55℃, output of the motor controller should meet the design peak characteristics of the motor
Temperature system. At ambient temperature of +55℃ to +85℃, the motor controller can work normally according to the specified requirements
(motor controller temperature derating requirements).
在环境温度为 -40℃~+85℃ ，相对湿度不超过 100% 的 《产
考
参
求
要
装
安
加
。
障
故
致
导
而
露
凝
因
不
作
工
常
正
能
应
器
制
控
机
电
，
下
况
情》。
书
明
说
用
使
品
湿度
When the ambient temperature is -40℃ to +85℃ and the relative humidity is not more than 100%, the motor controller can work
Humidity
normally without faults due to condensation. For installation requirements of motor and controller, refer to the Product Instructions.
防护等级 防护等级应满足 GB4208-2008 IP67 、 IP68 要求。
Protection grade The protection grade should meet the IP67 and IP68 requirements specified in GB4208-2008.
电机控制器壳体机械强度
电机控制器壳体应能承受不低于 10kPa 的压强而不发生明显的塑性变形。
Mechanical strength of
The motor controller housing can withstand a pressure of not less than 10kPa without significant plastic deformation.
motor controller housing

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GLOBAL TRAINING 10
3 、 组成结构 Components

3.1 外观结构
3.1 Appearance and structure
4. 电加热
Electric heater

3. 电除霜
Electric defroster

7. DCDC
2. 主电机 Main motor
1. 动力电池 Traction battery
8. 电空调 Electric A/C
6. 助力转向 Power steering
5. 空压机 Air compressor
进水口 Water inlet
出水口 Water outlet

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GLOBAL TRAINING 11
 3 、 组成结构 Components

3.2 外观结构
3.2 Appearance and structure

35Pin 信号端子 35Pin signal terminal

CAN 调试端子 CAN commissioning terminal

旋变端子 Resolve terminal

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GLOBAL TRAINING 12
 4 、工作原理 Working Principle
4.1 控制器端子
4.1. Controller terminal

Microsoft Word
Îĵµ

35pin 端子：整车低压控制信号输入、输出端口
8pin 旋变端子 针脚定义
35pin terminal: Vehicle low-voltage control signal
8pin resolve terminal Definition of pins
input and output ports

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GLOBAL TRAINING 13
 4 、工作原理 Working Principle
4.2 五合一控制器原理图：
4.2 5-in-1 Controller Schematic Diagram:
工作：整车 ON 电源上电，整车控制器 CN6-12 孔 H19 输出 24V 高电平使能信号至封闭电器盒，控制 K5 继电器闭合，
输出电源 H05 至电机控制器 1 、 2 、 5 孔，电机控制器低压上电；
Operate: power on the vehicle ON power supply. The vehicle control unit CN6-12
hole H19 outputs 24V high level enable signal to the sealed electric box to close
the K5 relay, and outputs power supply H05 to 1, 2 and 5 holes of the motor
controller to make the motor controller powered by how voltage.
停机：整车 ON 档电源断开或整车控制器检测到电池系统报故障码 8 （绝缘电阻低）、 13 （电源系统严重故障），使能信号
整车控制器 电机控制器
Vehicle control unit 封闭电器盒 H19 断开，电机控制器低压供电断开。
Sealed electric box Motor controller
Shut down: When disconnecting ON power supply of the vehicle or the vehicle
control unit inspects that battery system reports fault code 8 (low insulation
总火电源
Power supply of resistance) or 13 (serious power supply system fault), the enable signal H19 is
master power disconnected, and low voltage power supply to motor controller is disconnected.

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GLOBAL TRAINING 14
 4 、工作原理 Working Principle
4.3 控制策略
4.3. Control strategy

序号 描述 备注
S/N Description Remarks
整车 ON 档电源断开
1
Disconnect ON power supply of the vehicle

满足以上 2 个条件中任意一个，电机控制器低压供电断开
If any of the above 2 conditions are met, low voltage power supply of the motor controller
电池系统报 8 或 13 故障码
2 is disconnected
The battery system reports fault code 8 or 13

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GLOBAL TRAINING 15
 4 、工作原理 Working Principle
4.4 内控制原理图 KM7 1/ 2

4.4 Internal control schematic diagram KM5 1/ 2

KM6 1/ 2
KM2: 主接缓冲 Main
F5/F6/F7 置于助力转向与空压机驱动控制板 contactor buffer
上 Place on the power steering KM2： 主 接 缓 冲
F5/ F6/ F7 KM4: 辅接缓冲
KM4： 辅 接 缓 冲
and air compressor 置drive
于助力转向与空
Auxiliary contactor F1/F2/F3/F4 置于高压仓内 Place in the
F1. 2 F1/ F2/ F3/ F4
control board 压机驱动控制板上 F3 F4
buffer high-voltage
置于高压仓内 compartment
F5
KM3 1/ 2 KM1 1/ 2

F6
AB C 动力电池 +
动 力battery+
Traction 电池+ C
F7 动力电池 -
动 battery-
Traction 力电池-
UV W UV W

N P N P N P N
助力转向与空压机驱动控制板 DC- DC+ 电除霜 电空调
电加热 TMTM驱 驱动板
助力转向与空压机驱动控制板 电加热 电除霜 电空调
DC- DC 动板
On the power steering and air compressor drive Electric Electric
J1 J2 DC- DC- Electric defroster A/C TM driver board
control
J1 board J1
heater
电除霜为 3pin, 外加电BMS
除 霜 为采样负
3piBMS
Electric defroster is 3pin, plus n, 外 加sampling negative
BMS采 样 负 TMJ 5控制板
J1 TM控 制 板

Contactor 1
Contactor 2
Contactor 3
Contactor 4
Contactor 5
Contactor 6
Contactor 7
接
TM control
J2 J4 J 3panel
接 接 接 接 接 接

接触器 1
接触器 2
接触器 3
接触器 4
接触器 5
接触器 6
接触器 7
触 触 触 触 触 触 触
器 器 器 器 器 器 器 霍尔霍 尔 TM
TM TM 旋变转接板
TM旋 变 转 接 板
1 2 3 4 5 6 7 TMHall TM J1
resolver adapter board
8PIN
8PI N 旋 变 旋变
TM TM
J2
高压仓控制板 Resolver
35PIN 客户端 高压仓控制板
High-voltage compartment
上盖开关
35PIN client
35PI N
客户
control panel J4
上Upper
盖 开 关 cover switch
J3
端

N P P1P2RD1GNDRD2GND
电压采样 Voltage
电 压 采sampling
样

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GLOBAL TRAINING 16
 4 、工作原理 Working Principle
4.5 内控制原理图
4.5 Internal control schematic diagram
正
Positive
熔断器 主接触器 驱动电机控制器 驱动电机
Fuse Main contactor Traction motor Traction motor
controller
Battery

预充接触器 预充电阻
电池

负 Pre-charging
Pre-charging
Negative resistance
contactor

接触器 熔断器
电除霜
Contactor Fuse
Electric defroster
Battery Electric Mold Opening Topology Diagram

接触器 熔断器 电加热

Contactor Fuse Electric heater
熔断器 电动空压机控制器 空压机
电附件接触器 Fuse Electric air Air compressor
Electric auxiliary contactor compressor controller
纯电动开模拓扑示意图

预充接触器 预充电阻 熔断器

Pre-charging contactor Pre-charging resistance 电动转向电机控制器 转向电机
Fuse
Electric steering motor Steering motor
controller
熔断器
24V 蓄电池
Fuse
24V battery

接触器 熔断器 空调
Contactor Fuse A/C

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GLOBAL TRAINING 17
 4 、工作原理 Working Principle

4.6 内控制原理图
4.6 Internal control schematic diagram

高压 +
High-voltage +

电附件
Electric accessories

电辅件
Electrical auxiliary
高压 -
High-voltage -

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GLOBAL TRAINING 18
 5 、专用工具 Special Tools
维修模块 工具 / 紧固件 图标
编号 No.
Repair module Tools/fasteners Icon

保险丝盖接线仓盖控制器上盖控制器下盖 规格 4mm 六角匙

Fuse cover, wiring Specifications: 4mm hex key
1 compartment cover, controller
接线仓盖、控制器下盖、保险丝盖：内六角螺 M5*10 控制器上盖：内六角螺钉 M5*15
upper cover, controller lower
Wiring compartment cover, controller lower cover, fuse cover: Hexagon socket screw M5*10.
cover
Controller upper cover: Hexagon socket screw M5*15

专用工具
Special tools
防水堵头
2
Waterproof plug
防水堵头
Waterproof plug

十字螺丝刀
Cross head screwdriver
PCB 板保险丝
3
PCB board fuse PCB 板：十字槽盘头弾平垫螺钉 M4*10 保险丝：十字槽盘头弾平垫螺钉 M5*12
PCB board: Cross recessed pan head screw with flat washer M4*10. Fuse: Cross recessed pan
head screw with flat washer M5*12

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GLOBAL TRAINING 19
 6 、 系统维护 System Maintenance
6.1 检查内容及标准
6.1 Check content and standards

总成 Assembly 检查内容 Check content 规范及标准 Specification and standard

集成控制器高压线状态 集成控制器接线盒处电缆绝缘层无破损、无干涉、无颜色和状态的异常（如发黑、烧蚀等）。
High-voltage wire status of integrated Cables at junction box of integrated control unit are free of insulation layer damage, interference and
control unit abnormal color and status (such as blackening, ablation, etc.)

接线端子紧固件螺栓和锁紧头无锈蚀、无松动、红漆划线标识无错位。
注：若未进行过维修，只检查外观；若之前进行过维修，对维修记录表中端子的紧固力矩和锁紧头的密封性进行校核；如无维修记录或未记录相关数据，需复查各接线端子紧固力矩
集成控制器
和锁紧头密封性。
Integrated control 集成控制器高压线接线端子
The terminal fasteners and locking heads are free of rust or looseness and the red paint marks are aligned.
unit Terminal of integrated control unit
Note: If no repair is performed, check the appearance only; if repair work was performed before, verify the
high-voltage wire
terminal tightening torque and locking head tightness in the repair records. If no repair records are
available or no relevant information is recorded, double check the terminal tightening torque and locking
head tightness.

集成控制器搭铁线 搭铁线螺栓固定牢固、无松动。
Integrated control unit grounding wire The grounding wire bolt should be firmly fixed and free of looseness.

全球匹配
GLOBAL TRAINING 20
 6 、 系统维护 System Maintenance
6.2 控制器零部件一览表
6.2 List of controller parts and components

序号 S/N 器件名称 Part name

① 保险丝盖板 Fuse cover plate
② 保险丝 Fuse
③ 端子排 Terminal block
④ 高压仓板 High-voltage compartment board
⑤ 端子盖 Terminal cover
⑥ 水嘴 Faucet
⑦ 下盖 Lower cover
⑧ M32 防水堵头 M32 waterproof plug
⑨ M25 防水堵头 M25 waterproof plug
⑩ 上盖 Upper cover
⑪ 控制板 Control board
⑫ 主箱体 Main box
⑬ 小箱体 Small box
⑭ DC-DC

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GLOBAL TRAINING 21
 6 、 系统维护 System Maintenance
6.3 更换保险丝
6.3. Replacement of fuse

安全注意事项：
Safety precautions:
◆ 拆卸时首先拔掉电池端快断器，拆卸盖板前，确保机器下电超过 10 分钟后用万用表测量控制器 DC+ 和 DC- 之间的电压，保证小于 36V 才能操作；
◆ When removing, first unplug the quick breaker at the battery end. Before removing the cover plate, it is powered off over 10 minutes. After that, measure the
voltage between the controller DC+ and DC- with a multimeter, and make sure the voltage is below 36V before going to next step;
◆ 拆卸时避免盖板脱落，可能对设备及人身造成伤害；
◆ During removal, prevent the cover plate from falling which may cause equipment damage and personal injury;
◆ 拆卸时避免螺钉、液体或者金属碎屑进入仓体，否则可能引发短路炸机；
◆ Prevent screws, liquids or metal debris from entering the compartment during removal, which may cause short circuit and therefore machine explosion;
◆ 拆卸时注意避免损坏盖板上密封圈，否则灰尘和水进入机箱，导致控制器寿命缩短甚至炸机；
◆ When removing, avoid damage to the sealing ring of the cover plate, otherwise dust and/or water may enter, resulting in shortening the life of the controller even
machine explosion;
◆ 更换保险丝避免换错；
◆ Do not replace the fuse with an improper one;
◆ 更换完后，需要拧紧盖板螺丝，保证气密性完好。
◆ After replacement, please tighten the cover plate screws to ensure good air tightness.

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GLOBAL TRAINING 22
 6 、 系统维护 System Maintenance
6.4 保险丝盖板拆装与保险丝更换
6.4 Removal and installation of fuse cover plate, replacement of fuse

1. 用规格 4mm 六角匙把保险丝盖板上 4 个 M5 六角螺钉拧下；

Unscrew the 4 M5 hexagon socket screws from the fuse cover plate with the 4mm hex key;

2. 对照盖板内贴纸，更换保险丝； 3. 用规格 4mm 六角匙把保险丝盖板上 4 个 M5 六角螺钉装上（扭紧力矩 2.5±0.3 N.M ），完成安装。

2. Replace the fuse according to the sticker at inner side of the cover plate; 3. Install 4 M5 hexagon socket screws to the fuse cover plate with the 4mm hex key
(tightening torque: 2.5±0.3 N.M) and the installation ends.

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GLOBAL TRAINING 23
 6 、 系统维护 System Maintenance
6.5 更换高压仓板与控制板
6.5 Replacement of high-voltage compartment board and control board

1 、用 4mm 六角匙拆除上盖 M5*15 螺钉，打开上盖 ; 2 、拔掉控制板相关线束，十字螺丝刀拆掉高压仓板螺钉（十字槽盘头螺钉组合件 M4*10 ，十字槽盘头自攻螺钉

1. Remove M5*15 screws from the upper cover with a 4mm hex key and PT3*10 ），取出并更换高压仓板。
2. Unplug wiring harness from the control board. Remove screws from
open the upper cover;
the high-voltage compartment board with a cross head screwdriver (cross
recessed pan head screw combination M4*10, cross recessed pan head
tapping screws PT3*10). Take out the high-voltage compartment board
and replace it.
安装时先将 M4*10 螺钉带上，锁紧 PT3*10 自攻螺钉后，再锁紧 M4*10 螺钉。
When installing, pre-install the M4*10 screws and tighten the PT3*10
tapping screws. After that, tighten the M4*10 screws.

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GLOBAL TRAINING 24
 6 、 系统维护 System Maintenance
6.5 更换高压仓板与控制板
6.5 Replacement of high-voltage compartment board and control board

3 、拔掉控制板相关线束，拆掉高压仓板螺钉（十字槽盘头螺钉组合件 M4*10 ）取出并更换 , 控制板，锁紧对应螺钉。 4 、线束插接 OK 后安装上盖，安装上盖时检查上盖与箱体配合的密封件是否安装良好

4. Insert wiring harnesses and then install the upper cover. When
3. Unplug wiring harness from the control board. Remove screws from installing the upper cover, check whether sealing parts for the upper
the high-voltage compartment board (cross recessed pan head screw cover and compartment are properly installed
combination M4*10). Take out the control board and replace it. Tighten
corresponding screws.

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GLOBAL TRAINING 25
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.1 通讯故障
7.1 Communication fault
通讯故障 Communication fault:
CAN_C 初始化故障： CAN_C 初始化超过 1.6S 未配置成功。
CAN_C initialization fault: The CAN_C initialization exceeds 1.6 seconds, and it is not successfully configured.
CAN_C 发送 / 接收超时故障：在宇通协议下， CAN_C 超过 2S 未发送成功。
CAN_C sending or receiving timeout fault: CAN C is not sent successfully over 2s under Yutong protocol.
故障对车辆的影响
Impact of the fault on the vehicle:
(1) 车辆无法上高压
(1) The high voltage of the vehicle cannot be powered on
(2) 上高压后出现车辆断动力
(2) After high voltage of the vehicle is powered on, power of the vehicle is cut off
解决措施 Solution:
1. 整车上低压电，用万用表测量低压 35PIN 端子， Pin13 、 Pin14 端子的阻值、
1. Power on low voltage of the vehicle, and measure resistance of low-voltage 35PIN terminal, Pin13 terminal and Pin14 terminal
with a multimeter
通讯电压是否在范围内、对地是否短路（对地短路确认控制器是否损坏） 阻值： 120±5Ω
Whether the communication voltage is within the range and whether there is a short circuit to the ground (If there is a short circuit Resistance: 120 Ω ± 5 Ω
to the ground, check whether the controller is damaged);
2. 测量低压供电是否正常（ 1 、 2 、 5Pin 对地电压是否正常 24V 以上） 电压： 2.5V±1V
2. Measure whether the low-voltage power supply is normal (Whether the voltage of Pin 1, 2 and 5 to the ground is normal. It Voltage: 2.5 V ± 1 V
should be above 24V).
3. 前两步操作测量正常情况下，更换控制器逻辑板 分别对地是否短路
3. If the values measured in the previous two steps are normal, replace the controller logic board. Whether short to the ground
respectively

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GLOBAL TRAINING 26
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.2 电除霜 / 电加热接触器粘连故障故障
7.2 Electric defroster/electric heating contactor adhesion fault
电除霜 / 电加热接触器粘连故障机制
Electric defroster/electric heating contactor adhesion fault mechanism:
主回路上电和下电时，通过两次采样，检测接触器前后端压差 <20V ，两次采样前后端压差差值小于 2V ，并且前端压差小于 20V ，认为发生接触器粘连，报故障；
Sample twice when the main circuit is powered on and off. Check if the voltage difference between the front and rear ends of the contactor < 20 V and voltage
difference of front/rear end before and after the two samplings is less than 2 V, and the voltage difference of front end is less than 20 V. If so, it is considered that
contactor adhesion occurs and fault is reported;
故障对车辆的影响
Impact of the fault on the vehicle:
车辆无法上高压
High voltage of the vehicle cannot be powered on;

解决措施
Solution:
1. 用万用表测量电加热、电除霜保险状态；
1. Measure fuses of the electric heater and electric defroster with a multimeter;
2. 用万用表测量电加热、电除霜接触器状态；
2. Measure contactors of the electric heater and electric defroster with a multimeter;
3. 测量外部电加热、电除霜的状态；
3. Measure exterior of the electric heater and electric defroster;

导致二次故障：上电预充超时故障
Secondary fault occur: Pre-charge timeout when powering on;
需要检查缓冲电阻、缓冲接触器
Check the buffer resistance and buffer contactor

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GLOBAL TRAINING 27
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.3 踏板异常故障、 Tm 无效指令故障
7.3 Abnormal pedal fault, invalid Tm command fault
踏板异常故障机制
Abnormal pedal fault mechanism:
1. 制动 AI 和 DI 同时有效
Braking AI and DI are valid at the same time;
2. 驱动模式下，发送目标转矩非零，且油门信号无效或制动信号有效；
In drive mode, the target torque sent is not zero, and the throttle signal is invalid or the brake signal is valid;
3. 防溜坡或蠕行或定速巡航工作模式下，制动信号有效
The braking signal is valid under anti-slipping mode, or creep mode or cruising operating mode;
对车辆影响：车辆无法完成上电
Impact on vehicle: The vehicle cannot be powered on;
解决措施 Solution:
1. 检查车辆的油门刹车踏板、传感器等
Check the accelerator pedal, brake pedal, sensors, etc.
2. 查看控制器的 U0-09 （ AI1 油门量） 0-10V 、 U0-10 （ AI2 刹车量） 0-10V ，是否在正常范围内。
Check whether U0-09 (AI1 accelerator amount) 0-10V and U0-10 (AI2 brake amount) 0-10V of the controller are within the normal range.

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GLOBAL TRAINING 28
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.3 踏板异常故障、 Tm 无效指令故障
7.3 Abnormal pedal fault, invalid Tm command fault
Tm 无效指令故障机制
Invalid Tm command fault mechanism:
TM 接收到的指令不符合 CAN 通讯协议约定指令
The command received by TM does not conform to the command agreed by CAN communication protocol
故障对整车的影响 Impact of the fault on the vehicle:
车辆正常上电，踩油门无法行驶，报出此故障。
When the vehicle can be powered on normally while it does not move when depressing the accelerator pedal, this fault is reported.
解决措施 Solution:
查看整车其他器件的故障
Check whether other components of the vehicle are faulty

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GLOBAL TRAINING 29
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.4 24V 输入欠压故障
7.4 24 V input undervoltage fault

24V 输入欠压故障机制：
24V input undervoltage fault mechanism:
1. 控制器开管
Controller switch;
2. 硬件 24V 欠压信号由高电平变为低电平（硬件阈值 16V ）；
The hardware 24 V undervoltage signal changes from high level to low level (hardware threshold 16 V);

故障对车辆的影响 ：
Impact of the fault on the vehicle:
1. 控制器无法上电
The controller cannot be powered on;
2. 车辆断动力
Power of the vehicle is cut off.

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GLOBAL TRAINING 30
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.4 24V 输入欠压故障
7.4 24 V input undervoltage fault

解决措施：
Solution:
1. 检查车辆低压保险、继电器是否正常；
Check whether low-voltage fuse and relay of the vehicle are normal;
2. 检查蓄电池电压是否正常；
Check whether the battery voltage is normal;
3. 看控制器单板插件是否松动，未松动进行单板更换；
Check whether connectors on the controller board are loose. If not, replace the board;
4. 进行低压搭电后，控制器上电，查看 DCDC 输出电压是否大约 26V
After connecting to a low-voltage power supply and powering on the controller, check whether output voltage of the DCDC is about 26V

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GLOBAL TRAINING 31
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.5 主 / 辅回路上电反向压差故障
7.5 Reverse voltage difference on main/auxiliary circuit when powering on

主 / 辅回路上电反向压差故障机制
Mechanism of reverse voltage difference on main/auxiliary circuit when powering on:
主 / 辅回路上电前检测到后端电压超过前端电压 15V 及以上
Before powering on, voltage at the rear end of the main/auxiliary circuit exceeds the voltage at the front end by 15 V or more.
故障对车辆影响
Impact of the fault on the vehicle:
车辆无法上高压
High voltage of the vehicle cannot be powered on;
解决措施 Solution:
1. 连接控制器后台，从连续示波器选择查看 U0-45 前端电压、 U0-46 后端 1 电压、 U0-47 后端 2 电压、 U0-48 回路 1 主接触器状态、 U0-49 回路 2 主接触器状态、 U0-50 回路 1 缓冲接触器状态、 U0-51 回路 2 缓冲接触器状态，点
击开始按钮
Connect the controller background. Select to check the followings on the continuous oscilloscope: U0-45 front end voltage, U0-46 rear end 1 voltage, U0-47 rear
end 2 voltage, U0-48 circuit 1 main contactor status, U0-49 circuit 2 main contactor status, U0-50 circuit 1 buffer contactor status, U0-51 circuit 2 buffer contactor
status. Click the Start button.

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GLOBAL TRAINING 32
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.5 主 / 辅回路上电反向压差故障
7.5 Reverse voltage difference on main/auxiliary circuit when powering on

2. 进入参数配置，选择 LOGIC 模块，修改 B0-02=0 （面板控制）， B0-04 先修改成 1 （下电流程）。等待 5S 后，再次修改 B0-04 为 2 （上电流程）。这时查看连续示波器上，后端 1.2 的电压与前端电压的比较，电压是否相差超过 15V 。
Go to Parameter configuration, select the LOGIC module, modify B0-02 to 0 (panel control), and modify B0-04 to 1 (power-off process).Wait 5 seconds and modify
B0-04 to 2 (power-on process).Check and compare the voltage of the rear end 1.2 with that of the front end on the continuous oscilloscope. Whether the voltage
difference exceeds 15 V.
3. 测量电池电压，确认是否与控制器检测的前端电压一致，若不一致，更换 LOGIC 板
Measu re the battery voltage and check whether it is consistent with the front-end voltage measured by the controller. If not consistent, replace the LOGIC board.
4. 若是后端电压不准，进行控制器的更换
If consistent, the rear end voltage is not correct. Replace the controller.

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GLOBAL TRAINING 33
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.6 主 / 辅回路上电预充超时故障
7.6 Main/auxiliary circuit pre-charging timeout during powering on
主 / 辅回路上电预充超时故障机制
Mechanism of main/auxiliary circuit pre-charging timeout during powering on:
主回路上电预充完成检测阶段，缓冲接触器闭合后， 3s 内前后端压差未稳定在 15V 以内保持 200ms 。
In main circuit power-on pre-charging completion and inspection stage, after the buffer contactor is closed, the pressure difference between the front and rear ends is
not stabilized within 15 V for a duration of 200 ms in 3 s.
故障对车辆影响 Impact of the fault on the vehicle:
车辆无法上高压 High voltage of the vehicle cannot be powered on;
解决措施 Solution:
1. 连接控制器后台，从连续示波器选择查看 U0-45 前端电压、 U0-46 后端 1 电压、 U0-47 后端 2 电压、 U0-48 回路 1 主接触器状态、 U0-49 回路 2 主接触器状态、 U0-50 回路 1 缓冲接触器状态、 U0-51 回路 2 缓冲接触器状态，点
击开始按钮。
Connect the controller background. Select to check the followings on the continuous oscilloscope: U0-45 front end voltage, U0-46 rear end 1 voltage, U0-47 rear end
2 voltage, U0-48 circuit 1 main contactor status, U0-49 circuit 2 main contactor status, U0-50 circuit 1 buffer contactor status, U0-51 circuit 2 buffer contactor status.
Click the Start button.

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GLOBAL TRAINING 34
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.6 主 / 辅回路上电预充超时故障
7.6 Main/auxiliary circuit pre-charging timeout during powering on
2. 进入参数配置，选择 LOGIC 模块，修改 B0-02=0 （面板控制）， B0-04 先修改成 1 （下电流程）。等待 5S 后，再次修改 B0-04 为 2 （上电流程）。这时查看连续示波器上，后端 1.2 的电压与前端电压的比较，电压是否相差超过 15V 。
Go to Parameter configuration, select the LOGIC module, modify B0-02 to 0 (panel control), and modify B0-04 to 1 (power-off process).Wait 5 seconds and modify
B0-04 to 2 (power-on process).Check and compare the voltage of the rear end 1.2 with that of the front end on the continuous oscilloscope. Whether the voltage
difference exceeds 15 V.
3. 测量电池电压，确认是否与控制器检测的前端电压一致，若不一致，更换 LOGIC 板。
Measure the battery voltage and check whether it is consistent with the front-end voltage measured by the controller. If not consistent, replace the LOGIC board.
4. 若是后端电压不准，进行控制器的更换。
If consistent, the rear end voltage is not correct. Replace the controller.
5. 测量缓冲电阻的状态，电阻是否失效
Measure the status of the buffer resistance to check whether the resistance is invalid;
6. 测量缓冲接触器的状态
Measure the status of the buffer contactor.

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GLOBAL TRAINING 35
 7 、 故障问题及操作步骤 Faults and Operation Steps

7.7 电压异常类故障
7.7 Abnormal voltage fault

BMS 下发电压平台异常故障机制
Mechanism of BMS sending abnormal voltage platform fault:
上电后 30s 内，没有收到 VCU （ 0x18FF33F4 ） 5 次连续一致的电压平台报文。
Within 30s after powering on, 5 consecutive consistent voltage platform messages of VCU (0x18FF33F4) are not received.
故障对车辆影响
Impact of the fault on the vehicle:
主回路不能上高压
The main circuit cannot be powered by high voltage;
解决措施 Solution:
1. 检查 VCU 是否正常，采集报文，查看 0x18FF33F4 报文是否发送；
Check whether the VCU collects message normally and check whether the 0x18FF33F4 message is sent.
2. 查看通讯线束、电压阻值是否在正常；
Check whether the communication wiring harness, voltage and resistance values are normal;

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GLOBAL TRAINING 36
 7 、 故障问题及操作步骤 Faults and Operation Steps

7.7 电压异常类故障
7.7 Abnormal voltage fault

电池电压不在控制器范围故障机制
Mechanism of battery voltage is out of controller range fault:
1. 主回路准备预充阶段，检测到电池电压低于欠压点（ A5-05 ） 10V 或高压过压 (A5-06) 点 10V ；
In the main circuit pre-charge preparation stage, it is inspected that the battery voltage is 10V lower than the undervoltage point (A5-05) or 10V higher than the over-voltage
point (A5-06);
2. 辅回路准备预充阶段，检测到电池电压低于欠压点（ A5-05 ） 10V 或高压过压 (A5-06) 点 10V ；
In the auxiliary circuit pre-charge preparation stage, it is inspected that the battery voltage is 10V lower than the undervoltage point (A5-05) or 10 V higher than the over-
voltage point (A5-06);
故障对车辆影响 Impact of the fault on the vehicle:
车辆无法上电，无法行车
The vehicle cannot be powered on and cannot move;
解决措施 Solution:
测量电池电压是否在正常范围内
Measure whether the battery voltage is within the normal range;

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GLOBAL TRAINING 37
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.8 电压异常类故障
7.8 Abnormal voltage fault
BMS 母线欠压故障机制
BMS busbar undervoltage fault mechanism:
1. 驱动模式下，母线电压低于欠压点（ A5-05)
In drive mode, the busbar voltage is lower than the undervoltage point (A5-05);
2. 制动模式下，母线电压低于欠压点（ A5-05)
In brake mode, the busbar voltage is lower than the undervoltage point (A5-05);
故障对车辆影响 Impact of the fault on the vehicle:
无法上电，车辆断动力
The vehicle cannot be powered on, and power of the vehicle is cut off;
解决措施 Solution:
1. 测量电池电压是否与控制器前端电压是否一致
Measure whether the battery voltage is consistent with that of the controller front end;
2. 测量主接状态是否异常，吸合后，主接是否产生阻抗，正常为 0Ω 。
Measure whether the status of the main contactor is abnormal. After engagement, whether there is resistance on the main contactor. The normal value should be 0 Ω.

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GLOBAL TRAINING 38
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.8 电压异常类故障
7.8 Abnormal voltage fault

输入过压断接触器故障机制
Over-voltage input contactor off fault mechanism:
1. 母线电压大于 780V ；
The busbar voltage is greater than 780V
2. 母线电压大于过压点（ A5-06 ） +20V （ A5-06 不等于 0 时）
The busbar voltage is greater than the over-voltage point (A5-06) + 20 V (When A5-06 is not equal to 0);
故障对车辆影响 Impact of the fault on the vehicle:
车辆无动力 No power for the vehicle;
解决措施 Solution:
1. 测量主接状态是否异常，吸合后，主接是否产生阻抗，正常为 0Ω 。
Measure whether the status of the main contactor is abnormal. After engagement, whether there is resistance on the main contactor. The normal value should be 0 Ω.
2. 查看电机旋变是否异常，调谐车辆电角度
Check whether the motor resolver is abnormal and tune the electric angle of the vehicle

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GLOBAL TRAINING 39
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.9 驱动过流故障、驱动欠压故障
7.9 Drive overcurrent fault, drive undervoltage fault
驱动过流故障机制
Drive overcurrent fault mechanisms:
当检测到硬件送过来的 Vce 过流开关信号由高变为低电平 ( 检测 Vce 饱和压降，如果发现饱和压降大于 7.5V)
When it inspects Vce overcurrent switch signal sent by the hardware changes from high to low (inspect Vce saturation voltage drop. If the saturation voltage drop is
inspected to be greater than 7.5V)
故障对车辆的影响 Impact of the fault on the vehicle:
车辆断动力，报故障后，一直无法上电
Power of the vehicle is cut off. After the fault is reported, it cannot be powered on;
解决措施 Solution:
1. 测量 IGBT 管压降，参考过流故障中的 IGBT 检测方法
Measure IGBT pipe voltage drop. Refer to IGBT inspection method in overcurrent fault;
2.IGBT 测量正常，更换整机或者更换底层驱动板
If the IGBT is normal, replace the whole unit or the bottom drive board;

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GLOBAL TRAINING 40
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.9 驱动过流故障、驱动欠压故障
7.9 Drive overcurrent fault, drive undervoltage fault
驱动欠压故障机制 Drive undervoltage fault mechanisms:
1. 控制器运行状态
Controller operation status,
2. 检测到硬件的欠压开关信号由高电平变为低电平 ( 驱动芯片供电电压低于 10~13V)
It inspects that hardware undervoltage switch signal changes from high to low (The voltage of driver chip is below 10~13V);
故障对车辆的影响 Impact of the fault on the vehicle:
车辆断动力，报故障后，一直无法上电
Power of the vehicle is cut off. After the fault is reported, it cannot be powered on;
解决措施 Solution:
1. 测量 IGBT 管压降，参考过流故障中的 IGBT 检测方法
Measure IGBT pipe voltage drop. Refer to IGBT inspection method in overcurrent fault;
2.IGBT 测量正常，更换整机或者更换底层驱动板
If the IGBT is normal, eplace the whole unit or the bottom drive board;

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GLOBAL TRAINING 41
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.10 上电输出缺相
7.10 Power-on output phase loss

上电输出缺相故障
Power-on output phase loss fault:
上电第一次运行前检测到一路缺相 ; 检测方法是在分别在 UV/VW/UW 两相通电 , 检测相电流是否达到阈值 , 如果相电流达到阈值 , 则认为无缺相故障。
After powering on, one phase loss is inspected before the first operation. Inspection method: Turn on two-phase power (UV/VW/UW) respectively, and check
whether the phase current reaches the threshold. If the phase current reaches the threshold, it is considered that there is no phase loss fault.
故障对车辆的影响
Impact of the fault on the vehicle:
车辆断动力，无法上高压电
Power of the vehicle is cut off. High voltage cannot be powered on;
解决措施 Solution:
1. 对电机进行绝缘检测、测量三相之间两两的阻值（阻值正常为 0 ）。
Check the motor insulation. Measure the resistance between the three phases (The resistance value should be 0 in normal condition).
2. 电机检测正常后，查看控制器的 IGBT 模块是否异常；
After the motor is inspected to be normal, check whether IGBT module of the controller is abnormal;
3. 若是检测模块正常，控制器上低压电，测量霍尔输出电压是否在 2.5V+0.1V 附近。
After the module is inspected to be normal, power on low voltage of the controller and measure whether the Hall output voltage is about 2.5 V + 0.1 V.

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GLOBAL TRAINING 42
 7 、 故障问题及操作步骤 Faults and Operation Steps
7.11 EPS/ACM 过流故障
7.11 EPS/ACM overcurrent fault

测量 EPS/ACM ， IGBT 模块与电机正常的情况下，进行以下操作

Measure EPS/ACM. If the IGBT module and motor are normal, do the followings:
1. 车辆下高低压电，拔掉相应模块报过流故障的航插口；
Power off high/low voltage of the vehicle, and unplug aviation connector from the module which reports overcurrent fault;
2. 车辆上低压电（ ON 档）
Power on low voltage of the vehicle (ON position);
3. 连接控制器后，登录超级管理员权限
Connect the controller and log in as the super administrator.
4. 修改写入 DF-18 为 12345 ；
Modify value of DF-18 to 12345.
5. 选择 EPS 或者 ACM 进入 BO 组（常用功能）， B0-01=2 （ V/F 控制）、 B0-02=0( 操作面板控制 ) 、 B0-03=0 （数字给定）， B0-08=30 ，写入参数；
Select EPS or ACM to enter the BO group (commonly used function), B0-01=2 (V/F control), B0-02=0 (operation panel control, B0-03=0 (digital preset),
B0-08=30 and write parameters;
6. 进入 BA 组（故障与保护），修改写入 BA-13=0 （无效）
Enter the BA group (fault and protection), and modify BA-13=0 (invalid);

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GLOBAL TRAINING 43
 7 、 故障问题及操作步骤 Faults and Operation Steps
7. 关闭后台，全车下单，维持 10S 后重新上电
Close the background, power off the vehicle, and power on again after 10s;
8. 连接后台打开 EPS 或者 ACM 控制面板，点击运行，维持 1 分钟左右，查看控制器后台是否报过流故障，无则查看相应电机和线束，有则更换辅驱控制板。
Connect to the background, open EPS or ACM control panel, click Run and maintain about 1 minute. Check whether the background of the controller reports an
overcurrent fault. If not, check the corresponding motor and wiring harness. If it reports, replace the auxiliary drive control panel.

7.12 电机温度传感器掉线故障
7.12 Motor temperature sensor off-line fault
电机温度传感器掉线故障机制
Motor temperature sensor off-line fault mechanism:
PT 断路保护
PT open circuit protection:
a) 电机控制器对电机温度传感器断线故障检测时间延长至 5s ，如果连续 5s 温度传感器检测都是断线状态，则上报温度传感器断线故障，上报电机温度 110℃ ，并开始限功率，将电机输出功率限制到 80%* 额定电流，该故障不可自动恢复，需重新上下电才恢复
The inspection time of motor controller for motor temperature sensor off-line fault is extended to 5 s. If it inspects that the temperature sensor is off-line for 5 consecutive
seconds, it reports motor temperature sensor off-line fault and reports that motor temperature is 110 ℃. It begins to limit power--limits the motor output power to 80% of
the rated current. The fault cannot be automatically recovered. Please power on and off again to make it recover.

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GLOBAL TRAINING 44
 7 、 故障问题及操作步骤 Faults and Operation Steps

b)5s 检测期间，上传之前未断线时电机温度值，如果 5s 检测期间电机温度传感器状态恢复正常，则退出本次温度传感器断线故障检测，上传正常检测的电机温度

During the 5 s inspection, the motor temperature value when it is on line will be uploaded. If the motor temperature sensor status returns to normal during 5 s inspection,
the current temperature sensor off-line fault inspection stops and the motor temperature normally inspected is uploaded.
c) 断路检测条件为： AD 端口输入电压大于 2.9V 。
Open circuit inspection condition: The input voltage of the AD port is greater than 2.9 V.
PT 短路保护
PT short circuit protection:
a) 电机控制器对电机温度传感器短路故障检测时间延长至 5s ，如果连续 5s 温度传感器检测都是短路状态，则上报温度传感器断线故障，上报电机温度 100℃ ，并开始限功率，将电机输出功率限制到 80%* 额定电流，该故障不可自动恢复，需重新上下电才恢复
The inspection time of motor controller for motor temperature sensor short circuit fault is extended to 5 s. If it inspects that the temperature sensor is short-circuited for 5
consecutive seconds, it reports motor temperature sensor off-line fault and reports that motor temperature is 100 ℃. It begins to limit power--limits the motor output power
to 80% of the rated current. The fault cannot be automatically recovered. Please power on and off again to make it recover.
b)5s 检测期间，上传之前未短路时电机温度值，如果 5s 检测期间电机温度传感器状态恢复正常，则退出本次温度传感器短路故障检测，上传正常检测的电机温度
During the 5 s inspection, the motor temperature value when there is no short circuit will be uploaded. If the motor temperature sensor status returns to normal during 5 s
inspection, the current temperature sensor short circuit fault inspection stops and the motor temperature normally inspected is uploaded.
c) 短路检测条件为：电机温度低于 -30 度，控制器温度高于 50 度
Short circuit inspection condition: The motor temperature is below -30 degrees, and the controller temperature is above 50 degrees.

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GLOBAL TRAINING 45
 7 、 故障问题及操作步骤 Faults and Operation Steps

7.13 旋变故障
7.13 Resolver fault
旋变故障 Resolver fault:
FVC 模式下，上电延时 2.5s 后开始开启旋变故障检测，当检测到 DOS 、 LOT 同时为为低电平，或旋变采样值出现较大无规律波动，在 100ms 出现 60% 故障率以上，报旋变故障
In FVC mode, the resolver fault inspection is enabled after the power-on delay of 2.5 s. When it inspects that both DOS and LOT are low or resolver sample values
fluctuate greatly and irregularly, if the fault rate is more than 60% within 100 ms, it reports resolver fault.
故障对车辆的影响
Impact of the fault on the vehicle:
（ 1 ）车辆静止状态下，能上高压但无法行驶
When the vehicle is stationary, the high voltage can be powered on but it cannot move
（ 2 ）车辆行驶状态下，降扭矩停机，车辆抛锚
When the vehicle is traveling, torque decreases and the vehicle breaks down

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GLOBAL TRAINING 46
 7 、 故障问题及操作步骤 Faults and Operation Steps

解决措施 Solution:
维修措施
步骤 排查描述 测试方法 判断标准
Repair
Step Troubleshooting description Test method Determination standard
measure
测量电机旋变 8pin Sin 与 cos 的阻值为 EXC 的一半 更换电机旋变
PIN1.2 为 sin ， PIN3.4 为 cos ， PIN5.6PT 阻值， PIN7.8 为 EXC 。
1 Measure the motor resolver The resistance of Sin and cos Replace the
PIN1.2 is sin, PIN3.4 is cos, PIN5.6PT resistance value. PIN7.8 is EXC.
8pin is half that of EXC motor resolver
更换旋变转接小板
万用表电阻档测量 8PIN 旋变小板 J1-J2 对应管脚（如 J1.1-J2.1 ） 阻值接近为 0
8PIN 旋变转接小板 Replace the
2 Measure pins for 8PIN resolver patch panel J1-J2 (such as J1.1-J2.1) with The resistance value is close
8PIN resolver patch panel resolver patch
resistance position of the multimeter to 0 panel
检查 8PIN 线束 33 号信号线是否存在退针情况万用表电阻档测量线阻，检查是否开路 无退针扩孔电阻为 0 更换连接器
8PIN 连接器（控制板 - 旋变转接板）
Check whether the 8PIN wiring harness No.33 signal wire for any withdrawal There is no withdrawal pin. The Replace the
3 8PIN connector (control board pin. Measure wire resistance with resistance position of the multimeter to hole resistance is 0 connector
- resolver patch panel) check if there is any open circuit
控制板 J3 接入旋变，万用表直流档测量 J3.1-J3.2 ， J3.3-J3.4 ， J3.7-J3.8 旋变比范围为 0.286/0.5±20% 更换控制主板
控制主板 Connect the control board J3 to resolver. Measure J3.1-J3.2, J3.3-J3.4, and The rotation ratio ranges from Replace the
4
Control mainboard J3.7-J3.8 with the multimeter in DC mode 0.286/0.5±20% control
mainboard

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GLOBAL TRAINING 47
8 、 系统调试 System Debugging
8.1 IGBT 测量方法
8.1 IGBT measurement metho

(1) 拔掉整车快断器，拆卸车厢内驱动器上方的地板，打开驱动器上盖板，按照下表测量数据。正常情况下，六个二极管的值基本相等，若某个桥臂的反并联二极管电压值不在表中的范围内时，则直接换机处理。
(1) Unplug the quick breaker of the vehicle. Remove the floor above the drive in the compartment. Open the upper cover plate of the drive and measure the data
according to the table below. Normally, the values of the six diodes are basically equal. If the anti-parallel connection diode voltage value of a bridge arm is not in the
range of the table, replace the unit directly.
(2) 若上述 IGBT 反并联二极管电压值无异常，则并不能 100% 确定 IGBT 是否完好，还需将 TM 或者 ISG 上高压电开管运行，看看是否报过流故障 Er001 、驱动过流故障 Er002 或者驱动欠压故障 Er003 ，若报故障，则可以肯定 IGBT 已损
坏，直接换机处理。
(2) If the voltage value of the above-mentioned IGBT anti-parallel connection diode is not abnormal, it is not yet clear whether the IGBT is OK. Please power on the
high-voltage for the TM or ISG and start to operate to check whether the overcurrent fault Er001, drive overcurrent fault Er002 or drive undervoltage fault Er003 is
reported. If any of them is reported, it is certain that the IGBT is damaged. Directly replace the unit.

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GLOBAL TRAINING 4
8 、 系统调试 System Debugging

IGBT 反并联二极管电压值（ V ）
桥臂 红表笔 黑表笔
Diode voltage value (V) of anti-parallel
Bridge arm Red testing lead Black testing lead
connection for IGBT
U 相动力端子
U-phase power terminal
下桥臂 母线负 V 相动力端子
Lower bridge arm Busbar negative V-phase power terminal
W 相动力端子
W-phase power terminal
0.3~1
U 相动力端子
U-phase power terminal
母线正 ( 主回路主接 KM1 后端 )
上桥臂 V 相动力端子
Busbar positive (main circuit main contactor
Upper bridge arm V-phase power terminal
KM1 rear end)
W 相动力端子
W-phase power terminal

Red

Black
图 6-8 TM 的下桥臂反并联二极管测量方法
Figure 6-8 Measurement Method the Diode of Anti-parallel Connection for Lower Bridge Arm of TM

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GLOBAL TRAINING 4
8 、 系统调试 System Debugging
8.2 霍尔传感器测量方法
8.2 Measuring method of Hall sensor

（ 1 ）拔掉整车快断器，拆卸车厢内驱动器上方的地板，打开驱动器上盖板，按照下表测量数据。正常情况下，六个二极管的值基本相等，若某个桥臂的反并联二极管电压值不在表中的范围内时，则直接换机处理
Unplug the quick breaker of the vehicle. Remove the floor above the drive in the compartment. Open the upper cover plate of the drive and measure the data
according to the table below. Normally, the values of the six diodes are basically equal. If the anti-parallel connection diode voltage value of a bridge arm is not in the
range of the table, replace the unit directly.
（ 2 ）若上述 IGBT 反并联二极管电压值无异常，则并不能 100% 确定 IGBT 是否完好，还需将 TM 或者 ISG 上高压电开管运行，看看是否报过流故障 Er001 、驱动过流故障 Er002 或者驱动欠压故障 Er003 ，若报故障，则可以肯定 IGBT
已损坏，直接换机处理
If the voltage value of the above-mentioned IGBT anti-parallel connection diode is not abnormal, it is not yet clear whether the IGBT is OK. Please power on the high-
voltage for the TM or ISG and start to operate to check whether the overcurrent fault Er001, drive overcurrent fault Er002 or drive undervoltage fault Er003 is
reported. If any of them is reported, it is certain that the IGBT is damaged. Directly replace the unit.

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GLOBAL TRAINING 5
8 、 系统调试 System Debugging
红表笔位置 黑表笔位置 正常电压范围
测量值代表的意义 Meanings represented by measured values
Position of red probe Position of black probe Range of normal voltage
J1 的 Pin7 霍尔传感器的供电电源
5±0.15 V
Pin7 of J1 Power supply of Hall sensor
J1 的 Pin1 U1 相电流霍尔检测基准值 Reference value of U1-phase current Hall inspection
2.5±0.1 V
Pin1 of J1
单板 4 个固定螺丝中任意一个 U2 相电流霍尔检测基准值（仅 10 米以上的才需要测试 U2 ）
J1 的 Pin8
Any of 4 fixing screws of 2.5±0.1 V Reference value of U2-phase current Hall inspection (U2 can only be tested for
Pin8 of J1
the single board vehicles over 10m)
J1 的 Pin5 W1 相电流霍尔检测基准值 Reference value of W1-phase current Hall inspection
2.5±0.1 V
Pin5 of J1
J1 的 Pin12 W2 相电流霍尔检测基准值（仅 10 米以上的才需要测试 W2 ） Reference value of W2-phase current
2.5±0.1 V
Pin12 of J1 Hall inspection (W2 can only be tested for vehicles over 10m)

黑 红 霍尔检测端子
Black Red Hall inspection
terminal

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GLOBAL TRAINING 5
 谢谢。
Thank you!