CM Hardware Users Manual

Document: 0A-0162-01

Installation guide for all CM series inverters

(CM200DX, CM200DZ, CM350DZ, and CM350SiC)
 7929 SW Burns Way [Link]
Wilsonville, OR 97070 sales@[Link]

Contents
1 Safety First 2

2 Functional Overview 3

3 Installing the Drive 4

3.1 Liquid Cooling connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 CM200 and CM350 Signal Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 External Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.1 DC+ / DC-: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.2 Phase A/Phase B/Phase C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.3 Pre-Charge Circuit: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.4 Main Contactor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.5 Main Fuse: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.6 Passive Discharge of High Voltage DC Bus: . . . . . . . . . . . . . . . . . . . . . 12
3.3.7 12/24V Power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.8 Grounding: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Typical Application Wiring 14

4.1 Inverter 12V Power Wiring: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Pre-charge Circuit Wiring: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Typical Motor Wiring: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 CAN Interface: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 RS-232 Interface: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Encoder Interface: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Resolver Interface: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.8 Analog Inputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.10 Digital Outputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

A Analog Input Motor Mapping 22

B Example Wiring Diagram 23

C Vehicle State Machine (VSM) Mode 24

D Position Sensor Input Options 25

E Revision History 26

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 7929 SW Burns Way [Link]
Wilsonville, OR 97070 sales@[Link]

1 Safety First
When you see this symbol, PAY ATTENTION. This
indicates that something important is about to be said,
that concerns your safety and the proper operation of
the equipment.
When you see this symbol, you are being alerted to an
IMMEDIATE DANGER that could cause severe injury
or even death. You MUST review these sections
carefully and do everything possible to comply with
installation and operation requirements, or you risk
injury or death to yourself or anyone else who uses the
equipment or the vehicle. Failure to comply with safety
requirements will void all warranties and could expose
you as the installer to liability in the event of an injury.
Use the equipment in the manner in which it was
intended.
When you see this symbol, you are being advised that
the issue under discussion has a serious safety or
equipment reliability implication. Use caution and be
conservative. Use equipment in the manner described in
this Hardware User’s Manual.
Safety is entirely the responsibility of the installer of this equipment. BorgWarner Portland (formerly
Cascadia Motion) has done everything it can to ensure that the traction inverter itself conforms to
international standards for safety. This does NOT mean that your installation will be safe, or that it
will not interfere with other systems on board your vehicle. It is your responsibility as the installer to
review this entire Hardware User’s Manual, to understand the implications of each and every section,
and to know what might be unique about your system application that then presents a unique hazard or
potential safety issue – and to solve it.

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2 Functional Overview
The CM inverter family is intended as a traction inverter for EV and HEV drive systems, and includes
both the motor control function and a rudimentary vehicle controller strategy in the same box. The
system uses a torque commanded vector control scheme that has been used on AC Induction and PM
Synchronous motors in many applications.

The motor control subsystem software is intended to mate one layer below the vehicle controller firmware.
This vehicle controller subsystem handles the driver interface (accel and decel / brake pedal inputs,
FWD/REV controls, etc) and the vehicle interface (power sequencing, built in test, fault handling and
safety issues). It is essentially a state machine in front of the motor inverter software with a defined
interface between the two software processes.

Vehicle Control Motor Control

User Controls Motor
Firmware Software

Figure 1: General Architecture of Vehicle Control.

The principle set of parameters used by the inverter to control its operation are are EEPROMs (electrically
erasable programmable read-only memory) loaded in the inverters internal memory. By default, integrated
modules are set up in Torque Control Mode, with default motor parameters loaded. Inverters purchased
standalone (without an attached or accompanying motor) will need to configure the parameters to
match the load motor and operating characteristics before running for the first time. These parameters
personalize the drive to the motor and the vehicle.

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3 Installing the Drive

All CM inverters have 4 mounting locations, one at each corner. Mounting orientation is not critical.
The inverter should be mounted in a location that is not exposed to direct spray from water. Each
mounting hole is sized to handle up to a M10 socket head cap screw. For dimensional drawings go the
Cascadia Motion website, links below:
• CM200DX/CM200DZ
• CM350DZ
• CM350SiC

3.1 Liquid Cooling connections

The inverter must be cooled by passing liquid through it. The inverter includes two ports to be used for
liquid cooling. The CM200DX and CM200DZ have a symmetrical design and are less sensitive to fluid
direction. The CM350DZ and CM350SiC should have fluid flow into the left port when looking at the
phase connections. See table below for coolant specifications:

50/50 mix; ethylene glycol (antifreeze) / water; with Aluminum

Coolant Type corrosion inhibitor additive*
50/50 mix; propylene (antifreeze) / water; with Aluminum
corrosion inhibitor additive*
-30°C to +45°C full power, 45°C to +80°C de-rated output
Coolant Temperature
-40 to +100°C max survivable range
12 LPM minimum, CM200DX/DZ
Flow Rate
24 LPM minimum, CM350DZ/SiC
CM200DX/DZ, 0.3 bar (4.3 psi) @ 12 LPM @ 25°C
Pressure Drop
CM350DZ/SiC, 0.3 bar (4.3 psi) @ 12 LPM @ 25°C
CM200, SAE ORB -06, comes with 5/8” hose barb and -8 AN
Port Size fitting
CM350, SAE ORB -10, comes with 5/8” hose barb and -10 AN
fitting
* Note: Many modern commercial antifreezes have this included in the formula.

For proper operation of the inverter the coolant must flow at a rate equal to or above the minimum
specified flow rate at all times that the motor is enabled. The flow rate should not be reduced when the
inverter is “not being run hard”. The design of the heat exchanger does not allow for reduced or no
coolant flow. It is possible to adjust the fan speed on the coolant radiator as needed depending on the
operating conditions of the inverter.

Since the maximum coolant temperature is less than the boiling point of water the cooling system does
not need to be operated under pressure. Other devices (e.g. motor, charger, DC/DC converter) that are

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added in series with the inverter increase the total pressure drop of the system. Even simple fittings and
hose length will contribute to the total system pressure drop. The total system pressure may add up to
a level that is beyond the capability of the chosen pump. The best practice is to measure the actual
coolant flow after the system has been assembled.

As noted above proper coolant flow is essential to the operation of the inverter. If the flow rate is not
sufficient the power module internal to the inverter can be damaged even though the indicated power
module temperatures are below an over-temperature threshold. The power module temperature sensors
are located in such a way that they are much closer to the temperature of the coolant than they are to
the temperature of the transistors and diodes used inside the power module.

Loss of coolant for even a few seconds can result in failure of the power module.

BorgWarner Portland (formerly Cascadia Motion) recommends that the user install a device to ensure
that the coolant pump is operating properly at all times when the inverter is enabled. The inverter
should be immediately stopped if the coolant is not flowing.

There are many ways that coolant flow could be measured. A flow sensor could be added to the cooling
loop. Often these types of sensors produce a pulse output. To read the pulse output would require the
use of a device to interpret this signal (BorgWarner Portland does not supply this).

Another option is to monitor the pressure in the cooling system. Typically the inverter would be placed
near the end of the cooling loop, just before the radiator. Thus a typical cooling loop application may
look like: pump outlet, inverter, radiator/reservoir, pump inlet. Typically the reservoir is at ambient
atmospheric pressure. Then the inverter should be at a pressure that is higher than ambient. If a pressure
switch is placed at the input coolant port of the inverter it should be able to detect that coolant is flowing.

Various types of coolant pressure switches exist. If a type is used that closes the switch when the
pressure is above a certain level is used then this could be inserted in series with the KL15_EN line or
just connected directly to one of the inputs for monitoring via CAN.

3.2 CM200 and CM350 Signal Connectors

The CM200DX/DZ and CM350DZ/SiC use the same Low Voltage I/O connector and have the
same connections. A Molex CMC 48 way connector is used for all low voltage signals. Note, the
iM-225/iM-375/iM-425 motor assemblies use variants of the CM200DX/DZ and CM350DZ/SiC that
have identical low voltage inverter connections.

Connector Information:

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• Mating Housing: Molex 64320-3311

• Strain Relief: Molex 64320-1301
• Contact, CP 0.6, 0.5mm2/20AWG, Wire OD 1.4-1.7mm: Molex 64322-1239
• Contact, CP 0.6, 0.75mm2/18AWG, Wire OD 1.4-1.7mm: Molex 64322-1219
• Contact, CP 1.5, 0.5-1mm2/18AWG, Wire OD 1.4-2.15mm: Molex 64323-1319
• Blind plug, CP 0.6: Molex 643251010
• Blind plug, CP 1.5: Molex 643251023

Please refer to the Molex web site for details on the connector. BorgWarner Portland (formerly
Cascadia Motion) highly recommends the use of the factory crimper for the contacts. Note that this
connector has two different contacts sizes, A1 thru K4 are the CP 0.6 size, L1 thru M4 are the CP 1.5 size.

I/O Connector - 48 Pin:

Pin
Pin Name Description Notes
Number
A1 /SIN Resolver Sine winding -
B1 SIN Resolver Sine winding +
C1 /COS Resolver Cosine winding -
D1 COS Resolver Cosine winding +
E1 EXC Resolver excitation output
F1 /EXC Resolver excitation return
DO NOT connect to
G1 GND Resolver Shield Ground 12V system ground or
motor case.
Refer to Appendix D
H1 ENC_A Encoder Channel A input for analog encoder and
hall sensor options.
Refer to Appendix D
J1 ENC_B Encoder Channel B input for analog encoder and
hall sensor options.
Refer to Appendix D
K1 ENC_Z Encoder Channel Z input (Index) for analog encoder and
hall sensor options.
If pre-charge function
is used this output
L1 RLY1 High Side Driver serves as the
pre-charge contactor
coil driving output
Intended for constant
12V power, when in
M1 KL30_BATT 12V/24V Constant Voltage the off state input
current is less than
1mA

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A2 CANA_H CAN Channel A High CAN high Port A

B2 CANA_L CAN Channel A Low CAN low Port A
Short to CANA_L to
include a 120 ohm
C2 CANA_T CAN A Terminator Loop
terminator from
CANA_H to CANA_L.
CAN is isolated from
GND/KL31. CAN
shield should be
D2 CAN_GND CAN ground
connected here. DO
NOT connect to 12V
system ground.
Short to CANB_L to
include a 120 ohm
E2 CANB_T CAN B Terminator Loop
terminator from
CANB_H to CANB_L.
F2 CANB_H CAN Channel B High
G2 CANB_L CAN Channel B Low
If connected to
RS232_GND at power
up inverter will go
into bootloader mode
H2 /PROG Program Enable
for use with C2prog
software. DO NOT
connect to 12V
system ground.
J2 EN_PWR 5V power for encoder
Ground return for
K2 DGND Digital Ground
encoder signals.
If the pre-charge
function is used this
L2 RLY2 (Main) High Side Driver output serves as the
main contactor
output.
Turns on internal
power supplies to
M2 KL15 Switched 12V/24V power up the inverter
and start
communications.
Allows connection of
PT100 or PT1000
A3 RTD1P RTD1 Positive
RTD for temperature
monitoring.

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B3 RTD1N RTD1 Negative See RTD1P

Allows connection of
PT100 or PT1000
C3 RTD2P RTD2 Positive
RTD for temperature
monitoring.
D3 RTD2N RTD2 Negative See RTD2P
Forward Enable
E3 DIN1 Digital Input 1 - STG
Switch (if used)
Reverse Enable
F3 DIN2 Digital Input 2 - STG
Switch (if used)
G3 DIN3 Digital Input 3 - STG Brake Switch (if used)
H3 DIN4 Digital Input 4 - STG Digital Input 4 - STG
When all high voltage
plugs are installed
J3 HVIL_IN High Voltage Interlock Input HVIL_IN will be
connected to
HVIL_OUT.
Used with sensors
K3 XDCR_PWR 5V power for transducers connected to analog
inputs.
OK Indicator Drive /
L3 RLY3 Lo-Side Relay Driver 12V Power Relay Coil
Drive
If voltage is removed
then inverter will
declare a hardware
gate fault, a
M3 KL15_EN Safety Switched 12V/24V
completely hardware
based disable of the
PWM from the
inverter.
For use with analog
inputs. DO NOT
A4 AGND Analog Ground
connect to 12V
system ground.
B4 AIN1 Analog Input 1
C4 AIN2 Analog Input 2
D4 AIN3 Analog Input 3
E4 AIN4 Analog Input 4

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Normally connected
to pin 5 of DB9
F4 RS232_GND RS232 Ground connector. DO NOT
connect to 12V
system ground.
Normally connected
G4 RS232_RXD RS232 Inverter Receive to pin 3 of DB9
connector.
Normally connected
H4 RS232_TXD RS232 Inverter Transmit
to pin 2 of DB9.
J4 HVIL_OUT High Voltage Interlock Output See HVIL_IN
For use with analog
inputs. DO NOT
K4 AGND Analog Ground
connect to 12V
system ground.
Fault Indicator Coil
L4 RLY4 Lo-Side Relay Driver
Drive
12V/24V system
M4 KL31_GND 12V/24V System Ground
return.

3.3 External Power Connections

3.3.1 DC+ / DC-:
High Voltage (traction) DC/Battery power is provided to the inverter via two wire ports located either

at the rear of the inverter (CM200DX/DZ) or the front (CM350DZ/SiC). The DC power must
be run through an external pre-charge circuit to safely charge the capacitors inside the inverter before
the main contactor engages (refer to application schematic in figure 4). The main contactor provides a
safety disconnect of the DC power in case of a fault condition. Make sure that the wire to the drive is
sized properly to handle the current.

DANGER Before changing the wiring make sure that the internal DC bus capacitors are discharged.
The voltage should be measured at the terminals before disconnecting. If there is any doubt about the
safety wait at least 10 minutes after power has been removed before touching the terminals.

The CM200DX/DZ uses Rosenberger HPK family connectors for making connection to the DC bus input
of the inverter. The HPK family is available in various wires sizes between 16mm2 and 50mm2 .

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The CM350DZ/SiC uses Amphenol Powerlock 2 family connectors, which offers wire sizing up to 120mm2 .
BorgWarner Portland (formerly Cascadia Motion) offers 70mm2 CM350 cables and 50mm2 CM200 cables
most commonly for purchase. Contact PDS PDX sales for information on custom wire sizing.

3.3.2 Phase A/Phase B/Phase C:

Phase A, Phase B, and Phase C are wired to the motor. It is important the 3 wires be wired to the
motor such that they give the proper direction of rotation. The motor wires are the most likely to
generate EMI and they also carry a higher average current than the DC power wires. When installed in
the vehicle these wires should be kept as short as possible, and shielded wire is required. This can be
done by adding a copper braid over the wires, or using wire that includes a shield.

The CM200DX/DZ uses Rosenberger HPK connectors for the AC connections. The CM350DZ/SiC
uses Amphenol Powerlock 2 family connectors. Again, the cables must use shielded wire. The shield is
connected to the chassis of the inverter and the chassis of the motor.

3.3.3 Pre-Charge Circuit:

An external pre-charge circuit must be used with the inverter. The circuit limits peak inrush
current into the inverter when the main contactor is engaged. The pre-charge circuit adds a resistor,
relay, and fuse in parallel with the main contactor. When the inverter is powered on the inverter will
first engage the pre-charge relay to charge the capacitors internal to the inverter. If the capacitors charge
properly then the main contactor can be engaged.

The pre-charge resistor should be sized to rapidly charge the capacitor, but not dissipate too much power
in a fault condition. The pre-charge resistor should be sized so that if the inverter had a short on its
input the pre-charge resistor would not fail. If using the built in pre-charge functionality, the pre-charge
relay will only remain closed for about 3 seconds. The pre-charge sequence must complete before this
time or the inverter will declare a fault condition and open the pre-charge relay. The pre-charge circuit
should be fused with a small fuse appropriate to the wire used. Since the pre-charge current is generally
very low, approximately 0.5 amps in the example below, small wire can be used (recommend 18 AWG).
A 5 amp fuse would be appropriate for this wire. Note, the inverter can be used bypassing the pre-charge
functionality built into the inverter software, in this case the user is responsible to complete the necessary
pre-charge and monitor voltage accordingly.

Sizing Example:

A typical application of the CM200DX could have a maximum DC bus voltage of 320 volts. If a 600
ohm resistor were chosen this would result in a power dissipation of 171 watts. This is typically within
the short term rating of a 50 watt wire-wound resistor. However make sure to consult the resistor

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manufacture data to ensure a sufficient surge tolerance. The internal capacitance of the inverter is
approximately 650uF. It takes approximately 3 time constants before the inverter will close the main
contactor, thus in this example it will take 1.17 seconds for the pre-charge to complete.

BorgWarner Portland (formerly Cascadia Motion) can provide the following parts if needed. Reference
the following:

DX Inverters
• Pre-charge Relay (30A, 12V COIL): p/n 77-0026
• Pre-charge Resistor (600 ohm 50W): p/n 53-0006
• Pre-charge Fuse (5A 500V): p/n G1-0013-01
DZ Inverters
• Pre-charge Relay (50A/1000V, 12V COIL): p/n 77-0034
• Pre-charge Resistor (1K ohm 100W): p/n 53-0008
• Pre-charge Fuse (5A 1000V): p/n G1-0015-01

BorgWarner
Internal Maximum
Model Portland Part
Capacitance Pre-charge Resistor
Number
CM200DX 650uF 600 ohms 53-0006
CM200DZ 255uF 2000 ohms 53-0008
CM350DZ 510uF 1000 ohms 53-0008
CM350SiC 700uF 1000 ohms 53-0008

3.3.4 Main Contactor:

The main contactor is the switching element between the DC high-voltage power source (typically a
battery) and the inverter. The main contactor must be sized to handle the operating currents of the
inverter. In addition the main contactor must be able to open under a fault condition. Generally only
one contactor is needed, the application schematic shows the main contactor in series with the positive
path from the battery to the inverter. BorgWarner Portland (formerly Cascadia Motion) has successfully
used the following: Gigavac GX14BA, p/n 77-0035. The contactor must be rated to handle DC voltage,
AC only rated contactors and relays must not be used. DC rated contactors are usually polarity sensitive.
That is, the normal operating current should flow in a particular direction. Refer to the contactor data
sheet for more information.

3.3.5 Main Fuse:

The DC Power input to the inverter must be fused. The fuse must be rated for the voltage
of the battery as well as rated to open under the short circuit current that the battery can produce.
Generally, this fuse (or equivalent fusible link) may be a part of the battery pack, but if the pack

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protection is not present or adequate, this fuse is required to prevent a potential battery pack fire. The
fuse should be rated to handle the maximum DC input current of the inverter. A semiconductor type
fuse is recommended.

3.3.6 Passive Discharge of High Voltage DC Bus:

As noted above, the inverter contains a large amount of DC bus capacitance. This capacitance
will store energy long after the high voltage has been removed from the unit. If other provisions have not
been made for discharging these capacitors then the unit wiring should not be touched for at least 10
minutes after the high voltage has been removed from it. The voltage will slowly decay due to internal
resistors inside the unit. The resistor values are shown in the table below:

Passive
DC Link Three time
Model discharge Y-Capacitance
Capacitance Constants
Resistance
CM200DX 70K ohms 650uF 137 s 136nF
CM200DZ 70K ohms 255uF 54 s 136nF
CM350DZ 60K ohms 510uF 92 s 188nF
CM350SiC 167K ohms 700uF 120 s 282nF
For reference the value of three time constants is shown. This time would dissipate the voltage to less
than 5% of the original value. Three time constants would allow the voltage to decay to a value that is
normally safe to touch. However, the capacitors will still have some energy stored in them.

The passive resistance value shown in the table in connected to the high voltage DC bus at all times. The
inverter will draw a corresponding amount of current from the high voltage at all times. For example if
a CM200DX is being used at 320V it would draw 320/70K = 4.6mA even when the inverter is disabled.
If it is desired to have the DC bus voltage discharge faster the user must either provide an external
method of discharge, or consider the use of the Active Discharge feature of the inverter. Consultant the
CM Software Users Manual for more information on Active Discharge.

The above table also shows the Y-Capacitance value for the inverter. The Y-Capacitance is the total
amount of capacitance connected between the DC bus and the chassis of the inverter. Half of the shown
amount is connected to each side of the DC bus (DC Bus Positive / DC Bus negative).

3.3.7 12/24V Power:

The inverter requires a source of 12V or 24V power to operate. The inverter will turn on and communicate
without high voltage present. This allows setup of parameters without high voltage.

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The CM200DX/DZ and CM350DZ/SiC all require a permanent low voltage connection and a switched
low voltage connection. Refer to Figure 2 for more details.

The CM200DX/DZ and CM350DZ/SiC allow for operation from both 12V and 24V systems.
12V, non-operating 0.6 A
12V, operating 1.0 A
CM200DX 24V, non-operating 0.3 A
@ 12 kHz 24V, operating 0.5 A
KL30 input current with KL15 off < 1 mA
12V, non-operating 0.6 A
12V, operating 1.2 A
CM200DZ 24V, non-operating 0.3 A
@ 12 kHz 24V, operating 0.6 A
KL30 input current with KL15 off < 1 mA
12V, non-operating 1.2 A
12V, operating 1.8 A
CM350DZ 24V, non-operating 0.6 A
@ 12 kHz 24V, operating 0.9 A
KL30 input current with KL15 off < 1 mA
12V, non-operating 0.6 A
12V, operating 1.1 A
CM350SiC 24V, non-operating 0.3 A
@ 12 kHz 24V, operating 0.6 A
KL30 input current with KL15 off < 1 mA
These currents do not include any high-side or low-side drivers:
• Any hi-side driver output currents, including the main and pre-charge contactor relay drive currents,
will come through the BATT+ pins and will add to the above currents.
• Any low-side driver output currents, including indicator lamp current, will come through the GND
pins, and should be considered in sizing this connection.

3.3.8 Grounding:
The inverter housing has a dedicated threaded hole for connecting the case to ground. The inverter
housing must be connected to the motor case. It must also be connected to the vehicle chassis and this
assumes that the vehicle chassis is at the same potential as the 12V GND. The inverter housing should
not be allowed to be more than a few volts above the 12V GND. If the inverter housing is isolated from
the rest of the system hazardous voltages could develop on the housing.

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4 Typical Application Wiring

4.1 Inverter 12V Power Wiring:
The CM drives require a permanent battery tie on KL30_BATT for proper operation. This channel draws
<1mA and ensures proper device start-up and shutdown sequencing. For vehicle applications it will be
desired to control each of the other 12V tied signals (KL15 and KL15_EN) independently as they each
have a unique functionality. The ideal wiring is presented in the Figure below.

 KL30_BATT
 KL15
12 V  KL15_EN

 KL31_GND

Figure 2: Vehicle Application for 12V Wiring

Each of the different KL inputs play a different role in startup and error communication. The functionality
is described below in more detail.

Pin
Pin Name Usage
Number
Permanently tied to the battery + and draws <1mA of
M1 KL30_BATT current. Used to keep low voltage live for proper
inverter enable and disable sequence.
The switched 12/24V used to turn on internal
M2 KL15 communications and wake the inverter for
communication.
The safety pin to allow a completely hardware based
disable of the [Link] inverter will throw a constant
M3 KL15_EN fault and the inverter output will be disabled if this pin
is open circuited. It needs to be tied to 12/24V to
enable the drive.
The 12/24V ground return that should be connected
M4 KL31_GND
permanently.
Note: KL30_BATT, KL15, and KL15_EN all have pull-downs applied internally in the inverter.

The CM200DX/DZ and CM350DZ vs the CM350SiC have slightly different internal applications of
KL15_EN presented below which impacts noise tolerance.

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(  TO DSP
5 kΩ 5 kΩ
KL15_EN 

4.7 kΩ

(a) CM200DX/DZ and CM350DZ KL15_EN Circuit

(  TO DSP
5 kΩ 5 kΩ
KL15_EN 
0.001 µF
0.001 µF 4.7 kΩ

(b) CM350SiC KL15_EN Circuit

Figure 3: KL15_EN Schematics for CM Inverters

Note: The CM350SiC has added capacitors for better noise rejection compared to the CM200DX/DZ
and CM350DZ.

4.2 Pre-charge Circuit Wiring:

The pre-charge circuit can be handled by the CM inverter or externally. The inverter relay connections
are not required unless the drive is configured to manage pre-charge.

RLY1

RLY2

 BATT+

High Voltage

 BATT-

Figure 4: Pre-charge Circuit Wiring

Generally the contactor with the resistor in series is a high voltage rated relay (such as Sensata Gigavac
P105 series) and the contactor connecting directly to the high current fuse is a high current, high voltage

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contactor such as the Sensata Gigavac GX16 series contactor. It is also generally a good idea to have
pre-charge coming after the main fuse, in case main fuse blows pre-charge will be disabled.

4.3 Typical Motor Wiring:

See Appendix B for a more detailed connection schematic.

4.4 CAN Interface:

The inverters have one active CAN interface (CAN A). The inverter contains hardware to support a
second CAN interface (CAN B), but currently only CAN A is active. CAN B is reserved for future use.
Refer to the CAN Protocol documentation in the CM Software Users Manual for the various ways that
the CAN bus can be configured.

The CAN interface has multiple purposes:

• Provides direct control of the motor.
• Provides diagnostic and monitoring capabilities.
• Provides user-adjustable configuration.
The user can change the following hardware related configuration parameters:

• Inverter Command Mode: Setting this parameter to 1 allows the CAN mode to become active.
• CAN Bus Speed: Allowed speeds are 125 Kbps, 250 Kbps, 500 Kbps, or 1 Mbps. Enter 125, 250,
500, or 1000 to program the configuration parameter.
• CAN Terminator Resistor: The resistor can be applied or opened.
For more information on CAN interface and messages, please refer to the CAN Protocol documentation
in the CM Software Users Manual.

4.5 RS-232 Interface:

There is one RS-232 serial interface. This port can be used to set up and tune the inverter, and to
download inverter software updates from a PC. With the RMS GUI this provides a simple Windows PC
based software package for monitoring and changing parameters.
By default the inverter will broadcast data as defined in the defsym files provided with the inverter
software. The data is broadcast at a rate of 3 Hz and can be used to monitor performance and energy
consumption data in real time.

For more information on RS232 data logging refer to the CM Software Users Manual.

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It is recommended to use an FTDI adapter for best results:

US232R from FTDI:

[Link]

It is highly recommended to use a galvanically isolated RS232 adapter like this one from Startech:
[Link]

4.6 Encoder Interface:

The CM inverters offer encoder support for motors equipped with a positional encoder. Specifically the
CM350SiC, CM350DZ, and CM200DX/DZ offer support for both digital and analog encoders. At this
phase all standard CM motor offerings use a resolver, and thus this is only for custom motors outside of
the CM catalog.

For a digital encoder, the inverter provides a 5V interface to power the external encoder then receives,
level translates, and filters the signals from A, B and INDEX channels.* For induction motor applications
the INDEX channel is not used, but it may be wired. The encoder is connected internally to the TI DSP
QEP Module (Quadrature Encoder Peripheral), which has special hardware for wide dynamic range
speed and angle calculation from the encoder data. The drive has internal pull-up resistors on these
inputs, and works with encoders that have either bi-polar or open-collector outputs.

+5V +5V

1 kΩ 1 kΩ

ENC_x  (  TO DSP ENC_x  (  TO DSP

100 Ω 1000 Ω
1500 pF 470 pF

(a) CM200DX/DZ and CM350DZ Digital Encoder (b) CM350SiC Digital Encoder

Figure 5: Digital Encoder Schematics

*Note: An INDEX channel is not provided for the CM350SiC.

There are options for analog encoder inputs and hall inputs for all CM inverters. Refer to Appendix D
for more info.

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4.7 Resolver Interface:

A resolver is a position sensor that is often used with Permanent Magnet type motors. There are various
types of resolvers. The resolver requires an excitation voltage and provides a SIN and COS feedback.

The CM inverters use a dedicated Resolver to Digital Converter (RDC) with predefined 10kHz excitation
frequency that is not synchronized with the PWM frequency. For CM inverters the target SIN/COS
voltage is dependent on how the RDC is configured. For all catalog BorgWarner Portland (formerly
Cascadia Motion) configurations (i.e. iM-225DX-D, iM425SiC-D, etc) this is pre-configured by default and
will not need user adjustment. For custom motors, contact BorgWarner Portland for more information.

4.8 Analog Inputs:

The CM Inverters have 4 analog inputs. The inputs are intended for general analog signal sensing (0
– 5V). There are also 2 RTD inputs, selectable as PT 100 or PT1000 by software. The CM inverters
provide programmable pull-up resistors (1K) on AIN1, AIN2, and AIN3. These pull-ups can be turned
on and off via software. This is shown in the Figure below.

+5V
Software
Controlled
Pull-up +5V
300 kΩ

1 kΩ 300 kΩ
41.2 kΩ 41.2 kΩ
AIN 1-3  TO DSP AIN 4 TO DSP

0.01 µF 4700 pF 10 kΩ 0.01 µF 4700 pF

(a) Analog Input Schematic with Programmable Pull-up. (b) Analog Input Schematic with Fixed Pull-down.

Figure 6: Analog Input Schematics

The inverter software assigns the analog inputs based on the motor type. See Appendix A, for more details.

A 5V power supply (XDCR_PWR) is provided for powering sensors or potentiometers. The total supply
current available from this supply is limited to 100mA.

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The analog signals should be referenced to one of the analog ground (AGND) pins available on A4 or K4.
This will reduce noise. Analog ground should NOT be connected to GND or the vehicle chassis.

Description Parameter Value

Analog Inputs
Input Range Vrange 0 - 5.00 V
Offset Voltage Vofs +50mV
Gain Accuracy G +5%
ADC Resolution 12b
RTD Inputs - PT 1000 type 1000 Ω / 0°C
Offset - 25°C ± 3°C
Temperature error - additional
± 3°C
error over temperature
RTD Inputs - PT 100 type 100 Ω / 0°C
Offset - 25°C ± 3°C
Temperature error - additional
± 3°C
error over temperature
The inverter provides two differential inputs for RTDs. RTD1 should be connected to RTD1N and RTD1P,
RTD2 should be connected to RTD2N and RTD2P. Do not tie the RTD lines to GND or AGND.

4.9 Digital Inputs

There are 4 Switch to Ground (STG) digital inputs for general interface to the vehicle and for feedback
from external contactors and switchgear as required in the application. These STG inputs are designed
to be used in an application that switches the input to ground.

+5V

10 kΩ

DINx  (  TO DSP
50 kΩ
1000 pF

Figure 7: Switch to Ground Schematic

The vehicle control system assigns the digital inputs as follows. Note: These are only active in VSM Mode.

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Input Type Signal Name Function

This input should be
connected to a switch that
DIN1 STG FWD_ENA grounds this input when the
user is commanding forward
direction.
This input should be
connected to a switch that
DIN2 STG REV_ENA grounds this input when the
user is commanding reverse
direction.
This input should be
connected to a switch that
DIN3 STG BRAKE
grounds the input when the
brake is pressed.
This input should be
connected to a switch that
DIN4 STG REGEN Disable grounds the input to enable
this feature (that is, disable
REGEN).
The electrical parameters of the digital inputs are shown in the table below.

Description Parameter Value

Voltage level for ON VSTG-ON <0.9 V
Voltage level for OFF VSTG-OFF >4.2 V
Pull-up resistor to 5V RSTG-PU 2.4 kΩ
Maximum Voltage on Input RSTG-MAX 18 V
Note: Digital inputs are equipped with some hysteresis to ensure a steady signal.

4.10 Digital Outputs:

There are 4 digital outputs available. These outputs are classified as High-Side Drivers (HSD), and
Low-Side Drivers (LSD). The schematics are provided below:

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Inverter Controlled Transistor Inverter Controlled Transistor

KL30_BATT   RLYx  RLYx
100 nF 100 nF

(a) High Side Driver (b) Low Side Driver

Figure 8: Digital Outputs

The vehicle control system assigns the outputs as follows:

Output Function
Type Function
Name Name
PRE-CHARGE This output provides power
RLY1 HSD
DRIVE to the pre-charge relay.
This output provides power
RLY2 HSD MAIN DRIVE
to the main contactor.
This output provides a
grounded signal to the OK
indicator. The indicator
turns on when power is
OK applied to the drive and the
RLY3 LSD
INDICATOR drive has completed the
pre-charge sequence. If
used, this output is also
used to power the external
12V power relay.
This output provides a
grounded signal to a fault
FAULT
RLY4 LSD indicator. The indicator
INDICATOR
will blink a fault code if the
drive has detected a fault.
The electrical parameters of the digital outputs are shown in the table below.

Description Parameter Value

Hi-Side Drivers (RLY1-2)
Output Current - Continuous ICONT-HSD 1A
Output Current - Surge IPK-HSD 5A
Lo-Side Drivers (RLY3-4)
Output Current - Continuous ICONT-LSD -1 A
Output Current - Surge IPK-LSD -5 A
Remember the voltage output of these drivers are limited to KL30_BATT voltage and 0.

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A Analog Input Motor Mapping

The standard CM offering of paired or remote motors will require the following analog input wiring.

AIN
CM Catalog Product Motor Connection
Channel
Motor Oil Temperature Sensor
iM-225DX-D AIN1
(External Connector)
iM-225DZ-S
Motor Temperature Sensor
iM-375DZ-D AIN2
(Resolver Connector)
iM-425DZ-D
Motor Temperature Sensor
iM-375SiC-D AIN3
(Resolver Connector)
iM-425SiC-D
Motor Oil Pressure Sensor
AIN4
(External Connector)
AIN1 -
iM-225DX-DW Motor Temperature Sensor
iM-225DZ-SW AIN2
(Resolver Connector)
iDM-190DX-D Motor Temperature Sensor
iDM-375SiC-D AIN3
(Resolver Connector)
AIN4 -
Remote Mount pairing will also follow this same wiring. To match a remote mounted inverter and motor
refer to its CM integrated equivalent. i.e. An SS-250-115-DOM with a CM200DX is the same electrically
as an iM-225DX-D.

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Figure 9: Example Wiring Diagram
Example Wiring Diagram
B
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C Vehicle State Machine (VSM) Mode

The majority of use cases for CM inverters is now via CAN communication. VSM Mode offer a method
of control via analog and digital inputs, given it is less common it has been moved to this appendix.

Documentation coming soon, for now refer to the legacy manual.

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D Position Sensor Input Options

The CM200DX/DZ and CM350DZ offer single ended analog encoder and hall sensor inputs for
position sensing through different hardware offerings (Contact BorgWarner Portland (formerly Cascadia
Motion) for support). The CM350SiC offers the same options though software based option enable.
Refer to the CM Software Users Manual for support on this.

Standard
Pin
Pin CM200 and CM350DZ Options CM350SiC Options
Number
Name
Digital Encoder Channel A input: Digital Encoder Channel A input:
ENC_A Standard Standard
H1
Analog Encoder Sin Input: Analog Encoder Sin Input:
Hardware Selected (different p/n) Software Selected
Hall A Input: Hall A Input:
Hardware Selected (different p/n) Software Selected
Digital Encoder Channel B input: Digital Encoder Channel B input:
Standard Standard
J1 ENC_B
Analog Encoder Cos Input: Analog Encoder Cos Input:
Hardware Selected (different p/n) Software Selected
Hall B Input: Hall B Input:
Hardware Selected (different p/n) Software Selected
K1 ENC_Z Digital Encoder Index input LIN communication channel

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E Revision History
Version Description Updated By Date
0A-0162-01 Base Manual Christian Tigges 10/23/2024

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