07/10/2024 09:11:20

Pyrotechnic Battery Disconnect (Remove and Replace)

Correction code 16300002 1.20 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so.NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2024-10-07: Updated figure in step 7 to display proper PPE.
  • 2024-01-31: Added images of real parts in the Hioki resistance test steps.
  • 2023-07-25: Added step to record replacement pyrotechnic battery disconnect serial number and part number for later entry into SCA.
  • 2023-06-29: Added a video at Step 5 in Install part.
  • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
  • 1057603-00-A Ext Bar, Wobble, 1/4" Dr, HV Insulated
  • 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
  • 1057607-00-A Magnet, Flexible, HV Insulated, 18"
  • 1127845-00-A Asy, Service Cover, Penthouse, Model 3
  • 1131071-00-A Dummy Disconnect, Pyro, Safety
  • 1133602-00-A Kit, HV Pyro-disconnect Replacement, BRP
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 1076927-00-A Resistance meter, microohm, Hioki RM 3548
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Torque Specifications

Table 1. Torque Specifications: Pyrotechnic Battery Disconnect (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the pyrotechnic battery disconnect to the HV battery
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 13 mm socket
    • 6 in extension
    • Ratchet/torque wrench
 Replace

Remove

  1. Remove the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
  2. If the logic connector cap is installed on the high voltage controller connector, remove it.
  3. Set the ancillary bay service cover over the ancillary bay.
  4. Remove the pyrotechnic battery disconnect shunt insulator(s).
    Figure 1. 1st Generation
    Figure 2. 2nd Generation
  5. Remove and discard the bolts that attach the pyrotechnic battery disconnect to the HV battery, and then remove the pyrotechnic battery disconnect from the vehicle.
  6. Install the dummy disconnect where the pyrotechnic battery disconnect was removed.

Install

  1. Tesla internal users only: record the replacement pyrotechnic battery disconnect serial number and part number for later entry into SCA.
  2. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
  3. Remove the dummy disconnect from where the pyrotechnic battery disconnect will install.
  4. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect.
  5. Set the multimeter to the "LoZ" (low impedance) mode.
    Informational PurposesAn informational icon, calling your attention
    Note
    For Fluke multimeters without "LoZ" mode on the mode selector, see Multimeter (LoZ Setting).
  6. Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points.
    Informational PurposesAn informational icon, calling your attention
    Note
    The voltage displayed on the multimeter is not as important as balancing the mount points.
  7. While still measuring the voltage, have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, and then press the pyrotechnic battery disconnect down onto the busbars.
  8. Continue to measure the voltage for another 10 seconds after the pyrotechnic battery disconnect has been set onto the busbars.
  9. Install the new bolts that attach the pyrotechnic battery disconnect to the HV battery, and then mark the bolts with a paint pen after they are torqued.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • 6 in extension
      • Ratchet/torque wrench
  10. Use the Hioki resistance meter to measure the resistance at the HV joint between the newly-installed pyrotechnic battery disconnect and the LH busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.060 mΩ (60 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  11. Use the Hioki resistance meter to measure the resistance at the HV joint between the newly-installed pyrotechnic battery disconnect and the shunt.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.045 mΩ (45 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
    Figure 3. Generic Measurement - Actual busbars and fasteners might appear different
  12. Install the pyrotechnic battery disconnect shunt insulator(s).
    Figure 4. 1st Generation
    Figure 5. 2nd Generation
  13. Remove the ancillary bay service cover from the ancillary bay.
  14. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).