23/08/2024 06:23:30
Rapid Mate - Low Voltage - HV Battery 2.0 (Remove and Replace)
Correction Code 16308602
- 2024-06-24: Added alternative sealants to replace Threebond 1216E due to non availability of Threebond in certain markets.
Sealant
required for this procedure:
- Threebond 1216E (1089956-00-A), Permatex Right Stuff (1031099-00-A), or Dowsil 7091 (1962594-00-A)
Supplier | Part Number | Description |
Tesla | 1038478-00-A | ASY,COVER,HV RAPID,HVBAT,MDLS |
Tesla | 1028325-00-A | ASY,COVER,LV RAPID,HVBAT,MDLS |
Tesla | 1059330-00-A | SOCKET,DR 5LOBE,E-TORX MAG,0.25INCH |
Tesla | 1076970-00-A | INSULATED TORX T20 TAMPER PROOF BITT25 INSULATED TORX |
Tesla | 1068957-00-A | INSULATED SOCKET T25 |
Tesla | 1068958-00-A | INSULATED SOCKET T30 |
Tesla | 1057254-00-B | FLAG,FUSE NOTIFICATION,ASSY |
Tesla | 1076988-00-A | ESD-SAFE EXPRESS PLUS HEPA VACUUM (VACEXP-04) |
Tesla | 1014593-00-A | HARNESS,LOGIC,HVBAT,SERVICE,MODEL S |
Tesla | 1076921-00-A | FLUKE 1587 MULTI-METER |
Tesla | 1076927-00-A | HIOKI MODEL 3548 RESISTANCE METER |
Tesla | 1076856-00-A | KNIPEX 1,000V INSULATED CABLE KNIFE MFR. PART N. 98 54 |
Tesla | 1076973-00-A | 26 OZ DEADBLOW HAMMER-GRN |
Tesla | 1076972-00-A | 4 PIECE NON-MARRING SCRAPER SET |
Tesla | 1060071-00-A | TORQUE WRENCH 1-5NM |
Tesla | 1057603-00-A | HV NON-CONDUCTIVE EXTENSION |
Tesla | 1026636-00-A | PACK ENCLOSURE LEAK TESTER ASSEMBLY |
Tesla | 1086930-00-A | HV CHISEL STOP |
- Threebond 1216E (1089956-00-A), Permatex Right Stuff (1031099-00-A), or Dowsil 7091 (1962594-00-A)
Warning
Do not place
anything on top of the HV battery other than the high voltage “Danger” placard.
The high voltage “Danger” placard is placed on top of the HV battery to warn
others of the potential exposure to high voltage.
Warning
This procedure
can only be performed in designated HV battery repair areas.
Warning
Only technicians
who have been certified to remove HV battery switches and fuses and have
completed all required certification courses (if applicable) or, in EMEA,
technicians who have successfully completed the training course HV Battery
Fuse Remove and Replace ILT - EMEA 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 any time a high voltage
cable is handled. Refer to TN-15-92-003, “High Voltage Awareness Care Points”
for additional safety information.
Warning
Proper personal
protective equipment (PPE) is required to perform this procedure:
- High voltage insulating gloves
- Leather glove protectors
- High voltage glove tester
- Safety glasses
- Electrical hazard rated safety shoes
Warning
Make sure that
the HV gloves are not expired.
- NA: HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12 month period. After either 12 months from the printed date or 6 months after first use, the gloves must be replaced with new gloves or recertified using a Tesla approved vendor. Gloves must also be recertified after use without outer protection gloves. An air leak test is not sufficient.
- EMEA: Class 0 (1000V) High Voltage gloves have no expiration date and may be used if they pass the pre-use assessment and the periodic inspection.
- APAC: Follow the
expiration date stated by the HV glove manufacturer, and:
- China only: Test the gloves every 6 months according to GB/T 17622.
Warning
HV gloves must
pass inflator testing before beginning this procedure. If either glove does not
pass the air check, cut off the glove fingers, and then discard the pair.
Warning
While performing
this procedure, always wear both rubber HV insulating gloves and leather glove
protectors. Do not remove the gloves until the ancillary tray cover and fuse
cover have been reinstalled.
Warning
Use only one
hand whenever possible. Keep the other hand behind the back to prevent a closed
circuit should a component with high voltage be touched.
Warning
When using a
multimeter, never use an e-coated surface as a path to ground.
Warning
Only use tools
that have been specifically designated for use with this procedure.
Warning
Obey these safe
work practices while performing this procedure:
- Do not wear headphones.
- No loud music in HV battery repair areas.
- Do not perform this procedure alone. Always have a certified assistant on hand, and alert the on-site manager that you will be performing this procedure.
- Always use 2 people to lift heavy equipment.
- Absolutely no horseplay.
- Avoid cluttering the battery rework area. Only tool carts that have tools that are needed for this procedure should be allowed in the battery rework area. Maintain tools and consumables in appropriate cabinets.
- Label all secondary chemical containers.
- Dispose of hazardous waste (such as adhesive, coolant, and other chemicals) in appropriate bins or containers.
CAUTION
Do not place
anything on top of the HV battery, other than the high voltage “Danger”
placard.
Discharge
Note
The steps of this procedure are
mostly touch time, and can be performed by the Service Advisors/Front of House
team as well as Service Technicians.
CAUTION
If an HV Battery is to be
shipped, such as returning a battery to MRB for refurbishment, the battery must have an SOC
of less than 50% for land transport, or an SOC of less than 30% for air transport. If the
SOC is greater than these values, the HV battery must be discharged to the acceptable values
before the battery can be shipped.
-
Identify the vehicle
SOC.
- If the SOC is less than the specified values, proceed with removal. See HV Battery (RWD/AWD) (Remove and Replace).
- If the SOC is greater than the specified values, lower all of the vehicle windows and turn on the climate control system to maximum defrost. This setting will discharge the battery by approximately 10% SOC every hour.
- Move the vehicle to a location where it can safely continue to discharge the battery unattended.
- Identify the vehicle SOC every half-hour.
- When the SOC is below 50% for land transport, or below 30% for air transport, turn off the climate control system, raise the windows, and then move the vehicle to the service bay.
Preparation
CAUTION
Make sure that removed fasteners do not get lost inside of the
HV battery by having a designated container available during the procedures. Pay
careful attention as to whether each fastener must be discarded or can be
saved.
Note
Allow the Hioki 3548 Resistance Meter to warm up for at least 60 minutes prior
to use.
- Create a Toolbox session if there isn’t already an open session related to this repair.
- Remove the HV battery from the vehicle. See HV Battery (RWD/AWD) (Remove and Install).
- Inspect the HV insulating gloves and leather glove protectors. See TN-15-92-003, “High Voltage Awareness Care Points” for more information.
- Remove all items from any clothing pockets.
- Make sure that there is no metal on your person; remove watches, belts, jewelry, identification badges, etc.
- Verify that the Fluke 1587 Insulation Multimeter works properly.
- Verify that the Hioki Impedance Tester works properly. Refer to the manufacturer's operating manual for details.
- Inspect the leads, probes, and insulation on all instrumentation.
- Make sure that the entire work area is clear, including the HV battery.
- Place the high voltage "DANGER" placard on top of the HV battery to warn others of the potential exposure to high voltage.
- Place barricades and "DANGER" barricade tape around the work area.
- Note the location of the fire extinguisher and the high voltage rescue hook.
- Inspect the HV battery for dents, fluid leaks, or other signs of instability. If any are found, stop work and escalate the Toolbox session.
DC Link Check
Warning
Make sure that both HV insulating gloves and leather glove
protectors are on before performing this procedure.
- Put on both the HV insulating gloves and the leather glove protectors.
-
Use a multimeter to check voltages at the HV Rapid Mate connector of the HV
battery.
NoteUse the ancillary cover as a path to ground:
- B+ to ground
- B- to ground
- B+ to B-
WarningIf any voltage is above 10V, mark the voltages on the lid near the HV Rapid Mate connector and escalate the Toolbox session. -
Set the Fluke insulation multimeter to check isolation at 500 VDC:
- B+ to ground (ancillary cover)
- B- to ground (ancillary cover)
NoteIf either isolation reading is less than 3 MΩ, escalate the Toolbox session.
HV Battery Enclosure Leak Test (Pre-Repair)
- Perform a HV battery enclosure leak test. See SI-20-16-004, “High Voltage Battery Enclosure Leak Testing and Repair, Model S and Model X”.
- Locate and repair any existing air leaks.
- Disconnect the quick connect coupling from the leak test port adapter, and leave the leak test port adapter connected to the HV battery.
-
Cover the high voltage
connector with a HV Rapid Mate cover. Cover the Low Voltage (LV) connector
with a LV Rapid Mate cover.
NoteIf these covers are not available, cover the Rapid Mate connectors with masking tape to prevent debris from falling in during this procedure.
- Clean the top surface of the HV battery with Isopropyl Alcohol (IPA) wipes.
Fuse Removal
Warning
Make sure that both HV insulating gloves and leather glove
protectors are on before performing this procedure.
- Remove the HV battery fuse. See “Fuse Removal” Fuse - Pyrotechnic - HV Battery 2.0 (Remove and Replace).
-
Put the M6 screws (x6) and the M8 bolts (x2) removed from the fuse cover
and the fuse into a designated container.
NoteThe M6 screws (x6) and the M8 bolts (x2) removed from the fuse cover and the fuse must be accounted for before reinstalling components.
LV Rapid Mate Removal
Warning
Make sure that the green fuse flag has been installed and both
HV insulating gloves and leather glove protectors are on before performing this
procedure.
CAUTION
Do not place anything (other than the HV warning placard) on
top of the HV battery.
-
Use an electrostatic discharge-safe (ESD-safe) vacuum to clean the area
around the ancillary tray, the LV Rapid Mate, and the HV Rapid Mate to make
sure that there is no dust or debris that can enter the HV battery.
-
Clean the area around the
ancillary tray with Isopropyl Alcohol (IPA) wipes. Allow 1 minute to dry
before continuing.
-
Remove the cover or tape from the LV and HV Rapid Mates.
-
Put a piece of tape along the rear of the HV battery to prevent accidental
removal of any fasteners that attach the pack cover.
-
Remove and discard the T25
screws (x6) that attach the top ring to the HV Rapid Mate connector.
Tip: Loosen the screws, and then lift the top ring with the screws still attached.NotePut these screws into the designated container so that they can be accounted for before reinstalling components.
-
Remove and discard the T25 screws (x6) that attach the ancillary cover to
the LV Rapid Mate connector.
NotePut these screws into the designated container so that they can be accounted for before reinstalling components.
-
Remove and discard the M5 screws (x28) that attach the ancillary cover to
the HV battery.
NotePut these screws into the designated container so that they can be accounted for before reinstalling components.
-
Install the HV chisel stop onto the non-marring scraper approximately 20 mm
from the end of the scraper.
CAUTIONTo avoid damaging internal components, do not insert the scraper unless the HV chisel stop is installed in the proper location.
-
Use the non-marring scraper
with a dead blow hammer to separate the sealant in the areas and order
shown.
NoteWork around the ancillary cover in a counter-clockwise manner.
- Lift the ancillary cover straight up off of the LH and RH pins, and then discard the ancillary cover.
-
Put on the HV-safe static control wrist strap, and then clip the strap’s
ground connection to the ground busbar.
CAUTIONPut the static control wrist strap on as soon as the cover is opened. Otherwise, damage to sensitive electrical components might result.
-
Disconnect the LV Rapid Mate electrical harness from the ancillary tray
circuit board RH side connector.
-
Release the retaining clips (x2) that attach the LV Rapid Mate connector to
the HV battery, and then slide the LV Rapid Mate connector up and off of the
dowel pin.
-
Put the LV Rapid Mate connector on top of the ancillary unit.
-
Release the LV Rapid Mate electrical harness from the ancillary unit
harness groove.
-
Release the retaining clip that connects the HVIL connector to the LV Rapid
Mate, and then remove the LV Rapid Mate from the ancillary unit.
Installation
-
Put the LV Rapid Mate onto the ancillary unit, and then connect the HVIL
connector and secure it with the retaining clip.
NotePerform a soft pull-push test to verify that the clip has engaged to the ancillary unit.
-
Align the dowel pins with
the guide holes in the ancillary unit, then install the ancillary unit into
the ancillary tray, and secure it with the retaining clips (x2).
-
Route the large LV Rapid
Mate harness along the rear RH side of the ancillary tray, and then connect
the harness to the ancillary tray circuit board RH side connector. Perform a
“push-pull-push” check at the connector to make sure that it is properly
secured.
-
Route the small LV Rapid
Mate harness in the groove in the ancillary tray and the groove in the Rapid
Mate bracket.
CAUTIONMake sure that the all slack in the harness is on the LH side of the tray. Use a trim tool to tuck the wire into the grooves.
-
Disconnect the HV-safe
static control wrist strap ground connection from the ground busbar.
-
Clean the sealing surface on
ancillary tray: Use the non-marring scraper to clean off any large chunks or
beads of old sealant from the sealing surface of the ancillary tray.
NoteThe sealing surface should be smooth and consistent. However, the sealant does not need to be completely removed.NoteUse a small pick to remove any old sealant from the ancillary tray screw holes, if necessary.
-
Use the ESD-safe vacuum to
clean the inside of the ancillary tray.
-
Clean all sealing surfaces
on the ancillary tray and new ancillary cover with IPA wipes. Allow 1 minute
to dry before continuing.
-
Load the sealant in the
caulking gun, and then cut the nozzle approximately 15 mm from the
tip.
CAUTIONDo not use expired sealant. Check the expiration date on the tube of sealant.
-
Apply a bead of sealant to
the ancillary tray sealing surface on the HV battery.
- Install the new ancillary tray cover: Position the LH hole of the new ancillary cover over the LH pin on the HV battery, then position the RH hole over the RH pin. Press down firmly on the cover.
-
Install new M5 screws (x28) to attach the ancillary cover to the ancillary
tray. Torque to 4.5 Nm and mark the head of each screw with an orange paint
pen.
-
Install new T25 screws (x6) to attach the LV Rapid Mate connector to the
ancillary cover. Torque the screws to 2.8 Nm in the order shown. Use an
orange paint pen to mark the head of each screw after it is torqued.
-
Install the top ring around
the HV Rapid Mate connector, and then install new T25 screws (x6) to attach
the HV Rapid Mate connector to the ancillary cover (torque 2.8 Nm). Use an
orange paint pen to mark the head of each screw after it is torqued.
-
Install a new HV warning
label to the ancillary cover.
-
Remove the tape from the
rear fasteners that attach the pack cover.
- Install the HV battery fuse. See "Hybrid Pyrotechnic Fuse Installation" in Fuse - Pyrotechnic - HV Battery 2.0 (Remove and Replace).
- Perform a HV battery enclosure leak test. See SI-20-16-004, “High Voltage Battery Enclosure Leak Testing and Repair, Model S and Model X”.
- Install the HV battery on the vehicle. See HV Battery (RWD/AWD) (Remove and Install).