05/03/2024 15:57:51
HV Battery Air Leak Test
FRT No. 16102100
Special tools required for this procedure:
Supplier | Part Number | Description |
Tesla | 1023867-00-A | PLUG, RUBBER, EPDM, 3/8ID, TAPERED* |
* Quantity of 1 of this part is included in the Contactor Service Field Repair Kit.
- 2024-03-05: Updated name to HV Battery Air Leak Test.
Preparation
- Remove all items from any clothing pockets.
- Ensure that there is no metal on your person; remove watches, belts, jewelry, identification badges, etc.
-
Inspect the HV insulating
gloves. Test the HV insulating gloves with a glove inflator.
WarningExpiry dates of HV gloves differ by region. Refer to TN-15-92-003 for details on HV gloves expiry dates.WarningUse a glove inflator to test the HV insulating gloves before beginning this procedure. Gloves that fail the test must be discarded. If one glove fails, discard both gloves of the pair.
- Put on the HV insulating gloves.
- Ensure that the entire work area is clear, including above and below the battery.
- Ensure the HV battery is in an area with a stable temperature. For example, the battery should not be in direct sunlight or near a heater or air conditioning duct.
- 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 fire extinguishers and the high voltage rescue hook.
- Inspect the HV battery for dents, fluid leaks, or other signs of instability. If any are found, escalate the Toolbox session, as appropriate.
Replacing Side Gore Breathers
Battery Enclosure Leak Test
-
Use a pick or small screwdriver to remove the cap and gore breather from
the front vent cover underneath the battery. Discard both components.
CAUTIONTake care not to scratch or damage the sealing surface on the front vent cover.
- Install a rubber plug in the gore breather hole.
- Remove the 1/8’’ NPT leak test plug from the left rear corner of the battery enclosure. Discard the plug.
- Install the leak test port adapter into the test port on the enclosure by hand, then torque it to 8 Nm.
-
Prepare the leakdown test tool:
- Attach the quick connect coupling to the leak test port adapter.
-
Open the valve that is closest to the battery to inject air into the HV
battery enclosure. When the interior pressure is approximately 0.165, close
the valve closest to the regulator.
CAUTIONInjecting more than 0.200 psi will damage the HV battery.
- Wait 60 seconds for the air pressure to settle.
- Record the pressure.
- Wait another 60 seconds, then record the pressure. If the pressure has dropped more than 0.010 PSI, the battery is not properly sealed.
Leak Troubleshooting
Slowly move around the battery, listening for hissing noises. Feel for cool air escaping the battery enclosure.
If there are no obvious sources of leakage, apply liquid leak detector to the following possible leakage locations, in the order listed.
After completing a repair, repeat the “Battery Enclosure Leak Test” section of this document.
- If the pressure drop is below the limit, skip to the “Reassembly” section of this document.
- If the pressure drop exceeds the limit, continue to the next step.
Check for leaks in the following areas:
- Leak tester/leak test port: If leakage is found, apply additional thread sealing tape.
-
2-way breather valve on the top cover: If leakage is found, try to reseat the o-ring inside the valve:
- Lower spline bolts: If leakage is found, install a new bolt with an M6 sealing washer (torque 12 Nm). The rubber surface of the washer must face toward the battery enclosure.
-
Lower sleeves: If leakage is found:
-
Side umbrella valves:
-
Front vent cover: Spread the liquid leak detector around the vent surface to create a complete seal. If leakage is found:
-
High Voltage (HV) and Low Voltage (LV) Rapid Mate connectors:
-
Weld joints and top cover/enclosure joint:
- Fuse cover.
- Seal around the coolant Rapid Mate.
- All remaining fasteners on the top cover.
Reassembly
- Disconnect the leak test port adapter from the HV battery.
- Install a new leak test plug (torque 8 Nm).
- Remove the rubber plug from the front gore breather hole.
- Install a new front gore breather and front vent cover cap.
- Mark the cap with an orange paint pen.
- If gore breathers on the sides of the battery were replaced with rubber plugs, remove the plugs and install new gore breathers.
- If liquid leak detector was applied to any top cover surfaces (steps 8–12 of the “Leak Troubleshooting and Repairs” section of this document), use alcohol wipes to clean the top cover near the battery blanket attachment surfaces very thoroughly. Liquid leak detector leaves a residue on the surface that can reduce the adhesion of the butyl rubber adhesive on the battery blanket.