04/06/2024 18:02:08

Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install)

  • 2023-09-14: Removed correction code and FRT.
  • 2023-07-25: Added step to record replacement pyrotechnic battery disconnect serial number and part number for later entry into SCA.
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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
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Note
The following procedures are not standalone. They conditionally supplement procedures that occur within the Model Y Structural Pack ancillary bay, and require that the ancillary bay cover has already been removed.

Remove

  1. Remove the pyrotechnic battery disconnect insulators (x2).
  2. Remove and discard the bolts (x2) that attach the pyrotechnic battery disconnect to the ancillary bay.
  3. Lift the pyrotechnic battery disconnect straight up to disconnect from the connector, and then remove the disconnect from the ancillary bay.
  4. Install the pyrotechnic battery disconnect dummy cover.
  5. Return to the procedure that requested the pyrotechnic battery disconnect to be removed.

Install

  1. If a new pyrotechnic battery disconnect is to be installed, record the 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).
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    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 pyrotechnic battery disconnect dummy cover.
  4. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect, and allow at least 1 minute to fully dry.
  5. Set the multimeter to the "LoZ" (low impedance) mode.
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    Note
    For Fluke multimeters without "LoZ" mode on the mode selector, see Multimeter (LoZ Setting).
  6. Measure the voltage between the shunt (left) and busbar (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points.
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    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 ancillary bay, align the pins of the connector with the disconnect, and then press the disconnect straight down onto the busbars.
  8. Continue to measure the voltage for another 10 seconds after the pyrotechic battery disconnect has been set onto the busbars.
  9. Install new bolts (x2) to attach the pyrotechnic battery disconnect to the HV battery, and then mark the bolts with a paint pen after they are torqued.
    5 Nm (3.7 lbs-ft) +60 deg
  10. Use the Hioki resistance meter to measure the resistance at the HV joint between the pyrotechnic battery disconnect and the RH busbar.
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    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
  12. Install the pyrotechnic battery disconnect insulators (x2).
  13. Return to the procedure that requested the pyrotechnic battery disconnect to be installed.