02/03/2020 13:50:14

Fuses - DCDC Converter - 1st Generation (Remove and Replace

Correction Code 44200202

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1080601-00-A WK6SET Btb Winged Scraper Set
Tesla 1086930-00-A Tool, HV Chisel Stop
Tesla 1076972-00-A 4 Piece Non-Marring Scraper Set
Tesla 1076988-00-A ESD-Safe Express Plus HEPA Vacuum 120V
Tesla 1076973-00-A 26oz Dead Blow Hammer

Parts required for this procedure:

Part Number Description Qty
1031238-00-A FUSE,CART,20A,500V,6.4,31.8,UL248-14 1
1019010-00-A FUSE,FAST,40A,700VAC/DC,14MM x 51MM 2
1460201-00-A Adhesive, Loctite 5910, SI 1
Informational PurposesAn informational icon, calling your attention
Note
These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Catalog.

Removal

  1. Remove the 1st generation DCDC converter. See DCDC Converter (Remove and Replace) .
  2. Remove the screws that attach the DCDC converter cover to the DCDC converter base plate.
  3. Use a winged scraper to start at the corner nearest the ground stud and initially break the silicone adhesive that holds the DCDC converter cover onto the DCDC converter base plate.
  4. Install a HV chisel stop onto a non-marring scraper, and set the stop at 23mm from the end of the scraper.
  5. Use the non-marring scraper to cut the rest of the silicone adhesive and separate the DCDC converter cover from the DCDC converter base plate.
  6. Disconnect the two yellow spade-lug connectors at the end of the unit.
  7. Use a hook pick to carefully remove the upper and lower 40A fuses from the clamps.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any of the surrounding components as the fuses are removed.
  8. Use the hook pick to carefully remove the lower 20A fuse identified as "F3" from the clamps at the side of the unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any of the surrounding components as the fuse is removed.
  9. Use isopropyl alcohol (IPA) wipes to clean the fuse clamps at the end and side of the unit, and then inspect the clamps for cracks or breakage.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If any clamp is cracked or broken, replace the DCDC converter.
    Figure 1. 40A Fuse Clamps
    Figure 2. 20A Fuse Clamps

Installation

  1. Use a digital multimeter to check that the continuity through each replacement fuse is no more than 0.3 ohms.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not install a fuse that has an internal resistance greater than 0.3 ohms.
  2. Install the lower 20A fuse into the clamps at the side of the unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The fuse must fit tightly and squarely into the clamps.
  3. Install the lower and then the upper 40A fuses into the clamps at the end of the unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The fuses must fit tightly and squarely into the clamps.
    Tip: Snap ring pliers might help to spread the clamps.
  4. Connect the two yellow spade-lug connectors at the end of the unit.
  5. Use the digital multimeter to verify continuity between the HV+ terminal of the HV input connector and the brown PTC heater connector HV+ terminal.
  6. Verify continuity between the HV+ terminal of the HV input connector and the gray coolant heater connector HV+ terminal.
  7. Verify continuity between the HV+ terminal of the HV input connector and the orange A/C compressor connector HV+ terminal.
  8. Verify continuity between the HV- terminal of the HV input connector and the brown PTC heater connector HV- terminal.
  9. Verify continuity between the HV- terminal of the HV input connector and the orange A/C compressor connector HV- terminal.
  10. If a resistance greater than 0.3 ohms is displayed for any measurement, check the seating and condition of the fuses.
  11. Use a blade scraper to remove the silicone adhesive from the DCDC converter cover and base plate.
    Tip: A scotch-brite type pad can help with clean up after using the blade scraper.
  12. Use an ESD-safe vacuum to clean any loose residue and debris from the DCDC converter cover and base plate.
  13. Wipe the mating surface of the DCDC converter cover and base plate with IPA wipes, and allow to dry.
  14. Dry fit the DCDC converter cover and base plate, and verify a tight fit without gaps or bends.
  15. Use a dead blow hammer (rubber mallet) to carefully flatten gaps and bends as necessary.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure not to damage any connectors, terminals, or fittings on the DCDC converter base plate.
  16. Perform a push-pull-push check of all spade-lug connections to verify that they are secure.
  17. Prepare a caulking gun with the Loctite 5910 silicone adhesive cartridge.
  18. Cut the tip of the silicone adhesive cartridge nozzle to have a triangular opening 1.5mm high, and 5mm wide.
  19. Apply a single continuous 5mm - 6mm wide bead of silicone adhesive to the mating surface of the DCDC converter cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply the bead of silicone adhesive to the inside of the screw holes. Do not cover the screw holes.
  20. Carefully align the DCDC converter cover to the base plate, and then place the cover onto the base plate.
  21. Install the screws that attach the DCDC converter cover to the DCDC converter base plate (torque 1.35 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The silicone adhesive requires 24 hours to fully cure.
  22. Install the 1st generation DCDC converter. See DCDC Converter (Remove and Replace) .