10/12/2024 19:40:39

Fuse - Pyrotechnic - HV Battery 2.0 (Remove and Replace)

FRT No. 16308502

  • 2024-06-11: Updated parts list, deleting the fuse cover bolts and fuse mounting bolts to be ordered.
  • 2024-06-03: Updated parts lists.
  • 2024-05-29: Added parts lists.
  • 2024-01-18: Updated Warning to permit performing this procedure by technicians in EMEA that have completed the training course HV Battery Fuse Remove and Replace ILT - EMEA.
  • 2023-11-28: Updated pyro fuse selection steps.
  • 2023-09-25: Updated to retain the fuse cover bolts and fuse mounting bolts.
  • 2023-09-19: Updated title and HV insulating glove information.
  • 2023-09-12: Made consistent with fuse Remove and Install procedure.
  • 2023-09-08: Removed step to perform the vehicle electrical isolation procedure.
  • 2023-09-07: Updated fuse matrix with Tesladex info.
  • 2023-09-06: Removed voltage check at fuse.
  • 2023-05-16: Added fuse cavity and cover area condition check with link to Toolbox article.
  • 2023-03-30: Updated with latest Toolbox 3 routine.

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1059330-00-A SOCKET,DR 5LOBE,E-TORX MAG,0.25INCH
Tesla 1057606-00-A 1/4" DRIVE 13MM SOCKET - CEMENTEX
Tesla 1076927-00-A HIOKI MODEL 3548 RESISTANCE METER
Select one of the tools listed below based on the region:
Tesla 1055662-00-A ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP– NORTH AMERICA
Tesla 1056154-01-B ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP – EU SCHUKO
Tesla 1056154-02-B ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP – UK, IRELAND
Tesla 1056154-03-B ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP – SWITZERLAND
Tesla 1056154-04-B ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP – DENMARK
Warning IconA warning icon, calling your attention to a possibly risky situation
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 IconA warning icon, calling your attention to a possibly risky situation
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 IconA warning icon, calling your attention to a possibly risky situation
Warning
Make sure that the HV insulating gloves are not expired. Refer to TN-15-92-003 for glove regional expiration information.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Use 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.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
While performing this procedure, always wear both rubber HV insulating gloves and leather glove protectors. Do not remove the gloves until the fuse cover has been reinstalled.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
When performing this procedure, use only one hand whenever possible. Keep your other hand behind your back to prevent the circuit from closing if you touch a component with high voltage.
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Warning
When using a multimeter, never use an e-coated surface as a path to ground.
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Warning
Only use tools that have been specifically designated for use with this procedure.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Required parts for 100 kWh HV Battery:

  • 1107227-00-B – FIELD KIT PYRO FUSE 100 KWH – 1 pcs

If fuse replacement kit 1107227-00-B is unavailable, procure the parts listed below:

  • 1055832-00-B – BOLT M6x15 PC109 MAT TAMPERPROOF – 1 pcs
  • 1111445-00-F – DISCONNECT,PYROTECHNIC,CUR POWERED,2366A – 1 pcs
  • 1004391-00-A – SCR,M8-1.25X21,HEX,STL,ZN,PATCH,W/WSHRS – 2 pcs

Required parts for all other HV Batteries:

  • 1084549-00-A – FIELD KIT PYRO FUSE PACK 2.0 – 1 pcs

If fuse replacement kit 1084549-00-A is unavailable, procure the part listed below:

  • 1111313-00-F – DISCONNECT,PYROTECHNIC,CUR POWERED,2000A – 1 pcs

Remove

  1. Use this table to determine the replacement hybrid pyro fuse type and application.
    Part Number Hybrid Pyro Fuse Type Vehicle Tesladex Info
    1111445-00-* Self-Powered cfg_energy = Energy100
    Informational PurposesAn informational icon, calling your attention
    Note
    A 100kW HV battery
    1111313-00-* Self-Powered NOT (cfg_energy = Energy100)
    Informational PurposesAn informational icon, calling your attention
    Note
    Not a 100kW HV battery
    1090924-00-* Self-Powered NOT (cfg_energy = Energy100)
    Informational PurposesAn informational icon, calling your attention
    Note
    Not a 100kW HV battery
    1056211-00-* Battery Powered Reject and seek self-powered
    1077177-00-* Battery Powered Reject and seek self-powered
    1086649-00-* Battery Powered Reject and seek self-powered
    1112479-00-* Battery Powered Reject and seek self-powered
    1112553-00-* Battery Powered Reject and seek self-powered
  2. If the replacement hybrid pyro fuse is battery powered, reject it and seek a self-powered fuse.
  3. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  4. Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  5. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  6. Disconnect 12V power. See Disconnect 12V Power.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow at least 2 minutes before disconnecting high voltage components.
  7. Raise the vehicle to service under the HV battery.
  8. Remove all items from pockets and make sure not to wear any metal items.
  9. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  10. Put on the HV insulating gloves and the leather over gloves.
  11. Put on the HV-safe static control wrist strap. Clip the strap's ground connection to a threaded hole on the edge of the HV battery enclosure.
  12. Clean the area around the fuse cover with alcohol wipes.
  13. Remove the bolts (x6) that attach the fuse cover to the HV battery.
  14. Release the tabs (x2) that attach the fuse access cover to the fuse cavity, and then remove the cover from the cavity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the outer seal.
  15. Visually inspect the fuse cavity for water, dirt, evidence of arcing, or any other kind of damage. If any damage is found, escalate a Toolbox session, as appropriate.
  16. Remove the bolts (x2) that attach the hybrid pyro fuse to the busbars.
  17. Release the tabs (x4) that retain the hybrid pyro fuse within the fuse cavity, and then carefully remove the fuse from the cavity.
    Informational PurposesAn informational icon, calling your attention
    Note
    Minor arcing is possible. Be sure to have proper PPE, including goggles, worn for this step.
  18. Inspect the fuse cavity and cover area for rust or corrosion, and if any is found, refer to Toolbox article #3207900 for further guidance.
  19. Visually inspect the hybrid pyro fuse and the busbars within the fuse cavity for evidence of arcing. If there is any evidence of arcing, escalate the Toolbox session, as appropriate.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. Remove the replacement hybrid pyro fuse from the antistatic packaging and place it onto an ESD safe surface.
  3. Use an IPA wipe to thoroughly clean the busbars within the fuse cavity and the terminals of the hybrid pyro fuse and allow at least 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    There is a dull busbar, and a shiny busbar.
  4. Position the hybrid pyro fuse with the embossed arrow pointing to the rear of the vehicle, and then install the fuse into the fuse cavity past the tabs (x4) that retain the fuse.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Minor arcing is possible. Be sure to have proper PPE, including goggles, worn for this step.
    Informational PurposesAn informational icon, calling your attention
    Note
    The dull terminal of the hybrid pyro fuse mates with the dull busbar, the copper terminal of the fuse mates with the shiny busbar.
  5. Install the bolts (x2) that attach the hybrid pyro fuse to the busbars, and then mark the bolts with a paint pen after tightening.
    9 Nm (6.6 lbs-ft)
  6. Use the Hioki resistance meter to measure the resistance at the HV joint of the hybrid pyro fuse dull terminal and the dull busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not short the side of the probe tip to the edge of the fuse terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is not within this range, reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed, proceed with the installation procedure.
  7. Use the Hioki resistance meter to measure the resistance at the HV joint of the hybrid pyro fuse copper terminal and the shiny busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not short the side of the probe tip to the edge of the fuse terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is not within this range, reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed, proceed with the installation procedure.
  8. Install the fuse access cover to the fuse cavity, and then fasten the tabs (x2) that attach the cover to the cavity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the outer seal.
  9. Use an IPA wipe to clean the sealing surface and gasket of the fuse cavity, the sealing surface of the fuse cover, and allow at least 1 minute to dry.
  10. Install the fuse cover to the HV battery, install new bolts (x6) that attach the fuse cover to the HV battery, and then mark the bolts with a paint pen after tightening.
    10 Nm (7.4 lbs-ft)
  11. Remove the leather glove protectors and the HV insulating gloves.
  12. Connect 12V power. See Disconnect 12V Power.
  13. If the vehicle is configured with a Tegra MCU, perform these substeps:
    1. Update the vehicle firmware to feature/2022.8.10.12 or later. See Firmware Update.
    2. Enable Service Mode Plus. See Service Mode Plus.
    3. Unlock the gateway. See Gateway Unlock.
    4. On the vehicle touchscreen, touch Service Mode > Set Pyro-Fuse Type, and then read the instructions.
    5. Touch SELF-POWERED, touch Set, and allow the routine to complete.
      Informational PurposesAn informational icon, calling your attention
      Note
      Touch the X in the upper left corner to close.
    6. Disable Service Mode Plus. See Service Mode Plus.
  14. If the vehicle is configured with an Intel MCU, perform these substeps:
    1. Update the vehicle firmware to develop/2023.12 or later. See Firmware Update.
    2. Enable Service Mode Plus. See Service Mode Plus.
    3. Unlock the gateway. See Gateway Unlock.
    4. On the vehicle touchscreen, touch HV Battery (Lightning Bolt), touch the green fuse in the graphic, touch Read/Write Fuse Type, and then read the instructions.
    5. From the Pyro fuse type drop down menu, select SELFPOWERED_HYBRIDPYRO, from the Write or read drop down menu, select WRITE, touch Run, and allow the routine to complete.
    6. Exit Service Mode Plus. See Service Mode Plus.
  15. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  16. Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  17. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.