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
Sealant required for this procedure:
  • Threebond 1216E (1089956-00-A), Permatex Right Stuff (1031099-00-A), or Dowsil 7091 (1962594-00-A)
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
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Warning
This procedure can only be performed in designated HV battery repair areas.
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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 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.
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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.
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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.
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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.
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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.
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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.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Do not place anything on top of the HV battery, other than the high voltage “Danger” placard.

Discharge

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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.
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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.
  1. 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.
  2. Move the vehicle to a location where it can safely continue to discharge the battery unattended.
  3. Identify the vehicle SOC every half-hour.
  4. 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

Warning IconA warning icon, calling your attention to a possibly risky situation
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.
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Note
Allow the Hioki 3548 Resistance Meter to warm up for at least 60 minutes prior to use.
  1. Create a Toolbox session if there isn’t already an open session related to this repair.
  2. Remove the HV battery from the vehicle. See HV Battery (RWD/AWD) (Remove and Install).
  3. Inspect the HV insulating gloves and leather glove protectors. See TN-15-92-003, “High Voltage Awareness Care Points” for more information.
  4. Remove all items from any clothing pockets.
  5. Make sure that there is no metal on your person; remove watches, belts, jewelry, identification badges, etc.
  6. Verify that the Fluke 1587 Insulation Multimeter works properly.
  7. Verify that the Hioki Impedance Tester works properly. Refer to the manufacturer's operating manual for details.
  8. Inspect the leads, probes, and insulation on all instrumentation.
  9. Make sure that the entire work area is clear, including the HV battery.
  10. Place the high voltage "DANGER" placard on top of the HV battery to warn others of the potential exposure to high voltage.
  11. Place barricades and "DANGER" barricade tape around the work area.
  12. Note the location of the fire extinguisher and the high voltage rescue hook.
  13. 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 IconA warning icon, calling your attention to a possibly risky situation
Warning
Make sure that both HV insulating gloves and leather glove protectors are on before performing this procedure.
  1. Put on both the HV insulating gloves and the leather glove protectors.
  2. Use a multimeter to check voltages at the HV Rapid Mate connector of the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the ancillary cover as a path to ground:
    • B+ to ground
    • B- to ground
    • B+ to B-
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    If any voltage is above 10V, mark the voltages on the lid near the HV Rapid Mate connector and escalate the Toolbox session.
  3. Set the Fluke insulation multimeter to check isolation at 500 VDC:
    • B+ to ground (ancillary cover)
    • B- to ground (ancillary cover)
    Informational PurposesAn informational icon, calling your attention
    Note
    If either isolation reading is less than 3 MΩ, escalate the Toolbox session.

HV Battery Enclosure Leak Test (Pre-Repair)

  1. 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”.
  2. Locate and repair any existing air leaks.
  3. Disconnect the quick connect coupling from the leak test port adapter, and leave the leak test port adapter connected to the HV battery.
  4. Cover the high voltage connector with a HV Rapid Mate cover. Cover the Low Voltage (LV) connector with a LV Rapid Mate cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    If these covers are not available, cover the Rapid Mate connectors with masking tape to prevent debris from falling in during this procedure.
  5. Clean the top surface of the HV battery with Isopropyl Alcohol (IPA) wipes.

Fuse Removal

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Make sure that both HV insulating gloves and leather glove protectors are on before performing this procedure.
  1. Remove the HV battery fuse. See “Fuse Removal” Fuse - Pyrotechnic - HV Battery 2.0 (Remove and Replace).
  2. Put the M6 screws (x6) and the M8 bolts (x2) removed from the fuse cover and the fuse into a designated container.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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 IconA warning icon, calling your attention to a possibly risky situation
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.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Do not place anything (other than the HV warning placard) on top of the HV battery.
  1. 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.
  2. Clean the area around the ancillary tray with Isopropyl Alcohol (IPA) wipes. Allow 1 minute to dry before continuing.
  3. Remove the cover or tape from the LV and HV Rapid Mates.
  4. Put a piece of tape along the rear of the HV battery to prevent accidental removal of any fasteners that attach the pack cover.
  5. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put these screws into the designated container so that they can be accounted for before reinstalling components.
  6. Remove and discard the T25 screws (x6) that attach the ancillary cover to the LV Rapid Mate connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put these screws into the designated container so that they can be accounted for before reinstalling components.
  7. Remove and discard the M5 screws (x28) that attach the ancillary cover to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put these screws into the designated container so that they can be accounted for before reinstalling components.
  8. Install the HV chisel stop onto the non-marring scraper approximately 20 mm from the end of the scraper.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To avoid damaging internal components, do not insert the scraper unless the HV chisel stop is installed in the proper location.
  9. Use the non-marring scraper with a dead blow hammer to separate the sealant in the areas and order shown.
    Informational PurposesAn informational icon, calling your attention
    Note
    Work around the ancillary cover in a counter-clockwise manner.
  10. Lift the ancillary cover straight up off of the LH and RH pins, and then discard the ancillary cover.
  11. Put on the HV-safe static control wrist strap, and then clip the strap’s ground connection to the ground busbar.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Put the static control wrist strap on as soon as the cover is opened. Otherwise, damage to sensitive electrical components might result.
  12. Disconnect the LV Rapid Mate electrical harness from the ancillary tray circuit board RH side connector.
  13. 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.
  14. Put the LV Rapid Mate connector on top of the ancillary unit.
  15. Release the LV Rapid Mate electrical harness from the ancillary unit harness groove.
  16. 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

  1. Put the LV Rapid Mate onto the ancillary unit, and then connect the HVIL connector and secure it with the retaining clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a soft pull-push test to verify that the clip has engaged to the ancillary unit.
  2. 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).
  3. 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.
  4. Route the small LV Rapid Mate harness in the groove in the ancillary tray and the groove in the Rapid Mate bracket.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make 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.
  5. Disconnect the HV-safe static control wrist strap ground connection from the ground busbar.
  6. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    The sealing surface should be smooth and consistent. However, the sealant does not need to be completely removed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a small pick to remove any old sealant from the ancillary tray screw holes, if necessary.
  7. Use the ESD-safe vacuum to clean the inside of the ancillary tray.

    Ancillary unit removed to aid clarity

  8. Clean all sealing surfaces on the ancillary tray and new ancillary cover with IPA wipes. Allow 1 minute to dry before continuing.

    Ancillary unit removed to aid clarity

  9. Load the sealant in the caulking gun, and then cut the nozzle approximately 15 mm from the tip.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use expired sealant. Check the expiration date on the tube of sealant.
  10. Apply a bead of sealant to the ancillary tray sealing surface on the HV battery.
  11. 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.
  12. 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.
  13. 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.
  14. 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.
  15. Install a new HV warning label to the ancillary cover.
  16. Remove the tape from the rear fasteners that attach the pack cover.
  17. Install the HV battery fuse. See "Hybrid Pyrotechnic Fuse Installation" in Fuse - Pyrotechnic - HV Battery 2.0 (Remove and Replace).
  18. 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”.
  19. Install the HV battery on the vehicle. See HV Battery (RWD/AWD) (Remove and Install).