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

  1. Remove all items from any clothing pockets.
  2. Ensure that there is no metal on your person; remove watches, belts, jewelry, identification badges, etc.
  3. Inspect the HV insulating gloves. Test the HV insulating gloves with a glove inflator.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Expiry dates of HV gloves differ by region. Refer to TN-15-92-003 for details on HV gloves expiry dates.
    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.
  4. Put on the HV insulating gloves.
  5. Ensure that the entire work area is clear, including above and below the battery.
  6. 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.
  7. Place the high voltage “Danger” placard on top of the HV battery to warn others of the potential exposure to high voltage.
  8. Place barricades and “DANGER” barricade tape around the work area.
  9. Note the location of fire extinguishers and the high voltage rescue hook.
  10. 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

  1. Shine a light through the slots in the side skis to see if the HV battery has gore breathers between the side umbrella valves
  2. If the HV battery has side Gore breathers:
    1. Remove and discard the bolts that secure the side skis to the battery enclosure (torque 12 Nm).
    2. Remove the side skis.
    3. Replace the side gore breathers with plugs or umbrella valves.

Battery Enclosure Leak Test

  1. Use a pick or small screwdriver to remove the cap and gore breather from the front vent cover underneath the battery. Discard both components.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to scratch or damage the sealing surface on the front vent cover.
  2. Install a rubber plug in the gore breather hole.
  3. Remove the 1/8’’ NPT leak test plug from the left rear corner of the battery enclosure. Discard the plug.
  4. Install the leak test port adapter into the test port on the enclosure by hand, then torque it to 8 Nm.
  5. Prepare the leakdown test tool:
    1. Make sure both valves on the tool are closed.
    2. Connect the tool to a compressed air supply.
    3. Open the valve closest to the regulator.
    4. Set the regulator to 0.190 PSI.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Injecting more than 0.200 psi will damage the HV battery.
  6. Attach the quick connect coupling to the leak test port adapter.
  7. 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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Injecting more than 0.200 psi will damage the HV battery.
  8. Wait 60 seconds for the air pressure to settle.
  9. Record the pressure.
  10. 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:

  1. Leak tester/leak test port: If leakage is found, apply additional thread sealing tape.
  2. 2-way breather valve on the top cover: If leakage is found, try to reseat the o-ring inside the valve:
    1. Slightly loosen the 2-way breather valve.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not remove the valve.
    2. Tap the cover in the area around the valve.
    3. Retorque the valve (torque 3.5 Nm).
      x
  3. 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.
  4. Lower sleeves: If leakage is found:
    1. Check for visible cracks in the enclosure near the sleeve. If there is a visible crack, escalate a Toolbox session, as appropriate. Otherwise, continue to step b.
    2. Remove the fastener for the sleeve that is leaking.
    3. If the sleeve did not fall out when the fastener was removed, temporarily place the fastener back into the hole, and lightly tap on the fastener with a dead-blow hammer to dislodge the sleeve.
    4. Remove the fastener.
    5. Place a new sleeve onto the sleeve installation tool with the O-rings down, and the notches aligned so that the sleeve sits flush with the tool.
      Figure 1. Sleeve On Sleeve Insertion Tool
    6. Insert the sleeve from the bottom of the HV battery, so that the 2 notches on the top of the sleeve align with the 2 notches inside of the HV battery.
      Informational PurposesAn informational icon, calling your attention
      Note
      If the notches are not aligned, slowly rotate the tool until the notches are aligned.
    7. Use a small screwdriver to compress the C-clip, and allow the sleeve to clear the lip on the bottom of the hole.
      Figure 2. C-Clip (Highlighted Yellow)
      Figure 3. Compress C-Clip
    8. Make sure that the sleeve is fully inserted into the bottom of the HV battery.
      Figure 4. Properly Fitted Sleeve
      Figure 5. Improperly Fitted Sleeve
    9. Install the fastener (torque 42.5 Nm).
    10. Apply liquid leak detector around the new sleeve, then repeat the “Battery Enclosure Leak Test” section of this document.
    11. If the sleeve is still leaking, apply Right Stuff sealant around the edge of the sleeve.
  5. Side umbrella valves:
    1. Spray liquid leak detector at the outboard sides of the umbrella valves. Keep the nozzle as close to horizontal as possible so the liquid leak detector fills the valve gaps.
    2. Spray liquid leak detector at the inboard sides of the umbrella valves. Keep the nozzle as close to horizontal as possible so the liquid leak detector fills the valve gaps.
    3. If no bubbles develop, spread the liquid leak detector on and around the umbrella valves. Make sure that the areas between the valves and the battery enclosure are completely covered with liquid leak detector.
    4. If leakage is found, replace the umbrella valve(s) as necessary.
  6. Front vent cover: Spread the liquid leak detector around the vent surface to create a complete seal. If leakage is found:
    1. Remove the bolts that secure the front vent cover, then remove the front vent cover (torque 1.4 Nm).
    2. Apply additional liquid leak detector.
    3. If leakage is found, replace the umbrella valve(s) or apply additional Right Stuff sealant, as necessary.
      Informational PurposesAn informational icon, calling your attention
      Note
      If there is a crack in the housing, return the battery to a remanufacturing center.
  7. High Voltage (HV) and Low Voltage (LV) Rapid Mate connectors:
    1. Clean the surfaces around the HV and LV Rapid Mate connectors with an alcohol wipe.
    2. Completely cover the HV and LV Rapid Mate connectors with 3M 2480S masking tape or 3M 471 vinyl tape. Ensure that the tape has no gaps and completely seals the area.
    3. If the tape protrudes in any area, the Rapid Mate is leaking. Replace the Rapid Mate plate.
  8. Weld joints and top cover/enclosure joint:
    1. Spray liquid leak detector in the area, then evenly spread the liquid leak detector over the weld or seam area.
    2. Highlighted areas of the top cover, near the Rapid Mate plate.
  9. Fuse cover.
  10. Seal around the coolant Rapid Mate.
  11. All remaining fasteners on the top cover.

Reassembly

  1. Disconnect the leak test port adapter from the HV battery.
  2. Install a new leak test plug (torque 8 Nm).
  3. Remove the rubber plug from the front gore breather hole.
  4. Install a new front gore breather and front vent cover cap.
  5. Mark the cap with an orange paint pen.
  6. If gore breathers on the sides of the battery were replaced with rubber plugs, remove the plugs and install new gore breathers.
  7. 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.