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Installing Cell Block Module In Module Group 4

WARNING: Incorrect handling of high-voltage components
  • Electric shock
  • Risk of short circuit
  • Risk of fire
  • Risk of explosion

    → Only appropriately trained and authorized persons are permitted to work on high-voltage vehicles and components.

    → Required qualification: High voltage expert.

    → Observe national requirements and legislation for this work.

    → Always use insulated tools, e.g. > VAS 6883 - Insulated tool set,  when working on these components.

    → Observe general warning notes for working on the high-voltage vehicle electrical system.

    > 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE VEHICLE ELECTRICAL SYSTEM

Information 

Information 

During disassembly and assembly, the battery housing can have a low-capacity charge - similar to a condenser! The capacity during disassembly and assembly is reduced beforehand by performing a voltage measurement. This also verifies the absence of electric charge so that the module connectors can be safely removed or fitted!

Information 

Mark the spacer sleeves for the cover of the high-voltage battery before removal and note the installation position. The spacer sleeves have different sizes (heights) and must not be interchanged.

  1. Before installing a new module, always write down or take a photo of the serial number.
    G15551417Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Serial number (example)

  2. Always use personal protective equipment.

    > 2X00IN SPECIFICATIONS FOR PREPARING A HIGH-VOLTAGE WORKPLACE

  3. Before installing a new module, the charge state of the new module must be adapted to the charge state of the other modules.

    > 270889 CHARGING AND DISCHARGING CELL MODULE 

  4. Heat the heat-conducting paste to approx. 60 °C in a water bath.
    G15551418Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Heat-conducting paste in water bath (shown as an example)

  5. Work out how much heat-conducting paste must be applied.
    1. 5.1  Set base on > VAS 231 007 - scale  and work out the "tare".
      G15551419Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Scale

    2. 5.2  Carefully scrape heat-conducting paste out of the module slot in the high-voltage battery using a plastic spatula and put heat-conducting paste on a base.
      G15551420Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Module slot (shown as an example)

    3. 5.3  Carefully scrape heat-conducting paste off the removed module using a plastic spatula and put it on a base.
      G15551421Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Module

    4. 5.4  Weigh heat-conducting paste.
      G15551422Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Weighing heat-conducting paste

  6. Apply heat-conducting paste on the new module.
    1. 6.1  Clean the underside of the module using a dry, lint-free cloth. Do not use any cleaning fluid.
    2. 6.2  Place module with > T90023 - template  on the > VAS 231 007 - scale  and determine the tare.
      G15551423Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Module with template

    3. 6.3  Apply the previously weighed amount of heat-conducting paste evenly in 6 lines on the module.
      G15551424Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Working out amount of heat-conducting paste required

    4. 6.4  Remove > T90023 - template  from the module.
    5. 6.5  Press heat-conducting paste gently onto the module.
      G15551425Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Pressing on heat-conducting paste gently

  7. Clean module slot using a dry, lint-free cloth. Do not use any cleaning agent.
    G15551426Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Module slot

  8. Fit two guide pins for the > 9860/2 - guide rod  module in diagonally opposite sequence.
    G15551427Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Guide pins on module (shown as an example)

  9. Turn the module on its side and fit module picker > T40424 - lifting tool  on the module.
    G15551428Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Module picker

  10. Carefully place the module and module picker > T40424 - lifting tool  into the module slot high-voltage battery using > VAS 6100 - workshop crane  .
  11. If installed: Fit spacer sleeve for high-voltage battery cover and tighten to > Tightening torque 8 Nm 

    Check spacer sleeve installation position and marking.

    G15551429Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Spacer sleeve (shown as an example)

  12. Unscrew guide pins on > 9860/2 - guide rod  module.
  13. Fit screws on the module and tighten to

    > Tightening torque 5 Nm 

    > Tightening torque 8 Nm 

    G15551430Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Screws on module (shown as an example)

    1. 13.1  Tighten screws on module in diagonally opposite sequence.
  14. Perform potential equalization measurement before fitting module connector and communication line.
    1. 14.1  Connect > VAS 6558A - high-voltage testing module  to > 9900 - PIWIS Tester 3  .
    2. 14.2  start the Tester.
    3. 14.3  Select Measurement program  .
    4. 14.4  Select HV measurements  .
    5. 14.5  Select potential equalization measurement  .
    6. 14.6  Perform self-test according to menu guidance.
    7. 14.7  Attach Kelvin clamp to the positive measuring probe (red).
    8. 14.8  Connect ground terminal to potential equalization line for battery housing.
    9. 14.9  Fit measuring probe with Kelvin clamp on the module housing and press it on.
      G15551431Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Potential equalization measurement (shown as an example)

      1. 14.9.1  Start the measurement.
      2. 14.9.2  Measured result: Resistance < 10 m Ohm.
  15. Remove protection caps on module terminals > T40421 - Shock-proof protection cap  .
    G15551432Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Protection cap on module terminals (shown as an example)

  16. Fitting and assembling module connector.

    Module connectors must be replaced following removal.

    G15551433Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Module connectors (shown as an example)

    1. 16.1.16.1.16.1  Before fitting the module connector, press screws to the rear (inner) -Arrow-  until they engage.
      G15551434Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Screws for module connector

    2. 16.2.16.2.16.2  Tighten module connector to > Tightening torque 6 Nm  .
  17. Insert communication wire harness at the module.

    The electric plug connection must engage securely.

    G15551435Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Communication wire harness (example)

  18. Discharge capacitive voltage.
    1. 18.1  Connect > VAS 6558A - high-voltage testing module  to > 9900 - PIWIS Tester 3  .
    2. 18.2  Start the Tester.
    3. 18.3  Select Measurement program  .
    4. 18.4  Select HV measurements  .
    5. 18.5  Select DC voltage measurement  .
    6. 18.6  Perform self-test according to menu guidance.
    7. 18.7  Connect test clamp to potential equalization line.
    8. 18.8  Place measuring probe on the module's positive terminal.
      G15551436Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Capacitive voltage (shown as an example)

      1. 18.8.1  Start the measurement.
      2. 18.8.2  Repeat the measurement until the voltage is < 10 volts.
  19. Have all previously loosened module connectors checked by a second person (dual control principle).
    1. 19.1  Set the torque wrench to the required torque value again.
    2. 19.2  Tighten all previously loosened module connectors again to > Tightening torque 6 Nm 
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