Removing Cell Block Module In Module Group 7

Information 

• The regulations for working on live systems apply from this point onwards  .
• Always use personal protective equipment (PPE). Observe national requirements and legal regulations  .

  > 2X00IN SPECIFICATIONS FOR PREPARING A HIGH-VOLTAGE WORKPLACE

• A second qualified person is required for all work on an open high-voltage battery. The second person must not actively work on the high-voltage battery, but is there as a safeguard in the event of an accident  .

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!

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Module group 7

1. Always use personal protective equipment.

   > 2X00IN SPECIFICATIONS FOR PREPARING A HIGH-VOLTAGE WORKPLACE

2. Discharge capacitive voltage.
   1. 2.1  Connect > VAS 6558A - high-voltage testing module  to > 9900 - PIWIS Tester 3  .
   2. 2.2  Start the Tester.
   3. 2.3  Select Measurement program  .
   4. 2.4  Select HV measurements  .
   5. 2.5  Select DC voltage measurement  .
   6. 2.6  Perform self-test according to menu guidance.
   7. 2.7  Connect test clamp to potential equalization line.
   8. 2.8  Place measuring probe on the module's positive terminal.

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      Capacitive voltage (shown as an example)

      1. 2.8.1  Start the measurement.
      2. 2.8.2  Repeat the measurement until the voltage is < 10 volts.
3. Disconnect communication wire harness at the module.

   If necessary: Use > T90027 - release tool  to release the electric plug connections.

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   Communication wire harness (example)

4. Loosen and remove module connectors.

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   Module connector (shown as an example)

5. Fit protection cap on module terminals > T40421 - shock-proof protection cap  .

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   Protection cap on module terminals (shown as an example)

6. Loosen the module.
   1. 6.1  Unscrew screws.

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      Screws on module (shown as an example)

   2. 6.2  Unclip communication wire harness if necessary.

      If necessary: Use > T90027 - release tool  to release the electric plug connections.

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      Communication wire harness (example)

   3. 6.3  Fit module picker > T40424 - module picker  and upper part of module picker > T40424/5 - supplement set  on the module. Lift the module until it comes loose.

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      Module picker with upper part of module picker (shown as an example)

      1. 6.3.1  If the module picker > T40424 - module picker  cannot be positioned correctly at the sides, loosen the module carefully using a plastic wedge and position the module in such a way that the module picker > T40424 - module picker  can be fitted correctly.

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         Loosening module

7. Remove upper part of module picker > T40424/5 - supplement set  from the module.

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   Module picker (shown as an example)

8. Carefully lift the module and module picker > T40424 - module picker  out of the high-voltage battery using > VAS 6100 - workshop crane  .

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   Module on workshop crane

   Do not place or set the module down on its underside. The heat-conducting paste on the underside of the module is required for installation.

   Set the module down on its side.

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   Module with module picker

   Only if cell module is replaced:

9. Record the serial number of the old cell module (note down or take a photo).

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   Serial number (example)