Removing Cell Block Module In Module Group 2

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!

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.

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Module group 2

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 connectors (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  If installed: Unscrew spacer sleeve for high-voltage battery cover.

      Mark installation position and spacer sleeve.

      Write marking on the head of the spacer sleeve.

      Marking on the head of the spacer sleeve is absolutely essential if a reorder via PET is required.

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      Spacer sleeve (shown as an example)

   2. 6.2  Unscrew screws.

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      Screws on module (shown as an example)

   3. 6.3  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)

   4. 6.4  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. 6.4.1  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)