HV Battery Charge/Discharge - 4th Generation Tool (Out of Vehicle)

FRT No: 16010700

Warning: Only technicians who have been trained in High Voltage Awareness are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

These instructions are for the 4th generation battery charger/discharger tool. The 4th generation tool has the following features:

Setup

  1. Connect the high voltage components to the charger/discharger tool, using the included harnesses.
    Warning: Cover the charger/discharger tool load bank connector with its protective flap when the HV cable is not installed.
    Note: Hot air is exhausted from the rear of the discharger box when the battery is discharging. Position the cables away from the vents on the rear of the discharger to prevent them from being overheated.
  2. Connect the components to the wall outlet, using the included power cables.
  3. Connect the signal and communication components, using the included cables. Some cables might already be connected.
    Note: The DB9-RJ45 Ethernet cable should be connected to the "IN" port on the power supply.
  4. Connect the low voltage (LV) connector to the battery, using the included harness.
  5. Set the front panel control switches to the indicated positions.

Starting the System

  1. Press the emergency stop button to disable HV systems.
  2. Pull out the display/keyboard/trackpad tray.
  3. Press the red power button to turn on the on-board PC.
  4. Follow the onscreen instructions to log in to the system.
    Username: batterytool
    Password: Tesla1234
    Domain: CHGDCH-PC#
    Note: The username and password are case-sensitive. Enter the username and password as shown above.
    Note: Do not set the domain to TESLAMOTORS.
  5. Launch the Model S Charger/Discharger GUI application from the Start menu or the shortcut on the desktop. The HV battery serial number, SOC, and shipping bit status are shown.

Discharging the Battery

  1. Select the desired SOC from the Charge/Discharge Mode menu.
  2. If Manual Mode is selected, type the desired SOC in the Target SOC% field, or drag the Target SOC% knob to the desired SOC.
  3. Set the load bank power switch to the on position. Set the load bank 7 kW switch to the 7 kW (off) position.
  4. Release the emergency stop button by turning the knob counter-clockwise.
  5. Select the Start button in the software application. The Start button changes to a Stop button.
  6. The battery contactors close and discharging begins. The pack current, discharging indicator, and estimated hours remaining display on the right side of the window.
  7. When the target SOC is reached, the tool automatically stops the discharging operation and opens the contactors. The discharging operation can be manually stopped by pressing the Stop button in the software application.
    Note: The emergency stop switch on the charger/interface box can be used to immediately open the contactors in an emergency. Do not press the emergency stop switch except in an emergency, as it opens the contactors under load and disconnects power to the BMS, causing the Charger/Discharger Tool to lose communication with the BMS.
  8. When the operation is complete, make sure the contactor state is "Open", then engage the emergency stop switch.
  9. Wait until the voltage displayed on the HV DC Link Voltmeter is less than 5V, then shut down the PC.
  10. Turn off all powered components.
  11. Disconnect the HV battery.

Charging the Battery

  1. Select Manual Mode from the Charge/Discharge Mode menu.
  2. Type the desired SOC in the Target SOC% field, or drag the Target SOC% knob to the desired SOC.
  3. Turn on the HV power supply.
  4. Release the emergency stop button by turning the knob counter-clockwise.
  5. When the green Ready light appears in the lower right corner of the software application, select the Start button. The Start button changes to a Stop button.
  6. The battery contactors close and charging begins. The pack current, charging indicator, estimated hours remaining, HV Power Supply Ready light, HV On light, and Max Current display on the right side of the window.
  7. When the target SOC is reached, the tool automatically stops charging and opens the contactors. The charging operation can be manually stopped by pressing the Stop button in the software application.
    Note: The emergency stop switch on the charger/interface box can be used to immediately open the contactors in an emergency. Do not press the emergency stop switch except in an emergency, as it opens the contactors under load and disconnects power to the BMS, causing the Charger/Discharger Tool to lose communication with the BMS.
  8. When the operation is complete, make sure the contactor state is "Open", then engage the emergency stop switch.
  9. Wait until the voltage displayed on the HV DC Link Voltmeter is less than 5V, then shut down the PC.
  10. Turn off all powered components.
  11. Disconnect the HV battery.

Troubleshooting

Charging does not start. The green "Ready" light in the software application is dimmed.

  • Check that the HV power supply is plugged in and turned on.
  • Check the connections at the rear of the charger/interface control box.

Discharging does not start.

  • Review the status box in the software application for information that could be helpful for troubleshooting.
  • Check that the discharger box is plugged in and its power switch is on.
  • Check that the load bank control cable is connected to the rear of the charger/interface control box.

The software application displays "Pack Communication Error!"

  • The emergency stop is engaged.
  • Check the LV connector to the battery pack.

The software application displays the "Safety Fault" light.

  • If the emergency stop is engaged then disengaged, the HV battery is reset. The software application reports a safety fault until the HV battery has completed all internal safety checks. Wait until the "Safety Fault" light is dimmed before continuing.

The software application status box displays HV connection errors.

  • Check for faulty HV connections.
  • Check for an open HVIL connection. Make sure all connections are fully seated--a plug might appear to be inserted without being fully seated.

The software application displays the "BMS Fault" light.

  1. Make sure the system is idle (select the Stop button in the software application if the pack is charging or discharging).
  2. Engage the emergency stop switch, then disengage it.
  3. Close the "Pack Communication Error!" warning in the software application.
  4. Wait until the "Safety Fault" light is dimmed, then try to charge or discharge the battery.
  5. If the BMS Fault light is displayed again, contact Service Engineering for assistance.