High Voltage Disabling

High Voltage Disabling

Danger:
Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.

Danger:
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

* Identify how to disable high voltage.

* Identify how to test for the presence of high voltage.

* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

* Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

* Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

- Visually and functionally inspect the gloves before use.

- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures exactly as written may result in serious injury or death.

Servicing the A4 Hybrid/EV Battery Pack, A15 Starter/Generator, High Voltage 3-Phase Cables, and General Vehicle Servicing

This disabling procedure should only be used when service is being performed on components that are located outside of the A4 hybrid/EV battery pack, such as the A15 starter/generator and high voltage 3-phase cables, or when the A4 hybrid/EV battery pack is being replaced as a complete assembly. This procedure will only verify that high voltage has been removed from locations outside the A4 hybrid/EV battery pack. If testing or replacement requires disassembling the A4 hybrid/EV battery pack and accessing any components within, Servicing Any Internal Components Within the A4 Hybrid/EV Battery Pack, located below, must be used. The Servicing Any Internal Components Within the A4 Hybrid/EV Battery Pack procedure must be used because of the constant presence of high voltage when the A4 hybrid/EV battery pack is disassembled.

1. Review the high voltage safety information. Refer to High Voltage Safety High Voltage Safety.

2. Disconnect and remove any 12 V battery chargers.

3. Turn the ignition OFF and wait 5 minutes to allow the high voltage capacitors to discharge.

4. Remove all vehicle keys and secure in a location outside the vehicle. If the vehicle is equipped with push button start, the keys must remain at least 3 meters (10 feet) away from the vehicle.

5. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

6. Lower the rear seatback and reposition the trunk liner to gain access to the A4 hybrid/EV battery pack.

7. Disengage the blue connector position assurance (1) from the high voltage interlock switch by pulling the CPA straight out. Do not fully remove the CPA from the switch or damage to the CPA will result.

8. Depress the white tab on the high voltage interlock switch and slide the interlock switch toward the left side of the vehicle (2).

9. Flip the S15 hybrid/EV battery pack high voltage manual disconnect lever, located on the A4 hybrid/EV battery pack, toward the right side of the vehicle and secure in the open position with a zip tie (3).

Danger:
Wear high voltage insulation gloves with leather protectors until it has been determined that a high voltage exposure risk is no longer present. Failure to follow the procedures exactly as written may result in serious injury or death.

10. Remove the F102 hybrid/EV battery pack cable cover from the A4 hybrid/EV battery pack.

Note:
A 9 V DC battery can be used to test the DMM.

11. Test the DMM by measuring a 12 V battery. The reading on the DMM should accurately reflect the battery voltage.

• If the DMM does not properly measure a 12 V battery

Repair or replace the DMM.

• If the DMM properly measures a 12 V battery

12. Verify that the voltage has been disabled at the energy storage system. Using the DMM on the DC voltage scale, test for less than 3 V at the following points:

* High voltage 3-Phase terminal V to vehicle chassis ground

* High voltage 3-Phase terminal W to vehicle chassis ground

* High voltage 3-Phase terminal U to vehicle chassis ground

* High voltage 3-Phase terminal U to High voltage 3-Phase terminal V

* High voltage 3-Phase terminal V to High voltage 3-Phase terminal W

* High voltage 3-Phase terminal W to High voltage 3-Phase terminal U

• If 3 V or greater

A contactor is stuck closed or a loss of isolation has occurred within the A4 hybrid/EV battery pack. Refer to Hybrid\EV Battery Voltage Present Hybrid/EV Battery Voltage Present.

• If less than 3 V

Note:
A 9 V DC battery can be used to test the DMM.

13. Test the DMM by measuring a 12 V battery. The reading on the DMM should accurately reflect the battery voltage.

• If the DMM does not properly measure a 12 V battery

Repair or replace the DMM and perform step 11 again.

• If the DMM properly measures a 12 V battery

14. If all the test results were less than 3 V, the A4 hybrid/EV battery pack, A15 starter/generator, high voltage 3-phase cables, or general vehicle can now be serviced.

Servicing Any Internal Components Within the A4 Hybrid/EV Battery Pack

This disabling procedure should be used when any service is being performed on components that are internal to the A4 hybrid/EV battery pack, such as the K59 starter/generator control module and K16 battery energy control module. If a diagnostic instructs to perform any testing or replacement of components within the A4 hybrid/EV battery pack, this procedure must be used. This procedure will completely disconnect and isolate the C4A hybrid/EV battery section 1 and C4B hybrid/EV battery section 2 from the vehicle, allowing testing or replacement to occur in a safer environment.

1. Review the high voltage safety information. Refer to High Voltage Safety High Voltage Safety.

2. Disconnect and remove any 12 V battery chargers.

3. Turn the ignition OFF and wait 5 minutes to allow the high voltage capacitors to discharge.

4. Remove all vehicle keys and secure in a location outside the vehicle. If the vehicle is equipped with push button start, the keys must remain at least 3 meters (10 feet) away from the vehicle.

5. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

6. Lower the rear seatback and reposition the trunk liner to gain access to the A4 hybrid/EV battery pack.

8. Depress the white tab on the high voltage interlock switch and slide the interlock switch (2) toward the left side of the vehicle.

15. Verify that the S15 hybrid/EV battery pack high voltage manual disconnect lever is functioning properly. Using the DMM on the DC voltage scale, test for less than 3 V between the High Voltage DC terminal (1) and the High Voltage DC terminal (2).

• If 3 V or greater

The S15 hybrid/EV battery pack high voltage manual disconnect lever is stuck closed. Replace the S15 hybrid/EV battery pack high voltage manual disconnect lever immediately after completing this disabling procedure.

• If less than 3 V

Danger:
High voltage insulation gloves with leather protectors MUST be worn at all times when the A4 hybrid/EV battery pack cover has been removed. 120 V WILL be present at the battery terminals. Failure to follow the procedures exactly as written may result in serious injury or death.

16. Flip open the orange battery terminal covers at the C4A hybrid/EV battery section 1 and C4B hybrid/EV battery section 2.

17. Disconnect the battery terminals at the C4A hybrid/EV battery section 1 and C4B hybrid/EV battery section 2 in the order specified in the above graphic.

18. Remove the high voltage cables from the battery terminals and close the battery terminal covers, with the cables on the outside of the closed terminal covers.

19. Tape the battery terminal covers closed with UL(R) listed, or equivalent, insulation tape rated at a minimum of 600 V.

Note:
A 9 V DC battery can be used to test the DMM.

20. Test the DMM by measuring a 12 V battery. The reading on the DMM should accurately reflect the battery voltage.

• If the DMM does not properly measure a 12 V battery

Repair or replace the DMM and perform the disabling procedure again.

• If the DMM properly measures a 12 V battery

21. Test for less than 1 ohms across the 125 A fuse located in the S15 hybrid/EV battery pack high voltage manual disconnect lever.

• If 1 ohms or greater

The 125 A fuse is open. If the fuse is open, verify the S15 hybrid/EV battery pack high voltage manual disconnect lever is also open by testing for infinite resistance across the switch terminals. Replace the fuse after high voltage testing is complete and a system repair has been made. Torque fasteners to 9 Nm (80 lb in).

• If less than 1 ohms

22. With the high voltage cables disconnected and the battery terminal covers secured, the K59 starter/generator control module, K16 battery energy control module, S15 hybrid/EV battery pack high voltage manual disconnect lever, KR38 main contactor, R25 hybrid/EV battery pre-charge resistor, KR134 pre-charge contactor, B30 hybrid/EV battery pack current sensor, C4A hybrid/EV battery section 1, C4B hybrid/EV battery section 2, and any components within the A4 hybrid/EV battery pack can now be serviced.