High-Voltage Battery Pack Repair
Module diagnostics, pyrofuse replacement, contactor verification, and cell rebalancing protocols.
Technical Scope of Battery Pack Repair
Targeted repair of a high-voltage (HV) battery pack involves replacing only damaged cell modules or internal electronic components (pyrofuse, main contactor relays, slave BMS boards), avoiding full battery replacement costs out of warranty.
Critical Workshop Protocol Steps:
- LOTO Lockout & HV-3 Certification: MSD disconnect, zero voltage verification (VAT) using CAT IV 1000V rated meters.
- Pressure Leak Testing: Low-pressure nitrogen testing (20 mbar) to verify pack enclosure gasket seals.
- Inter-Module Voltage Balancing: Matching module voltages prior to reconnection (ΔV < 10mV) to prevent high-current surge during contactor engagement.
Need a specific diagnostic or technical advisory call?
Contact our senior engineering team or schedule a consultation slot.