How to De-energize the High Voltage System of a Mach-E GT

Рет қаралды 24,353

Күн бұрын

See how to de-energize the high voltage (HV) system of a 2021 Ford Mustang Mach E GT! This new Low Voltage Service Disconnect (LVSD) method is used by all 2020 and newer Ford electric vehicles and hybrid electric vehicles.
TIMELINE:
0:00 Start
0:08 Introduction
0:45 High voltage connectors at the HV battery
1:10 The Ford scan tool method of de-energizing the high voltage system
3:00 Starting the Ford Diagnostic and Repair System (FDRS) software
3:19 Connecting the vehicle communication module II (VCM II)
3:50 Vehicle Diagnostic Trouble Code (DTC) Check results
4:40 Running the BECM - High Voltage System De-Energizing tool
6:12 Checking for loss of high voltage isolation DTCs
6:34 MUST SEE: The live isolation resistance value
7:20 Checking for stuck closed or stuck open contactor DTCs
7:40 The basic function of the contactors
8:00 MUST SEE: The live high voltage values at each high voltage component
9:34 MUST SEE: The function of the Low Voltage Service Disconnect (LVSD) connector.
11:08 The ON and OFF positions of the Low Voltage Service Disconnect (LVSD) connector.
12:03 The OSHA 1910.147 Lockout-Tagout hole and procedure
13:25 Waiting five minutes for the passive discharge of the inverter capacitors
14:16 MUST SEE: The live low voltage values at each high voltage component
14:38 Contactors are open, it is safe to remove high voltage connections at HV battery without Personal Protective Equipment (PPE).
15:23 The Manual high voltage de-energizing procedure
16:54 The General Motors Version of the LVSD; the High Voltage Service Lockout (HVSL).
17:45 Ford uses the LVSD on all new 2020 and above electric vehicles and hybrid electric vehicles.
18:49 the Manual Service Disconnect (MSD) levers are slowly being phased out.
19:40 Video Summary
ABOUT US
Weber State University (WSU) - Davis Campus - Department of Automotive Technology - Ardell Brown Technology Wing - Transmission Lab. We teach current vehicle technologies to our automotive students at Weber State University and online. For more information visit: www.weber.edu/automotive
This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see www.weber.edu/automotive/J_Kel...
ADDITIONAL TRAINING FOR YOU
Join us for hybrid and electric vehicle training with two online courses and in a 5-day on-campus boot camp with Professor John D. Kelly. See www.weber.edu/evtraining
DONATE TO OUR DEPARTMENT
Please consider a donation to the Department of Automotive Technology at Weber State University here: advancement.weber.edu/Automotive

Пікірлер: 120

@timbrown9731 Жыл бұрын

I work for Robert Mondavi winery as a mechanic and anything we work on the lockout tag out anything electrical water hydraulic pneumatic but on our giant presses that press the grapes when we have to go inside the tanks we lock out each device power air water with its own lock then depending on how many guys are working on the unit we have a main lock box and we put all those keys in there and then on that lock box we put all our personal locks on, Per OSHA requirement!

@WeberAuto Жыл бұрын

Good job. Great to hear!

@zainelmasr1621 Жыл бұрын

فكرة الترجمة أكثر من رائعة

@WeberAuto Жыл бұрын

شكرا لمشاهدتك

@MegaHugro Жыл бұрын

Wow, I haven't watched in a while and now you've had an upgrade with that nice-looking polo shirt. I will most likely never have a chance to work on a car like this but it is cool to watch you dissect them.

@WeberAuto Жыл бұрын

Thank you

@KashifTanweerOfficial 8 ай бұрын

Fantastic Mr. John

@petermolnar6017 Жыл бұрын

Welcome back to youtube! We have been missing your videos Professor Kelly!

@WeberAuto Жыл бұрын

More to come! Thank you

@speedy_pit_stop Жыл бұрын

This channel is awesome. I'm glad I've finally found it.

@MrPatdeeee Жыл бұрын

Awesome and very interesting. But that is always the case; with this Professor. In other words...."NONE FINER"! Thank you kind Sir.

@WeberAuto Жыл бұрын

Glad you enjoyed it!

Жыл бұрын

2 in one week. Thank you so very much. I'll enjoy this,

@WeberAuto Жыл бұрын

Thank you!

@Maltanx Жыл бұрын

"Hello, I'm professor John Kelly and this is the Weber Auto youtube channel" Always a pleasure to hear these word, your lessons keep providing us with information so specialised it can't be found anywhere else on the Internet. Do you have plans for a full video teardown and analysis of the battery like you did with the Chevrolet bolt? I love your hours long videos with deep analysis of every component.

@WeberAuto Жыл бұрын

Thank you. Partial disassembly coming soon. No time for complete disassembly

@Miata822 Жыл бұрын

@@WeberAuto Oh. I do hope we get to take out a module. I'm particularly interested in the cell cooling heat sinks. I've seen a quick clip elsewhere, but not with the level of detail you are known for.

@TheDisgruntledMechanic Жыл бұрын

Thanks Prof. Kelly! Keep the great content coming.

@WeberAuto Жыл бұрын

Thank you!

@davidkarkoski3437 Жыл бұрын

Really enjoy this channel. It has been very informative on both electric cars and transmissions.

@WeberAuto Жыл бұрын

Glad you like them!

@djosbun Жыл бұрын

Thank you for another superb video, Professor Kelly. I always learn a few new things from every video that you upload, to which I am extremely appreciative.

@WeberAuto Жыл бұрын

Thank you

@Martinsp16 Жыл бұрын

Thank you for this video professor

@WeberAuto Жыл бұрын

You are very welcome

@frederickwalker4450 Жыл бұрын

Once again, a wonderful and informative video - up to your usual high standards.

@WeberAuto Жыл бұрын

Glad you enjoyed it!

@Pablo_Automotive Жыл бұрын

Thanks a lot for another great class

@WeberAuto Жыл бұрын

My pleasure

@MissingPersonsMysteries Жыл бұрын

So happy to see you are well Professor Kelly!

@WeberAuto Жыл бұрын

Thank you very much!

@MissingPersonsMysteries Жыл бұрын

@@WeberAuto Thank you! I've learned so much watching your videos. My hobby is buying broken down hybirds (mostly the Second Gen Toyota Prius's) and bringing back to life and making them road ready. I donate the cars i fix to families in need. Your videos have helped tremendously in restoring the hybird systems/hybird batteries on these cars. So far i've been able to donate a total of 12 Prius's and 4 Honda Civic Hybirds to families without vehicles - thanks to your videos! You and the knowledge you share is much appreciated! Thank you!!!

@WeberAuto Жыл бұрын

That is awesome!

@Garage_KAXOBKA Жыл бұрын

Спасибо мужик. Ты очень помог нашему Жеке! 😁👍👍👍

@WeberAuto Жыл бұрын

Thank you

@Geka-garage Жыл бұрын

Дуже дякую за відео 👍👍👍

@billiken27 Жыл бұрын

Welcome back professor

@WeberAuto Жыл бұрын

Thank you!

@TechScottBrown Жыл бұрын

Thank you!

@WeberAuto Жыл бұрын

My pleasure, thanks Scott.

@billyhouse1943 Жыл бұрын

Thank you

@WeberAuto Жыл бұрын

You're welcome. Thanks for watching

@traqnsavov822 Жыл бұрын

welcome back professor kelly 😀😃

@WeberAuto Жыл бұрын

Thank you!

@ravishkasilva2851 Жыл бұрын

thanks prof.

@WeberAuto Жыл бұрын

You are welcome

@HanifEFIMechanical Жыл бұрын

Good work

@WeberAuto Жыл бұрын

Thank you so much

@hybridsolutiondiagnostics Жыл бұрын

Wonderful video professor many thanks for keeping us updated 👋😎👋😎💥💥💥

@WeberAuto Жыл бұрын

My pleasure!!

@pradolover Жыл бұрын

Great series, thank you! Even though I've got a 5VZ-FE/A343F old Toyota I really love the EV videos.

@WeberAuto Жыл бұрын

Glad you like them!

@V10PDTDI Жыл бұрын

thanks John you are the reference for technical information on Electric and Hybrid cars it have been watching your videos for a long time. Soon I will take the online high voltage safety class for me to be able to work on high voltage cars in my shop because when I call Autologic they won't help me if i don't have these qualifications. and it really good to have so it's safe for me and any one around me.

@WeberAuto Жыл бұрын

Thank you very much!

@rcarhouse Жыл бұрын

👍👍👍👍 Muchas gracias por el video, un saludo.

@WeberAuto Жыл бұрын

Thank you!

@storm4710 Жыл бұрын

As a previously BMW trained and certified HV mechanic in Europe, I really appreciate this setup, It's clearly design to be easy to De-energize the HV system.

@WeberAuto Жыл бұрын

Agreed! Thanks for watching

@yalcnarslan4087 Жыл бұрын

A few days ago I was thinking that where the prof.John Kelly is and I said to my wife I hope my favorite best person on youtube is fine than I saw your new video . Thanks for your great explanation for especially for non-native english person like me .

@WeberAuto Жыл бұрын

Wow, thank you!

@Kevvvinus1 4 ай бұрын

Excellent job, thank you. Just doing a ev course as we speak 😅

@killercan10 Жыл бұрын

That green disconnect. Have yet to see one of those (parts mgr at a Chevrolet dealership). I've seen the Volt and Bolt batteries come out, and have done my fair share of help on Bolt recalls as I'm the forklift certified person at work. I don't recall the Bolt having that green disconnect from watching our EV tech do them. If I recall correctly, the disabling procedure on the Bolt via GDS 2 essentially has the high voltage system "think" that the vehicle has been in an accident. The horn will beep for a minute or two during this time, and then this lets you then remove the battery service disconnect under the rear seat. So sounds like that green disconnect is heading towards being an industry standard? Haven't watched any of the GM Ultium training at work yet. It almost reminds me of the Ford fuel pump inertia switches which are a quick way to disable the fuel pump on those.

@smtshrek3674 Жыл бұрын

It gets real fun when the dc fast charge contactors weld shut but do not set any stuck shut dtcs. Fdrs can not de-energize the hv system but ford wants me to replace the hv junction box inside the battery and ford tells me to do things to a $26,000 I don’t expect to ever do to get at least one contactor to unstick so I can remove and open the battery. Good thing it worked because next step was to get in contact with a battery engineer to walk me through how to “carefully de-energize the battery”

@WeberAuto Жыл бұрын

Keep in mind that the input side of the contactors is always live high voltage. If the contactors are stuck shut, the output side of the contactors will also have live high voltage. It is not more dangerous than working inside the battery. Just use your PPE high voltage gloves, tools, and safety glasses and follow the step-by step procedure to replace the battery junction block. My next video will show the procedure. Thanks for your feedback.

@MarioDallaRiva Жыл бұрын

It’s always a pleasure to see your brilliant content, Prof. JK! 👏🏼 It’s also nice to know you’re well, and busy as ever. Any updates in your home garage, vehicle wise?

@WeberAuto Жыл бұрын

Thanks! No, we still have our 2019 Bolt EV with the new battery. We are very happy with it.

@MarioDallaRiva Жыл бұрын

@@WeberAuto That’s great to hear you’re happy with the (new!) Bolt! I had to laugh thinking you could have changed the HV battery yourself 💪🏼

@Karreth Жыл бұрын

This looks like a very convenient way to de-energize the HV system, but having the physical service HV disconnect like in the Bolt seems like it would be handy if you do get a contactor welded shut.

@WeberAuto Жыл бұрын

Agreed

@user-zk6mx3fm7y Жыл бұрын

Thank you for the useful information you provide, great video keep posting and we want information about the Toyota RAV4 EV and can I increase the mileage of the charge

@jonnycando Жыл бұрын

Drive slower, and don’t go uphill….it’s just basics….nothing mechanical or electrical you can do, but maybe if a bigger battery is available at some point.

@WeberAuto Жыл бұрын

Keep your tire pressures in spec too.

@diyEVguy Жыл бұрын

Check my channel for the 2012-2014 RAV4 EV

@ouch1011 Жыл бұрын

Great video! Seems like this is mostly a bunch of safety checks done by the scan tool and a software lock-out of the HV contactors. Any of the interlock connectors would prevent the contactors from closing anyway. There should be no power outside of the HV battery (i.e. the contactors are open) when the vehicle is off and not charging anyway, except in situations where it may be charging the 12V battery. Perhaps that’s the reason why they have a software lockout. It’s probably a smart choice anyway, just to give an extra layer of safety.

@WeberAuto Жыл бұрын

Thank you, that is correct. The contactors are normally open when the car of off. This new LVSD, is a great extra layer of protection.

@traqnsavov822 Жыл бұрын

@@WeberAuto never trust contactors, they might stick closed!!

@WeberAuto Жыл бұрын

@@traqnsavov822 Agreed

@highcheker Жыл бұрын

Measuring into plugs is dangerous and not recommended. Use measuring adapters for that. Edit: we had a case here with a first failure and welded relais, the guy who was measuring made accidently contact with probes between shielding and opposite potential, he was a few weeks in hospital. And there are more reasons to not do that

@WeberAuto Жыл бұрын

That is a good point. Thanks for your feedback!

@diyEVguy Жыл бұрын

Interesting. What is a "first failure"? Were *both* contactors (relais) welded closed?

@highcheker Жыл бұрын

@@diyEVguy first failure means you have HV plus or minus potential on the chassis what normally is not the case. Than it's enough when only the opposite potential relay is welded, than you have both potentials in the plug very close to each other.

@dtemp132 Жыл бұрын

Thank you John. I'm curious what the (rough) procedure would be if indeed the contactors are welded shut, and you find 400V on the terminals. Cover them with a wad of electrical tape and keep the linesman's gloves on as you remove the battery?

@WeberAuto Жыл бұрын

Nothing special. Just keep your PPE on as you continue working.

@Daaremikkel Жыл бұрын

You can try to gently tap on the battery/contactors. I have done that successfully on other types of equipment.

@petepetess Жыл бұрын

HV Connectors meet IPXXB ingress rating in the unmated condition, meaning they are by that definition fingerproof. By SAE Hv Battery Safety standard (forgot which one), do not need a manual service disconnect (for instance of both contactors are welded) if HV connectors are IPXXB rated.

@TheGibby3340 Жыл бұрын

I am kinda surprised there is no requirement to remove the ground from the AUX battery. Guess it is required to run the scan tool for the automated process. Also strange the low voltage service disconnect is pull up to disconnect...lean hazard if not locked ??? Awesome Vid. Cheers 👍

@WeberAuto Жыл бұрын

We do not need to remove the 12V battery ground because opening the LVSD circuit accomplishes the same thing; not power to activate the contactors. Thank you! I had the same thought the first time I saw this method.

@MarioDallaRiva Жыл бұрын

John, why is the HV battery to Front Inverter cable connector a grey colour and not orange?? Also, I’m curious as to how the welded contactors (D’oh!!) get de-energized 😖 Very carefully I imagine!

@WeberAuto Жыл бұрын

Only cables are required to be orange, connectors are not. Welded contactors can not be de-energized, so you just need to be careful working around their output terminals. Their input terminal are always live anyway.

@RobertKohut Жыл бұрын

What happens if you plug a charge cable into the charge port? (While the car is in the de-energized state)

@SylvainPro2222 Жыл бұрын

Do you will made a video on re-powering the system ?

@WeberAuto Жыл бұрын

Yes I will after I put the battery back in the car. Thanks for the suggestion.

@SylvainPro2222 Жыл бұрын

@@WeberAuto 🙂

@anthonyrstrawbridge Жыл бұрын

👍✌️♥️⚡

@WeberAuto Жыл бұрын

Thank you

@jeremykeaton274 Жыл бұрын

If Tesla's equivalent of that Low Voltage Service Disconnect is a cut loop, then how do you do this procedure for regular service like working inside or replacing the battery? I'm assuming it isn't just to cut the loop and replace it with a new loop each time. Do they have an automated process with a connector that talks to the battery contactors like the Ford scan tool does?

@WeberAuto Жыл бұрын

The Tesla cut loop also unplugs. No automated process that I am aware of, they use the manual verification method with high voltage PPE and a CAT-III multimeter.

@jeremykeaton274 Жыл бұрын

@@WeberAuto Okay, that makes sense! Thanks!

@tamaseduard5145 Жыл бұрын

👍💖🙏

@WeberAuto Жыл бұрын

Thank you

@CarlosHernandez-ds2hi Жыл бұрын

Hello professor Jhon, I am from Colombia..are you have information electric engine byd model TZX500 XSA permanent magnet synchronous motor ...Thank you

@WeberAuto Жыл бұрын

Sorry, no

@houtansadeghi Жыл бұрын

Just as I was getting really attached to the Manual Service Disconnect, mustang got rid of it. I also note it disrupted your collection.

@WeberAuto Жыл бұрын

Yes, thank you

@davidck1 Жыл бұрын

why not discharge battery under 10% before service.

@WeberAuto Жыл бұрын

Because a discharged lithium-Ion battery still has 282 volts

@jaybird7534 Жыл бұрын

You gonna make it even faster professor?

@WeberAuto Жыл бұрын

LOL, no ;)

@tamasreiter9114 10 ай бұрын

High voltage over 120kV, middle voltage 0,4...120kV, low voltage 0...0,4kV.

@oleksii.zagorskyi Жыл бұрын

I feel like your microphone sound level is a little overloaded. I wish you to try to decrease recording level a little and try to listen.

@WeberAuto Жыл бұрын

Thanks for your feedback. I will adjust it

@408asesino Жыл бұрын

If anyone is in the market for a vcm2, I have one I'm not using anymore due to not working for ford anymore. Let me know

@WeberAuto Жыл бұрын

They are still a great tool

@408asesino Жыл бұрын

@@WeberAuto yea but I don't work at a shop that doesn't do automotive so it's just sitting in my ship collecting dust and I'm not going to pay for the license to run it on the off chance I do something on fords.