Model S QC Test Drive – Level 3

VIN:___________

Tools required: Laptop with Model S GUI, PCAN

Info:

Level 3 test drives are required after HV battery repairs. Make sure the battery is balanced and showing no “Acceleration reduced” messages, since we want full power for testing purposes. The procedure is as follows:

1. Charge vehicle to 100% soc using slow 110v cable. This gives plenty of time for cells to balance.
2. Drive vehicle under normal loads and driving scenarios over the course of a few days until the battery reaches around 40% soc or below. DO NOT CHARGE VEHICLE, NO HARD DRIVING.
3. At around 40% SOC, Cruise the car for 15 minutes on a stretch of highways has wide shoulders.
4. Without hesitation, open the throttle to 100% after cruising on highway in the right hand lane. Be prepared to pull over. This sudden load will cause a voltage drop which may trigger HV battery to fail. Test repeated runs for any errors.
5. If load test passes, it is safe to charge the car with AC. Or if convenient/safe, attempt to Supercharge the vehicle:
6. Attempting to supercharge: Park the car in a safe area. Use car navigation system to navigate to supercharger. This will begin the pack heating process, which may cause HV pack to fail.
7. Try to arrive at Supercharger with a low state of charge, and charge vehicle to 100%.
8. If everything passes up to this point, simply drive and charge the vehicle freely with variance for another week or so. If it passes this test, it is ready for the customer.

Author: Ian Ffield