TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: STANDARD OPERATING PROCEDURE ALL WORK CARRIED OUT MUST BE DONE IN ACCORDANCE WITH THE MAGTEC HEALTH AND SAFETY POLICY. SAFETY GLASSES AND BOOTS, SPECIFIED AND PROVIDED BY MAGTEC MUST BE WORN AT ALL TIMES IN PRODUCTION AREAS. THIS STANDARD OPERATING PROCEDURE (SOP) HAS BEEN WRITTEN TO ENSURE, SO FAR AS REASONABLY PRACTICABLE, THAT ALL RISK TO PRODUCT, EMPLOYEE, HEALTH, SAFETY AND ENVIRONMENT HAVE BEEN EVALUATED AND MINIMISED. ALL SOP’S ARE DESIGNED TO WORK IN CONJUNCTION WITH THE RELEVANT ENGINEERING DRAWINGS. ALL COMPONENTS LISTED ARE CORRECT AT TIME OF WRITING, AND THE PROCEDURE PHOTOGRAPHED IS TAKEN AS “BEST PRACTICE”. EMPLOYEES ARE EXPECTED TO PERFORM THE OPERATIONS DETAILED IN THIS SOP USING GOOD PRACTICES ALIGNED WITH COMPANY POLICY. ANY DEVIATION FROM STANDARD OPERATING PROCEDURES MUST BE REPORTED TO SUPERVISION/ MANAGEMENT. 1 TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 2 PPE REQUIRED EQUIPMENT: STAGE: SAFETY BOOTS ALL SAFETY GLASSES ALL GLOVES TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 3 PARTS NUMBER: DESCRIPTION: TOOLING NUMBER: DESCRIPTION: TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 4 Cleanliness check 1. Ensure the box is free of debris/swarf 2. Ensure holes/tapped holes are free of debris/swarf TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 5 Fit Earth Bolt KA.507.050.00 KA.507.533.00 17mm socket Torque to 17Nm KA.507.956.00 KA.507.181.00 Torque to 10Nm KA.507.050.00 KA.507.052.00 KA.507.126.00 1 2 6 4 3 5 1. Fit bolt and washer from the inside to outside of box. 2. Torque to 17Nm 3. Fit Dowty washer 4. Fit half nut and washer 5. Fit spring washer 6. Fit nut hand tight TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 6 Cut & fit Insulation Tape KA.119.037.00 measure and cut tape to 300mm Front of Box 1 TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 7 Assemble & fit 3 Phase Connector Assy 2 3 4 1. Fit blue and brass parts together 2. Ensure chamfer can be seen in the orientation shown 3. Position and lightly screw 4 capscrews with 2.5mm allen key. 4. Insert dummy connector into front of box to align the assy, then hand tighten. Apply Loctite 243 OK NG KA.507.401.00 x4 MB.531.126.00 MB.531.125.00 MB.852.031.00 x 3 Chamfer Chamfer Chamfer 1 TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 8 Fit Precharge Resistor Assy 1. Apply Wacker Paste to underside of Resistor Assembly 2. Loctite 243 screws and fasten resistor assy down 3. Fit P clip, Loctite screw and fasten down. KA.507.300.00 x 8 M3x6 KA.507.993.00 x 8 M3 Washer 1 2 3 KA.513.016.00 PCLIP KA.507.601.00 CAPSCREW KA.507.025.00 WASHER KA.507.027.00 SPRING WASHER TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 9 Fit Pillars 1 1. Fit 3 Pillars & Nylon Spacer. Loctite 243 on threads MB.530.837.00 MB.530.837.00 KA.507.852.00 TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 10 Fit Balancing Loom 1. Apply Wacker Paste to underside of Balancing Loom Assembly. Apply Loctite 243, fasten down hand tight. KA.507.300.00 M3x6 Capscrew x 4 KA.507.993.00 M3 Washer x 4 TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 11 Fit Capacitors 1 1. Ensure cutout for the capacitors are free from debris/swarf. Apply 5ml blob of heat transfer paste to the 10 cutouts. 2 KB.301.049.00 x 10 KA.125.079.00 x 10 +ve +ve +ve +ve +ve +ve +ve +ve +ve +ve 2. Fit top row of capacitors with +ve to the left. Fit 2 nd row of capacitors with +ve to the right. TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 12 Fit Thermistor O’Rings 1 1. Ensure the holes are free from debris/swarf. Fit the 3 o’rings for the thermistors. (o’ring colour varies between blue and orange) KA.503.195.00 x 3 TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 13 Fit 1 st Thermistor into groove 1. Fit the first thermistor identified as TH1 (brown). Ensure the TH1 wires are securely within the groove and not protruding. 1 MB.417.008.00 TH1 Brown TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 14 Check IGBT, Fit heat pad, Fit IGBT & Pillar 1. Wear ESD wrist strap 2. Check that all 6 IGBT have the same letter 3. Remove the paper seperator and fit the heat transfer pad in position. Ensure thermistor cable is in its groove and hasn’t moved out. 4. Carefully lower the IGBT into position (in the orientation shown) and secure to the box. Use Loctite 243. Fit pillar to bottom left. Torque all to 4.5Nm in sequence a,b,c,d. Apply red witness mark 1 2 3 4 KB308.055.00 KA.125.076.00 KA.507.562.00 M6x12 Pozi Pan x3 KA.507.034.00 M6 spring washer x3 KA.507.031.00 washer x3 MA.530.836.00 a b c d TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 15 Fit 2 nd thermistor 1. Fit the 2nd thermistor identified as TH2 (red). Ensure the TH2 wires are securely within the groove and not protruding. 1 MB.417.008.00 (TH2) red TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 16 Check IGBT, Fit 2nd heat pad & IGBT 1. Wear ESD wrist strap 2. Check that the IGBT has the same letter 3. Remove the paper seperator and fit the heat transfer pad in position. Ensure thermistor cable is in its groove and hasn’t moved out. 4. Carefully lower the IGBT into position (in the orientation shown) and secure to the box. Use Loctite 243. Torque all to 4.5Nm in sequence a,b,c,d. Apply red witness mark 1 2 3 4 KB308.055.00 KA.125.076.00 KA.507.562.00 M6x12 Pozi Pan x4 KA.507.034.00 M6 spring washer x4 KA.507.031.00 washer x4 a b c d TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 17 Fit 3 rd thermistor 1. Fit the 3rd thermistor identified as TH3 (orange). Ensure the TH3 wires are securely within the groove and not protruding. MB.417.008.00 (TH3) orange 1 TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 18 Check IGBT, Fit 3 rd heat pad, IGBT & Pillar 1. Wear ESD wrist strap 2. Check that the IGBT has the same letter 3. Remove the paper seperator and fit the heat transfer pad in position. Ensure thermistor cable is in its groove and hasn’t moved out. 4. Carefully lower the IGBT into position (in the orientation shown) and secure to the box. Use Loctite 243. Fit pillar to bottom right. Torque all to 4.5Nm in sequence a,b,c,d. Apply red witness mark 1 2 3 4 KB308.055.00 KA.125.076.00 KA.507.562.00 M6x12 Pozi Pan x3 KA.507.034.00 M6 spring washer x3 KA.507.031.00 washer x3 MA.530.836.00 a b c d TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 19 Fit IGBT 4,5,6 with heat pads 4 5 6 1. Wear ESD wrist strap 2. Check that the IGBTs have the same letter 3. Remove the paper seperator and fit the heat transfer pad in position. Ensure thermistor cable is in its groove and hasn’t moved out. 4. Carefully lower the IGBT into position (in the orientation shown) and secure to the box. Use Loctite 243. Fit pillar to bottom right. Torque all to 4.5Nm in sequence a,b,c,d. Apply red witness mark 1 2 3 KB308.055.00 KA.125.076.00 4 KA.507.562.00 M6x12 Pozi Pan x4 KA.507.034.00 M6 spring washer x4 KA.507.031.00 washer x4 a b c d TASK: Stage 1 Assembly AUTHOR: PW PC5: P183 XB.851.084.00 Build Docs SOP 20220805 1120 PRODUCT: XB.851.084.00 CHECKED: REVISION: 1 st Draft AREA: Controller Assembly DATE: Aug 2022 PAGE: 20 Remove Abspulse cover plate KB.305.042.00 Absopulse Cover Plate 1 1. Remove the 6 Cover Plate fixing screws and lift off the cover plate. (keep the 6 screws) Exposing the Absopulse as shown below. (Remove terminal plastic cover and save for later)