HV BATTERY DISCHARGING

PROCEDURE


  1. DISCHARGING (WHEN USING THE LI-ION BATTERY DISCHARGER)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note


      Make sure to observe the following points when using the Li-ion battery discharger.

    • Set it in a secure, flat place.

    • Set it in a dry place protected from dust and water.

    • Set it in a position where illumination of the LED indicators can be observed.

    • Do not block the ventilation holes or cooling fans.


    1. Select Li-ion battery connection cables


      1. B006I91C02
        *a Li-ion Battery Connection Cable (A)
        *b Li-ion Battery Connection Cable (B)

        Confirm the type of the Li-ion battery connection cable as indicated by the tag shown in the illustration. (Type: TM4216-54.TM4216-55)

    2. Install Li-ion battery connection cable


      1. A003P6H

        Set the Li-ion battery discharger as shown in the illustration.

      2. B006IE3C04
        *a Connector A

        Connect the Li-ion battery connection cable connector (A) to the Li-ion battery discharger connector (A).

        Note

        Make sure that the connector is connected securely.

      3. B006I60C04
        *a Connector B

        Connect the Li-ion battery connection cable connector (B) to the Li-ion battery discharger connector (B).

        Note

        Make sure that the connector is connected securely.

      4. A003LVO

        Set the Li-ion battery discharger as shown in the illustration.

        Tech Tips

        The Li-ion battery discharger is set on its side so that the ventilation holes will not be blocked.

    3. Connect Li-ion battery connection cable


      1. Remove the upper hybrid battery cover sub-assembly.

        Click here

      2. A003O3J

        Disconnect the 5 high-voltage connectors (orange) from the battery ECU assembly.

        Note


        • B006HNCC01
          *a Lever Lock

          Make sure to release the lock of the lock lever before moving it.

        • If the connector cannot be disconnected, check if the lock lever is completely unlocked.

      3. When discharging the No. 1 HV supply stack sub-assembly and No. 2 HV supply stack sub-assembly:


        1. B006I3KC01
          *a Li-ion Battery Connection Cable (A)

          Connect the Li-ion battery connection cable connectors (orange) to the 2 high-voltage connectors (orange) of the HV battery.

        2. A003LBP

          Confirm that all of the LED indicators are illuminated as shown in the following table.

          CAUTION:

          If all of the LED indicators of the Li-ion battery discharger listed in the following table are not illuminated, the HV battery cannot be discharged using the Li-ion battery discharger. Make sure to soak the HV battery in a salt water solution to complete discharging.

          LED Indicator Illumination Status (When discharge has started normally)
          LED Indicator No. LED Indicator Illumination Status LED Indicator No. LED Indicator Illumination Status LED Indicator No. LED Indicator Illumination Status
          1 Illuminated 2 Illuminated 3 Illuminated
          4 Illuminated 5 Illuminated 6 Illuminated
          7 Illuminated 8 Illuminated 9 Illuminated
          10 Illuminated 11 Illuminated 12 Illuminated
          13 Illuminated 14 Illuminated 15 Illuminated
          16 Illuminated 17 Illuminated 18 Illuminated
          19 Illuminated 20 Illuminated 21 Illuminated
          22 Illuminated 23 Illuminated 24 Illuminated
          25 Illuminated 26 Illuminated 27 Illuminated
          28 Illuminated 29 Illuminated 30 Illuminated
          31 Illuminated 32 Illuminated 33 Illuminated
          34 Illuminated 35 Illuminated 36 Illuminated
          37 Illuminated 38 Illuminated 39 Not illuminated
          40 Not illuminated 41 Not illuminated 42 Not illuminated
          43 Not illuminated 44 Not illuminated 45 Not illuminated
          46 Not illuminated 47 Not illuminated 48 Not illuminated
          49 Not illuminated 50 Not illuminated 51 Not illuminated
          52 Not illuminated 53 Not illuminated 54 Not illuminated
          55 Not illuminated 56 Not illuminated 57 Not illuminated
          58 Not illuminated 59 Not illuminated 60 Not illuminated
          61 Not illuminated 62 Not illuminated 63 Not illuminated
          64 Not illuminated 65 Not illuminated 66 Not illuminated
          67 Not illuminated 68 Not illuminated 69 Not illuminated
          70 Not illuminated 71 Not illuminated 72 Not illuminated
          73 Not illuminated 74 Not illuminated 75 Not illuminated

      4. When discharging the No. 3 HV supply stack sub-assembly, No. 4 HV supply stack sub-assembly and No. 5 HV supply stack sub-assembly:


        1. B006JB6C01
          *a Li-ion Battery Connection Cable (B)

          Connect the Li-ion battery connection cable connectors (orange) to the 3 high-voltage connectors (orange) of the HV battery.

        2. A003N20

          Confirm that all of the LED indicators are illuminated as shown in the following table.

          CAUTION:

          If all of the LED indicators of the Li-ion battery discharger listed in the following table are not illuminated, the HV battery cannot be discharged using the Li-ion battery discharger. Make sure to soak the HV battery in a salt water solution to complete discharging.

          LED Indicator Illumination Status (When discharge has started normally)
          LED Indicator No. LED Indicator Illumination Status LED Indicator No. LED Indicator Illumination Status LED Indicator No. LED Indicator Illumination Status
          1 Illuminated 2 Illuminated 3 Illuminated
          4 Illuminated 5 Illuminated 6 Illuminated
          7 Illuminated 8 Illuminated 9 Illuminated
          10 Illuminated 11 Illuminated 12 Illuminated
          13 Illuminated 14 Illuminated 15 Illuminated
          16 Illuminated 17 Illuminated 18 Illuminated
          19 Illuminated 20 Illuminated 21 Illuminated
          22 Illuminated 23 Illuminated 24 Illuminated
          25 Illuminated 26 Illuminated 27 Illuminated
          28 Illuminated 29 Illuminated 30 Illuminated
          31 Illuminated 32 Illuminated 33 Illuminated
          34 Illuminated 35 Illuminated 36 Illuminated
          37 Illuminated 38 Illuminated 39 Illuminated
          40 Illuminated 41 Illuminated 42 Illuminated
          43 Illuminated 44 Illuminated 45 Illuminated
          46 Illuminated 47 Illuminated 48 Illuminated
          49 Illuminated 50 Illuminated 51 Illuminated
          52 Illuminated 53 Illuminated 54 Illuminated
          55 Illuminated 56 Illuminated 57 Illuminated
          58 Not illuminated 59 Not illuminated 60 Not illuminated
          61 Not illuminated 62 Not illuminated 63 Not illuminated
          64 Not illuminated 65 Not illuminated 66 Not illuminated
          67 Not illuminated 68 Not illuminated 69 Not illuminated
          70 Not illuminated 71 Not illuminated 72 Not illuminated
          73 Not illuminated 74 Not illuminated 75 Not illuminated

      5. Confirm that the cooling fans operate.

        B006HY5C03
        *a Cooling Fans - -

        Tech Tips


        • To discharge the HV battery completely, continue discharging for at least 1 hour after the LED indicators have turned off.

        • Discharge of a fully charged HV battery will complete within 25 hours (including 1 hour waiting time after the LED indicators have turned off).

    4. Confirm discharge completion


      1. Confirm that all of the LED indicators of the Li-ion battery discharger have turned off.

      2. Continue to discharge the battery for 1 hour after all of the LED indicators of the Li-ion battery discharger have turned off.

    5. Disconnect Li-ion battery connection cable


      1. A003LKC

        When discharging the No. 1 HV supply stack sub-assembly and No. 2 HV supply stack sub-assembly:


        1. Disconnect the Li-ion battery connection cable connector (orange) from the 2 high-voltage connectors (orange) of the HV battery.

      2. A003LSP

        When discharging the No. 3 HV supply stack sub-assembly, No. 4 HV supply stack sub-assembly and No. 5 HV supply stack sub-assembly:


        1. Disconnect the Li-ion battery connection cable connector (orange) from the 3 high-voltage connectors (orange) of the HV battery.

    6. Remove Li-ion battery connection cable


      1. A003OOL

        Set the Li-ion battery discharger as shown in the illustration.

      2. B006J9FC04
        *a Connector B

        Disconnect the Li-ion battery connection cable connector (B) from the Li-ion battery discharger connector (B).

      3. B006J57C04
        *a Connector A

        Disconnect the Li-ion battery connection cable connector (A) from the Li-ion battery discharger connector (A).

  2. DISCHARGING (WHEN USING THE SALT WATER SOLUTION)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note


    • When discharging using salt water solution, first add a measured amount of water to the container, and then add the concentrated salt water solution.

    • Calculate the salt water concentration based on the measured volume of water in the container so that a 1% salt water solution will be made after adding the concentrated salt water solution to the water in the container where HV battery is set.


    1. Prepare HV battery


      1. B006J4HC01

        Set the HV battery in the container (A).

    2. Prepare to discharge (Add water to container)


      1. B006HR5C01
        *a Example
        *b Container B

        Measure the water capacity of the container (B).

        Tech Tips

        Water capacity of the container (B) is assumed as X (liters).

      2. B006HQJC01
        *a Example
        *b Water Surface
        *c Container A
        *d Container B

        Using the container (B), add water to the container (A) until the HV battery is completely submerged.

        Note

        Make sure to record the times the container (B) was filled with water to add water to the container (A).

      3. Using the following formula, calculate the amount of water added to the container (A).

        Amount of water added to the container (A)
        Y (liters) = Water capacity of the container (B) x Number of times the container (B) was filled with water to submerge the HV battery

        Tech Tips

        Amount of water added to the container (A) is assumed as Y (liters).

    3. Prepare salt water solution


      1. B006IZFC01
        *a Example
        *b Container B

        While measuring the amount of water, fill about half of the container (B) with water.

        Tech Tips

        Amount of water added to the container (B) is assumed as Z (liters).

      2. Calculate the amount of salt to be added to the container (A) so that a 1% salt water solution will be made.

        Amount of Salt
        Amount of salt (kg) = (Y (liters) + Z (liters)) x 0.01
      3. B006HVDC01
        *a Example
        *b Container B

        Add the calculated amount of salt to the container (B) and stir it thoroughly.

    4. Add salt water solution


      1. A003MXR

        Add the concentrated salt water solution to the container (A).

    5. Discharge


      1. Leave the HV battery as is for 24 hours or more until discharge is complete.

        CAUTION:


        • Do not place a lid on the container.

        • Make sure to leave the HV battery and container as is for 24 hours or more.

        • Display a warning sign to inform others that discharge is being performed.

    6. Confirm discharge completion


      1. Check that bubbles are not forming in the container.

        Note

        If bubbles are forming, discharge may not be completed yet. Do not place a lid on the container.

    7. Display a warning sign such as "DO NOT TOUCH! (DISCHARGE BEING PERFORMED) to inform others. Make a copy of the warning sign and place it near the HV battery being discharged.

      A003LR6