HV BATTERY STACK DISCHARGING


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

    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. A0040CB

        Confirm the type of the Li-ion battery connection cable as indicated by the tag shown in the illustration. (Type: TM4216-21)

    2. Install Li-ion battery connection cable


      1. A00430N

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

      2. A00406VE01
        Text in Illustration
        *1 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. A0043U3E01
        Text in Illustration
        *1 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. A004492

        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

      CAUTION:

      Wear insulated gloves.


      1. A0041YBE01
        Text in Illustration
        *1 Li-Ion Battery Connection Cable
        *2 Connection for No. 1 Hybrid Vehicle Supply Stack Sub-assembly Connector
        *3 Connection for No. 2 Hybrid Vehicle Supply Stack Sub-assembly Connector
        *4 Connection for No. 3 Hybrid Vehicle Supply Stack Sub-assembly Connector
        *5 Connection for No. 4 Hybrid Vehicle Supply Stack Sub-assembly Connector

        Connect the connector of the hybrid vehicle supply stack sub-assembly to be discharged to the Li-ion battery connection cable (orange).

      2. A0042EV

        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, discharge using the Li-ion battery discharger cannot be performed for this hybrid vehicle battery supply stack sub-assembly. Make sure to soak the hybrid vehicle supply stack sub-assembly in a saltwater solution to complete discharging.

        LED Indicator Illumination Status (When discharge has started normally)
        Item LED Indicator No. LED Indicator Illumination Status
        No. 1 hybrid vehicle supply stack sub-assembly 62 to 75 Illuminated
        No. 2 hybrid vehicle supply stack sub-assembly 46 to 59 Illuminated
        No. 3 hybrid vehicle supply stack sub-assembly 25 to 38 Illuminated
        No. 4 hybrid vehicle supply stack sub-assembly 1 to 14 Illuminated

      3. Confirm that the cooling fans operate

        A0041TRE01
        Text in Illustration
        *1 Cooling Fans

        Tech Tips


        • To discharge the hybrid vehicle supply stack sub-assembly completely, continue discharging for at least 1 hour after the LED indicators have turned off.

        • Discharge of a fully charged hybrid vehicle supply stack sub-assembly will complete within 20 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

      CAUTION:

      Wear insulated gloves.


      1. A0042S9

        Disconnect the connector (orange) of the hybrid vehicle supply stack sub-assembly from the Li-ion battery connection cable (orange).

        Note

        Make sure to install a shorting connector within 1 minute of disconnecting the Li-ion battery connection cable, as the hybrid vehicle supply stack sub-assembly voltage may recover unexpectedly.

    6. Install shorting connector

      CAUTION:

      Wear insulated gloves.


      1. A0042UEE01
        Text in Illustration
        *1 Shorting Connector
        *2 Connection for No. 1 Hybrid Vehicle Supply Stack Sub-assembly Connector
        *3 Connection for No. 2 Hybrid Vehicle Supply Stack Sub-assembly Connector
        *4 Connection for No. 3 Hybrid Vehicle Supply Stack Sub-assembly Connector
        *5 Connection for No. 4 Hybrid Vehicle Supply Stack Sub-assembly Connector

        Connect the shorting connector to the high-voltage connector (orange) of the hybrid vehicle supply stack sub-assembly.

        Note

        Make sure to install a shorting connector within 1 minute of disconnecting the Li-ion battery connection cable, as the hybrid vehicle supply stack sub-assembly voltage may recover unexpectedly.

    7. Remove Li-ion battery connection cable


      1. A0042G1

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

      2. A0041VEE01
        Text in Illustration
        *1 Connector B

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

      3. A0042M9E01
        Text in Illustration
        *1 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)

    Note


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

    • Calculate the saltwater concentration based on the measured volume of water in the container so that a 1% saltwater solution will be made after adding the concentrated saltwater solution to the water in the container where hybrid vehicle supply stack sub-assembly is set.


    1. Prepare hybrid vehicle supply stack sub-assembly

      CAUTION:

      Be sure to wear insulated gloves and protective goggles.

      Note


      • Perform discharging in a well-ventilated area.

      • Perform discharging in a dry area protected from rain.


      1. A0043V1E02
        Text in Illustration
        *a Example
        *b Container (A)

        Set the hybrid vehicle supply stack sub-assembly in a container (A).

    2. Prepare to discharge (Add water to container)

      CAUTION:

      Be sure to wear insulated gloves and protective goggles.


      1. A0042B2E01
        Text in Illustration
        *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 (liter).

      2. A003ZXRE01
        Text in Illustration
        *a Example
        *b Water Surface
        *c Container (A)
        *d Container (B)

        Using the container (B), add water to the container (A) until the hybrid vehicle supply stack sub-assembly 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 (liter) = Water capacity of the container (B) x Number of times the container (B) was filled with water to submerge the hybrid vehicle supply stack sub-assembly

        Tech Tips

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

    3. Prepare saltwater solution


      1. A0040A7E01
        Text in Illustration
        *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 (liter).

      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 (liter) + Z (liter)) x 0.01
      3. A0042H7E01
        Text in Illustration
        *a Example
        *b Container (B)

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

    4. Add saltwater solution

      CAUTION:

      Be sure to wear insulated gloves and protective goggles.


      1. A0042IY

        Add the concentrated saltwater solution to the container (A).

    5. Discharge


      1. Leave the hybrid vehicle supply stack sub-assembly 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 hybrid vehicle supply stack sub-assembly 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

      CAUTION:

      Be sure to wear insulated gloves and protective goggles.


      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.

      A0040J4