Lexus ES manuals

Lexus ES: Discharging

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / Hybrid / Battery Control / Hv Battery (for Lithium-ion Battery) / Discharging

DISCHARGING

PROCEDURE

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

CAUTION:

Be sure to wear insulated gloves and protective goggles.

NOTICE:

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.

(a) Select Li-ion battery connection cables

(1) Confirm the type of the Li-ion battery connection cable as indicated by the tag shown in the illustration. (Type: TM4216-71)

(b) Install Li-ion battery connection cable

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

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

NOTICE:

Make sure that the connector is connected securely.

*a

Connector (A)

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

NOTICE:

Make sure that the connector is connected securely.

*a

Connector (B)

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

HINT:

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

(c) Connect Li-ion battery connection cable

(1) Move the lock lever while pushing the lock, and disconnect the 2 high-voltage connectors (orange) from the battery ECU assembly.

NOTICE:

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

    *a

    Lever Lock
  • If the connector cannot be disconnected, check if the lock lever is completely unlocked.
  • Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

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

(3) 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

Illuminated

59

Illuminated

60

Illuminated

61

Illuminated

62

Illuminated

63

Illuminated

64

Illuminated

65

Illuminated

66

Illuminated

67

Illuminated

68

Illuminated

69

Illuminated

70

Illuminated

71

Not illuminated

72

Not illuminated

73

Not illuminated

74

Not illuminated

75

Not illuminated

(4) Confirm that the cooling fans operate.

*a

Cooling Fans

-

-

HINT:

  • 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 5 hours (including 1 hour waiting time after the LED indicators have turned off).

(d) 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.

(e) Disconnect Li-ion battery connection cable

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

(f) Remove Li-ion battery connection cable

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

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

*a

Connector (B)

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

*a

Connector (A)

2. DISCHARGING (WHEN USING THE SALT WATER SOLUTION)

CAUTION:

Be sure to wear insulated gloves and protective goggles.

NOTICE:

  • 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.

(a) Prepare HV battery

(1) Set the HV battery in the container (A).

*a

Example

*b

Container (A)

(b) Prepare to discharge (Add water to container)

(1) Measure the water capacity of the container (B).

HINT:

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

*a

Example

*b

Container (B)

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

NOTICE:

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

*a

Example

*b

Water Surface

*c

Container (A)

*d

Container (B)

(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 HV battery

HINT:

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

(c) Prepare salt water solution

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

HINT:

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

*a

Example

*b

Container (B)

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

*a

Example

*b

Container (B)

(d) Add salt water solution

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

(e) 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.

(f) Confirm discharge completion

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

NOTICE:

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

(g) 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.

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