Lexus ES manuals

Lexus ES: Discharging

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / Hybrid / Battery Control / Hv Battery Stack (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) Connect the connector (orange) of the HV supply stack sub-assembly to be discharged to the Li-ion battery connection cable (orange).

*a

Li-Ion Battery Connection Cable

*b

HV Supply Stack Sub-assembly Connector

*c

Connection for No. 1 HV Supply Stack Sub-assembly Connector

*d

Connection for No. 2 HV Supply Stack Sub-assembly Connector

(2) 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 supply stack sub-assembly cannot be discharged using the Li-ion battery discharger. Make sure to soak the HV supply stack sub-assembly in a salt water solution to complete discharging.

LED Indicator Illumination Status (When discharge has started normally)

Item

LED Indicator No.

LED Indicator Illumination Status

No. 1 HV supply stack sub-assembly

1 to 35

Illuminated

No. 2 HV supply stack sub-assembly

36 to 70

Illuminated

(3) Confirm that the cooling fans operate.

*a

Cooling Fans

-

-

HINT:

  • To discharge the HV supply stack sub-assembly completely, continue discharging for at least 1 hour after the LED indicators have turned off.
  • Discharge of a fully charged HV supply stack sub-assembly 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 HV 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 connector (orange) of the HV supply stack sub-assembly from the Li-ion battery connection cable (orange).

(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 the HV supply stack sub-assembly is set.

(a) Prepare HV supply stack sub-assembly

(1) Set the HV supply stack sub-assembly 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 supply stack sub-assembly 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 supply stack sub-assembly

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 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 HV 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.

(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 supply stack sub-assembly being discharged.

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