Circuit/System Testing
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure includes the following steps:
- Identify how to disable high voltage.
- Identify how to test for the presence of high voltage.
- Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
- Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
- Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
- Visually and functionally inspect the gloves before use.
- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedures may result in serious injury or death.
High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures may result in serious injury or death.
This vehicle is equipped with a high voltage battery that is completely isolated from the chassis ground. Never utilize AC powered test equipment to probe the high voltage system. Serious injury, death and component damage could occur if the high voltage system is grounded through the electric utility.
Failure to follow the procedure exactly as written may result in serious injury or death.
Damage to a Lithium Ion hybrid/EV battery pack could result in fire, loss of electrical isolation or exposure to high voltage. Until the high voltage system inspection has been completed, store the vehicle with hybrid/EV battery pack installed outside in a secure area away from buildings and other vehicles and protected from rain, snow and other moisture. Remove the hybrid/EV battery pack high voltage manual disconnect lever and store it in a secure place outside the vehicle. Cover the exposed high voltage opening with UL® listed, or equivalent, insulation tape rated at a minimum of 600 V.
Failure to follow these precautions could result in personal injury, death and property damage.
Inspection Procedure
- Connect the EL-50332-145 Black Banana Jack Cable, EL-50332-150 Red Banana Jack Cable, and EL-50332-155 Green Banana Jack Cable to the EL-50332-105 Universal Fuse Box.
- Connect the EL-50332-120 High Voltage Interface Cable to the EL-50332-105 Universal Fuse Box.
- Connect the EL-50332-120 High Voltage Interface Cable to the EL-50332 Hybrid/EV Battery Service Tool.
- Connect the EL-50332-135 Hybrid/EV Battery Contactor Assembly Interface Cable to the EL-50332-110 Vehicle Interface Module.
- Connect the EL-50332-125 Vehicle Interface Module Low Voltage 24-Pin Cable to the EL-50332-110 Vehicle Interface Module.
- Connect the EL-50332-125 Vehicle Interface Module Low Voltage 24-Pin Cable to the EL-50332 Hybrid/EV Battery Service Tool.
- Connect the appropriate regional power cord to the EL-50332 Hybrid/EV Battery Service Tool.
- Connect the appropriate regional power cord into a known good power outlet.
- Turn ON the EL-50332 Hybrid/EV Battery Service Tool using the power switch.
- At the MAIN MENU, select SECTION BALANCE, press the SELECT soft key.
- At the TYPE menu, select VOLTEC, press the NEXT soft key.
- At the TARGET menu, select appropriate section to be balanced, press the NEXT soft key.
- Connect the EL-50332-155 Green Banana Jack Cable to the A4 Hybrid/EV Battery Pack ground G340.
- Connect the EL-50332-145 Black Banana Jack Cable to the appropriate section negative stud to be balanced. Refer to Hybrid/EV Energy Storage Schematics for Hybrid Battery Section 1, Hybrid Battery Section 2, or Hybrid Battery Section 3.
- Connect the EL-50332-150 Red Banana Jack Cable to the appropriate section positive stud to be balanced. Refer to Hybrid/EV Energy Storage Schematics for Hybrid Battery Section 1, Hybrid Battery Section 2, or Hybrid Battery Section 3.
- Press the NEXT soft key.
- Connect the EL-50332-135 Hybid/EV Battery Contactor Assembly Interface Cable to the A4 Hybrid/EV Battery Pack.
- Press the NEXT soft key.
- An audible tone will sound at the end of balancing or in the event of a fault condition.
- A fault condition was detected
Refer to the EL-50332 Hybrid/EV Battery Service Tool Instruction Manual.
- Section balancing completed successfully
- A fault condition was detected
- At the Completed menu, press the NEXT soft key. Record warranty code. Press the EXIT soft key.
- All OK.
Before balancing a battery section, make sure all of the external EL-50332 components and cables are in good condition and working order.
Refer to the Special Tools for the correct regional power cord.
Depending on the charge condition of the battery pack and the section being balanced, this process can take up to 4 hours to perform.
The EL-50332 will now balance the selected section by charging/discharging, as appropriate. Target voltage will be based on measured pack cell group voltages. Initial balancing will be in a constant current mode (max 5 amp charge, 7.5 amp discharge). The tool will transition to a constant voltage mode (decreasing current) near the end of the event. A warranty code and pack voltage current data will be displayed at the conclusion of the balancing event.