Used high voltage battery system storage, transportation, disposal guide
• When working on the high voltage system, the work should be performed by technicians who have completed the relevant training. A lack of understanding of the high voltage system can lead to serious accidents due to electric shock or short circuit.
• When working on the high voltage system or related components, be sure to observe and be aware of the "Safety Precautions, Cautions and Warnings". If not, it may cause serious accidents due to electric shock or short circuit.
• When working on the high voltage system, make sure to check the Personal Protective Equipment (PPE) and high voltage shut-off procedure.
Used High Voltage Battery System Handling Procedure
How to handle/inspect the Used High Voltage Battery System
Undamaged Battery
| Item | Correction |
| Storage | Storing/Packaging the battery under the same conditions as a new battery |
| Transportation | Minimize impact and transport it separately with other general parts to prevent from getting mixed. |
| Disposal | Transport to the battery disposal company and discharge it completely with salt precipitation and perform disposal according to the disposal company's procedures. |
Damaged Battery
1.Inspect the damaged battery
| Item | How to inspect | Inspection standard | Correction |
|
Voltage Failure Inspection (Using Digital Multimeter) |
Measure the voltage between high voltage battery the main connector ( + ) terminal and ( - ) terminal | Approximately 268 - 418 V | If abnormal, immediately perform the saltwater precipitation to prevent from the fire on high voltage battery |
|
Abnormal Temperature Inspection (Using Non-contact Thermometer) |
1) Check external temperature of battery system assembly case 2) Check the change of the initial temperature and the temperature measured after 30 minutes. |
1) Temperature change of 3°C (37.4°F) or less 2) Max temperature of 35°C (95°F) or less |
- When the maximum temperature is 35°C or higher, leave it in a dry cool
place and check the temperature at around 35°C – If the difference between the initial temperature and the temperature after 40 minutes rises by more than 3°C, perform saltywater precipitation immediately - When temperature continues to rise after the temperature measurement at 30 minutes interval, perform the salty water precipitation immediately. |
|
Check the insulation resistance for abnormality (Use Mega ohm tester) |
1) Measure isolation resistance between the Power Relay Assembly (PRA) (
+ ) terminal and battery pack cover 2) Measure isolation resistance between the Power Relay Assembly (PRA) ( - ) terminal and battery pack cover |
Insulation resistance is 2 MΩ or more (when applying 500 V) |
Insulating and packing exterior insulator |
|
Insulate where may be caused a short circuit (Visual inspection) |
1) Power Relay Assembly (PRA) connecting cable terminal 2) Battery Management Unit (BMU) voltage sensing connector |
– |
- Requires to put insulating tape/rubber cap to prevent from a short circuit
between packs, cells and modules. – Fix the cable terminal to minimize the movement. |
| Check for electrolyte leakage |
Check the odor within 30 cm (11.8 in.) of battery system assembly (Similar to chemical and acrylic odor) |
– | Perform the salty water precipitation immediately when it stinks like electrolyte leakage |
2.Result of damaged battery inspection
| Inspection Results | Item | Correction |
| Normal | Storage | Storing/Packaging the battery under the same conditions as a new battery |
| Transportation | Minimize impact and transport it separately with other general parts to prevent from getting mixed. | |
| Disposal | Transport to the battery disposal company and discharge it completely with salt precipitation and perform disposal according to the disposal company's procedures. | |
| Abnormal | Storage |
- Insulate the exposed area of terminal by using external insulator that
prevents the short circuit. (Insulating tape, rubber cap or etc) - Package after packing the exterior of battery pack by using the insulator (Vinyl, wrap or etc) and putting shock absorbing material. - Store volatile and combustible materials separately in a dry cool area |
| Transportation | Minimize impact and transport it separately with other general parts to prevent from getting mixed. | |
| Disposal | Transport to the battery disposal company and discharge it completely with salt precipitation and perform disposal according to the disposal company's procedures. |
Procedure for insulation of where may be caused the short circuit.
1.Insulating method of Power Relay Assembly (PRA) connection cable terminal
– Insulate PRA ( + ), ( - ) cable by using a rubber cap or insulating tape to prevent Battery System Assembly (BSA) short circuit.
– To minimize the movement, fix the cable terminal into BSA case by using an insulating tape.
2.Procedure for insulation of BMU voltage signal connector
– Insulate the connector (A) by using rubber cap or insulating tape to prevent the short circuits between the cells and modules.
– To minimize the movement, fix the wiring into BSA case by using an insulating tape.
Used high voltage battery system discharging procedures
1.The technicians have to wear Personal Protective Equipment (PPE) to prevent safety accidents before working on high voltage system.(Refer to High Voltage System General Safety Information and Caution - "Personal Protective Equipment (PPE)")
2.After removing the main fuse, package and store it safely on the same basis as the new battery system.
3.After finishing the exterior of high voltage battery system assembly (BSA) with insulators (vinyl, wrap, etc.), pack it adding an anti-shock material.
4.Transport to the battery disposal company and discharge it completely with salt precipitation and dispose of batteries according to the disposal company's procedures.
5.The high voltage battery may cause electric shock and other accidents. If the high voltage battery shows any abnormal symptom as shown below, immediately discharge the battery using the salt precipitation method (soaking in salt water) at the service center.
– When there are signs of fire or smoke.
– When the high voltage battery voltage is abnormally high
– When the high voltage battery temperature continues to increase abnormally
– When occurring an odor like leaking electrolyte is suspected (similar to chemical or acrylic odor)
[Salt Solution Discharge Method]
(1)Pour enough water into a large container (or similar sized container) to completely submerge the battery.
(2)Immerse the high voltage battery assembly in water using a crane jack.
(3)Leave the battery in water and discharge it for 90 hours.
(4)Add salt to until the concentration of salt water to be approximately 3.5%.
(5)Discharge the battery in salt water for additional 48 hours.
(6)Take out the high voltage battery from the container and dry it.
• Salt increases the speed of discharge rate but also increases the risk of heat generation, so immerse the battery in general water and add the salt.
• After the salt precipitation discharge is completed, BSA voltage should be less than 230.4 V.
