12-Module Replacement Procedure

INSPECTION BEFORE REPLACEMENT
Check the date of production of all the new modules to see that they are 1-month-old or less.

CAUTION: Never use modules older than one year.

NOTE: The manufacturing date is stamped on the side of module.

YY. MM. DD Y = Year

M = Month

D = Date

Example: 10. 11. 02 = November 2, 2010

Is the production date within 1 month?

YES: Voltage adjustment is not necessary. Assemble and install module to vehicle. Refer to "MODULE STACK: DISASSEMBLY AND ASSEMBLY ".

NO: GO TO 2.
CHECK CELL VOLTAGE DIFFERENCE AMONG MODULES
1. Measure cell voltage of each module, using a module charge balancer.
  NOTE: Record measured cell voltage.
2. Identify the difference between the maximum voltage and the minimum voltage in the same module, according to the measured cell voltage of each module.
  Standard: 100 mV or less
  
  CAUTION: Never use module of which cell voltage in the same module is more than 100 mV.
  
  Is the voltage difference 100 mV or less?
  
  YES: GO TO 3.
  
  NO: After replacing applicable module, GO TO 3.
CHECK CELL VOLTAGE DIFFERENCE AMONG MODULES
Check all the cell voltages (96 cells) measured at Step 2 to see the voltage difference between the maximum and the minimum.

Standard: 100 mV or less

Is the voltage difference 100 mV or less?

YES: Voltage adjustment is not necessary. Assemble and install module to vehicle. Refer to "MODULE STACK: DISASSEMBLY AND ASSEMBLY ".

NO: GO TO 4.
CHECK ADJUSTMENT VOLTAGE VALUE
1. Check all the cell voltages measured at Step 2 to identify the module of which voltage is minimum.
  NOTE: CELL VOLTAGE x 8 = MODULE VOLTAGE
2. Use the minimum module voltage for the adjustment voltage value of module voltage.
  CAUTION:
  - If the measured minimum module voltage is less than 28.0 V, use 28.0 V for the adjustment voltage.
  - Adjustment voltage must be in 100 mV. (Drop all digits less than 100.)
  Example: 28.825 V (MINIMUM MODULE VOLTAGE) = 28.800 V (Adjustment voltage value)
  
  Adjustment voltage value: MINIMUM MODULE VOLTAGE (If MINIMUM VOLTAGE VALUE is less than 28.0 V, use 28.0 V.)
  
  : GO TO 5.
CHECK MODULE VOLTAGE
CAUTION:
- This operation must be performed in an ambient temperature of 0 to 40°C.
- For details on the module charge balancer operation, refer to the adjuster operation manual.
1. Set the new module to the module charge balancer.
2. Measure module voltage and compare it with "adjustment voltage value" confirmed in STEP 1.
  Module voltage is lower than adjustment voltage value: GO TO 7.
  
  Module voltage is higher than adjustment voltage value: GO TO 6.
DISCHARGE OF MODULE VOLTAGE
CAUTION:
- This operation must be performed in an ambient temperature of 0 to 40°C.
- For details on the module charge balancer operation, refer to the adjuster operation manual.
Discharge the module to 26.0 V using module charge balancer.

Discharge voltage: 26.0 V

: GO TO 7.
MODULE VOLTAGE ADJUSTMENT
CAUTION:
- This operation must be performed in an ambient temperature of 0 to 40°C.
- For details on the module charge balancer operation, refer to the adjuster operation manual.
1. Enter the "adjustment voltage value" in the module charge balancer.
  Adjustment voltage value: MINIMUM MODULE VOLTAGE (If MINIMUM VOLTAGE VALUE is less than 28.0 V, use 28.0 V.)
2. Start the voltage adjustment.
  : After module voltage adjustment, GO TO 8.
CHECK CELL VOLTAGE
With CONSULT
1. After adjusting the voltage, install the module to the vehicle.
2. Select "DATA MONITOR" mode.
3. Check the difference between "MAXIMUM CELL VOLTAGE" and "MINIMUM CELL VOLTAGE" to see that the difference is within the specified value.
  Standard: 100 mV or less
  
  CAUTION: If the difference between the maximum cell voltage and the minimum cell voltage is more than 100 mV, DTC is detected. Be sure to check that the difference is 100 mV or less.
  
  : END