Hybrid Control System
Safety Precaution
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
In a hybrid vehicle accident, high voltage battery system inspection procedure by type
3) Collision
4) Submersion
High Voltage Shutoff Procedure
WARNING:
Shut off the high voltage circuit before doing any work related with the high voltage system (Battery Pack Assembly, Power Relay Assembly, HPCU, BMS ECU, Hybrid Drive Motor, Inverter, HSG, LDC Power Cable, Electric Compressor, and so on).
1. Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) cable.
2. Remove the safety plug.
(1) Open the safety plug service cover (A).
(2) Pull out/down the lever (A) in the direction of the arrow after lifting the locking hook (B), and then pull the safety plug.
3. Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
4. Make sure that the capacitor has been discharged.
(1) Remove the rear seat and partition tray trim .
(2) Remove the high voltage front cover (A).
High voltage front cover installation bolt :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
(3) Measure the voltage between the inverter positive and negative power cable terminals.
Below 30V :High voltage circuit properly shut
More than 30V :High voltage circuit faulty
WARNING:
If the measured voltage is more than 30V, check the removal of the safety plug again.
If it is above 30V even though the safety plug is properly removed, there must be any serious problem in high voltage circuit. In this case, do the DTC troubleshooting first ; don't do any work related to the high voltage system.
Main Fuse Inspection
1. Remove the safety plug cover (A).
2. Remove the main fuse (B) after removing bolts.
3. Check the continuity between ends of the main fuse.
Specification:1 Ohms or less (If not, it means there is open circuit.)
Checking for Welding in the High Voltage Main Relay
In order to safely remove the battery pack assembly, you must first inspect the high voltage main relay for signs of melting.
You can use GDS service data to detect welding in the high voltage main relay.
[Using GDS service data to check for main relay melting]
1. Connect the GDS to the self-diagnosis connector (DLC).
2. Turn on the ignition.
3. Check the BMS melt state in the GDS service data.
[Using a Multimeter to measure welding]
WARNING:
The high voltages (270V) used in a hybrid system could cause loss of life or damage to the vehicle. Always comply with the "Hybrid System Precautions" while working (refer to the general precautions listed in the "Hybrid system Precautions").
1. Cut off the high voltage (refer to the "High voltage Cut-Off Process").
2. Unfasten bolt (A) and nut (B) and remove the rear cover from the high voltage battery (C).
3. Remove the high voltage protection cover (A) from the power relay assembly (PRA).
4. Measure the high voltage main relay resistance and check for signs of melting (1Ohms or less means there is welding).
Isolation Resistance Inspection
The high voltage insulation used in hybrid systems can be checked using GDS service data or by measuring it directly.
[Using GDS service data to check insulation resistance]
1. Connect the GDS to the self-diagnosis connector (DLC).
2. Turn on the ignition.
3. Check the insulation resistance in the GDS service data.
Normal insulation resistance range:1.0 - 4.0 MOhms
[Measuring insulation resistance using an insulation tester (MOhms tester)]
WARNING:
The high voltages (270V) used in a hybrid system could cause loss of life or damage to the vehicle. Always comply with the "Hybrid System Precautions" while working (refer to the general precautions listed in the "Hybrid system Precautions").
1. Cut off the high voltage (refer to the "High voltage Cut-Off Process").
2. Unfasten bolt (A) and nut (B) and then remove the rear cover of the high voltage battery (C).
3. Remove the high voltage protection cover (A) from the power relay assembly (PRA).
4. Connect the insulation tester (-) terminal (A) to the battery system case (or ground).
5. Connect the insulation tester (+) terminal to the high voltage battery (+) and (-). Measure the resistance.
[Measure the insulation resistance on the power relay assembly high voltage power terminal (+)]
(1) Connect the insulation tester (+) terminal to the (+) PRA high voltage power terminal (A).
(2) Supply 500V through the insulation tester and wait one minute to measure the stable resistance.
(3) Check the insulation resistance.
[Measure the insulation resistance on the power relay assembly high voltage power terminal (-)]
(1) Connect the insulation tester (+) terminal to the (-) PRA high voltage power terminal (B).
(2) Supply 500V through the insulation tester and wait one minute to measure the stable resistance.
(3) Check the insulation resistance.
[Measure the insulation resistance on the power relay assembly inverter power terminal (+)]
(1) Connect the insulation tester (+) terminal to the (+) PRA inverter power terminal (A).
(2) Supply 500V through the insulation tester and wait one minute to measure the stable resistance.
(3) Check the insulation resistance.
[Measure the insulation resistance on the power relay assembly inverter power terminal (-)]
(1) Connect the insulation tester (+) terminal to the (-) PRA inverter power terminal (B).
(2) Supply 500V through the insulation tester and wait one minute to measure the stable resistance.
(3) Check the insulation resistance.
Handling Guide for Storing, Transporting, and Disposing of Defective High Voltage Battery Systems
1. Defective high voltage battery system handling process
2. Defective high voltage battery system handling / Inspection
Voltage Check
1. Measure the voltage between the safety plug upper (+) terminal and [High voltage battery -PRA] connecting cable (-) terminal.
-> Specification: About 150 V
2. Measure the voltage between the safety plug lower (-) terminal and [High voltage battery -PRA] connecting cable (+) terminal.
-> Specification: About 120 V
Take insulation actions for parts that may short circuit
1. High voltage battery - PRA cable terminal
A. Put the insulation tape or rubber cap to the (+), (-) cable terminal to prevent short circuit to the battery pack.
B. Fix the cable to the battery pack case with the insulation tape to prevent cables from moving.
2. BMS voltage sensing connector
> Insulation actions
A. Put the insulation tape or rubber cap to connectors to prevent short circuit to the battery cells, modules.
B. Fix the wiring to the battery pack case with the insulation tape to prevent wiring from moving.
Discharging defective high voltage batteries
CAUTION:
Never put more than two high voltage batteries in a single salt water tank.