Kia Niro: Hybrid Control System / General safety information and caution

Kia Niro 2017 (DE HEV) Service Manual / Hybrid Control System / General safety information and caution

Safety Precaution

Precautions to take before servicing high voltage system

Hybrid vehicles have high voltage batteries. Incorrect handling of high voltage system or vehicle may lead to serious accident including electric shock and electric leakage.

•	Be sure to shut off the high voltage by removing the safety plug before performing inspection or repairing the high voltage system.(Refer to “High Voltage Shut-off Procedures”)

•	Keep the safety plug completely removed to prevent the plug from being connected by mistake.

•	Do not wear metallic objects (watch, ring etc.) while working on the high voltage system, due to risk of serious accidents like electric shock.

•	Whenever working on the high voltage system, wear personal protective equipment to prevent accidents. (Refer to “Personal Protective Equipment”)

•	Technicians not wearing personal protective equipment must not be allowed to work on high voltage systems. Cover high voltage components with an insulated sheet to prevent accidents.

•	Use insulation tools when working on the high voltage system.

•	Put the removed high voltage components on the insulation mat.

•	All the high voltage wiring and connectors are orange.

•	A caution label for high voltage is attached to the high voltage components.

•	High voltage components include: High Voltage Battery Pack Assembly, Power Relay Assembly (PRA), BMS ECU, Hybrid Power Control Unit (HPCU), Hybrid Drive Motor, HSG, Electric A/C Compressor, Low DC/DC Converter (LDC), Power Cable, Electric Compressor, etc.

•	To prevent injury to technician, place "High Voltage" caution sign as shown.

Personal Protective Equipment

Name	Illustration	Description
Insulation gloves		Used when inspecting or working on the high voltage components [Insulation performance : 1000V / 300A or above]
Insulation shoes		Used when inspecting or working on the high voltage components
Insulation clothes
Insulation helmet
Safety glasses		Used in the following cases : • During removal & installation or inspection of the high voltage battery terminals or wiring, where spark might happen. • When working on the high voltage battery pack assembly.
Face shield
Insulation mat		All removed high voltage components are placed on an insulation mat to prevent accident.
Insulation sheet		Insulation sheet is used to cover high voltage components to protect people not wearing personal protective equipment from accident.
Warning tape		Used for informing that it is dangerous past this line.

Personal Protective Equipment Inspection

•	Check that the personal protective equipment is not damaged.

•	Check that the insulation gloves are not torn or damaged.

•	Wear the insulation glove after removing moisture.

① Fold the insulation glove as above.

② Fold again 3~4 times to make it airtight.

② Squeeze the inflated glove to see if the glove is torn or damaged.

Precautions to take when handling power cable

•	Immediately insulate the high voltage terminal after reconnecting the terminal (use insulation tape).

•	Tighten the high voltage terminal screw to torque specifications.

•	Be careful that (+) and (-) terminals do not come in contact when connecting or disconnecting power cable and busbar.

Precautions to take when handling high voltage battery

•	When transporting high voltage battery, be sure to keep it flat and leveled. Failure to do so may decrease the battery performance and/or its life-span.

•	High voltage battery's performance may decrease if it is exposed to high temperature for a lengthy period. As a result, heat-treatment after painting must not exceed 70°C (158°F) / 30 minutes, or 80°C (176°F) / 20 minutes.

Precautions in case of fire on high voltage battery system

•	If the fire occurs indoor, ventilate the area to let out hydrogen gas.

•	ABC fire extinguisher is recommended for putting out the fire. (water may also be used).

Precautions in case of high voltage battery gas or electrolyte leakage

•	Turn OFF the Start button. Keep the Smart Key at least 2 meters (78.7 inch, 6.5 feet) away from the vehicle to prevent unintended engine start.

•	Gas is hydrogen and alkaline vapor. If the leakage is indoor, ventilate the area immediately and evacuate to a safe location.

•	If the leaked liquid comes in contact with skin, immediately neutralize the affected area with boric acid solution, then clean with tap water or saline solution.

•	If the leaked vapor or liquid gets in the eye, immediately clean the affected eye with water then get medical attention.

•	If the gas leakage is caused by high temperature, then do NOT use the battery until the high voltage battery fully cools down to room temperature.

Precautions when handling the vehicle after an accident

•	Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.

•	Do NOT touch bare cable under any condition (refer to "Precautions when handling power cable.")

•	In case of vehicle fire, put out the fire with ABC extinguisher. Do NOT use water (usage of large volume of water is okay, but small volume can worsen the situation).

•	If more than half of the vehicle is submerged, then do NOT go near the Safety Switch or other high voltage related components. If such a component must be accessed, then move the vehicle to the safe location first before handling the component.

•	Gas is hydrogen and alkaline vapor. If the leakage is indoor, ventilate the area immediately and evacuate to a safe location.

•	If the leaked liquid comes in contact with skin, immediately neutralize the affected area with boric acid solution, then clean with tap water or saline solution.

•	Refer to "High voltage cut-off procedure" if the high voltage needs to be cut off.

Preparations when servicing the accident vehicle

•	Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.

•	Boric acid power or solution

•	ABC Extinguisher

•	Towel for cleaning electrolyte

•	Vinyl tape (for insulating terminal)

•	Mega ohm tester (for checking high voltage)

Precautions in case HEV is left unattended for a lengthy period

•	Turn OFF the Start button. Keep the Smart Key at least 2 meters (78.7 inch, 6.5 feet) away from the vehicle to prevent unintended engine start.

•	We recommend that HEV is driven at least 1 time for over 30 minutes every 2 months to protect and manage the high voltage battery (inquire at relevant team in HMC).

•	When inspecting or exchanging the auxiliary battery, check high voltage battery SOC reset related problems.

Hybrid Control System

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