Kia Niro: Hybrid Control System / Specifications
Kia Niro 2017 (DE HEV) Service Manual / Hybrid Control System / Specifications
| Specification |
| Hybrid Control System |
Hybrid Power Control Unit (HPCU)
|
Item |
Specification |
|
Operating Voltage (V) |
204 - 275.2 |
|
Operating Frequency (Hz) |
Max. 826 |
|
LDC Output Voltage (V) [Auxiliary 12V Battery] |
12.8 - 15.1 |
|
LDC Rated Power (kW) |
1.8 |
|
Cooling Method |
By water |
Brake Switch
▷ Type: ON/OFF Switch
|
Item |
Brake Pedal Release |
Brake Pedal Depressed |
|
|
Switch 1 |
Max. 0.5V |
Battery Voltage |
|
|
Switch 2 |
IG OFF |
Max. 50mV |
|
|
IG ON |
Battery Voltage |
Max. 0.5V |
|
|
Item |
Specification |
|
Gap [mm (in)] |
1.0 - 2.0 (0.039 - 0.079) |
DC Fuse
|
Item |
Specification |
|
Rated Current (A) |
30 |
|
Installation position |
Inside HPCU |
| High Voltage Battery System |
Battery Pack Assembly
[General Specification]
|
Item |
Specification |
Remarks |
|
Number of Cells |
16 Cells × 4 Modules [64 Cell] |
1 Cell = 3.75 V |
|
Cell Voltage Range (V) |
2.5 - 4.2 |
|
|
Cell Voltage deviation (V) |
40 mV or less |
|
|
Type |
LiPB (Lithium ion Polymer Battery), Pouch type |
|
|
Rated Voltage (V) |
240 |
Terminal voltage at 1C rated discharging, 55% SOC, 20°C (68°F) |
|
Nominal Capacity (Ah) |
6.5 |
[Battery initial performance, 20°C (68°F)] |
[Operating Specification]
|
Item |
Specification |
|
Max. Discharging Power (kW) |
Max. 42 [55% SOC] |
|
Max. Charging Power (kW) |
Max. (-) 32 [55% SOC] |
|
Operating Voltage (V) |
160 - 275 [2.5V ≤ Cell Voltage ≤ 4.2V] |
|
Operating Current (A) |
(-) 250 - (+) 250 |
Power Relay Assembly (PRA)
|
Item |
Specification |
|
Rated Voltage (V) |
240 |
|
Rated Current (A) |
80 |
| High Voltage Battery Control System |
Safety Plug
|
Item |
Specification |
|
|
Rated Voltage (V) |
450 |
|
|
Rated Current (A) |
80 |
|
|
Fuse Rated Current (A) |
125 |
|
|
Fuse Melting Time |
Rated Current × 110% |
Min. 4 hr |
|
Rated Current × 200% |
5 - 100 s |
|
|
Rated Current × 300% |
0.5 - 15 s |
|
|
Rated Current × 500% |
Max. 1 s |
|
Main Fuse
|
Item |
Specification |
|
|
Rated Current (A) |
450 |
|
|
Fuse Rated Current (A) |
125 |
|
|
Installation position |
Inside safety plug |
|
|
Fuse Melting Time |
Rated Current × 110% |
Min. 4 hr |
|
Rated Current × 200% |
5 - 100 s |
|
|
Rated Current × 300% |
0.5 - 15 s |
|
|
Rated Current × 500% |
Max. 1 s |
|
Main Relay (+)/ (-)
|
Item |
Specification |
|
|
Contact |
Rated Voltage (V) |
450 |
|
Rated Current (A) |
80 |
|
|
Coil |
Operating Voltage (V) |
12 |
|
Resistance (Ω) |
29.7 - 36.3[20°C (68°F)] |
|
Pre-Charge Relay
|
Item |
Specification |
|
|
Contact |
Rated Voltage (V) |
450 |
|
Rated Current (A) |
20 |
|
|
Coil |
Operating Voltage (V) |
12 |
|
Resistance (Ω) |
57 - 63 [20°C (68°F)] |
|
Pre-Charge Resistor
|
Item |
Specification |
|
Resistance (Ω) |
40 [20°C (68°F)] |
|
Rated power (W) |
40 |
Battery Current Sensor
|
Item |
Output Voltage (V) |
|
|
Max. Current (A) |
-300 (Charge) |
0.5 |
|
0 |
2.5 |
|
|
+300 (Discharge) |
4.5 |
|
|
Rated Current (A) |
-80 (Charge) |
0.5 |
|
0 |
2.5 |
|
|
+80 (Discharge) |
4.5 |
|
Battery Temperature & Air Inlet Temperature Sensor
[Air Inlet]
|
Temperature |
Resistance (kΩ) |
|
|
°C |
°F |
|
|
-50 |
-58 |
314.9 - 344.6 |
|
-40 |
-40 |
181.1 - 196.0 |
|
-30 |
-22 |
107.5 - 115.2 |
|
-20 |
-4 |
65.82 - 69.77 |
|
-10 |
14 |
41.43 - 43.52 |
|
0 |
32 |
26.74 - 27.83 |
|
10 |
50 |
17.67 - 18.25 |
|
20 |
68 |
11.94 - 12.24 |
|
30 |
86 |
8.214 - 8.411 |
|
40 |
104 |
5.738 - 5.918 |
|
50 |
122 |
4.082 - 4.239 |
|
60 |
140 |
2.954 - 3.087 |
|
70 |
158 |
2.172 - 2.284 |
|
80 |
176 |
1.621 - 1.715 |
|
90 |
194 |
1.227 - 1.305 |
|
100 |
212 |
0.941 - 1.006 |
|
110 |
230 |
0.731 - 0.785 |
[Battery Temperature Sensor (Side of cell)]
|
Temperature |
Resistance (kΩ) |
|
|
°C |
°F |
|
|
-50 |
-58 |
351.1 - 385.0 |
|
-40 |
-40 |
196.6 - 213.1 |
|
-30 |
-22 |
114.4 - 122.7 |
|
-20 |
-4 |
68.94 - 73.15 |
|
-10 |
14 |
42.59 - 44.76 |
|
0 |
32 |
27.14 - 28.27 |
|
10 |
50 |
17.78 - 18.36 |
|
20 |
68 |
11.96 - 12.25 |
|
30 |
86 |
8.202 - 8.399 |
|
40 |
104 |
5.721 - 5.901 |
|
50 |
122 |
4.069 - 4.226 |
|
60 |
140 |
2.945 - 3.078 |
|
70 |
158 |
2.169 - 2.280 |
|
80 |
176 |
1.622 - 1.715 |
|
90 |
194 |
1.228 - 1.306 |
| High Voltage Battery Cooling System |
Cooling Fan
Current
|
Item |
Specification |
|
Motor max current (A) |
Below. 3.8 |
Duty
|
Duty (%) |
Fan Speed (rpm) |
|
10 |
500 |
|
20 |
1,000 |
|
30 |
1,300 |
|
40 |
1,600 |
|
50 |
1,900 |
|
60 |
2,200 |
|
70 |
2,500 |
|
80 |
2,800 |
|
90 |
3,100 |
|
95 |
3,850 |
| Low Voltage DC/DC Converter (LDC) |
Low Voltage DC/DC Converter (LDC) [Inside HPCU]
|
Item |
Specification |
|
Input Voltage (V) |
204 - 275.2 |
|
Operating Frequency (Hz) |
Max. 826 |
|
Output Voltage (V) [Auxiliary 12V Battery] |
12.8 - 15.1 |
|
LDC Rated Power (kW) |
1.8 |
|
Cooling Method |
By water |
| Tightening Torques |
Hybrid Control System
|
Item |
kgf·m |
N·m |
lb·ft |
|
Low Voltage DC/DC Converter (LDC) power output cable mounting bolt |
1.1 - 1.4 |
10.8 - 13.7 |
7.9 - 10.1 |
|
Low Voltage DC/DC Converter (LDC) ground cable mounting bolt |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
Reservoir mounting bolt |
0.4 - 0.6 |
3.9 - 5.9 |
2.9 - 4.3 |
|
Hybrid Power Control Unit (HPCU) mounting bolt |
2.2 - 2.4 |
21.6 - 23.5 |
15.9 - 17.4 |
|
Hybrid Power Control Unit (HPCU) Tray mounting bolt |
2.2 - 2.4 |
21.6 - 23.5 |
15.9 - 17.4 |
|
DC Fuse [Inside HPCU] cover mounting bolt |
0.5 - 0.7 |
4.9 - 6.9 |
3.6 - 5.1 |
|
DC Fuse [HPCU] mounting bolt |
0.95 - 1.05 |
9.3 - 10.3 |
6.9 - 7.6 |
High Voltage Battery System
|
Item |
kgf·m |
N·m |
lb·ft |
|
Auxiliary 12V Battery wiring harness mounting nut |
0.8 ~ 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
Safety plug cable mounting nut |
0.8 ~ 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
High voltage battery system assembly upper frame mounting bolt |
2.0 ~ 3.0 |
19.6 - 29.4 |
14.5 - 21.7 |
|
High voltage battery system assembly upper frame mounting nut (M8) |
2.0 ~ 3.0 |
19.6 - 29.4 |
14.5 - 21.7 |
|
High voltage battery system assembly upper frame mounting nut (M6) |
0.8 ~ 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
High voltage battery rear cover mounting bolt / nut |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
High voltage battery front cover mounting bolt / nut |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
Power relay assembly mounting nut |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
Power relay assembly mounting nut [High voltage battery bus bar ↔ Power
relay assembly terminal side] |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
High Voltage Battery Control System
|
Item |
kgf·m |
N·m |
lb·ft |
|
BMS ECU mounting nut |
0.8
- 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
Safety plug cable mounting nut [Frame] |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
Safey plug cavle mounting bolt [Module] |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
High Voltage Battery Cooling System
|
Item |
kgf·m |
N·m |
lb·ft |
|
Cooling fan mounting bolt / nut |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
Low Voltage DC/DC Converter (LDC)
|
|
kgf·m |
N·m |
lb·ft |
|
LDC power output cable mounting nut |
1.1 - 1.4 |
10.8 - 13.7 |
7.9 - 10.1 |
|
LDC ground (-) cable mounting bolt |
0.8 - 1.2 |
7.8 - 11.8 |
5.8 - 8.7 |
|
Hybrid Power Control Unit (HPCU) mounting bolt |
2.2 - 2.4 |
21.6 - 23.5 |
15.9 - 17.4 |
Power Cable
|
Item |
kgf·m |
N·m |
lb·ft |
|
Ground cable mounting bolt (M6) |
1.1 - 1.4 |
10.8 - 13.7 |
7.9 - 10.1 |
|
Auxiliary 12V battery (+) cable mounting nut [Engine room fuse & relay box]
|
1.1 - 1.4 |
10.8 - 13.7 |
7.9 - 10.1 |
|
Power cable mounting nut [Invertor & Engine Room Box ↔ High Voltage Battery
System] |
1.1 - 1.4 |
10.8 - 13.7 |
7.9 - 10.1 |
Troubleshooting
Basic Troubleshooting
Basic Inspection Procedure
Measuring Condition of Electronic Parts' Resistance
The measured resistance at high temperature after vehicle running may be high
...
Special service tools
Special Service Tools
Tool Name / Number
Illustration
Description
Insulated Tool Set
0K375-4U000
Use ...
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...
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