Kia Niro: 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

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