Kia Niro: High Voltage Battery Control System / Main Relay (+) / (-) Repair procedures

Kia Niro 2017 (DE HEV) Service Manual / Hybrid Control System / High Voltage Battery Control System / Main Relay (+) / (-) Repair procedures

Removal

•	Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

•	Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.

1.	Shut off the High Voltage circuit. (Refer to Hybrid Control System - “High Voltage Shutoff Procedure”)

2.	Remove the power relay assembly. (Refer to High Voltage Battery System - "Power Relay Assembly (PRA)")

3.	Remove the main relay (A). [Main Relay (-)] [Main Relay (+)]

Installation

•	Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

•	Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.

1.	Install the main relay in the reverse order of removal.

Inspection

•	Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

•	Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.

Checking for Welding in the High Voltage Main Relay

[Using KDS/GDS service data to check for main relay weld damage]

1.	Connect the KDS/GDS to the Data Link Connector (DLC).

2.	Switch "ON" the ignition.

3.	Check for BMS welding damage from KDS/GDS service data.

[Using a Multimeter to measure weld damage]

1.	Shut off the high voltage. (Refer to "High Voltage Shut-off Procedures")

2.	Remove the rear seat cushion. (Refer to Body - "Rear Seat Assembly")

3.	Remove the rear door scuff trim. (Refer to Body - "Door Scuff Trim")

4.	Remove the inlet cooling duct. (Refer to High Voltage Battery Cooling System - "Cooling Duct")

Measure the high voltage main relay resistance and check for signs of weld damage.

Specification : ∞Ω[20°C(68°F)]

High voltage main relay (-) switch resistance

[Use multi tester (relay OFF)]

This inspection method using a multi-tester is conducted with high voltage (-) relay turned OFF.

1.	Shut off the high voltage. (Refer to "High Voltage Shut-off Procedures")

2.	Remove the side luggage form(LH). (Body - "Trunk Trim")

3.	Remove the high battery top cover. (High Battery System -"Case")

Measure the resistance between the high voltage power terminal (-) and the inverter power terminal (-).

Specification : ∞Ω[20°C(68°F)]

5.	If the measured resistance is not within the specification, replace the main relay (-) by referring to repair procedures.

[Circuit inspection (Relay ON)

Inspect the high voltage main relay (-) activated by KDS/GDS.

1.	Connect the KDS/GDS to the Data Link Connector (DLC).

2.	Switch "ON" the ignition.

Activate the main relay by using "Actuation Test" on the KDS/GDS as shown in the illustration below.

When the relay is ON, there is a relay operation sound.

High Voltage Main Relay Coil Resistance

1.	Shut off the high voltage. (Refer to "High Voltage Shut-off Procedures")

2.	Remove the power relay assembly. (High Battery System - "Power Relay Assembly")

Check for continuity between the terminals using an ohmmeter.

Specification : 29.7 - 36.3 Ω [20°C(68°F)]

Main Relay (+) / (-) Schematic diagrams

Circuit Diagram [B03-C] (Relay Control) [B03-S] (Relay Control) ...

Pre-Charge Relay Specifications

Specification Item Specification Contact Rated Voltage (V) 450 Rated Current (A) 10 ...

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