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
Contact	Rated Current (A)	80
Coil	Operating Voltage (V)	12
Coil	Resistance (Ω)	29.7 - 36.3[20°C (68°F)]

Pre-Charge Relay

Item		Specification
Contact	Rated Voltage (V)	450
Contact	Rated Current (A)	20
Coil	Operating Voltage (V)	12
Coil	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	Resistance (kΩ)
-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	Resistance (kΩ)
-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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