Hyundai Ioniq HEV 2017 Manual
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Hyundai Ioniq HEV 2017 Manual

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Hybrid Control System
Safety Precaution
Precautions to take before servicing high voltage system
• Since hybrid vehicles contain a high voltage battery, if the high voltage system or vehicles are handled incorrectly, this might lead to
a serious accidents like 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")
• The responsible worker keeps the removed safety plug to prevent the plug from being connected by mistake.
• Do not keep any metal objects (watch, ring etc.) while working on the high voltage system, which it can cause serious accidents like
electric shock.
• Before beginning work on the high voltage system, the worker should wear personal protective equipment to prevent safety
accidents.
(Refer to "Personal Protective Equipment")
• Never allow workers who are not wear personal protective equipment to touch the high voltage system. High voltage components
should be covered with an insulation sheet to prevent safety 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 :
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.
• Inform of danger of high voltage by putting the "high voltage caution" on the vehicle as image below.

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  • Page 1 Hybrid Control System Safety Precaution Precautions to take before servicing high voltage system • Since hybrid vehicles contain a high voltage battery, if the high voltage system or vehicles are handled incorrectly, this might lead to a serious accidents like electric shock and electric leakage. •...
  • Page 2 Personal Protective Equipment Name Illustration Description Used when inspecting or working on the high voltage components Insulation glove [Insulation performance : 1000V / 300A or above] Used when inspecting or working on the high voltage components Insulation shoes...
  • Page 3 Insulation clothes Insulation helmet Safety glasses Used in the case below • During Removal & installation or inspection of the high voltage battery terminals or wiring, which spark might happen. • During working on the high voltage battery pack assembly. Face shield Putting the removed high voltage components on the Insulation mat...
  • Page 4 Turn OFF the Start button. Keep the Smart Key at least 2 meters 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. •...
  • Page 5 2. Remove the safety plug cover (A). 3. Unfasten the hook (A) and then remove the safety plug (C) by pulling the lever (B) to the direction of arrow. 4. Wait for more than 5 minutes so that the capacitor in the high voltage system can be fully discharged. 5.
  • Page 6 (3) Measure the voltage between the inverter (+) terminal and the inverter (-) terminal. Less than 30V : High voltage circuit properly shut More than 30V : Fault on high voltage circuit • If measured more than 30V, check if the safety plug is removed completely.If measured more than 30V despite the safety plug is removed, there can be serious problems on the high voltage circuit.
  • Page 7 ※Example) 2. Check for visible damage of the high High voltage battery insulation Remove the high voltage battery voltage battery. damaged and repair the coating/insulation. Trunk fire 3. Check the high voltage main relay for signs High voltage DTC code If a DTC code occurs, perform of welding after shutting off the high voltage battery not...
  • Page 8 3. Measure the resistance of main fuse. Specification:1 Ω or less Ω [20°C(68°F] 4. If the measured resistance is not within the specification, replace the main fuse. Checking for Welding in the High Voltage Main Relay In order to safely remove the battery pack assembly, you must first inspect the high voltage main relay for signs of weld damage. You can use Gloval Diagnostic System (GDS) service data to detect weld damage in the high voltage main relay.
  • Page 9 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 duct. (Refer to Hybrid Control System - "Cooling Duct") 5.
  • Page 10 [Measuring isolation resistance using an insulation tester (MΩ tester)] • 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. 1.
  • Page 11 [Measure the isolation resistance on the power relay assembly high voltage power terminal (-)] (1) Connect the insulation tester (+) terminal to the (-) PRA high voltage power terminal (B). (2) Supply 500V through the insulation tester and wait one minute to measure the stable resistance. (3) Check the isolation resistance.
  • Page 12 (1) Connect the insulation tester (+) terminal to the (+) PRA inverter power terminal (A). (2) Supply 500V through the insulation tester and wait one minute to measure the stable resistance. (3) Check the isolation resistance. Normal insulation resistance range : Above 1.0 MΩ [20°C (68°F)] [Measure the isolation resistance on the power relay assembly inverter power terminal (-)] •...
  • Page 13 (3) Check the isolation resistance. Normal insulation resistance range :Above 1.0 MΩ [20°C (68°F)] Handling Guide for Storing, Transporting, and Disposing of High Voltage Battery Systems 1. High voltage battery system handling process...
  • Page 14 2. Defective high voltage battery system handling / Inspection Classification Item Measures Storage Remove the service disconnect and store the battery under the same conditions as a new battery. Undamaged Battery Transport Minimize impacts and ensure the battery does not come in contact with other parts. Disposal Transport the battery to the designated disposer Damaged...

  • Page 15: Voltage Check

    If the temperature continues to rise when measuring it at 30 minute intervals, submerse the battery in salt water immediately. 3. Isolation resistance check(using a MΩ tester) (1) Measure the isolation resistance between the power relay terminal (+) and the battery pack cover.
  • Page 16 Take insulation actions for parts that may short circuit 1. High voltage battery – PRA cable terminal – Place the insulation tape or rubber cap around the (+), (-) cable terminal to prevent short circuit to the battery pack. – Secure the cable to the battery pack case with the insulation tape to prevent cables from moving. 2.
  • Page 17 ▶ Insulation actions – Place the insulation tape or rubber cap around connectors to prevent short circuit to the battery cells, modules. – Secure the wiring to the battery pack case with the insulation tape to prevent wiring from moving. Discharging high voltage batteries •...

  • Page 18: Basic Troubleshooting

    • Put only one high voltage battery in a single salt water tank. • If you discharge more than one battery, put in the battery after discharging the previous battery completely to ensure safety. • If not, unexpected accidents such as burns may occur by exothermic reaction. Hybrid Control System Procedure for entering engine forced activation mode If the engine needs to be running constantly while the vehicle is stopped to inspect emission gas or perform maintenance on the vehicle, follow...
  • Page 19 3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace the component that has a problem. 5. Verify that the problem has disappeared with the road test. ● Simulating Vibration a. Sensors and Actuators : Slightly vibrate sensors, actuators or relays with finger. •...
  • Page 20 b. When removing the connector with a lock, press or pull locking lever. c. Listen for a click when locking connectors. This sound indicates that they are securely locked. d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side. e.

  • Page 21: Electrical Circuit Inspection Procedure

    • Use a fine wire to prevent damage to the terminal. • Do not damage the terminal when inserting the tester lead. 2. Checking Point for Connector a. While the connector is connected: Hold the connector, check connecting condition and locking efficiency. b.
  • Page 22 If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check Method) as shown below. 2. Continuity Check Method • When measuring for resistance, lightly shake the wire harness above and below or from side to side. Specification (Resistance) 1Ω...
  • Page 23 ● Check Short Circuit 1. Test Method for Short to Ground Circuit • Continuity Check with Chassis Ground If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2 (Continuity Check Method with Chassis Ground) as shown below.

  • Page 24: Personal Protective Equipment

    Hybrid Control System Personal Protective Equipment Name Illustration Description Used when inspecting or working on the high voltage components Insulation glove [Insulation performance : 1000V / 300A or above] Insulation shoes Used when inspecting or working on the high voltage Insulation clothes components Insulation helmet...
  • Page 25 Covering the high voltage components with insulation Insulation sheet sheet to prevent people who don’t wear the personal protective equipment from safety accidents. Hybrid Control System Hybrid Electric Vehicle (HEV) The Hybrid Electric Vehicle (HEV) uses hybrid power source (Engine, Electric motor), so its fuel efficiency is relatively high and exhaust emission is very small compared to the traditional vehicle which uses only engine as power source.
  • Page 26 [Warning Lamp] Items Description Related Control Module 1. MIL Lamp • Lamp ON : Engine Management System (EMS) fault ECM, TCM, OPU, HCU, MCU, BMS, AAF 2. Service Lamp • Lamp ON : Hybrid related system fault HCU, MCU, BMS, LDC, OPU 3.
  • Page 27 1. Engine 4. Transaxle 2. Hybrid Drive Motor 5. High Voltage Battery System 3. HSG (Hybrid Starter Generator) 6. Power Cable Hybrid Control System Specifications Hybrid Control System Brake Switch ▷ Type: ON/OFF Switch ▷ Specification Item Brake PedalRelease Brake PedalPush Switch 1 Max.
  • Page 28 ▷ Specification [General Specification] Item Specification Remarks Number of Cells 16 Cells × 4 Modules 1 Cells = 3.75 V Rated Voltage (V) Terminal voltage at Rated 1C discharge, SOC 55%, 20°C (68°F) Nominal Capacity (Ah) [Beginning of life, 20°C (68°F)] Rated Energy (Wh) 1,560 Rated Voltage ×...
  • Page 29 -300(Charge) +300(Discharge) Battery Temperature Sensor (HEV) ▷ Type: Thermisor type ▷ Specification [Air Inlet] Temperature Resistance (kΩ) °C °F 314.9 - 344.6 181.1 - 196.0 107.5 - 115.2 65.82 - 69.77 41.43 - 43.52 26.74 - 27.83 17.67 - 18.25 11.94 - 12.24 8.214 - 8.411 5.738 - 5.918...

  • Page 30: High Voltage Battery Cooling System

    Auxiliary Battery Temperature Sensor ▷ Type: Thermisor type ▷ Specification Temperature Resistance (kΩ) °C °F 251.7 - 291.9 90.1 - 100.2 29.10 - 30.90 10.41 - 11.51 3.56 - 4.11 High Voltage Battery Cooling System Cooling Fan ▷ Specification Duty (%) Fan Speed (rpm) 1000 1300...
  • Page 31 High Voltage Battery Control System Item kgf.m lb-ft BMS ECU installation nut 0.8 - 1.2 7.8 - 11.8 5.8 - 8.7 High Voltage Battery Cooling System Item kgf.m lb-ft Cooling fan installation nut 0.8 - 1.2 7.8 - 11.8 5.8 - 8.7 Cooling fan bracket installation nut 0.8 - 1.2 7.8 - 11.8...
  • Page 32 The HCU controls power & torque distribution of the engine and motor, regenerative brake, and fail-safe mode based on the vehicle information, driver’s demand, engine information and high voltage battery information.
  • Page 33 [HCU Main Functionalities] Item Functionality Demand Torque Determination • Driver Creep Demand Torque Calculation • Driver Acceleration/Deceleration Torque Calculation • Driver Total Demand Torque Calculation Regeneration Brake Control • Regeneration Brake Demand Torque Control • Regeneration Brake Estimated Torque Calculation EV/HEV Mode Determination •...

  • Page 34: Component Location

    • Engine, Hybrid Drive Motor, HSG Torque Limit Control Torque Monitoring • Hybrid powertrain torque monitoring Fail-Safe • Hybrid control system fail-safe control Auxiliary System Control • Electric Oil Pump Control • Variable Voltage Control of Low Voltage DC/DC • A/C & Heater Control •...
  • Page 35 1. HPCU(Hybrid Power Control Unit) 3. Brake Switch 2. HCU(Hybrid Control Unit) 4. DC Fuse • HPCU includes the HCU (Hybrid Control Unit), Inverters (for Drive Motor, HSG and Electric A/C Compressor), MCU (Motor Control Unit) and LDC (Low DC / DC Converter). •...
  • Page 36 4. DC Fuse Hybrid Control System Description The Hybrid Power Control Unit (HPCU) is an integrated power conversion unit which consists of the two inverters, LDC, and HCU. Hybrid Control System Components...
  • Page 37 1. Hybrid Control Unit(HCU) 5. Connector (↔ Motor) 2. Inverter 6. Connector (↔ HSG) 3. Low DC/DC Converter (LDC) 7. Low Voltage Power Outlet Terminal 4. Connector (↔ High Voltage Battery) 8. DC Fuse Hybrid Control System 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.
  • Page 38 6. Disconnect the motor power cable connector (A) and HSG power cable conector (B). 7. Disconnect the power cable (A) [↔ High voltage battery system assembly] and power cable (B) [↔ HSG & Electric A/C compressor]. • Remove the inverter power cale in the follwing order. 8.

  • Page 39: Installation

    9. Disconnect the coolant outlet hose & pipe (A) after loosening the mounting bolt. 10. Disconnect the LDC power output cable (A) and LDC ground (-) cable (C) after loosening the mounting bolt and nut. 11. Remove the HPCU (A) after loosening the mounting bolts. Installation •...
  • Page 40 2. Refill the hybrid motor cooling system coolant and perform air bleeding by using the GDS. (refer to Hybrid Motor Cooling System - "Coolant"). • Perform HCU Variant Coding and Engine Clutch / Motor Resolver learning after replacing the HPCU. HCU Variant Coding 1.
  • Page 41 Hybrid Control System HCU Terminal And Input/Output Signal Terminal Function Connector [C133-S] Pin No. Description Connected to HCU ground Chassis ground HCU ground Chassis ground HCU ground Chassis ground Battery power (B+) Battery Battery power (B+) Battery Battery power (B+) Battery Brake Switch 2 signal input Brake Switch (NC, IG1)
  • Page 42 Start signal input Smart Key Unit IGN signal input Smart Key Unit Powertrain CAN [High] signal input Other control modules Powertrain CAN [Low] signal input Other control modules Hybrid CAN [High] signal input Other control modules Hybrid CAN [Low] signal input Other control modules...
  • Page 43 Input/Output signal Connector [C133-S] Pin no. Description Condition Type Level HCU ground Always DC Voltage Max. 50mV HCU ground Always DC Voltage Max. 50mV HCU ground Always DC Voltage Max. 50mV Battery power (B+) Always DC Voltage Battery Voltage Battery power (B+) Always DC Voltage Battery Voltage...

  • Page 44: Circuit Diagram

    IGN signal input IG ON DC Voltage Battery Voltage Dominant:2.75 - 4.5(3.5)V Powertrain CAN [High] signal input IG ON Pulse Receive:2.0 - 3.0(2.5)V Receive:2.0 - 3.0(2.5)V Powertrain CAN [Low] signal input IG ON Pulse Dominant:0.5 - 2.25(1.5)V Dominant:2.75 - 4.5(3.5)V Hybrid CAN [High] signal input IG ON Pulse...
  • Page 45 Hybrid Control System 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. 1. Refer to “HPCU”. •...

  • Page 46: Specification

    • The HCU is integrated into the HPCU that can’t be disassembled. So refer to “HPCU” for the removal or installation procedure of the HCU. 2. Perform the clutch pressure sensor calibration (Refer to "Clutch Pressure Sensor"). Hybrid Control System Description The Brake Switch is installed on the brake pedal and linked with the HCU and stop lamp.

  • Page 47: Component Location

    Hybrid Control System Removal 1. Refer to Brake System - "Brake System". Installation 1. Refer to Brake System - "Brake System". Inspection 1. Refer to Brake System - "Brake System". Adjustment 1. Refer to Brake System - "Brake System". Hybrid Control System Specification Item Specification...
  • Page 48 Hybrid Control System Component Location...
  • Page 49 1. DC Fuse 2. Inverter Connector [↔ Power Relay Assembly (PRA)] 3. Inverter Connector [↔ Electric A/C compressor] Hybrid Control System 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.
  • Page 50 4. Remove the DC fuse cover (A) after loosening the mounting bolt. DC fuse cover installation bolt: 4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft) 5. Remove the DC fuse seal cover (A). 6. Remove the DC fuse (A) from the HPCU after loosening the mounting bolt. DC fuse installation bolt: 9.3 - 10.4 N.m (0.95 - 1.06 kgf.m, 6.9 - 7.7 lb-ft) Installation...
  • Page 51 1. Install the DC fuse in the reverse order of removal. Hybrid Control System Description The High Voltage Battery System provides the hybrid drive motor, HSG, and electric A/C compressor with electric energy and also reserves the electric energy generated during regeneration braking.It consists of the battery pack assembly, BMS ECU, power relay assembly, case, control wiring, cooling fan, and cooling ducts.
  • Page 52 [Operational Specification] Item Specification Discharge Power (kW) Max. 42 Charge Power (kW) Max. 39 160 - 275 Operation Voltage (V) [2.5V ≤ Cell Voltage ≤ 4.3V] Operation Current (A) -250 - 250 Power Relay Assembly (PRA) ▷ Specification Item Specification Rated Voltage (V) Rated Current (A) Hybrid Control System...
  • Page 53 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. 1. Shut off the high voltage. (Refer to "High voltage Shut-off Procedures") 2.
  • Page 54 10. Remove the installation bolt (A) and nut (B), then remove the power relay assembly. 11. Remove the installation bolts and nut, then remove the high voltage battery front cover (A). 12. Disconnect the BMS connector (A). 13. Remove the installation nut (B), then remove the BMS. 14.
  • Page 55 17. Remove the installation bolts and nut (A), then remove the cooling fan. 18. Remove the installation bolts,then remove the high voltage battery pack (A). 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.
  • Page 56 3. Remove the installation nut, then remove the battery pack assembly front cover (A). 4. Remove the installation nut, then remove the battery pack assembly rear cover (A). 5. Remove the battery temperature sensor (A). 6. Remove the installation nut, then remove the battery module connector (A). 7.
  • Page 57 8. Remove the installation nut, then remove the safety plug bus bar (A). 9. Remove the installation bolt, then remove the battery pack bracket (A). 10. Remove the installation bolt, then remove the battery module (A) from the high voltage battery plate.
  • Page 58 Reassembly • This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution. 1. Install the battery pack assembly in the reverse order of removal. Battery pack frame installation bolt&nut : 7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft) Battery pack cover installation bolt :...
  • Page 59 For voltage check, refer to “Battery Voltage Inspection” • For battery voltage sensing circuit, refer to "Voltage Sensing Circuit Inspection" • For isolation resistance check, refer to “Isolation Resistance Inspection” [SOC Level and Follow-up] Warning Lamp Symptom Follow-up Service Fuel •...
  • Page 60 [Voltage Sensing Circuit Inspection] 1. Shut off the high voltage circuit (Refer to "High Voltage Shutoff Precedure"). 2. Remove the battery temperature sensor (Refer to "Battery Temperature Sensor"). 3. Check the continuity of the wiring between the harness connectors of the module and BMS ECU. Specification: below 1Ω...
  • Page 61 Specification : 1MΩ or higher [Isolation Resistance Inspection] 1. Connect the GDS to the Data Link Connector (DLC). 2. Turn the ignition switch ON. 3. Check the isolation resistance in GDS service data. Isolation Resistance:Around 1.0 MΩ Hybrid Control System Description The Power Relay Assembly (PRA) consists of the positive and negative main relays, pre-charge relay, pre-charge resistor and battery current sensor.
  • Page 62 [PRA Operation Sequence] Hybrid Control System Removal...
  • Page 63 • 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. 1. Shut off the high voltage. (Refer to "High voltage Shut-off Procedures").
  • Page 64 10. Remove the installation bolt (A) and nut (B), then remove the power relay assembly. 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. 1.

  • Page 65: Specification

    Hybrid Control System Specification Item Specification Rated Voltage (V) 63 (DC) Rated Current (A) 2 (DC) Hybrid Control System Trouble Symptom Charts – Follow the guide in case of DTC. Hybrid Control System Circuit Diagram...
  • Page 67 Hybrid Control System 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. 1. Shut off the high voltage. (Refer to "High voltage Shut-off Procedures").
  • Page 68 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. 1. Install the battery fuse box in the reverse order of removal. 2.
  • Page 69 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 upper frame (A) after loosening the mounting bolts and nuts. 5.
  • Page 70 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. 1. Install the case in the reverse order of removal. High voltage battery rear and front cover installation bolt/nut :7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft) Battery pack rear and front cover installation nut:7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft) Hybrid Control System...
  • Page 71 Main Relay ▷ Specification Item Specification Rated Voltage (V) Contact Rated Current (A) Operating Voltage (V) Coil Resistance (Ω) 29.7 - 36.3[20°C (68°F)] Pre-Charge Relay ▷ Specification Item Specification Rated Voltage (V) Contact Rated Current (A) Operating Voltage (V) Coil Resistance (Ω) 59.4 - 72.6[20°C (68°F)] Pre-Charge Resistor...

  • Page 72: Component Location

    [Cell] Temperature Resistance (kΩ) °C °F 351.1 - 385.0 196.6 - 213.1 114.4 - 122.7 68.94 - 73.15 42.59 - 44.76 27.14 - 28.27 17.78 - 18.36 11.96 - 12.25 8.202 - 8.399 5.721 - 5.901 4.069 - 4.226 2.945 - 3.078 2.169 - 2.280 1.622 - 1.715 1.228 - 1.306...

  • Page 73: Troubleshooting Flow

    1. BMS ECU 4. Battery Temperature Sensor 2. Power Relay Assembly (PRA) 5. Battery Ambient Sensor 3. Safety Plug • Main Relays (Positive, Negative), Pre-Charge Relay, Pre-Charge Resistor, and Battery Current Sensor are integrated into the PRA. Hybrid Control System Troubleshooting Flow...

  • Page 74: Schematic Diagram

    Hybrid Control System Schematic Diagram...
  • Page 76 Hybrid Control System BMS ECU Terminal And Input/Output Signal...
  • Page 77 Terminal Funxtion Connector [B01-VC] (24pin) : High Voltage Battery Cell Voltage Check Connector Pin No. Description Connected to Battery Voltage [Module 1/ Cell 0] signal input Battery Module [1] Battery Voltage [Module 1/ Cell 2] signal input Battery Module [1] Battery Voltage [Module 1/ Cell 4] signal input Battery Module [1] Battery Voltage [Module 1/ Cell 6] signal input...
  • Page 78 Battery Voltage [Module 2/ Cell 6] signal input Battery Module [1] Battery Voltage [Module 2/ Cell 8] signal input Battery Module [1] Connector [B01-VD] (28pin) : High Voltage Battery Cell Voltage Check Connector Pin No. Description Connected to Battery Voltage [Module 3/ Cell 1] signal input Battery Module [2] Battery Voltage [Module 3/ Cell 3] signal input Battery Module [2]...
  • Page 79 Battery Voltage [Module 5/ Cell 5] signal input Battery Module [3] Battery Voltage [Module 5/ Cell 7] signal input Battery Module [3] Battery Voltage [Module 6/ Cell 0] signal input Battery Module [3] Battery Voltage [Module 6/ Cell 2] signal input Battery Module [3] Battery Voltage [Module 6/ Cell 4] signal input Battery Module [3]...

  • Page 80: Circuit Diagram

    Clash signal input BMS Extension Connector BF11 (18) Safety Plug Interlock signal input Safety Plug Sensor ground Battery Current Sensor [PRA] VPD Relay Control VPD Relay Main Relay [-] Control Main Relay [-] Circuit Diagram...
  • Page 83 Hybrid Control System Removal 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.

  • Page 84: Installation

    5. Remove the high voltage battery rear cover (A) after loosening the mounting bolts and nuts. 6. Remove the high voltage battery front cover (A) after loosening the mounting bolts and nuts. 7. Disconnect the BMS connector (A). 8. Remove the installation nut (B), then remove the BMS. Installation •...

  • Page 85: Specification

    Hybrid Control System Description Safety Plug is installed on the rear side of the high voltage battery and it can mechanically shut the high voltage circuit off when servicing the high voltage system (i.e. High Voltage Battery, Power Relay Assembly, HPCU, BMS ECU, Hybrid Drive Motor, Inverter, HSG, LDC, Power Cable, etc.).
  • Page 86 Hybrid Control System Removal 1. Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) terminal. 2. Remove the safety plug cover (A). 3. Unfasten the hook (A) and then remove the safety plug (C) by pulling the lever (B) to the direction of arrow.
  • Page 87 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. 1. Install the Safety Plug in the reverse order of removal. Hybrid Control System Description The Power Relay Assembly (PRA) consists of the positive and negative main relays, pre-charge relay, pre-charge resistor and battery current...
  • Page 88 Hybrid Control System Specification Item Specification Rated Voltage (V) Contact Rated Current (A) Operating Voltage (V) Coil Resistance (Ω) 29.7 - 36.3[20°C (68°F)] Hybrid Control System Circuit Diagram...
  • Page 89 Hybrid Control System 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. 1. Shut off the high voltage. (Refer to "High voltage Shut-off Procedures").
  • Page 90 4. Remove the upper frame (A) after loosening the mounting bolts and nuts. 5. Remove the high voltage battery rear cover (A) after loosening the mounting bolts and nuts. 6. Remove the inlet cooling duct. (Refer to Hybrid Control System - "Cooling Duct") 7.
  • Page 91 1. Install the main relay in the reverse order of removal. High voltage battery top cover installation bolt/nut:7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft) 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.
  • Page 92 (Refer to "High Voltage Shut-off Procedures") 2. Remove the high voltage battery rear cover. (Refer to "High Voltage Battery System - "Case") 3. Remove the inlet cooling duct. (Refer to Hybrid Control System - "Cooling Duct") 4. Measure the resistance between the high voltage power terminal (-) and the inverter power terminal (-). [Circuit inspection (Relay ON) •...
  • Page 93 Hybrid Control System Description The Power Relay Assembly (PRA) consists of the positive and negative main relays, pre-charge relay, pre-charge resistor and battery current sensor. It is located inside the battery pack assembly and controls the high voltage power circuit between the high voltage battery and inverter by the control signal of BMS ECU.
  • Page 94 Hybrid Control System Specification Item Specification Rated Voltage (V) Contact Rated Current (A) Operating Voltage (V) Coil Resistance (Ω) 59.4 - 72.6[20°C (68°F)] Hybrid Control System Circuit Diagram...
  • Page 95 Hybrid Control System Removal 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.
  • Page 96 5. Remove the high voltage battery rear cover (A) after loosening the mounting bolts and nuts. 6. Remove the inlet cooling duct. (Refer to Hybrid Control System - "Cooling Duct") 7. Disconnect the pre-charge relay (A). 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.
  • Page 97 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. 1. Remove the power relay assembly. (High Battery System - "Power Relay Assembly") 2.
  • Page 98 High Voltage Per-Charge 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") 3. Check for continuity between the terminals using an ohmmeter. Hybrid Control System Description Pre-Charge Resistor is integrated into the Power Relay Assembly (PRA).
  • Page 99 Hybrid Control System Specification Item Specification Resistance (Ω) 40 [20°C (68°F)] Rated Current (A) Hybrid Control System Circuit Diagram...
  • Page 100 Hybrid Control System Removal 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.
  • Page 101 5. Remove the high voltage battery rear cover (A) after loosening the mounting bolts and nuts. 6. Remove the inlet cooling duct. (Refer to Hybrid Control System - "Cooling Duct") 7. Disconnect the pre-charge resistor (A). 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.
  • Page 102 Inspection 1. Remove the pre-charge resistor. (Refer to High Voltage Battery Control System - "Pre-Charge Resistor") 2. Check for continuity between the terminals using an ohmmeter. Specification :40Ω[20°C(68°F)] Hybrid Control System Description Battery Current Sensor is integrated into the Power Relay Assembly (PRA) and measures the current of the high voltage battery during charging or discharging.
  • Page 103 Hybrid Control System 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. • Battery Current Sensor are integrated into the PRA which can’t be disassembled. So refer to “Power Relay Assembly (PRA)” for removal or installation procedure.
  • Page 104 • 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. • Battery Current Sensor are integrated into the PRA which can’t be disassembled. So refer to “Power Relay Assembly (PRA)” for removal or installation procedure.
  • Page 105 Rated current (A) 125 (DC) Hybrid Control System Circuit Diagram Hybrid Control System 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. 1.
  • Page 106 5. Remove the main fuse cover and then revmoing the main fuse (A). 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. 1.
  • Page 107 Battery Temperature Sensor is installed inside the high voltage battery pack assembly. It measures the temperature of the battery module 1, 4 and air inlet. In addition, it integrates the voltage sensing wiring for each module. Hybrid Control System Specification [Air Inlet] Temperature Resistance (kΩ)
  • Page 108 4.069 - 4.226 2.945 - 3.078 2.169 - 2.280 1.622 - 1.715 1.228 - 1.306 Hybrid Control System Circuit Diagram...
  • Page 109 Hybrid Control System 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. 1. Shut off the high voltage. (Refer to "High Voltage Shut-off Procedures") 2.
  • Page 110 4. Remove the battery temperature sensor (A). 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. 1.

  • Page 111: Component Location

    5. Disconnect the battery temperature signal connector (A). 6. Measure resistances of the temperature signal terminals (Refer to the table below), then compare the value with the GDS service data. Item Terminals Module 1 BMS ECU B01-T(1),(7) Module 4 BMS ECU B01-T(2),(8) Air Inlet BMS ECU B01-T(4),(10) Specification: Refer to “Specification”...
  • Page 112 1. Cooling Fan 3. Cooing Duct (Outlet) 2. Cooling Duct (Inlet) Hybrid Control System Description The cooling Fan consists of the main connector, the cooling fan relay and the BLDC motor. It is controlled by the BMS ECU PWM signal which varies with the high voltage battery condition (9-Speed).
  • Page 113 1. Main Connector 2. BLDC Motor Hybrid Control System Specification Duty (%) Fan Speed (rpm) 1,000 1,300 1,600 1,900 2,200 2,500 2,800 90(Max.) 3,100 95(Max.) 3,850 Hybrid Control System 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.
  • Page 114 5. Remove the high voltage battery rear cover (A) after loosening the mounting bolts and nuts. 6. Remove the high voltage battery front cover (A) after loosening the mounting bolts and nuts. 7. Remove the outlet cooling duct. (Refer to Hybrid Control System - "Cooling Duct") 8.
  • Page 115 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. 1. Install the cooling fan in the reverse order of removal. Cooling fan installation nut:7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft) Inspection 1.
  • Page 116 [Cooling Fan at 2st]...
  • Page 117 [Cooling Fan at 3st]...
  • Page 118 [Cooling Fan at 4st]...
  • Page 119 [Cooling Fan at 5st]...
  • Page 120 [Cooling Fan at 6st]...
  • Page 121 [Cooling Fan at 7st]...
  • Page 122 [Cooling Fan at 8st]...
  • Page 123 [Cooling Fan at 9st]...
  • Page 124 Hybrid Control System 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. Cooling Duct (Inlet) 1.
  • Page 125 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. 1. Install the cooling ducts in the reverse order of removal. Outlet cooling duct installation nut: 7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft) Hybrid Control System...
  • Page 126 Rated Power (kW) Cooling Method Water-cooled Hybrid Control System Schematic Diagram Hybrid Control System 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. •...
  • Page 127 6. Disconnect the motor power cable connector (A) and HSG power cable conector (B). 7. Disconnect the power cable (A) [↔ High voltage battery system assembly] and power cable (B) [↔ HSG & Electric A/C compressor]. • Remove the inverter power cale in the follwing order. 8.
  • Page 128 9. Disconnect the coolant outlet hose & pipe (A) after loosening the mounting bolt. 10. Disconnect the LDC power output cable (A) and LDC ground (-) cable (C) after loosening the mounting bolt and nut. 11. Remove the HPCU (A) after loosening the mounting bolts. Installation •...
  • Page 129 3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft) LDC ground cable installation bolt: 3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft) 2. Refill the hybrid motor cooling system coolant and perform air bleeding by using the GDS. (refer to Hybrid Motor Cooling System - "Coolant") •...
  • Page 130 Hybrid Control System Components 1. Power Cable (Main) 2. Power Cable (Inverter ↔ HSG & A/C Electric Compressor) Hybrid Control System...
  • Page 131 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. 1. Shut off the high voltage circuit. (Refer to Hybrid Control System - “High Voltage Shutoff Procedure”) 2.
  • Page 132 7. Disconnect the power cable connector (-) (A) and power cable connector (+) (B). 8. Disconnect the auxiliary 12V battery positive (+) cable after loosening the mounting nut (C). 9. Disconnect the ground cable (D) after loosening the mounting bolt. 10.
  • Page 133 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").

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