Kia Soul EV: High Voltage Battery System / Inspection

Inspection

Be sure to read and observe the "General Safety Information and Caution" before performing any work on the high voltage system. Failure to follow the safety instructions may result in serious electrical injury.
Before performing any work, be sure to disconnect high voltage related to the high voltage system (refer to "High Voltage Disconnection Procedure"). Failure to follow safety instructions may result in serious electric shock.

When removing the battery for inspection of the high voltage battery system, it can be connected to the vehicle using SST 0K918-E4100, 0K375-E4100, 0K375-E4200.

[High Voltage Battery Pack Assembly Inspection]

		Specification	Method	Countermeasure
Disconnection		-	Visual inspection	-
Rust
Discoloration
Installation Status
Leakage
BMS ECU DTC		Refer to the Trouble Code Troubleshooting manual	Refer to the Trouble Code Troubleshooting manual	Refer to the Trouble Code Troubleshooting manual
SOC		5% ~ 95%	Check the "Current Data" using GDS	Refer to "SOC Level and Countermeasures".
Voltage	Cell	2.5 ~ 4.3 V	Check the "Current Data" using GDS	Check the battery voltage sensor circuit (Refer to "Battery Voltage Measurement Circuit").
	Pack	240 ~ 413 V
	Cell Voltage Deviation	Less than 40 mV
Insulation resistance		300 kΩ ~ 1000 kΩ	Check the "Current Data" using GDS	Refer to "Insulation Resistance Circuit".
		More than 2 MΩ	Using a Megohmmeter
		More than 2 MΩ	Using a Megohmmeter

[Visual Inspection]

Item - Electrical system, cooling system, high voltage battery pack assembly. Problem - Disconnection, rust, component condition, oil leak

[SOC Inspection]

1
Turn the ignition OFF.
2
Connect GDS to the DLC.
3
Turn the ignition on.
4
Check the SOC in the GDS service data.
SOC: 5 ~ 95 %

[Battery Voltage Inspection]

1
Turn the ignition OFF.
2
Connect GDS to the DLC.
3
Turn the ignition on.
4
Check the Cell Voltage and Pack Voltage in the GDS service data. Cell Voltage: 2.5 ~ 4.3 V Pack Voltage: 240 ~ 413 V Cell Voltage Deviation: Less than 40 mV

[Voltage Measurement Circuit Inspection]

1
Remove the high voltage battery assembly. (Refer to High Voltage Battery System - "Battery Assembly")
2
Disconnect the voltage and temperature sensor harness. (Refer to High Voltage Battery System - Repair Procedures - Removal - "Voltage and Temperature Sensor Harness".)
3
Perform a continuity inspection of the battery module and BMS ECU connector.
Specified value: Less than 1 Ω (20°C)
4
Place the BMS ECU in the lower case.
5
Connect the voltage and temperature sensor harness to the BMS ECU.
6
Measure the insulation resistance between the battery module harness and the lower case.
Specified value: More than 1 MΩ (20°C)

[Insulation Resistance Inspection (Vehicle)]

The insulation condition between the vehicle and the battery can be checked using GDS or resistance measurement. [GDS - Service Data]

1
Turn the ignition off.
2
Connect GDS to the DLC.
3
Turn the ignition on.
4
Check the insulation resistance in the GDS service data.
Specified value: 300 kΩ ~ 1000 kΩ
5
Disconnect high voltage. (Refer to High Voltage Battery Management System - "High Voltage Disconnection Procedure")
6
Connect the negative (-) lead of the megohmmeter (A) to the vehicle body ground.

For accurate measurement, connect the negative (-) lead to unpainted parts.
7
After connecting the positive (+) terminal to the battery positive (+) terminal, measure the resistance as follows. [Insulation Resistance of Battery Pack Positive (+) Terminal]
1. Apply 500 V with the megohmmeter, then wait approximately 1 minute to measure a stable resistance value.
2. Check the resistance.
Specified value: more than 2 MΩ (20°C)
8
After connecting the positive (+) terminal to the battery negative (-) terminal, measure the resistance as follows. [Insulation Resistance of Battery Pack Negative (-) Terminal]
1. Apply 500 V with the megohmmeter, then wait approximately 1 minute to measure a stable resistance value.
2. Check the resistance.
Specified value: More than 2 MΩ (20°C)

[Using a megohmmeter]

[Insulation Resistance Inspection (Battery)]

[Using a megohmmeter]

1
Remove the high voltage battery assembly. (Refer to High Voltage Battery System - "Battery Assembly")
2
Remove the high voltage battery upper case assembly. (Refer to High Voltage Battery System - Case)
3
Remove the protective cover (A) of the Power Relay Assembly (PRA).
4
Connect the negative (-) lead of the megohmmeter to the lower case.

For accurate measurement, connect the negative (-) lead to unpainted parts.
5
Connect the positive (+) lead to the high voltage battery terminals to measure the resistance. [Insulation Resistance of High Voltage PRA Positive (+) Terminal]
1. Connect the positive (+) lead of the megohmmeter (A) to the PRA high voltage positive (+) terminal.
2. Apply 500 V with the megohmmeter, then wait approximately 1 minute to measure a stable resistance value.
3. Check the resistance value.
  Specified value: more than 2 MΩ (20°C)
[Insulation Resistance of High Voltage PRA Negative (-) Terminal]
1. Connect the positive (+) lead of the megohmmeter (B) to the PRA high voltage negative (-) terminal.
2. Apply 500 V with the megohmmeter, then wait approximately 1 minute to measure a stable resistance value.
3. Check the resistance value.
  Specified value: more than 2 MΩ (20°C)
[Insulation Resistance of PRA Inverter Power Positive (+) Terminal]
1. Connect the positive (+) lead of the megohmmeter (A) to the PRA inverter power positive (+) terminal.
2. Apply 500 V with the megohmmeter, then wait approximately 1 minute to measure a stable resistance value.
3. Check the resistance value.
  Specified value: more than 2 MΩ (20°C)
[Insulation Resistance of PRA Inverter Power Negative (-) Terminal]
1. Connect the positive (+) lead of the megohmmeter (A) to the PRA inverter power negative (-) terminal.
2. Apply 500 V with the megohmmeter, then wait approximately 1 minute to measure a stable resistance value.
3. Check the resistance value.
  Specified value: more than 2 MΩ (20°C)