Kia Soul EV: High Voltage Battery Control System / Main Relay Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / EV Battery System / High Voltage Battery Control System / Main Relay Repair procedures

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.
   
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100, 0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
Main Relay (-) Inscpection
[Using multi tester (Relay OFF)]
   
Inspect the high voltage main relay (-) by using multi tester when the relay is off
1.
Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
3.
Measure the resistance between the high voltage (-) power terminal and the Inverter (-) terminal.

Specification : ??(20°C)

[Using GDS (Relay ON)]
1.
Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
3.
Connect the SST No: 0K918-E4100, 0K375-E4100, 0K375-E4200 to the vehicle.

4.
Connect the GDS to DLC.
5.
Turn the ignition switch ON.
6.
Activate the main relay (-) by using "Actuation Test" on the GDS as shown in the illustration below.
   
When the relay is ON, there is a relay operation sound.

Main Relay Coil Resistance
1.
Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2.
Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly (PRA)")
3.
Measure the resistance of the main relay (+) (between the No.6 and the No.10) and the main relay (-) (between the No.4 and the No.6).

Specification : 21.6 ~ 26.4 ? (20°C)

Removal
   
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly (PRA).
Installation
   
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly (PRA).
Main Relay Schematic Diagrams
System Circuit Diagram With High Voltage Battery Heater System Without High Voltage Battery Heater System Circuit Diagram Without High Voltage Battery Heater System With High Voltage Batt ...

Pre-charge Relay Specifications
Specification ItemSpecificationONRated Voltage(V)450Rated Ampere(A)10Voltage Drop(V)Less than 0.5 (10A)CoilOperation Voltage(V)12Resistance(?)104.4 ~ 127.6 (20°C) ItemSpecificationRemarkM ...

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