W/Harness Inspection

HEV Battery System
P1B62 High Voltage Battery Current Sensor Circuit - Inspection/Repair:_:W/Harness Inspection

Terminal & Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.
3. Has a problem been found ?






Checking the voltage of high voltage battery

Checking the voltage of high voltage battery
1. Ignition OFF.
2. Unplug Safety Plug and wait 5 minutes.
3. Connect a Voltmeter between the (+) terminal and (-) terminal of High Voltage Busbar at the High Voltage Relay Assembly.
4. Re-Connect Safety Plug.
5. Ignition ON (SSB LED "BLUE").
6. Check the voltage between the (+) terminal and (-) terminal of High Voltage Busbar at the High Voltage Relay Assembly.

Specification :about 200 - 310V

WARNING:
** Warning & Notice
Hybrid Battery system uses around 270V voltage.
It may cause death or damage due to electrical shock, if you do not follow below Instructions.
▪ Follows instructions of workshop manual.
▪ Wear and use insulated glooves and tools.
▪ IG "OFF", Disconnect ground cable of auxiliary battery and "OFF" the safety connector of the high voltage battery.
▪ Check high voltage terminal on Power Relay Assembly is lower than 30V.
▪ Be careful that it should not be short between terminals when measuring battery cell voltage. You may be injured due to spark, parts damage or electrical shock.
▪ Metalic material cause high voltage short that may cause damage of life or vehicle. Therefore, get rid of all the metalic material before working. (Metalic Material : Watch, Ring, any metalic products etc.)
▪ After disconnect W/H goes to BMS ECU from High voltage battery, be careful not to happen short between exposed terminal and terminal on high voltage connector.




















7. Are measured value within specification ?






Checking the power line and ground line of a current sensor

Checking the power line and ground line of a current sensor
1. Ignition OFF.
2. Pull the Safety Plug and confirm the high voltage terminals are under 30V.
3. Disconnect the BMS, PRA and extension connector.
4. Ignition ON (SSB LED "BLUE").
5. Check the Voltage of the power line and ground line of the Current Sensor near to BMS ECU.

Specification :about 5V between power line and ground line, If it is not normal, replace the BMS ECU

6. Connect the BMS and PRA again.
7. Connect the Voltmeter between the power line terminal and the ground line terminal the Current Sensor near to PRA.
8. Connect the Voltmeter between the signal line terminal and the ground line terminal of the Current Sensor near to PRA.
9. Ignition ON (SSB LED "BLUE").
10. Check between the power line terminal and the ground line terminal of the Current Sensor and between the signal line terminal and the ground line terminal of the Current Sensor.

Specification :about 5V(power line and ground line),
signal 1 and the ground line : about 2.5V±0.1V
signal 2 and the ground line : about 2.5V±0.1V
if it is not normal, Replace the PRA.





















WARNING:
** Warning & Notice
Hybrid Battery system uses around 270V voltage.
It may cause death or damage due to electrical shock, if you do not follow below Instructions.
▪ Follows instructions of workshop manual.
▪ Wear and use insulated glooves and tools.
▪ IG "OFF", Disconnect ground cable of auxiliary battery and "OFF" the safety connector of the high voltage battery.
▪ Check high voltage terminal on Power Relay Assembly is lower than 30V.
▪ Be careful that it should not be short between terminals when measuring battery cell voltage. You may be injured due to spark, parts damage or electrical shock.
▪ Metalic material cause high voltage short that may cause damage of life or vehicle. Therefore, get rid of all the metalic material before working. (Metalic Material : Watch, Ring, any metalic products etc.)
▪ After disconnect W/H goes to BMS ECU from High voltage battery, be careful not to happen short between exposed terminal and terminal on high voltage connector.

11. Are measured value within specification ?





Inspection with Analysis of Current Data
1. Ignition OFF.
2. Ignition ON (SSB LED "BLUE") and Ignition OFF. (A current sensor might be zero setting)
3. Ignition ON (SSB LED "BLUE").
4. Connect the GDS.
5. Ignition ON/Hybrid Ready (Cluster Indicator "READY" On), select "Current Data" and check data under acceleration.

Specification :Voltage value : about 200 - 310V
Current value : about (-) 200A ~ (+) 200A








Fig.1) SOC 46% of high voltage battery - in the EV Mode, the battery pack current value is -13.2A, and hybrid battery voltage is 273V.
Fig.2) SOC 47% of high voltage battery - in the EV Mode, the battery pack current value is 2.5A, and hybrid battery voltage is 268.3V.
6. Are measured value within specification ?