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# Kia Soul EV: EV Battery System / High Voltage Battery Handling Guide

Kia Soul EV (PS EV) 2015-2020 Service Manual / EV Battery System / High Voltage Battery Handling Guide

High voltage battery system inspection guide

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. | Carry out a visual inspection to determine whether the vehicle requires general repair or accident repair.
2. | For the general repair, repair according to the repair process of the corresponding DTC code.
3. | For the car accident repair, determine the accident type before repairing.
1) Electrical Accidents
– | Over-charge/discharge: Displays a battery over voltage (P1B71) code /low voltage (P1B70) code (Refer to the DTC diagnosis guide).
– | Short: Displays a high voltage short (P1B77, P1B25) codes (Refer to the DTC diagnosis guide).
2) Fire

Classification | Inspection process | Inspection results | Measures
Fire outside the high voltage battery mount e.g. fire in engine |
1. | Perform visual inspections (deformation, corrosion, wire coating, odor, connector).
2. | Check for main fuse open circuit after shutting off the high voltage.
3. | Check the high voltage main relay for signs of welding.
4. | Measure the high voltage battery/chassis insulation resistance.
5. | Check other parts for failure.
6. | Check the DTC code in the BMS ECU.
| High voltage battery insulation damaged | Remove the high voltage battery and repair the insulation process/coating.
High voltage battery not damaged | DTC code | If a DTC code occurs, comply with DTC diagnosis guide and repair process.
No DTC code and battery appears normal | Do not replace the high voltage battery (if the battery is damaged and must be disposed of, perform the high voltage battery disposal process).
Fire in the high voltage battery mount e.g. fire in trunk |
1. | Perform visual inspections (deformation, corrosion, wire coating, odor, connector).
2. | Check for visible damage of the high voltage battery.
3. | Check the high voltage main relay for signs of welding after shutting off the high voltage if no visible damage is found in the high voltage battery.
4. | Measure the high voltage battery/chassis insulation resistance.
5. | Check other parts for failure.
6. | Check the DTC code in the BMS ECU.
| High voltage battery appears damaged (heat, soot, etc.) | Remove the service disconnect plug and perform the salt water battery disposal process.
High voltage battery insulation damaged | Remove the high voltage battery and repair the coating/insulation.
High voltage battery not damaged | DTC code | If a DTC code occurs, perform the repair process outlined in the DTC diagnosis guide.
No DTC code and battery appears normal | Do not replace the high voltage battery (if the battery is damaged and must be disposed of, perform the high voltage battery disposal process).

3) Collision

Classification | Inspection process | Inspection results | Measures
Collision damage to areas other than the high voltage battery mount e.g. front/side collisions |
1. | Perform visual inspections (deformation, corrosion, wire coating, odor, connector).
2. | Check for main fuse open circuit after shutting off the high voltage.
3. | Check the high voltage main relay for signs of melting.
4. | Measure the high voltage battery/chassis insulation resistance.
5. | Check other components.
6. | Check the DTC code in the BMS ECU.
| High voltage battery insulation damaged | Remove the high voltage battery and repair the coating/insulation.
High voltage battery not damaged | DTC code | If a DTC code occurs, perform the repair process outlined in the DTC diagnosis guide.
No DTC code and battery appears normal | Do not replace the high voltage battery (if the battery is damaged and must be disposed of, perform the high voltage battery disposal process).
Collisions involving the high voltage battery mount ?Example) Rear-end collision |
1. | Perform visual inspections (deformation, corrosion, wire coating, odor, connector).
2. | Check for main fuse open circuit after shutting off the high voltage.
3. | Check the high voltage main relay for signs of melting.
4. | Measure the high voltage battery/chassis insulation resistance.
5. | Check other components.
6. | Check the DTC code in the BMS ECU.
| High voltage battery insulation damaged | ? Follow the measures outlined above. ? If the high voltage battery mount is inaccessible due to trunk or door damage, bend or cut the exterior panels without damaging the high voltage system and carry out the inspection and repair process.
High voltage battery not damaged | DTC code
No DTC code and battery appears normal

4) Submersion

Classification | Inspection process | Inspection results | Measures
High voltage battery not submerged |
1. | Perform a visual inspection (deformation, corrosion, wire coating, odor, connector).
2. | Check for main fuse open circuit after shutting off the high voltage.
3. | Check the high voltage main relay for signs of melting.
4. | Measure the high voltage battery/chassis insulation resistance.
5. | Check other components.
6. | Check the DTC code in the BMS ECU.
| High voltage battery insulation damaged | Remove the high voltage battery and repair the coating/insulation.
High voltage battery not damaged | DTC code | If a DTC code occurs, perform the repair process outlined in the DTC diagnosis guide.
No DTC code and battery appears normal | Do not replace the high voltage battery (if the battery is damaged and must be disposed of, perform the high voltage battery disposal process).
High voltage battery submerged [Regardless of water conditions] |
1. | Check for main fuse open circuit after shutting off the high voltage.
2. | Check the high voltage main relay for signs of melting.
3. | Measure the high voltage battery/chassis insulation resistance.
4. | Check the DTC code in the BMS ECU.
| Carry out these measures regardless of the inspection results | Remove the high voltage battery and repair the coating/insulation.

Main Fuse 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.

Method 1

1. | Remove the safety plug. (Refer to High Voltage Battery Control System - "Safety Plug")

2. | Measure the resistance of safety plug cable which is connected to main fuse.
Specification : Less than 1? (20°C)

Method 2

1. | Turn the ignition switch OFF and disconnect the auxiliary battery negative (-) terminal.

2. | Shut off the high voltage. (Refer to Battery Control System - "High Voltage Shut-off Procedure")

3. | Remove the high voltage battery upper case. (Refer to High Voltage Battery System - "Case")

4. | Remove the upper fuse box (A).

5. | Perform the electrical test of main fuse.
Specification : Less than 1? (20°C)

Checking for Welding in the High Voltage Main Relay

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.

In order to safely remove the battery pack assembly, you must first inspect the high voltage main relay for signs of damage on welding.
You can use Global Diagnostic System (GDS) service data to detect weld damage in the high voltage main relay.

1. | Connect the GDS to DLC.

2. | Turn the ignition switch ON.

3. | Check the BMS weld damage state in the GDS service data.
Specification : NO

• | 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.

1. | Shut off the high voltage. (Refer to "High voltage Shut-off Procedures”)

2. | Remove the high voltage battery pack assembly. (Refer to High Voltage Battery System - "Battery Pack Assembly")

3. | Remove the upper case. (Refer to High Voltage Battery System - "Case")

4. | Remove the protect cover (A) of power relay assembly (PRA).

5. | Check for damage on welding in the high voltage main relay.
Specification : ??(20°C)

Insulation Resistance Inspection (With vehicle)

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.

The insulation status between the vehicle and the battery pack assembly can be checked on GDS or by measuring the resistance.

1. | Connect the GDS to DLC.

2. | Turn the ignition switch ON.

3. | Inspect the insulation resistance in the GDS service data.
Specified value : 300K? ~ 1000K?

• | 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.

1. | Shut off the high voltage. (Refer to Battery Control System - "High Voltage Shout-off Procedure")

2. | Connect the negative (-) terminal of mega ohm meter (A) to ground of the vehicle.
For precise measuring, connect the negative (-) terminal to the parts not painted.

3. | After connecting the positive (+) terminal to positive (+) terminal of the battery, measure the resistance as follows.
(1) | Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2) | Check the resistance.
Specified value : More than 2M? (20°C)

4. | After connecting the positive (+) terminal to negative (-) terminal of the battery, measure the resistance as follows.
(1) | Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2) | Check the resistance.
Specified value : More than 2M? (20°C)

Insulation Resistance Inspection (With battery)

• | 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.

1. | Remove the high voltage battery pack assembly. (Refer to High Voltage Battery System - "Battery Pack Assembly")

2. | Remove the upper case of high voltage battery pack assembly. (Refer to High Voltage Battery System - "Case")

3. | Remove the protect cover (A) of power relay assembly (PRA).

4. | Connect the negative (-) terminal of mega ohm meter to lower case.
For precise measuring, connect the negative (-) terminal to the parts not painted.

5. | Connect the positive (+) terminal to high voltage battery (+, -) terminals to measure the resistance.
(1) | Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA high voltage.
(2) | Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) | Check the reistance value.
Specified value : More than 2M? (20°C)
(1) | Connect the positive (+) terminal of mega ohm meter (B) to negative (-) terminal of PRA high voltage.
(2) | Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) | Check the reistance value.
Specified value : More than 2M? (20°C)
(1) | Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA inverter power.
(2) | Supply the 500V voltage through mega ohm meter and then wait about 1 minutes to measure the stable resistance value
(3) | Check the reistance value.
Specified value : More than 2M? (20°C)
(1) | Connect the positive (+) terminal of mega ohm meter (A) to positive (-) terminal of PRA inverter power.
(2) | Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) | Check the reistance value.
Specified value : More than 2M? (20°C)

Handling Guide for Storing, Transporting, and Disposing of High Voltage Battery Systems

1. High voltage battery system handling process

2. Defective high voltage battery system handling / Inspection

Classification |

##### High Voltage Shut-off Procedures

High Voltage Shut-off Procedure Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage syst ...

##### Specifications

Specification High Voltage Shut-off Procedures ? Specification ItemSpecificationRemarkCapacitor Voltage between the inverter terminalsLess than 30VCheckable by multi tester High Voltage Ba ...

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