Hyundai Ioniq: High Voltage Battery Control System / Pre Charge Relay. Repair procedures

Hyundai Ioniq (AE) 2017-2025 Service Manual / Hybrid Control System / High Voltage Battery Control System / Pre Charge Relay. Repair procedures

Removal
1.
Shut off the high voltage.
(Refer to Hybrid Control System - "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.
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.
1.
Install the pre-charge relay in the reverse order of removal.
High voltage battery rear cover installation bolt / nut :
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-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.
1.
Remove the power relay assembly.
(High Battery System - "Power Relay Assembly")
2.
Measure the resistance between the PRA connector terminals #6 and #5.
Specification : Refer to "Specification"
High Voltage Pre Charge Relay Switch Resistance
[Use Multi Tester (Relay OFF)]
1.
Shut off the high voltage.
(Refer to Hybrid Control System - "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 (+).
Specification : ∞Ω [20°C (68°F)]

[GDS - Relay ON]
1.
Connect the GDS to the Data Link Connector (DLC).
2.
Turn the ignition switch ON.
3.
Activate the pre-charge 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.

High Voltage Per-Charge Relay Coil Resistance
1.
Shut off the high voltage.
(Refer to Hybrid Control System - "High Voltage Shut-off Procedures")
2.
Remove the power relay assembly.
(Refer to High Battery System - "Power Relay Assembly")
3.
Check for continuity between the terminals using an ohmmeter.

    Pre Charge Relay. Schematic diagrams

    C..

    Pre-Charge Resistor. Description and operation

    DescriptionPre-Charge Resistor is integrated into the Power Relay Assembly (PRA). It protects the high voltage circuit by limiting the current while the inverter capacitor is being charged...

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