KIA Niro: Measuring insulation resistance using an insulation tester

Warning

  • 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 read and follow the "High Voltage Shut-off Procedures" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
  1. Shut off the high voltage circuit.

    (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 inlet cooling duct..

    (Refer to High Voltage Battery Cooling System - "Cooling Duct")

  5. Open the high voltage battery cushion (A) in the direction of an arrow.

  1. Remove the upper frame (A) after loosening the mounting bolts and nuts.

  1. Remove the high voltage cable cover (A) after loosening the mounting bolt.

  1. Connect the insulation tester (-) terminal (A) to the battery system case (or ground).

  1. Connect the insulation tester (+) terminal to the high voltage battery (+) and (-). Measure the resistance.

Measure the isolation resistance on the power relay assembly high voltage power terminal (+))

(1) Connect the insulation tester (+) terminal to the (+) PRA high voltage power terminal (A).

(2) Supply 500V through the insulation tester and wait one minute to measure the stable resistance.

(3) Check the isolation resistance.

Normal insulation resistance range : Above 1.0 MΩ (20ºC (68ºF))

Measure the isolation resistance on the power relay assembly high voltage

Measure the isolation resistance on the power relay assembly high voltage power terminal (-)

  1. Connect the insulation tester (+) terminal to the (-) PRA high voltage power terminal (B).
  2. Supply 500V through the insulation tester and wait one minute to measure the stable resistance.
  3. Check the isolation resistance.

Normal insulation resistance range : Above 1.0 MΩ (20ºC (68ºF))

Measure the isolation resistance on the power relay assembly inverter

Measure the isolation resistance on the power relay assembly inverter power terminal (+)

Warning

When measuring the insulated resistance on each PRA inverter, use a contact pin to prevent damage on the connector and for more accurate measurement.

  1. Connect the insulation tester (+) terminal to the (+) PRA inverter power terminal (A).
  2. Supply 500V through the insulation tester and wait one minute to measure the stable resistance.
  3. Check the isolation resistance.

Normal insulation resistance range : Above 1.0 MΩ (20ºC (68ºF))

Measure the isolation resistance on the power relay assembly inverter

Measure the isolation resistance on the power relay assembly inverter power terminal (-)

Warning

When measuring the insulated resistance on each PRA inverter, use a contact pin to prevent damage on the connector and for more accurate measurement.

  1. Connect the insulation tester (+) terminal to the (-) PRA inverter power terminal (B).
  2. Supply 500V through the insulation tester and wait one minute to measure the stable resistance.
  3. Check the isolation resistance.

Normal insulation resistance range : Above 1.0 MΩ (20ºC (68ºF))

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

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