KIA Niro: Safety Plug Description and operation

Description

Safety Plug is installed on the rear side of the high voltage battery and it can mechanically shut the high voltage circuit off when servicing the high voltage system. (i.e. High Voltage Battery, Power
Relay Assembly, HPCU, BMS ECU, Hybrid Drive Motor, Inverter, HSG, LDC, Power Cable, etc.)
It includes a fuse in order to prevent the high voltage system from overcurrent

Circuit Diagram

Circuit Diagram

Harness Connector (Interlock)

Harness Connector (Interlock)

Safety Plug Repair procedures

Safety Plug Repair procedures

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. Turn the ignition switch OFF.
  2. Remove the auxiliary 12V battery cover (A).

  1. Disconnect the auxiliary 12V battery negative (-) terminal.

  1. Remove the luggage board (A).

  1. Remove the safety plug cover (A) after loosening the mounting bolts.

Installation

Installation

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. Install the Safety Plug in the reverse order of removal.

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     The Power Relay Assembly

    Specification Description The Power Relay Assembly (PRA) consists of the positive and negative main relays, pre-charge relay, pre-charge resistor and battery current sensor. It is located inside the battery pack assembly and controls the h

     Pre-Charge Relay

    Specification Description The Power Relay Assembly (PRA) consists of the positive and negative main relays, pre-charge relay, pre-charge resistor and battery current sensor. It is located inside the battery pack assembly and controls the h

     Pre-Charge Resistor

    Specification Description Pre-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. PRA Operation Sequence Cir

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     High Voltage (HV) battery (lithium-ion polymer)

    On-Board Charger (OBC): Transforms (inverts) AC power charge power, to DC power, to charge the high voltage battery Inverter: Transforms direct current into alternating current to supply power to the motor, and transforms alternating

     Electrical System

    Be sure to disconnect the battery cable from the negative (-) terminal of the battery. Never pull on the wires when disconnecting connectors. Locking connectors will click when the connector is secure. Handle sensors and relays carefully.

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