2022 Hyundai IONIQ Electric (AE EV) 100KW Service & Repair Manual

IONIQ Electric(AE EV) > 2022 > 100KW > General Information - Electrical System Precautions Precautions when servicing the high voltage system • Since the electric vehicle contains a high voltage battery, if the system or vehicle is handled improperly, it may result in a severe accident such as an electrical short, shock, etc. Therefore, make sure to comply with the following before working on the system. • Make sure to cut off the high voltage by separating the service plug before inspecting or repairing the high voltage system. (Refer to Hybrid Control System - "High Voltage Shut-off Procedure") • The separated service plugs should be kept by the person in charge of work to prevent it from being connected by another person by mistake. • Metallic object may cause short circuit, leading to personal injury or vehicle damage. Be sure to remove all metallic objects from the body before starting the task. (Metallic objects : watch, ring, and other metallic objects) • Before working on the high voltage system, equip personal protective equipment to prevent safety-related accidents. (Refer to "Personal Protective Equipment") • Make sure not to let anyone other than the person in charge of the work equipped with the protective equipment touch the high voltage-related parts. In order to prevent it, cover any high voltage system not related to the work with an insulation cover. • When working on the high voltage system, make sure to use insulated tools. • Organize and store the removed high voltage parts on an insulated mat to prevent a short circuit. • Check that the voltage between high voltage terminals is 30V or lower. • All high voltage wiring and connectors are marked in orange. • "High Voltage Warning" labels are affixed to high-voltage components. • High Voltage System Components: High Voltage Battery, Power Relay Assembly (PRA), High Voltage Junction Box Assy, Motor, Power Cable, BMS ECU, Inverter, LDC, ON-Board Charger (OBC), Main Relay, 7Pre-charge Relay, Pre-charge Resistor, Battery Current Sensor, Service Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charging Port, Electric Compressor, Electronic Power Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay, etc. •When servicing a high voltage component, post a "High Voltage Vehicle Warning" sign as shown below to warn others.

Personal Protective Equipment Name Shape Purpose

Insulated Gloves Equipped for high voltage component inspection and related tasks [Insulation Performance : 1000V/300A or Greater] Insulated Boots Equipped for high voltage component inspection and related tasks Insulated Suit Insulated Safety Helmet Protective Goggles Wear in the Following Cases • Install, remove, or inspect the high voltage battery terminal or wiring which may cause a spark • Work on the high voltage battery pack assembly Face Protection Insulated Mat Organize and store the removed high voltage parts on an insulated mat to prevent any electric shock accident. Insulated Cover Cover the high voltage parts with an insulation cover to prevent any safety-related accidents of a person not equipped with the protective equipment.

Warning Tape Install around the vehicle to block the people from approaching it in order to prevent any accident during the work. Personal Protective Equipment Inspection • Check that the insulated boots, insulated suit, insulated helmet, and safety guards are not torn or damaged. • Check that the insulated gloves are not torn or damaged. • Make sure the insulated gloves are dry before wearing them. ① Fold the insulated gloves as shown above. ② Fold 3 to 4 more times to prevent air discharge. ③ Check for any torn or damaged parts. Precautions when handling the power cable • Insulate the high voltage terminal immediately after reconnecting the terminal (using insulation tape). • Fasten the high voltage terminal screw with the specified torque. • Exercise caution to ensure that the (+) and (-) terminals do not come into contact when connecting or removing the power cable and busbar. Precautions when handling the high voltage battery • Refer to Battery Control System - "High Voltage Handling Guide". • High voltage battery's performance may decrease if it is exposed to high temperature for a lengthy period. As a result, heat-treatment after painting must not exceed 70°C/30 minutes, or 80°C/20 minutes. Precautions in case of fire on the high voltage battery system • Turn OFF the Start button. Keep the Smart Key at least 2 meters away from the vehicle to prevent unintended engine start. • Quickly disconnect the service interlock connector plug in the early stage of fire. (Refer to Battery Control System - "High Voltage Shut-off Procedure") • Turn OFF the vehicle key as soon as possible and evacuate to the outside if the vehicle stops after a flooding/collision accident. • If a small fire occurs, use an extinguisher for electrical fire (ABC or BC) to extinguish.

• If the fire has not been put down in early stage, escape to the safe place and keep people out of the vehicle. • Call fire station and report the vehicle is on fire. Follow the instruction from the fire station. • If it is difficult to supress the fire, promptly move to safe place and wait until the rescue arrives. • The fire on the drive motor battery at the bottom of the vehicle requires constant supply of a large volume of water to extinguish. It is difficult to extinguish the fire if there are not enough water or proper fire extinguisher. Approaching the vehicle may lead to life damage such as electrical shock. Precautions in case of high voltage battery gas or electrolyte leakage • Turn OFF the Start button. Keep the Smart Key at least 2 meters away from the vehicle to prevent unintended engine start. • Quickly turn OFF the service plug in the early stage of fire. (Refer to the "High Voltage Cut-off Procedure") • Gas is hydrogen and alkaline vapor. If the leakage is indoor, ventilate the area immediately and evacuate to a safe location. • If the leaked liquid comes in contact with skin, immediately neutralize the affected area with boric acid solution, then clean with tap water or saline solution. • If the leaked vapor or liquid gets in the eye, immediately clean the affected eye with water then get medical attention. • If the cause of gas leakage is a high temperature, then do NOT use the high voltage battery until the battery is fully cooled down to room temperature. Precautions when handling the vehicle after an accident • Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit and insulated boots. • Do not touch bare cable under any condition. (Refer to "Precautions when handling the power cable") • If the vehicle is flooded, do not come close to the high voltage related parts. If the situation is unavoidable, move the vehicle to a safe place before taking action. • Gas is hydrogen and alkaline vapor. If the leakage is indoor, ventilate the area immediately and evacuate to a safe location. • If the leaked liquid comes in contact with skin, immediately neutralize the affected area with boric acid solution, then clean with tap water or saline solution. • To cut off the high voltage, refer to "High Voltage Cut-off Procedure." Precaution for vehicle fire If a small fire occurs, use an extinguisher for electrical fire (ABC or BC) to extinguish. • If the fire has not been put down in early stage, escape to the safe place and keep people out of the vehicle. • Call fire station and report the vehicle is on fire. Follow the instruction from the fire station. • If it is difficult to supress the fire, promptly move to safe place and wait until the rescue arrives. • The fire on the drive motor battery at the bottom of the vehicle requires constant supply of a large volume of water to extinguish. It is difficult to extinguish the fire if there are not enough water or proper fire extinguisher. Approaching the vehicle may lead to life damage such as electrical shock. Preparations when servicing the accident vehicle • Insulated gloves (or rubber gloves), protective goggles, insulated suit and insulated boots • Boric Acid Power or Solution • Carbon Dioxide Fire Extinguisher or Other Fire Extinguisher • Towel for cleaning electrolyte

• Vinyl Tape (for insulating terminal) • Megohm Tester (for checking high voltage insulation resistance) Precautions in Case Electric Vehicle Is Left Unattended for a Lengthy Period • Turn OFF the Start button. Keep the Smart Key at least 2 meters away from the vehicle to prevent unintended engine start. (Prevents deep discharge of high voltage battery due to dark current, etc.) • If the high voltage battery SOC (State Of Charge) is 30% or lower, the state should not be left unattended for a lengthy period. • If the vehicle will be left unattended for a lengthy period, charge the battery to the full at a normal rate every three months in order to prevent the high voltage battery SOC from becoming 0. • When inspecting or exchanging the auxiliary battery, check high voltage battery SOC reset related problems. Precautions when retrieving/refilling electric vehicle refrigerant • The electric compressor of an electric vehicle using high voltage uses POE oil of high insulating performance. • Use a separate equipment (refrigerant retrieval/charging device) for maintenance of an electric vehicle to prevent the PAG oil of a general vehicle from flowing in upon retrieving/refilling the refrigerant. • Use the refrigerant retrieval/charge device exclusively used for the electric compressor to inject the designated refrigerant (R-134a) and refrigeration oil (POE). If the refrigeration oil (PAG) for the ordinary car is injected, the compressor may be damaged or a safety-related accident may occur.

IONIQ Electric(AE EV) > 2022 > 100KW > General Information - High Voltage Cut-off Procedure • When working on the high voltage system, make sure that you are familiar and comply with the "Safety Precautions, Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric shock or leakage may occur. • When working on the high voltage system, make sure to cut off the high voltage first according to the "High Voltage Cut-off Procedure." If you do not comply with the instructions, serious accidents due to electric shock or leakage may occur. • High Voltage System Components: High Voltage Battery, Power Relay Assembly (PRA), High Voltage Junction Box Assy, Motor, Power Cable, BMS ECU, Inverter, LDC, ON-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge Resistor, Battery Current Sensor, Service Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charging Port, Electric Compressor, Electronic Power Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay, etc. 1. Turn OFF the ignition switch and disconnect the (-) cable on the auxiliary battery (12V). 2. Remove the trunk luggage board. (Refer to Body - "Trunk") 3. Remove the service plug service cover (A). 4. Remove the service plug (A).

• Remove the service plug in the following order. 5. Be sure to wait 5+ minutes for the capacitor inside the inverter to discharge after removing the service plug. 6. Measure the voltage between the inverter terminals to check that the inverter capacitor is discharged. (1) Lift the vehicle. (2) Remove the mounting nuts and remove the high voltage battery under cover (A).

(3) Disconnect the high voltage cable (A). (4) Measure the voltage between the high voltage terminals to check that the inverter capacitor is discharged. 30V or Below : High Voltage Circuit Normal Cut-off Over 30V : High Voltage Circuit Failure

2022 Hyundai IONIQ Electric (AE EV) 100KW Service & Repair Manual

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