Charging System Insulation Resistance Inspection

1. Charge the vehicle with a working EVSE (regular charging station).
2. If unable to charge, check the EVSE (standard charger) status.
3. Is there a leakage current fault in the EVSE (standard charger)? Does the leakage circuit breaker of the electrical equipment work?

Good 

• Go to "Proximity Detection (PD) Signal Inspection" procedure.

No Good 

• Go to next procedure.

Inspection Condition	(+) Probe		(-) Probe		Specification
	Connector	Terminal	Connector	Terminal
Ignition "OFF". Disconnect main battery safety plug, and wait for 5 minutes. Check high voltage terminal is lower than 30V. See if the AC power high voltage cable connector is connected to the OBC.	Charge connector	1 (AC neutral)	Chassis ground	-	Above 10MΩ (mega Ω meter: when DC is 500V)
	Charge connector	2 (AC live)	Chassis ground	-	Above 10MΩ (mega Ω meter: when DC is 500V)

Good 

• If the measured value is normal when re-measure "Insulation Resistance of Charging System AC Input", thoroughly check the EVSE (standard charger).
• For further checking of the vehicle charging system, go to "Proximity Detection (PD) Signal Inspection" procedure.

No Good 

• Go to next procedure for more precise diagnosis.

Inspection Condition	(+) Probe		(-) Probe		Specification
	Connector	Terminal	Connector	Terminal
Ignition "OFF". Disconnect main battery safety plug, and wait for 5 minutes. Check high voltage terminal is lower than 30V. See if the AC power high voltage cable connector is connected to the OBC.	Charge connector	1 (AC neutral)	Chassis ground	5 (ground)	Above 10MΩ (mega Ω meter: when DC is 500V)
	Charge connector	2 (AC live)	Chassis ground	5 (ground)	Above 10MΩ (mega Ω meter: when DC is 500V)

Good 

• Go to next procedure.

No Good 

• Repair or replace the wire as necessary and than Go to "Verification Of Repair " procedure.

Inspection Condition	(+) Probe		(-) Probe		Specification
	Connector	Terminal	Connector	Terminal
Ignition "OFF". Disconnect main battery safety plug, and wait for 5 minutes. Check high voltage terminal is lower than 30V. Disconnect the AC power high voltage cable of OBC.	OBC (component side)	1 (AC neutral)	Chassis ground	-	Above 10MΩ (mega Ω meter: when DC is 500V)
	OBC (component side)	3 (AC live)	Chassis ground	-	Above 10MΩ (mega Ω meter: when DC is 500V)

Good 

• Carefully re-do "Charging System Insulation Resistance Inspection" procedure.
• Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.

No Good 

• Replace the "OBC" with a working one and than Go to "Verification Of Repair " procedure.

Proximity Detection (PD) Signal Inspection
Inspection Condition	Inspection Procedure	Reference
Ignition "ON".	Connect KDS to "Data Link Connector (DLC)". Operate vehicle or system in accordance with Enable Condition in DTC Detecting Condition. Monitor "PD Status" and "Charging Plug Connection Status" parameters in "Current Data" with KDS during connect or remove charging connector.	Fig.1 to 2

Courtesy of KIA MOTORS AMERICA, INC.

Courtesy of KIA MOTORS AMERICA, INC.

Good 

• Go to "Inlet Lock Device Inspection" procedure.

No Good 

• See if there is any foreign substance around the charger connector or charger terminal.
• Go to "Charging Cable (charging connector) Inspection" procedure.

Charging Cable (charging connector) Inspection
Inspection Condition	(+) Probe		(-) Probe		Specification
	Connector	Terminal	Connector	Terminal
Check if there was any external damage to the charging connector. Measure the proximity detection (PD) resistance of the charging connector.	EVSE cable connector	Detection	EVSE cable connector	Ground	Approx. 1500Ω (10A) Approx. 680Ω (16A) Approx. 220Ω (32A) Approx. 100Ω (64A)

Courtesy of KIA MOTORS AMERICA, INC.

Good 

• Go to "Charging Connector Inspection" procedure.

No Good 

• Repair or replace the EVSE charging cable (charging connector) and than Go to "Verification Of Repair " procedure.
• If able to replace the charging cable, replace it and start charging.
• If unable to replace the charging cable, charge it with a different EVSE.

Charging Connector Inspection
Inspection Condition	(+) Probe		(-) Probe		Specification
	Connector	Terminal	Connector	Terminal
Ignition "OFF". Disconnect main battery safety plug, and wait for 5 minutes. Check high voltage terminal is lower than 30V.	Charge connector	5 (ground)	Chassis ground	-	Approx. below 1Ω
	Charge connector	4 (detection)	Charge connector	5 (ground)	Approx. 2.7kΩ
Ignition "OFF". Disconnect main battery safety plug, and wait for 5 minutes. Check high voltage terminal is lower than 30V. Disconnect the OBC connector.	Charge connector	4 (detection)	OBC connector	32 (detection)	Approx. below 1Ω
	Charge connector	4 (detection)	Chassis ground	-	0V

Good 

• Go to "Control Pilot (CP) Signal Circuit Inspection" procedure.

No Good 

• See if there is any defect on the exterior of the charging connector.
• Repair or replace the fault in the inlet lock device and than Go to "Verification Of Repair ".

Control Pilot (CP) Signal Circuit Inspection
Inspection Condition	(+) Probe		(-) Probe		Specification
	Connector	Terminal	Connector	Terminal
Ignition "OFF". Disconnect main battery safety plug, and wait for 5 minutes. Check high voltage terminal is lower than 30V. Disconnect the OBC connector.	Charge connector	3 (control pilot)	OBC connector	24 (control pilot)	Approx. below 1Ω
	Charge connector	3 (control pilot)	Charge connector	5 (ground)	∞ (infinity)Ω

Good 

• Go to "AC Power High Voltage Cable Inspection" procedure.

No Good 

• Repair or replace the fault in the wire harness and than Go to "Verification Of Repair ".

AC Power High Voltage Cable Inspection (Charging connector - OBC)
Inspection Condition	(+) Probe		(-) Probe		Specification
	Connector	Terminal	Connector	Terminal
Ignition "OFF". Disconnect main battery safety plug, and wait for 5 minutes. Check high voltage terminal is lower than 30V. Disconnect the AC power high voltage cable of OBC.	Charge connector	1 (AC neutral)	High voltage cable of OBC	1 (AC neutral)	Approx. below 1Ω
	Charge connector	2 (AC live)	High voltage cable of OBC	3 (AC live)	Approx. below 1Ω
	Charge connector	5 (ground)	High voltage cable of OBC	2 (ground)	Approx. below 1Ω
	Charge connector	1 (AC neutral)	Charge connector	2 (AC live)	∞ (infinity)Ω
	Charge connector	1 (AC neutral)	Charge connector	5 (ground)	∞ (infinity)Ω
	Charge connector	2 (AC live)	Charge connector	5 (ground)	∞ (infinity)Ω

Good 

• If you cannot charge the vehicle through a different EVSE, replace the OBC and re-try charging.

No Good 

• Repair or replace the fault in the wire harness and than Go to "Verification Of Repair ".