Battery: Kia Niro Hyundai Kona 64 kWh - dalathegreat/Battery-Emulator GitHub Wiki

[!CAUTION] Working with high voltage is dangerous. Always follow local laws and regulations regarding high voltage work. If you are unsure about the rules in your country, consult a licensed electrician for more information.

Kia e-Niro 64 kWh / Hyundai Kona Electric 64 kWh

A word of caution about battery fires 🔥

[!CAUTION] The batteries manufactured by LG Chem were recalled due to fire risk. If you are using a battery from a vehicle that did not get the recall, there is a higher risk to re-use these 64kWh batteries. The recall started in 2021, so if you are using a battery from a vehicle that was crashed before 2021, there is a high probability you have an pre-recall battery. You have been warned!

What are the affected vehicles? The subject vehicles include:

• Approximately 4,694 model year 2019-2020 Hyundai Kona Electric vehicles produced from August 28, 2018 through March 2, 2020.

• Approximately 2 model year 2020 Hyundai Ioniq Electric vehicles produced from November 8, 2019 through November 11, 2019.

This was done under program Recall 200 - https://static.nhtsa.gov/odi/rcl/2021/RCMN-21V127-9103.pdf

So can it be that the battery donor car is from 2020 or 2021 but has received the new battery, good to check then the battery label production date.

Specifications

  • 64kWh, 98s, 352v nominal, 180Ah (Approx size 147cm w x 197cm l x 33cm) ~450kg
    • Note: 64kWh, 96S 358V, 68kWh net ( 37501-AO050 ) 2022+ is not supported. See part numbers for more info
  • 39kWh, 90s, 324v nominal, 120Ah (Approx size 147cm w x 197cm l x 33cm) ~350kg

Part numbers for batteries

Here is a list of Kia / Hyundai stickers. The Number K is used for Kona, and Number Q is used for Niro. ✅ means that someone has succesfully used the pack with the Battery-Emulator

  • 37501 AO050 is Hyundai Kona / Kia e-niro 64kWh ❌ This battery uses CAN-FD, not compatible.
  • 37501 CV050 is Kia EV6 78kWh (For this battery see EGMP)
  • 37501 DD150 is Hyundai Kona 64kWh ✅
  • 37510 E4050 is Kia Soul 27kWh ❌ (pinout unclear)
  • 37501 K4003 is Hyundai Kona 64kWh
  • 37501 K4050 is Hyundai Kona 64kWh? (reports itself as 40kWh) ✅
  • 37501 K4054 is Hyundai Kona 64kWh ✅
  • 37501 K4454 is Hyundai Kona 40kWh ✅
  • 37501 G7200 is Hyundai Ioniq 28kWh
  • 37501 G7250 is Hyundai Ioniq 28kWh
  • 37501 G7650 is Hyundai Ioniq 40kWh
  • 37501 GI050 is Hyundai Ioniq 5 72kWh (For this battery see EGMP)
  • 37501 Q4000 is Kia Niro 64kWh ✅
  • 37501 Q4052 is Kia eSoul 64kWh ✅
  • 37501 Q4050 is Kia Niro 64kWh ✅
  • 37501 Q4053 is Kia eSoul/Niro 64kWh ✅
  • 37501 Q4151 is Kia Niro 64kWh ✅

How to compile the software for this battery type

Make sure that the settings in the USER_SETTINGS.h file are correct. The line:

#define KIA_HYUNDAI_64_BATTERY

Needs to be uncommented for the software to interface correctly with the battery.

Next step is then to select the inverter protocol that you intend to use. After setting this up, press compile and upload to the board!

remark; It is possible the BMS in the battery needs a 12v powercycle for 10 ~ 20 sec , after that or at the same time boot the Lilly and contractors are closed and HIGH VOLTAGE !! is active on the battery pins.

This also applies when a emergency knob/button is installed in the interlock lus. when lus is interupted the whole battery systems needs a 12v powercycle to be active again.

Part numbers

Incase your battery is missing some wires/disconnect switches, here are the OEM part numbers and purchase links. Do note that it might be cheaper to source from your local scrapyard!

Product Purchase Link
Service disconnect switch E437586000 Ebay
High voltage cable 91662-K4500 x
Low voltage connector KET MG656922-5 (requires C025 and C060 pins) Alibaba

Wiring info

⚠️ The CAN communication has no error checking. This means it is prone to corruption if it sits close to a high voltage line. Use shielded twisted pair cables for CAN-H and CAN-L , and connect the shield to protective earth in one end of the circuit.

Attached below are pictures of the BMS pinouts. Connect the pins to the LilyGo and 12V supply like this:

  • Pin 10 to LilyGo CAN - H
  • Pin 11 to LilyGo CAN - L
  • Pin 1/2 to 12V
  • Pin 33 to 12V GND
  • Place 12k resistor between Pin9 and Pin31
  • Place 12k resistor between Pin8 and Pin30

bild

Pinout as viewed from the outside of the pack

Kona LV Connector

pinout 2023-11-30 222912

bild

batt-bms-connector

bms-conn-wiring

Schematic

HighVoltage Wiring

see picture for positive ( red ) and negative ( black ).

HV-pos-neg

Hv cable

Battery specs.pdf

HVIL

The battery packs has interlock monitoring on all high voltage connections. To get the contactors to engage, the battery needs to see that all plugs have been seated. If you dont have the original plugs, these are the HVIL connectors that need to be connected together to make the battery think the connectors are seated:

Low voltage side: Pin 3 and 14 must be connected on data plug

These two pins on the high voltage plug:

image

Two pins on the heater plug must be joined:

image

If the service disconnect switch is missing, these two small pins must be shorted together.

image

Plus, the HV side must be connected together (diagram missing for running without service disconnect plug). Due to this, it is recommended to get the OEM service disconnect plug before continuing.

Special notes on 37501-AO050 battery

There is a 2022-2023 Hyundai Kona or Kia e-niro battery that is currently NOT SUPPORTED by the emulator. It is CATL made, it consist in 24 modules(2.835 kwh) x 4 cells(3.7v), configured 96s1p(358v in total) 64.8kwh(68.4 in total)

This battery has the part number 37501-AO050 , and this battery talks CAN-FD. This battery is not yet supported by the Battery-Emulator. Log files needed from a functional vehicle that uses this battery!

image

Troubleshooting

If you see Battery Voltage being reported as 6553.5V, it means that the battery is having internal issues.

  • Check if all cells are visible on the Cellmonitor page
    • If all cells are not visible, you have a blown fuse on one of the balancing lines
    • Another user reported corrosion on one of the balance lead plugs
    • Whatever the case, opening the battery and investigating is required if cellvoltages are missing

Credits

Here are the sources used Kona.64.kWh.contactors.log.files.zip