Hyundai/Kia Batteries

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bobby_come_lately
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Hyundai/Kia Batteries

Post by bobby_come_lately »

Seeing more and more of the Hyundai/Kia battery modules on eBay thanks to Ioniqs, Souls and Niros now getting broken. Thought it might make sense to start a thread on them - and maybe a section on the hardware from them?

I have found this resource so far that is quite helpful about the Niro: http://www.kniro.net/description_and_operation-827.html

And @Bigpie found this on the Ioniq: https://www.hyundai.com/content/dam/hyu ... _FINAL.pdf

Does anyone else have any knowledge of/experience with these - e.g. format, size, BMS integration etc?

What would be really useful would be to understand the visual and model number differences between the 1.5kwh unit from the hybrid and the 8.9kwh unit from the plug-in. Hard to get a sense of them from eBay photos.

Update: Think I've confirmed that part number 37501-G2100 is the 1.56Kwh pack. This makes the packs on eBay at £600+ pretty unattractive from a cost/kwh perspective.
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Re: Hyundai/Kia Batteries

Post by celeron55 »

I looked into these some time ago.

The PHEV battery electrical specs are similar to the BMW ones.

The PHEV pack is split into two parts, one is located behind the rear seat and the other one underneath the seat.

When you go shopping, first you need to discern the PHEV and non-PHEV packs.

The PHEV pack underneath the rear seat looks similar (but not exactly) to the non-PHEV pack, which is also located underneath the rear seat, but is lower voltage and is wired in series with the rear pack.

Some look decently priced initially, until you notice that most sellers are selling only the under-seat pack or only the behind-seat pack.

The PHEV packs also are very rare compared to the non-PHEV ones.

The non-PHEV pack is obviously only useful for testing, just like a Prius pack. Even if it was cheap per kWh, it's still way too large and heavy per kWh.
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Re: Hyundai/Kia Batteries

Post by bobby_come_lately »

Hoping this will improve with future generations. But right now it does seem as if these are best ignored. Shame.
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Re: Hyundai/Kia Batteries

Post by Isaac96 »

If Niro/Kona EV batteries are available that would be a good option - 64KWh and 39.2KWh cars seem to be for sale, but since the car is only recently released packs aren't very available. Maybe there are more in the US (worse drivers here).
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Re: Hyundai/Kia Batteries

Post by Domt177 »

Does anyone have any info on the modules (i.e dimensions, weight, BMS) from the Kona EV e-niro as they have started to crop up at under £100/kWh so could be a good option

Cant seem to find much about them online yet
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Re: Hyundai/Kia Batteries

Post by zippy500 »

I have a 30kw soul pack, I can give dimensions and weight of the packs, if it helps anyone, I also have the BMS unit, be nice if it could be put to use. I could not find any info on the net about it. Last resort would be try and adapt the leaf BMS with it, Came with a nice Contactor/Precharge control box.
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Re: Hyundai/Kia Batteries

Post by SuperV8 »

this is data I found from various searching.

ImageKia Hundai Battery Pack Spec
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Re: Hyundai/Kia Batteries

Post by bexander »

Some information regarding Kia BMS:
viewtopic.php?f=26&t=1179
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Re: Hyundai/Kia Batteries

Post by Domt177 »

I asked EV-Breakers for some info on the pack and they came back with this

450kg pack
10 modules
4x ‘short modules’ 430 x 370 x 300mm - 27 cells
6x ‘long modules’ 480 x 370 x300mm - 30 cells

Seems a bit heavy for a 64kwh (net) pack but good value per kWh
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Re: Hyundai/Kia Batteries

Post by Markos »

I see there are different battery packs, does anyone know the differences between them? I found these part numbers:
37510-G2000
37501-G5000
37501-G5100
37501-DD150
37501-CM020
37501-K4050
37501-CM020

These are all Hyundai Kona / Kia Niro batteries.
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Re: Hyundai/Kia Batteries

Post by Markos »

I'm not sure I have looked at the right part numbers. I saw some photos of a battery assembly with both P/N 37510-G2000 and 37501-G5000.
bexander wrote: Thu Sep 30, 2021 5:07 am Some information regarding Kia BMS:
viewtopic.php?f=26&t=1179
You are using batteries from the Kia Niro PHEV, do you have some knowledge at what number I should be looking to gather more information about the batterypack? What pack are you using?
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Re: Hyundai/Kia Batteries

Post by bexander »

Markos wrote: Fri Oct 08, 2021 9:57 am I'm not sure I have looked at the right part numbers. I saw some photos of an battery assembly with both P/N 37510-G2000 and 37501-G5000.
bexander wrote: Thu Sep 30, 2021 5:07 am Some information regarding Kia BMS:
viewtopic.php?f=26&t=1179
You are using batteries from the Kia Niro PHEV, do you have some knowledge at what number I should be looking to gather more information about the batterypack? What pack are you using?
No, sorry, I don't have any numbers. I only know my pack is from a Kia Niro PHEV.
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Re: Hyundai/Kia Batteries

Post by paaa »

I have a PHEV Niro im working on at the minute ill share part numbers next weekend. Pack is split into two parts master BMS on top of rear pack and contactor parts on side of pack under seats. Packs both have same voltage so 96s overall and must be 48s in each pack. Main fuse is on rear pack along with safety disconnect.
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Re: Hyundai/Kia Batteries

Post by Cookie6000 »

Here's a very recent video from Korea of the new higher capacity CATL 68.4kWh battery in the new Kia Niro sent on to me earlier. The design and engineering in the Kia/Hyundai camp is becoming so much simpler and refined as they evolve. Wonder how long before we find one of these in Calvin (ev-breakers) yard!
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Re: Hyundai/Kia Batteries

Post by paaa »

Cookie6000 wrote: Sat Aug 27, 2022 9:48 pm Here's a very recent video from Korea of the new higher capacity CATL 68.4kWh battery in the new Kia Niro sent on to me earlier. The design and engineering in the Kia/Hyundai camp is becoming so much simpler and refined as they evolve. Wonder how long before we find one of these in Calvin (ev-breakers) yard!
Interesting the switch over to the housed modules and departure from LG chem , I would imagine the recall didn't help. There is a teardown video for the 800v battery from Ioniq 5 [media]] funny how different they are considering catl do up to 16s modules in the standard module format so should be possible to build 800v pack that way.
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Re: Hyundai/Kia Batteries

Post by paaa »

And then the EV6 battery is different again
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Re: Hyundai/Kia Batteries

Post by canadasconvert »

I am also looking for information on these batteries. In September, I finished a project where I installed a Tesla LDU into an older Porsche Boxster. The car was powered by an 8 module 96 cell battery pack from a 2015 KIA Soul EV rated at 384V. I have been testing the maximum charging voltages and minimum battery voltages. Charging to 400V and discharging to 300V would give me a range of about 100-120KM. On the last charge, I went to 405V. When I got back to the car about an hour later, there was a definite smell of nail polish remover in the garage. When I checked the individual cell voltages, there was one cell showing 0.84V while all the other cells were between 3.96V and 4.02V. I pulled the pack and you can see the ballooned cell in the attached image. I placed the ballooned module below a normal module so you can see the difference. I am looking for information on how I proceed with repairs. I know that KIA North America has a 6 month backlog of battery warranty claims, so there are no full packs available in the marketplace. Can I simply buy a new individual cell or module and install it. What battery balancing or recalibration is required?
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Re: Hyundai/Kia Batteries

Post by celeron55 »

Do you have a BMS that will keep the cell voltages in a safe range or are you solely going by the total pack voltage?

Do you think your system was allowing charge or discharge current beyond the 2.5...4.2V range for that cell or do you suppose the cell went to 0.84V on its own, without any current flowing?

It doesn't make sense to replace anything before figuring out what went wrong.
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Re: Hyundai/Kia Batteries

Post by arber333 »

I recommend you simply pull the damaged cell(s) off and use 95S or 94S. And use a BMS at least one for protection while charging.
As for the reason... just calculate 405V / 96 = 4.21V! And that is for perfectly balanced cells. Yours are obviously not.
You should be careful. Charge shouldnt be higher than 4.1V, too much risk.
Discharge is best down to 3.3V.
I noticed if i go lower than 3.2V cells start to heatup.

28kWh pack should be able to give more than 130km i think. But not on the highway. I think your range estimation would be correct for 3.1V when empty.
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Re: Hyundai/Kia Batteries

Post by Dxtawise »

You can actually get a replacement module on eBay. I have done same for a Hyundai sonata 2012 hybrid some years ago, and it worked.
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Re: Hyundai/Kia Batteries

Post by arber333 »

Hi folks.
I came across some kia 64kW modules. They have neat cell wires comming from the module sides. There is a circuit on the sides and i am wondering if those wires are fused? I would like to use this modules with my active BMS and it balances at 1A. Too much?
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Re: Hyundai/Kia Batteries

Post by midway »

wire with a cross section of 0.5 mm withstands continuously 11 amperes.
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Re: Hyundai/Kia Batteries

Post by arber333 »

midway wrote: Tue Nov 22, 2022 10:32 am wire with a cross section of 0.5 mm withstands continuously 11 amperes.
No i meant if someone can tell if those connections are fused. No matter because i tested that myself and at 0.2A the fuse popped! :twisted:
Its official, those contacts are limited to 200mA.
As a friend intends to use 1A active BMS we will add our own wires to contacts.
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Re: Hyundai/Kia Batteries

Post by Kutato72 »

arber333 wrote: Sat Nov 19, 2022 5:28 pm Hi folks.
I came across some kia 64kW modules. They have neat cell wires comming from the module sides. There is a circuit on the sides and i am wondering if those wires are fused? I would like to use this modules with my active BMS and it balances at 1A. Too much?
The cell terminals are protected by SMD fuses with the letter "N". In principle, this means 2.0A. I tried it for your pleasure with 2.2A, it didn't melt in 10 seconds. So 2.0A is correct.
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