Hyundai NEXO Emergency Response Manual
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Hyundai NEXO Emergency Response Manual

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Emergency Response Guide
HYUNDAI ROADSIDE ASSIST
•
If severe damage causes high-voltage components to become exposed, emergency responders should take
appropriate precautions and wear appropriate insulated personal protective equipment.
Do not attempt to remove the safety plug while standing in the water.
•
Never cut or disconnect the high voltage orange cabling and connectors without first disabling the system by
•
removing the safety plug.
•
Exposed cables or wires may be visible inside or outside the vehicle. Never touch the wires, cables, connectors, or
any electric components before disabling the system, to prevent injury or death due to electrical shock.
Failure to follow any of these instructions may result in serious injury or death by electrocution.
Do not cut through any component of the Airbag (SRS) system (Supplementary Restraint System)
•
•
SRS components may remain powered and active for up to 3 minutes after the 12V electrical system is shut off or
disabled.
Disconnect the battery negative cable and wait for at least 3 minutes before beginning work.
Failure to follow any of these instructions may result in serious injury or death from accidental deployment of the
.
airbag system
NEXO
1800 186 306

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Summary of Contents for Hyundai NEXO

  • Page 1 NEXO Emergency Response Guide HYUNDAI ROADSIDE ASSIST 1800 186 306 • If severe damage causes high-voltage components to become exposed, emergency responders should take appropriate precautions and wear appropriate insulated personal protective equipment. Do not attempt to remove the safety plug while standing in the water.
  • Page 2 Important Safety Information This manual includes information titled as DANGER, WARNING, CAUTION & NOTICE. These titles indicate the following: DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 3: Table Of Contents

    - Safety Precautions for Hydrogen Electric Vehicle ·············································· 4 NEXO Identification ··················································································· - General Vehicle Description ··········································································· 5 - Identifying a Hyundai Hydrogen Electric Vehicle ················································ 5 NEXO Main Systems ··················································································· - Key Specifications ························································································ 9 - Vehicle Components Location ········································································· 10 - Vehicle Components ·····················································································...

  • Page 4: Introduction

    The purpose of this document is to familiarize emergency responders and the towing/roadside assistance industry with the proper methods to handle the Hyundai NEXO in an emergency situation. This guide offers a basic overview of key vehicle systems and provides instructions for dealing with the different types of situations encountered by emergency responders.

  • Page 5: High Voltage Safety System

    The following items are safety guidelines of the high voltage in the fuel cell stack of NEXO. 1)A metal chassis and electro-conductive enclosure is located in the fuel cell stack to prevent an electrical shock due to the direct or indirect contact of users.

  • Page 6: Safety Issues Of Compressed Hydrogen

    Safety Issues of Compressed Hydrogen General Characteristics of Hydrogen Hydrogen is a gas with the smallest molecular weight of all gasses. It is colorless, odorless, tasteless, and noncorrosive with combustibility and fast diffusivity. It needs to be handled with caution. However, hydrogen is not dangerous in any other way and could even be less dangerous than other fuels in some aspects.

  • Page 7: Safety Precautions For Hydrogen Electric Vehicle

    Safety Precautions for Hydrogen Electric Vehicle The NEXO uses approximately 250 ~ 450 DC voltage and high pressure hydrogen gas. Be sure to follow the safety instructions below. Failure to follow the safety instructions may result in serious injury or death.

  • Page 8: Nexo Identification

    The Hyundai NEXO hydrogen electric vehicle is built on a chassis specifically developed to handle the fuel cells. The safest method is to assume that the NEXO you respond to is equipped with high voltage and hydrogen systems because the NEXO is an exclusive hydrogen electric vehicle model.
  • Page 9 NEXO Identification VIN Number The Vehicle Identification Number (VIN) identifies an electric vehicle with a “6” displayed in the 8th position, as shown in the below drawing. The VIN is embedded on the floor under the passenger seat. The number “6” in the 8th character of the VIN indicates that it is an electric vehicle with batteries [LiPB 240 V, 6.5 Ah] and a motor [3-...
  • Page 10 NEXO Identification Fuel Cell Power Module Compartment The NEXO has a fuel cell stack cover with “HYDROGEN” clearly shown on it. Additionally, there are orange colored high- voltage electrical cables in the fuel cell power module compartment. Vehicle Underside Orange colored cables are hidden by the under cover.
  • Page 11 NEXO Identification Hydrogen Electric Vehicle - Cluster Instrument Panel The instrument cluster panel displays the vehicle’s specific features that identify the NEXO as a hydrogen electric vehicle. : Hydrogen fuel gauge indicates the approximate : Regeneration brake/ECO/power gauge amount of fuel remaining in the fuel tank : Power Down Warning Light indicates that : The “Ready”...

  • Page 12: Nexo Main Systems

    NEXO Main Systems Key Specifications Item Value Type Permanent Magnet Synchronous Motor Electric Max. Output (kW) Driving Motor Max. Torque (Nm) Reduction Gear Gear Ratio 7.981 Inverter Input Voltage (V) 240~450V Input Voltage (V) 160~275.2V BHDC Output Voltage (V) 250~450V...

  • Page 13: Vehicle Components Location

    NEXO Main Systems Vehicle Components Location High Voltage Junction BHDC/LDC High-Voltage Cable 12V Auxiliary Battery High-Voltage Battery Assembly Fuel Cell System Reduction Gear Fuel Supply Tube Electric Drive Motor Hydrogen Tank Creates electric energy through an electro-chemical reaction Fuel Cell System...

  • Page 14: Vehicle Components

    NEXO Main Systems Vehicle Components 12V Auxiliary Battery The 12V Lithium-ion polymer auxiliary battery is located in front of the high-voltage battery in the trunk. This battery supplies power to all the standard electric devices such as the audio and instrument cluster.
  • Page 15 NEXO Main Systems Motor Control Unit The inverter coverts the direct current of the high-voltage battery to alternative current and supplies it to the driving motor. Also, the inverter converts the alternative current of the regenerative braking to the direct current to recharge the high-voltage battery.
  • Page 16 NEXO Main Systems High-Voltage Cabling The high-voltage cabling in the NEXO is orange per the SAE standard. These cables run from the rear of the vehicle to the front, where they connect the high-voltage battery to the Electric Drive Motor and other high-voltage components.
  • Page 17 NEXO Main Systems High-Voltage Electrical Isolation Unlike the 12V electrical system that is grounded to the vehicle’s chassis, the NEXO’s high-voltage electrical system is designed to be isolated from the vehicle. Regulation of High-Voltage Electrical Current Current from the high-voltage battery is...

  • Page 18: Airbag System (Srs : Supplemental Restraint System)

    Airbag System (SRS : Supplemental Restraint System) Airbag Six airbags are installed in the NEXO as shown below. Before starting any emergency procedure, make sure that the vehicle ignition is turned off and disconnect the negative cable from the 12V auxiliary battery to prevent accidental deployment of airbags.
  • Page 19 NEXO Main Systems Seat Belt Pretensioners The NEXO is equipped with seat belts with pretensioners. When the seat belt pretensioners are activated in a collision, a loud noise may be heard and fine dust, which may appear to be smoke, may be visible in the passenger compartment.

  • Page 20: Emergency Procedures

    Emergency Procedures Initial Response: The following procedures should be used whenever you are dealing with a NEXO at an emergency scene. All other operations should be consistent with your department’s standard operating procedures or guides. Hydrogen electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard.
  • Page 21 The first step is to immobilize the vehicle to prevent any accidental movement that can endanger the emergency response personnel and any crash victims. Since the NEXO doesn’t have an engine, there will be instances where the vehicle appears to be off because of the absence of engine noise.
  • Page 22 Emergency Procedures Disable The next step in the initial response process, conducted after the vehicle is secured to prevent movement, is to disable the vehicle, its SRS components and the high voltage electrical system. To prevent current flow through the system, use one of the following procedures to disable the vehicle.
  • Page 23 Emergency Procedures 2. Before disconnecting the 12V battery, move the smart key at least 2 meters away from the vehicle to prevent accidental starting. 3. Disconnect the negative (-) 12V battery cable (A), Smart Key located in the motor compartment, to further prevent the risk of accidental starting.
  • Page 24 Emergency Procedures Ⅱ. Disabling the system – IG Relay Removal (Alternate Method) 1. Open the hood. 2.Remove the fuel cell power module compartment fuse box cover. 3. In the event the vehicle cannot be disabled using the “Power” START/STOP Button, pull the IG1, IG2 fuses or relays from the motor compartment room fuse box.
  • Page 25 Emergency Procedures 5. Use the following procedures to remove the safety plug and disable the high voltage battery: a) Remove the safety plug cover (A) located in the trunk. b) Remove the safety plug using the following procedure : 1: Unlock → 2 : Release → 3 : Remove WARNING •...

  • Page 26: Extraction Operations

    Emergency Procedures Extrication Operations The extrication operations for the NEXO are similar to the conventional vehicle. However, the first responder should pay special attention when they extract occupants in the vehicle. Before extrication operations, the first responders should carry out “Initial Response: Identify, Immobilize and Disable”...
  • Page 27 Emergency Procedures Extrication tools and procedure When responding to an incident involving a NEXO, we recommend that the first responders follow their organization’s standard operating procedures for assessing and dealing with vehicle emergencies. When the first responders cut the vehicle, they should always pay special attention to the airbag system, orange colored high voltage cables and other high voltage components to avoid damage to these parts, which may increase the risks of explosion.

  • Page 28: Submersion

    Emergency Procedures Submersion Some emergency responses can involve a submerged vehicle. A NEXO that is submerged does not have high-voltage components on the vehicle’s body or framework. It is safe to touch the vehicle’s body or framework if there is no severe damage to the vehicle, whether it is in water or on land.

  • Page 29: Vehicle Fire

    Firefighting Operations If the high-voltage battery pack is either involved in or at risk of being involved in a fire in a NEXO, strict cautions must be taken while conducting firefighting operations due to following reasons: • Lithium-ion polymer batteries contain gel electrolytes that can vent, ignite, and produce sparks when subjected to temperatures above 300°F.
  • Page 30 Emergency Procedures Extinguishers • For small fires where the high voltage battery is not involved, extinguish using an ABC extinguisher for an electric fire. • For fires where the high voltage battery is involved or the high voltage battery is heated, extinguish using large and sustained amount of water to cool the high voltage battery.

  • Page 31: High-Voltage Battery Damage And Fluid Leaks

    Emergency Procedures High-Voltage Battery Damage and Fluid Leaks The high voltage battery assembly is enclosed in a sturdy metal case that is rigidly mounted to the structural components of the vehicle. This construction helps prevent damage to the high voltage battery assembly, even in severe crashes.

  • Page 32: Roadside Assistance

    Roadside Assistance Towing Towing the Nexo is the same as towing other vehicles with a gasoline engine. If emergency towing is necessary, we recommend having it done by an authorized HYUNDAI dealer or a commercial tow- truck service. Proper lifting and towing procedures are necessary to prevent damage to the vehicle.

  • Page 33: Jump Starting

    9. With the 「 」 (READY) indicator turned on, stop or drive the vehicle for about 30 minutes. 10.If the cause of your battery discharging is not apparent, we recommend that the system be checked by an authorized HYUNDAI dealer.
  • Page 34 HYUNDAI ROADSIDE ASSIST 1800 186 306 © 2020 Copyright Hyundai Motor Company, Australia Pty Limited All rights reserved. This document may not be altered without the written permission of Hyundai Motor Company or Hyundai Motor Company Australia Pty Ltd...

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