Hyundai KONA Electric Emergency Response Manual
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Hyundai KONA Electric Emergency Response Manual

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KONA Electric
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
1800 186 306

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  • Page 1 KONA Electric 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

    Contents Important Safety Information Introduction ······························································································ KONA Electric Identification ········································································· - General Vehicle Description ··········································································· - Identifying a Hyundai electric vehicle································································ KONA Electric Main Systems ········································································· - Key Specifications ························································································ - Vehicle Components Location ········································································· - Vehicle Components ····················································································· - Airbag system (SRS : Supplemental Restraint System) ········································...

  • Page 4: Introduction

    The purpose of this document is to familiarise emergency responders and the towing/roadside assistance industry with the proper methods to handle the Hyundai KONA Electric 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 KONA Electric Identification General Vehicle Description The Hyundai KONA Electric is built on a conventional KONA chassis and therefore the five door hatch back looks very similar to its conventional counterpart with a few notable exceptions. The safest method is to assume that any KONA you respond to is a electric vehicle until proven otherwise. Using the information provided in this section, responders will be able to differentiate between the two.
  • Page 6 KONA Electric Identification VIN number The Vehicle Identification Number (VIN) identifies the Electric Vehicle with a “G” / ”H” displayed in the 8th position, as shown in the below drawing. The VIN is punched on the floor under the driver seat. The letter H in the 8th character of the VIN indicates that it is an electric vehicle with battery (G : [LiPB 356 V, 180 Ah] + Motor [3-phase AC 150 kw], H : G : [LiPB 327 V, 120 Ah] + Motor [3-phase AC 150 kw].
  • Page 7 KONA Electric Identification Motor Compartment The KONA Electric has a plastic power electric cover with “EV” clearly shown on it. Additionally, there are orange colored high- voltage electrical cables in the motor compartment. Vehicle Underside An orange colored cable covered by the under cover is also visible on the underside of the vehicle.
  • Page 8 KONA Electric Identification Charging Port The Charging Port is located on the front bumper covered by the charging port cap and it has one port for AC Slow, Fast and DC rapid. How to open the charging port 1. Depress the brake pedal and apply the parking brake.

  • Page 9: Kona Electric Identification

    KONA Electric Identification Electric Vehicle Cluster Instrument Panel The Electric Vehicle Instrument Cluster Panel displays the electric vehicle specific features that identify the KONA as a electric vehicle. : Regeneration brake : SOC(high voltage battery) /ECO/power gauge Indicator indicates the charge state of the high voltage battery.

  • Page 10: Kona Electric Main Systems

    KONA Electric Main Systems Key Specifications Item Electric 150kW 100kW Type Permanent Magnet Synchronous Motor Motor Max. Output (kW) Max Torque (Nm) Maximum torque (Nm) Reduction Gear Gear Ratio 7.981 EPCU Inverter Input Voltage(V) 245 ~ 421V Max. Output (kW)

  • Page 11: Vehicle Components Location

    KONA Electric Main Systems Vehicle Components Location EPCU On Board Charger (OBC) High-Voltage Cable Reduction Gear High-Voltage Battery Assembly Electric Drive Motor High-voltage It supplies electricity from battery to the inverter, LDC, air Junction box conditioner compressor, etc... On-Board Charger: Battery charging equipment (AC→DC)
  • Page 12 KONA Electric Main Systems Electrocution Risk! • 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.

  • Page 13: Vehicle Components

    KONA Electric Main Systems Vehicle Components 12V Auxiliary Battery The 12V auxiliary battery is located on the drivers side of the motor compartment, and powers all of the vehicle’s standard electronics like radio, air conditioner, etc. Also, it powers the EPCU...
  • Page 14 KONA Electric Main Systems Electrocution Risk! • 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.
  • Page 15 KONA Electric Main Systems Electric Power Control Unit (EPCU) The EPCU includes an Inverter, LDC (Low Power DC-DC Converter) and VCU in one housing. The inverter converts DC to AC to supply electricity to the motor. It also converts AC to DC to charge the high voltage battery.
  • Page 16 KONA Electric Main Systems Electrocution Risk! • 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.
  • Page 17 KONA Electric Main Systems High-Voltage Cabling The high-voltage cabling in the KONA Electric is orange per the SAE standard. These cables run from the rear of the vehicle where they connect to the HV battery up to the front of the vehicle where they connect to the Electric Drive Motor and other HV components.
  • Page 18 KONA Electric Main Systems Electrocution Risk! • 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.
  • Page 19 KONA Electric Main Systems High-Voltage Electrical Isolation Unlike the 12V electrical system that is grounded to the vehicle’s chassis, the KONA Electric’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 20: Airbag System (Srs : Supplemental Restraint System)

    Airbag system (SRS : Supplemental Restraint System) Airbag Seven airbags are installed in the KONA Electric as shown below. Before starting any emergency procedure, make sure the vehicle ignition is turned off, disconnect the negative cable from the 12V auxiliary battery to prevent accidental deployment of airbags.
  • Page 21 KONA Electric Main Systems Seat Belt Pretensioners The KONA Electric 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 22: Emergency Procedures

    Emergency Procedures Initial Response: The following procedures should be used whenever you are dealing with a KONA Electric at an emergency scene. All other operations should be consistent with your department’s standard operating procedures or guides. Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard.
  • Page 23 The next step is to immobilize the vehicle to prevent any accidental movement that can endanger the emergency response personnel and any crash victims. Since the KONA Electric doesn’t have an engine, there will be instances where the vehicle appears to be off because of the absence of engine noise.
  • Page 24 Emergency Procedures Disable The final 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. Ⅰ.
  • Page 25 Emergency Procedures 2. Before disconnecting the 12V battery, move the smart key at least 2 meters away from the vehicle to prevent accidental restart. 3. Disconnect the negative (-) 12V battery cable (A), Smart Key located in the motor compartment, to further prevent the risk of accidental restart.
  • Page 26 Emergency Procedures Ⅱ. Disabling the system – IG Relay Removal (Alternate Method) 1. Open the bonnet. 2. Remove the motor 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 27 Emergency Procedures 5. Use the following procedure to remove the Service Disconnect Plug and disable the high voltage battery: a) Remove the Service Disconnect Plug cover (A) located in the trunk. b) Remove the Service Disconnect Plug using the following procedure : ①: Unlock, Release →...
  • Page 28 Emergency Procedures 6. Use the following procedure – Cut the Service Interlock Connector and disable / isolate the high voltage battery system. If all three methods of disabling system are unsuccessful, the vehicle is not secured from accidental deployment of airbags and electric shock from high-voltage components. Electrocution Risk! •...

  • Page 29: Extraction Operations

    Emergency Procedures Extrication Operations The extrication operations for the KONA Electric 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 30 Emergency Procedures Extrication tools and procedure When responding to an incident involving an KONA Electric, 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 airbag system, orange colored high voltage cables and other high voltage components to avoid damage to parts which may increase the risks of explosion.

  • Page 31: Submersion

    Emergency Procedures Submersion Some emergency responses can involve a submerged vehicle. A KONA Electric that is submerged does not have high-voltage component 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 32: Vehicle Fire

    After Initial Emergency Response Procedures have been applied, Firefighting Procedures may begin. Hyundai recommends that each response team follow their own department’s standard operating procedures for fighting vehicle fires in combination with the KONA Electric specific details that are covered in this section.

  • Page 33: High-Voltage Battery Damage And Fluid Leaks

    Emergency Procedures High-Voltage Battery Damage and Fluid Leaks The HV Battery assembly is enclosed in a sturdy metal case that is rigidly mounted to structural components of the vehicle. This construction helps prevent damage to the HV Battery assembly even in severe crashes. This section provides emergency responders with information regarding how to mitigate the severity of a damaged HV Battery assembly or gel electrolyte spill, however unlikely that might be.

  • Page 34: Roadside Assistance

    Roadside Assistance Towing When towing KONA Electric vehicle, all wheels should be off the ground and not in contact with the road. If emergency towing is necessary, we recommend having it done by an authorized Hyundai dealer or a commercial tow-truck service. The use of wheel dollies or flatbed is recommended.

  • Page 35: To Jump Start The Car

    6. After a few minutes, turn off both of the vehicles. 7. Remove the negative terminal cable first, and then remove the positive terminal cable. If the cause of your battery discharging is not apparent, we recommend that the system be checked by an authorized HYUNDAI dealer.
  • Page 36 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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