Summary of Contents for Faun ENGINIUS BLUEPOWER BP27E
- Page 1 11. JUNI 2024 ENGINIUS BLUEPOWER® GEN 1.0 03.2022 ESCUE UIDE FROM TECHNICAL EDITORIAL OFFICE ENGINIUS GMBH WALTER-GEERDES-STRASSE 22, D-28307 BREMEN...
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Page 2: Enginius Gmbh - About This Document
ENGINIUS GMBH – About this document This Emergency Rescue Guide is part of the existing safety concept and contains supplementary information on the vehicle-specific rescue card and applies to the following vehicle types: BP27E BP19E Target group: Emergency services and first aiders. The current edition is based on the requirements of ISO 17840-3 and ISO 7000 in terms of structure, colours and pictograms. -
Page 3: Impressum
Impressum ENGINIUS GmbH Walther-Geerdes-Straße 22 28307 Bremen Deutschland Redaktion: ENGINIUS Tec GmbH Wetzlarer Straße 64 14482 Potsdam Deutschland All rights reserved: No part of this rescue guide may be reproduced in any form (print, photocopy, microfilm or any other process) or processed using electronic systems without the written permission of ENGINIUS GmbH. ©... -
Page 4: Validity
Validity From publication, until cancelled or replaced BluePower® series vehicles with production site ENGINIUS (Bremen) Recognisable by number 11 in the VIN: WK7 XXXXXXX B XXXXXX Retention and completeness This Emergency Rescue Guide is a fully-fledged component of the BluePower® safety concept and must be accessible to authorised and authorised persons at all times. -
Page 5: Table Of Contents
Contents ENGINIUS GMBH – ABOUT THIS DOCUMENT ..................2 ..............................3 MPRESSUM ..............................4 ALIDITY ........................4 ETENTION AND COMPLETENESS ..........................4 COPE OF APPLICATION ..........................4 PPLICABLE DOCUMENTS IDENTIFICATION / RECOGNITION......................7 .....................7 REAKDOWN OF VEHICLE IDENTIFICATION NUMBER ............................8 YPE DESIGNATION IMMOBILISATION / STABILISATION / LIFTING ..................10 ............................11 ECURE THE CAB ..........................13... - Page 6 A ..............................39 IRE CLASS B...............................39 IRE CLASS C...............................39 IRE CLASS D ..............................39 IRE CLASS ..........................40 OLTAGE ATTERY ..........................41 XTINGUISHING MEDIA ......................41 ECOMMENDATION FOR FIREFIGHTING IN CASE OF SUBMERSION ........................42 ..........................42 NVIRONMENTAL HAZARD ...................42 ECOMMENDATION FOR RECOVERING FROM THE WATER TOWING / TRANSPORTATION / STORAGE...................43 .........44 ECOMMENDATION FOR TOWING A VEHICLE WITH A HIGH VOLTAGE ELECTRICAL SYSTEM...
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Page 7: Identification / Recognition
Identification / Recognition ENGINIUS GmbH, a subsidiary of Kirchhoff Ecotec AG, produces fuel cell electric vehicles (FCEV) at its site in Bremen. A "Glider" from Daimler Truck AG is used as the basic vehicle. Gliders are vehicles that are produced without a drivetrain (engine, transmission and exhaust system). ENGINIUS GmbH is a selected original equipment manufacturer and completes the Glider into a high-voltage vehicle with fuel cell technology. -
Page 8: Type Designation
Type designation BP27E BluePower® Technically permissible total mass (x 1000) in kg Electric drive BP19E BluePower® Technically permissible total mass (x 1000) in kg Electric drive Rescue Guide from 03.2022 0.07 8 / 49... - Page 9 LI ION Kirchhoff LOGO ENGINIUS Lettering Model designation CCS Typ 2 Charging interface Power display in instrument cluster Piktogram Hydrogen-based vehicle According to Fuel cell electric vehicle ISO 17840-4 Depending on country-specific legislation, the licence plate number may indicate the drive type. High-voltage components are labelled with a warning sticker and high-voltage cables have orange insulation.
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Page 10: Immobilisation / Stabilisation / Lifting
Immobilisation / stabilisation / lifting Modern vehicles have components and systems installed that can be active even when the drive system is switched off. The ignition delay of the Glider, from the Daimler Benz AG brand, is up to 30 minutes. Depending on the accident situation, the vehicle status cannot be determined. -
Page 11: Secure The Cab
Secure the cab To secure the cab against unnecessary movement, a suitable lashing strap can be used and lashed to the ladder frame as an attachment point. This measure prevents unnecessary movement and slipping of the cab if the cab bearings are damaged. The lashing straps must be fastened in such a way that no subsequent rescue operation is impeded. - Page 12 Cab / front wheels Fasten the tensioning strap with ratchet including eye hook to the rim. On the other side of the vehicle, attach the tensioning strap to the rim with eye hooks. Throw the tensioning strap over the cab. Thread the tensioning strap into the ratchet.
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Page 13: Stabilisation And Lifting
Stabilisation and lifting Jacking points (6x2/4) A = At the paddock mouth D = On the drive axle B = At the front end of the vehicle frame E = In the area of the trailing axle (only with plate) C = On the front axle If possible, the jacking points provided should be used to stabilise and lift the vehicle. -
Page 14: Disable Direct Hazards / Safety Regulations
Disable direct hazards / safety regulations No crash sensors are installed in the BluePower® vehicles of generation 1.0. The high-voltage system cannot be switched off by means of pyrotechnic devices. This means that various systems cannot be switched off. Before starting rescue operations, it is essential to ensure that the vehicle is switched off. -
Page 15: 24 Vdc De-Energise The Vehicle Electrical System
24 VDC De-energise the vehicle electrical system LI ION Low-voltage battery pictogram The batteries are located on the right-hand side of the vehicle behind the cab in the Electrical Equipment Box (EEB). Reach over the side panelling on the left and right and open the latches Pull off the cover of the electrical equipment box First disconnect the negative terminal... -
Page 16: De-Energise High-Voltage System
De-energise high-voltage system LI ION High-voltage cut-off device: The high-voltage cut-off devices are located on both sides behind the mainframe on the mudguard, on the driver's and passenger's side and are labelled. To ensure that there is no residual voltage in the high-voltage system, wait 10 minutes after switching off. -
Page 17: Switch Off The Hydrogen System
Switch off the hydrogen system Extremely flammable gas Contains pressurised gas; may explode when heated Flammable Manual gas shut-off valve Automatic hydrogen overpressure safety valve Rescue Guide from 03.2022 0.07 17 / 49... - Page 18 Electrical shut-off valve Controlled via software. NC - normally closed. Valve only open when voltage is applied. Only open when fuel cell is switched on. Closed during refuelling. Flow through bypass line with non-return valve. Manual shut-off valve Closing is achieved by actuating in a clockwise direction. 24 Nm -1/+0 Nm A standard Allen key 7 is required.
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Page 19: Access Tot He Occupants
Access tot he occupants Access via the roof hatch Another alternative for accessing the cab is via the roof hatch. As this can be electrically operated, only a hatch that is already open should be used. For vehicles in a sideways position, it may make sense to use a roof hatch as a first access point even when it is closed. -
Page 20: Emergency Opening Folding Door From The Inside
Emergency opening folding door from the inside The folding door can be unlocked using the emergency opening rotary switch Vehicles with locking cylinder: Unlock the door lock on the outside of the folding door. Open: Turn emergency opening rotary switch by 90°. - Page 21 Reduce rescue height with frame air suspension Test ports Control unit LI ION Compressed air tank Air bellows In vehicles with full air suspension, the chassis is equipped with air suspension. By far the most common variant is to equip only the rear axle suspension with air suspension. On a vehicle with full air suspension, the rescue height can be reduced by lowering the air suspension.
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Page 22: Shell Construction
Shell construction Daimler Truck AG – Econic, Typ 956 © Daimler Truck Ag / Auszug W60.80-A020-79 The type and percentage of the respective materials differ for the individual Daimler Truck AG model series. The aim of the design is to achieve high operational stability and optimised crash behaviour. DANGER Risk of injury: Warning of sharp-edged interfaces after cutting or severing vehicle parts... -
Page 23: Glass Management
Glass management ATTENTION Risk of injury: Warning due to glass splinters when removing vehicle windows. Cover vehicle occupants. Use personal protective equipment including dust masks. Removal of vehicle windows It is essential to remove panes from adjacent components that are being worked on before using hydraulic tools. - Page 24 First, a hole is made in the disc (outside the danger zone for the patient). Then, starting from this hole, the windscreen is torn open all the way round. The windscreen cut in this way can then be removed. Large tin snips are another alternative.
- Page 25 Removing discs with the spring centre punch Panes of toughened safety glass (ESG), usually side windows and rear windows, can be removed with the spring centre punch. The pane to be removed is covered with a self-adhesive film or adhesive tape. The glass pane is then scored in one corner with the spring centre punch.
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Page 26: Vehicle Control
Vehicle control Steering column adjustment, pneumatic Seat height adjustment, pneumatic Seat length adjustment, mechanical Steering column adjustment Pneumatic fuse switch (on the steering column) By adjusting the steering column, the vehicle occupant's abdomen and chest can be relieved. The basic requirement is a sufficient supply of compressed air. - Page 27 Seat adjustment To adjust the seat length, lift the locking bar move the seat using the buttock muscles. The ignition must be switched on and a sufficient supply of compressed air must be available to adjust the seat height of the air-sprung suspension seat. The seat can be raised or lowered continuously by pressing the seat height button.
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Page 28: Stored Energy / Liquids / Gases / Solids
Stored energy / liquids / gases / solids Corrosion antifreeze Corrosion antifreeze deionised; fuel cell cooling circuit Windscreen washer concentrate Axle oil Air conditioning refrigerant Steering oil Energy source: Hydrogen Compressor oil High-voltage battery Mounting position LI ION Rescue Guide from 03.2022 0.07 28 / 49... -
Page 29: Cooling System
Cooling system Corrosion antifreeze Cooling module fuel cell 3* Cooling module fuel cell 2* Cooling module fuel cell 1 Cooling module cooling system Main cooling circuit FC2* FC3* Water-glycol mixture 50/50 38,5 20 L 20 L 20 L *Option - depending on the vehicle configuration Rescue Guide from 03.2022 0.07 29 / 49... -
Page 30: Fuel Cell Cooling System
Fuel cell cooling system Corrosion antifreeze deionised; fuel cell cooling circuit Each fuel cell has a separate cooling circuit. The heat is transferred from the deionised cooling water to the cooling water filled at the factory via a heat exchanger. FC3* FC2* LI ION... -
Page 31: Windscreen Washer Concentrate
Windscreen washer concentrate The wiper fluid tank for the windscreen washer concentrate has a capacity of approx. 16 litres. Due to the wide range of over-the-counter products available from wholesalers and retailers, it is not possible to carry out a hazard analysis of the ingredients. Basically the following applies: Inhalation: Supply the affected person with fresh air and consult a doctor depending on the symptoms. -
Page 32: Refrigerant
Refrigerant LI ION Refrigerant R134a Filling quantity 750 g Compressor oil quantity 90 ml Compressor oil type POE-ÖL RL68H Inhalation: Supply affected person with fresh air and, depending on symptoms, consult a doctor. In case of respiratory arrest, initiate resuscitation. Skin contact: In case of cold burns, rinse with water for at least 15 minutes. -
Page 33: Steering Oil
Steering oil LI ION The factory-filled steering oil corresponds to an "ATF oil". Filling quantity front axle: 2.0 litres Filling quantity trailing axle: 9.0 litres The following always applies: Inhalation: Supply the affected person with fresh air and consult a doctor depending on the symptoms. -
Page 34: Hydrogen
Hydrogen LI ION The hydrogen tank system is refuelled with a pressure of 70 MPa. Refuelling at filling stations with a system pressure of 35 MPa is only permitted with the written approval of ENGINIUS GmbH. Total Total 412 L 309 L 206 L 103 L... -
Page 35: Compressor Oil
Compressor oil LI ION The factory-filled compressor oil complies with the ISO 46 standard. Filling quantity: 1.2 litres The following always applies: Inhalation: Supply the affected person with fresh air and consult a doctor depending on the symptoms. Skin contact: Product is not irritating to the skin Eye contact: Remove contact lenses. -
Page 36: High-Voltage Battery
High-voltage battery DANGER Danger de mort : mise en garde contre les hautes tensions Do not touch damaged or defective live components and cables or uninsulated electrical connections and cables. Use personal protective equipment High-voltage batteries with lithium-ion (NCM) battery cells are used in the ENGINIUS BluePower® vehicle. The voltage range in the driving cycle is between 474 VDC - 662 VDC. - Page 37 Basically the following applies: Use conventional binding agent Wear personal protective equipment Inhalation: Supply affected person with fresh air and consult a doctor depending on symptoms. Skin contact: Rinse skin with water and brush off loose particles from skin. Immediate medical treatment necessary, as untreated burns lead to wounds that are difficult to heal.
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Page 38: High-Voltage Cables
High-voltage cables DANGER Danger to life: Warning of high voltages Do not touch damaged or defective live components and cables or uninsulated electrical connections and cables. Use personal protective equipment High-voltage cables have orange insulation and are the connecting elements between the high-voltage components and the high-voltage battery. -
Page 39: In Case Of Fire
In case of fire When motor vehicles catch fire, harmful fumes can be produced due to the different burning materials and fuels. In general, caution is required in the event of fires, as plastics, composite materials and liquids can generate toxic vapours at high temperatures and plastics can drip at certain temperatures, which is not unusual in vehicle fires. -
Page 40: High Voltage Battery
High Voltage Battery GEFAHR Danger to life: Warning of high voltages Do not touch damaged or defective live components and cables or uninsulated electrical connections and cables. Use personal protective equipment Extinguish a vehicle fire in which the high-voltage battery is not affected using typical fire-fighting measures for a vehicle fire in accordance with fire brigade guidelines. -
Page 41: Extinguishing Media
Escaping gases can usually also be detected by a pungent, acrid odour. Extinguishing media In the event of a fire in a hydrogen/electric vehicle, it is possible that the high-voltage battery may also ignite, e.g. due to prolonged thermal exposure. In principle, water is also the most suitable extinguishing agent in this case. -
Page 42: In Case Of Submersion
In case of submersion In principle, there is no difference between conventional vehicles and vehicles with a high-voltage electrical system when recovering vehicles partially or fully submerged in water. In principle, there is no increased risk of electric shock from the high-voltage electrical system surrounded by water. Rescue the vehicle partially or completely submerged in water in accordance with the fire brigade's guidelines. -
Page 43: Towing / Transportation / Storage
Towing / transportation / storage Towing the BluePower® vehicle by axle is only permitted with the drive shaft removed. When recovering a vehicle from the danger zone, the vehicle with electric drive may only be moved at walking speed. The coupling jaw is located behind the licence plate holder. -
Page 44: Recommendation For Towing A Vehicle With A High-Voltage Electrical System
Recommendation for towing a vehicle with a high-voltage electrical system Once it has been ensured that there is no further danger, the vehicle can be made accessible to the following emergency services (e.g. police, tow truck). The high-voltage battery must be completely cooled down before the vehicle is made accessible to the following emergency services or the scene of the incident is left. -
Page 45: Warehousing
Warehousing Various measures must be carried out in order to park an accident vehicle safely. If the vehicle is taken to a workshop, the responsible specialist personnel must be informed of the measures already carried out (e.g. high-voltage cut-off device has been activated). Recommendation for storing a vehicle with a high-voltage electrical system For fire safety reasons, vehicles with a high-voltage electrical system that have been involved in an accident must be parked in a cordoned-off area in an outdoor parking area... -
Page 46: Important Additional Information
Important additional information Triangular spanner A triangular socket spanner (h=6.5 mm) is required to open the charging interface and hydrogen refuelling interface Safety belt The BluePower® vehicle is fitted with seat belts without pyrotechnic restraint systems. High-voltage battery charging stop There is a button under the outer passenger seat to interrupt the charging of the high-voltage batteries. -
Page 47: Electrical Equipment Box
Electrical Equipment Box The On Board Charger* (OBC) is located underneath the battery VDC). *Option - depending on the vehicle configuration High-voltage power distribution unit (HV-PDU) The high-voltage distribution unit is the central interface of the high- voltage system, where all cables are brought together. The high-voltage distribution unit contains electrical switching and switching devices. -
Page 48: Explanation Of Pictograms Used
Explanation of pictograms used Use eye protection Observe instructions ISO 7010-M004 ISO 7010-M002 Use hand protection Use foot protection ISO 7010-M009 ISO 7010-M008 Use breathing protection Utiliser des vêtements de protection ISO 7010-M017 ISO 7010-M010 General warning Warning of electrical voltage ISO 7010-W001 ISO 7010-W010 Warning of hot surface... - Page 49 Air conditioning: Refrigerant Compressor oil Compressed air system ISO 7000-0027 ISO 7000-0138 Cooling system Fuel cell cooling system ISO 7000-0246 ISO 7000-0246 Battery charging Windscreen washer fluid ISO 7000-0247 ISO 7000-1422 Seat adjustment Battery charging stop ISO 7000-1428 ISO 7000-2063 Steering column adjustment Steering oil ISO 7000-2064...
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