Hyundai NEXO 2018 Emergency Response Manual
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Hyundai NEXO 2018 Emergency Response Manual

Hyundai NEXO 2018 Emergency Response Manual

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NEXO
Emergency Response Guide
N E W T H I N K I N G .
N E W P O S S I B I L I T I E S .

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Summary of Contents for Hyundai NEXO 2018

  • Page 1 NEXO Emergency Response Guide N E W T H I N K I N G . N E W P O S S I B I L I T I E S .

  • Page 2: Table Of Contents

    - Safety Issues of Compressed Hydrogen···························································· - Safety Precaution for Hydrogen Electric ·························································· NEXO Identification ··················································································· - General Vehicle Description ··········································································· - Identifying a Hyundai Hydrogen Electric vehicle ················································ NEXO main systems ··················································································· - Key Specifications ························································································ - Vehicle Components Location ·········································································...

  • Page 3: 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 4: High Voltage Safety System

    High Voltage Safety System Fuel Cell Stack Hydrogen electric vehicle, unlike the regular internal combustion engine vehicle, use an high voltage electrical energy generated in the fuel cell stack as a power source. Owing to this high voltage electricity, it requires to handle with a care for the high voltage hazard. The followings are safety guideline of high voltage in fuel cell stack of ix35.

  • Page 5: Safety Issues Of Compressed Hydrogen

    Safety Issues of Compressed Hydrogen General Features of Hydrogen Hydrogen is gas with the smallest molecular weight of all the gas. As it is colorless, odorless, tasteless, and noncorrosive with combustibility and fast diffusivity, it has to be dealt with caution. However, hydrogen is not dangerous in any other way and could even be less dangerous than other fuels in some aspects.

  • Page 6: Safety Precaution For Hydrogen Electric

    Safety Precaution for Hydrogen Electric Vehicle NEXO uses approximately DC 250 ~ 450 voltage and high pressure hydrogen gas. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution. [Safety precaution for Hydrogen system] NOTICE A hydrogen gas leak should be prevented for hazard of ignition or detonation for a safety point of view.

  • Page 7: Nexo Identification

    ‘NEXO’ on Trunk and Blue Drive badge on side of Vehicle The Hyundai NEXO can be easily identified by the ‘NEXO’ and the ‘Fuel Cell’ badge located on the trunk lid and the ‘BLUE-DRIVE’ badge on the left side of the vehicle.
  • Page 8 NEXO Identification VIN number The Vehicle Identification Number (VIN) identifies the Electric Vehicle with a “6” displayed in the 8th position, as shown in the below drawing. The VIN is punched on the floor under the passenger seat. The letter 6 in the 8th character of the VIN indicates that it is an electric vehicle with battery [LiPB 240 V, 6.5 Ah] + Motor [3-phase AC 113 kw].
  • Page 9 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 An orange colored cable covered by the under cover is also visible on the underside of the vehicle.
  • Page 10 NEXO Identification Hydrogen Electric Vehicle Cluster Instrument Panel The Hydrogen Electric Vehicle Instrument Cluster Panel displays the Hydrogen electric vehicle specific features that identify the NEXO as a Hydrogen electric vehicle. : Hydrogen fuel gauge indicates the : Regeneration brake/ECO/power gauge approximate amount of fuel remaining in the fuel tank : Power Down Warning Light indicates that...

  • Page 11: Nexo Main Systems

    NEXO main systems Key Specifications Item Value Type Permanent Magnet Synchronous Motor Electric Driving Max. Output (kW) 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 Input Voltage (V) 250~450V Output Voltage (V)

  • Page 12: 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 electrochemical reaction Fuel Cell System between the hydrogen and oxygen Hydrogen Tank Stores hydrogen fuel...

  • Page 13: Vehicle Components

    NEXO main systems Vehicle Components 12V Auxiliary Battery The 12V Lithium-ion Polymer auxiliary battery is located at the front of the high-voltage battery in the trunk. This battery supplies power to all the standard electric devices such as audio, instrument cluster, etc. Also, the battery supplies power to the control unit which controls the flow of the high-voltage current and supply of hydrogen.
  • Page 14 NEXO main systems Motor Control Unit The inverter coverts the direct current of the high-voltage battery to the alternative current and supplies the current to the driving motor and converts the alternative current of the regenerative current to the direct current to charge the high-voltage battery.
  • Page 15 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 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 16 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 controlled by the Power Relay Assembly (PRA), which consists of Positive and Negative Main Relays, a Pre-charge Relay,...

  • Page 17: Airbag System (Srs : Supplemental Restraint System)

    NEXO main systems Airbag system (SRS : Supplemental Restraint System) Airbag Six airbags are installed in the NEXO 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 18 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 19: 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 20 Emergency procedures Immobilize 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 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 21 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.
  • Page 22 Emergency procedures 2. Before disconnecting the 12V battery, move the smart key at least 2 meters away from the vehicle to prevent accidental restart. Smart Key 3. Disconnect the negative (-) 12V battery cable (A), located in the motor compartment, to further prevent the risk of accidental restart.
  • Page 23 Emergency procedures 4-2 . For emergency situations where the safety plug can not be removed, Cut the high-voltage disable cable, which is accessible from either the trunk or the fuel cell power module compartment.
  • 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 procedure to disable the high voltage battery. 5-1 . If the safety plug located in the trunk is accessible, remove the safety plug as shown below. a) Remove the safety plug cover (A) located in the trunk.
  • Page 26 Emergency procedures If both 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! WARNING • Before engaging in emergency response procedures, ensure the vehicle is disabled and wait for more than 5 minutes to allow the capacitor in the high voltage system to discharge to avoid electrocution.

  • Page 27: 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 28 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 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 29: Submersion

    Emergency procedures Submersion Some emergency responses can involve a submerged vehicle. A NEXO 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. In the event the vehicle is submerged or partially submerged, remove the vehicle from the water before attempting to disable the vehicle.

  • Page 30: Vehicle Fire

    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 NEXO specific details that are covered in this section.
  • Page 31 Emergency procedures Extinguishers • Small fires that high voltage battery is not involved : Extinguish fires using a ABC extinguisher for an electric fire. • Fires that the high voltage battery is involved or the high voltage battery is heating : Extinguish fires using large and sustained amount of water to cool the high voltage battery.

  • Page 32: 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 33: Roadside Assistance

    Towing the Nexo is not very different from towing the existing vehicles with the 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 34: To Jump Start The Car

    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 35 Ⓒ 2018 Hyundai Motor Company All rights reserved. This document may not be altered without the written permission of Hyundai Motor Company.

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