Hyundai NEXO Manual

Introduction

Document Purpose

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. The emergency response procedures for this vehicle are somewhat similar to a conventional vehicle with additional information provided on dealing with the high-voltage electrical and hydrogen system.

Vehicle Description

Hydrogen electric vehicle is an electric vehicle that generates an electrical energy by a fuel cell system. While general vehicles use an internal combustion engine and gasoline as fuel, Hydrogen electric vehicles use electrical energy that is produced by the reaction of hydrogen and oxygen. As a result, Hydrogen electric vehicles are eco-friendly in that they do not emit exhaust gases.

When decelerating or driving downhill, regenerative braking is utilized to charge the high voltage battery. This minimizes energy loss and increases the distance to empty.

1. Powertrain (Stack)
2. High voltage battery
3. Hydrogen tank

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.

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. Fuel cell stack has a high protection degree of IPXXB.
2. Live parts and high voltage buses which are generating over DC 400V in the fuel cell stack are designed to maintain a reliable insulation resistance with an electro-conductive enclosure. When the insulation resistance is lower than the regulated value, it is alarmed to the user and limited the output current of fuel cell stack.

High voltage battery system

This system supplies the energy which can be applied vehicle's acceleration phase. The system also is being used to store the energy generated during regeneration braking phase.

1. High voltage system is located in trunk area and protected with a steel case.
2. The system consists of 64 cells. Each cell is sealed with an aluminum case to protect an electrolyte spillage. There is rare possibility to spill the electrolyte in the cell even if a battery module is cracked.
3. For safety, an over-current protection and ceramic coating isolation layer are used.
4. Non-flammable material electrolyte is applied to prevent explosions or fire in an emergency case such as a car accident.
5. High voltage cable(orange color) is connected to the battery system with DC converter.
6. There is a high voltage regulator to control the high voltage line. In addition, there are a high voltage fuse and safety plug to separate the electrical sources in the system for safety.

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. As Hydrogen is the lightest element and it rapidly rises and disperses in the atmosphere without mixing with the air, hydrogen is relatively safe as it does not easily reach the concentration for explosion.

Hydrogen Gas Features

A hydrogen gas leak should be prevented for hazard of ignition or detonation for a safety point of view.

The followings are properties of gaseous hydrogen.

• It has the lowest molecular weight, and is the smallest molecules of any elements.
• It has the lowest density and the highest buoyancy of any element.
• It can cause brittleness in some materials, including metals (but materials chosen for hydrogen applications are not susceptible to brittleness).
• It is colorless, odorless and tasteless.
• It burns invisibly and without smoke.
• It has the lowest ignition energy of any fuel (less than one-tenth that of other fuels).
• It has a wide flammability concentration range of 4% to 75%

Diffusion Velocity Ratio of Diffusion and Flow in the air

Gas	CH4	C3H8	H2
Diffusion	1.0	0.63	3.8
Turbulent Flow	1.0	0.6	2.83

Hydrogen Gas Leak Detection System

Hydrogen gas detection sensor detects a hydrogen leak. If there is a hydrogen leak, a hydrogen storage system and electrical systems will be shut down. Sensors illuminates a waring light at concentrations the minimum flammability limit of hydrogen.

Sensors are installed at the fuel cell stack, fuel supplying system, in-between hydrogen storage tank ceiling of vehicle. These sensors detects the hydrogen leak under emergency allowing the system to block the hydrogen.

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.

The followings are properties of gaseous hydrogen.

• It has the lowest molecular weight, and has the smallest molecules of any elements.
• It has the lowest density and the highest buoyancy of any element.
• It can cause brittleness in some materials, including metals (but materials chosen for hydrogen applications are not susceptible to brittleness).
• It burns invisibly and without smoke.
• It has the lowest ignition energy of any fuel (less than one-tenth that of other fuels).
• It has a wide flammability concentration range of 4% to 75%

• There must be no ignition sources around the vehicle. For example, exposed flame, sparks, electrostatic discharge or hot surfaces that could cause hydrogen gas to ignite.
• Caution labels for hydrogen are attached to the hydrogen storage system components. The hydrogen storage system is composed of two cylinders which are filled with Hydrogen gas. Each tank is made of aluminum and covered additionally with carbon fiber which makes the storage tank sustain high pressures. This cylinder contains flammable gas under high pressure. Serious injury or death can result from improper installation, lack of maintenance or overfilling. Do not attempt to remove this cylinder or any of its fittings from this vehicle. It may contain residual gases under pressure, which could cause fire or explosion.

[Safety precaution for High voltage system]

Warning labels for high voltage are attached to the high voltage components. The color of the high voltage cables and connectors are orange. Do not touch any of these high voltage components, cables, and connectors without proper Personal Protection Equipment (PPE).

NEXO Identification

General Vehicle Description

The Hyundai NEXO hydrogen electric vehicle is built on a chassis developed for hydrogen electric vehicle. The safest method is to assume that the NEXO you respond to is equipped the high voltage and hydrogen system because the NEXO is exclusive model for hydrogen electric vehicle. Using the information provided in this section, responders will be able to recognize the NEXO.

Identifying a Hyundai NEXO vehicle

'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.

Electrocution Risk!
Badging can become hidden after a crash due to damage to the vehicle. Always be sure to utilize additional methods if identification before determining there is no badge present.

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].

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. This cable runs from the rear of the vehicle to the fuel cell power module compartment.

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.

1. Regeneration brake/ECO/power gauge
   
2. Hydrogen fuel gauge indicates the approximate amount of fuel remaining in the fuel tank
   
3. The "Ready" Light indicates the vehicle is ready for driving.
   
4. Power Down Warning Light indicates that there may be a malfunction with the fuel cell stack. It comes on during driving the vehicle power should be limited due to a malfunction with fuel cell stack.
   

NEXO main systems

Key Specifications

Item		Value
Electric Driving Motor	Type	Permanent Magnet Synchronous Motor
	Max. Output (kW)	113
	Max. Torque (Nm)	395
Reduction Gear	Gear Ratio	7.981
Inverter	Input Voltage (V)	240~450V
BHDC	Input Voltage (V)	160~275.2V
	Output Voltage (V)	250~450V
LDC	Input Voltage (V)	250~450V
	Output Voltage (V)	12.8~13.9V
Hydrogen Fuel Tank	Capacity (ℓ)	156.6 (52.2 x 3)
Stack	Max. Output (kW)	95
	Output Voltage (V)	250~450V
High Voltage Battery	Type	Lithium-ion polymer
	Rated Voltage (V)	240
	Capacity (Ah) / Energy (kwh)	6.5 / 1.56
	Weight (kg)	51.2

Vehicle Components Location

Fuel Cell System	Creates electric energy through electrochemical reaction between the hydrogen and oxygen
Hydrogen Tank	Stores hydrogen fuel
LDC	Low Power DC-DC Converter: Charge 12V supplementary battery
Inverter	DC → AC (from battery or fuel cell stack to drive motor) AC → DC (charge using regenerative braking)
High Voltage Junction Box	It supplies electricity from battery to the inverter, LDC, air conditioner compressor, etc...
BHDC	Converts voltages among high-voltage battery, fuel cell stack and inverter
Electric Drive Motor	When current flows through the coil, it generates a rotating magnetic field and generates motor torque
Reduction Gear	Increases Motor Torque and increased Torque is transferred to the wheels
High-Voltage Battery Assembly	Supplies electric energy to drive motor and stores generated electric energy

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.

High-Voltage (HV) Battery

The Lithium-ion Polymer HV battery contains a gel electrolyte and is made up of 64 - 3.75V cells wired in series for a nominal voltage of 240V with 6.5 Ah of capacity. The battery is located in the trunk area.

Fuel Cell System

The fuel cell system is composed of

1. the fuel cell which generates electric energy through electrochemical reaction between the hydrogen and oxygen,
2. the oxygen supply system which supplies the hydrogen (fuel),
3. the heat control system which manages the heat and
4. the air supply system which supplies oxygen. The electricity generated by the fuel cell system drives the high-voltage battery and the electric motor and makes the vehicle move.

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. The inverter is equipped with a Motor Control Unit (MCU) to control the motor torque. When dealing with the high-voltage related items, stand by for about 5 to 10 minutes in order to discharge the high-voltage charged in the capacitor (condenser) located in the inverter.

Electric Drive Motor

Mounted in fuel cell power module compartment with the gear reduction unit, the Electric Drive Motor is used for vehicle propulsion. During deceleration or braking, it acts as an alternator and charges the HV battery by converting the vehicle's kinetic energy into electrical energy.

Gear Reduction Unit

The Gear Reduction Unit increases Motor Torque and transfers increased Torque to the wheels with Max. torque of 395Nm.

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.

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, connecters, or any electric components before disabling the system, to prevent injury or death due to electrical shock.

Failure to follow these instructions can lead to death by electrical shock.

Safety Plug

When dealing with high-voltage battery or components related to the high-voltage battery, make sure to remove the safety plug before start servicing. Even after the safety plug is removed, stand by for about 5 to 10 minutes in order to discharge the high-voltage charged in the capacitor (condenser) located in the inverter.

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, Pre-charge Resistor, and the Battery Current Sensor. The PRA is mounted front side of the High-Voltage Battery Pack Assembly and controls the high-voltage power circuit between the High-Voltage Battery and the Electric Power Control Unit.

High-Voltage Safety System

There are multiple safety systems incorporated into the NEXO. The system that protects the High-Voltage Electrical System is called the Battery Management System (BMS). The BMS is located inside the Power Relay Assembly and measures several parameters to maintain the optimal performance of the High-Voltage Battery. It controls the battery cooling fan to ensure proper battery operation. In addition, if a system fault occurs, the BMS turns off the PRA to protect the 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 the vehicle ignition is turned off, disconnect the negative cable from the 12V auxiliary battery to prevent accidental deployment of airbags.

* The actual air bags and seats in the vehicle may differ from the illustration

Number	Name	Location
1	Driver's front airbag	Driver side
2	Passenger's front airbag	Passenger side
3, 4	Side airbag	Driver / Passenger side
5, 6	Curtain airbag	Driver / Passenger side

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. These are normal operating conditions and are not hazardous. The seat belt pretensioner assembly mechanisms may become hot during activation, and may need several minutes to cool after they have been activated.

Sensors and Control Module

The airbags and pretensioners are managed by the SRS Control Module, or SRSCM, which is located below the front of the center console. In addition, there are four side impact sensors: two conventional accelerometer sensors in the B-pillars, and two pressure sensing sensors inside of the front door modules. Their locations are illustrated in the image below.

1. Steering Wheel
2. Clock Spring
3. Front Seat Belt Pretensioner (FBPT)
4. Side Impact Sensor (GSIS)
5. Front Impact Sensor (FIS)
6. Pressure Side Impact Sensor (PSIS)
7. Supplemental Restraint System Control Module (SRSCM)
8. Airbag Warning Lamp
9. Emergency Fastening Device (EFD)
10. Rear Seat Belt Pretensioner (RBPT)
11. Active Hood System

• Do not cut through any component.
• 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.

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. Exercise caution and wear appropriate personal protective equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings.

Identify

When dealing with a NEXO at the scene of an accident, emergency responders should always assume that it is a electric model until it can be proven otherwise using the identification features outlined in this ERG. External badging will usually be the first clue but it can often be hidden by damage caused in a crash. Always be sure to inspect multiple sides of the vehicle as well as using the clues found under the hood and in the interior of the vehicle.

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. When in its "ready" mode, the vehicle can move almost silently using the electric drive motor. Responders should approach the vehicle from the sides and stay away from the front or rear as they are both potential paths of travel. Instructions for immobilizing the vehicle are shown below.

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.

1. Disabling the system – Smart Key System and "POWER" START/STOP BUTTON
   
   1. Check the status of the READY light on the instrument panel. If the READY light is illuminated, the vehicle is on.
      1. If the READY light is NOT illuminated, the vehicle is off, Do not push the "POWER" START/STOP button because the vehicle may restart.
      2. To turn off the system, put the shift lever in the P (Park) position and press the POWER button beside a shift lever.

Without depressing the brake pedal

Pressing POWER button	Button Position	Vehicle condition
	OFF	Off
One time	ACC	Electrical accessories are operational.
Two times	ON	The warning lights can be checked before the vehicle is started.
Three times	OFF	Off

Depressing the brake pedal while a shift lever is in the P (Park) position

Pressing POWER button			Button Position	Vehicle condition
			OFF	Off
One time			-	Ready to drive

NOTICE
To turn off the vehicle while driving under emergency, press the start button for over 2 seconds or press the button three times within 3 seconds. Then, the vehicle will turn off and switch to 「ACC」 status. In this case, while driving, it is possible to turn on the vehicle again by placing the shift gear in N (Neural) without depressing the brake. Never turn off the vehicle while driving under the normal driving conditions.

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), located in the motor compartment, to further prevent the risk of accidental restart.
   
   NOTICE
   If necessary, lower the windows, unlock the doors and open the trunk as required, before disconnecting the 12V battery. Once the 12V battery is disconnected, power controls will not operate.

4. Use the following procedure to disable the high voltage battery.
   1. If the safety plug located in the trunk is accessible, remove the safety plug as shown below.
      
      1. Remove the safety plug cover (A) located in the trunk.
      2. Remove the safety plug using the following procedure:
         1. Unlock → 2: Release → 3: Remove
            
            
            Even after the safety plug is removed, stand by for about 5 to 10 minutes in order to discharge the high-voltage charged in the capacitor (condenser) located in the inverter.
   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.
      

2. 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. If the IG fuses cannot be located, pull out all the fuses and relays in the fuse box.
      
   4. Disconnect the negative (-) 12V battery cable (A), located in the motor compartment, to further prevent the risk of accidental restart.
      
      NOTICE
      If necessary, lower the windows, unlock the doors and open the trunk as required, before disconnecting the 12V battery. Once the 12V battery is disconnected, power controls will not operate.
   5. Use the following procedure to disable the high voltage battery.
      1. If the safety plug located in the trunk is accessible, remove the safety plug as shown below.
         1. Remove the safety plug cover (A) located in the trunk.
            
         2. Remove the safety plug using the following procedure:
            1. Unlock → 2: Release → 3: Remove
               
               
               Even after the safety plug is removed, stand by for about 5 to 10 minutes in order to discharge the high-voltage charged in the capacitor (condenser) located in the inverter.
      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.
         

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!

• 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.
• Exposed cables or wires may be visible inside or outside the vehicle. To prevent injury or death due to electrical shock, never touch the wires or cables 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.

Explosive Risk!

• Do not cut through any component.
• 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.

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" procedure section.

How to open a door manually

(When airbags are deployed, the outside door handles pop out automatically. However, the door handle might not pop out under certain conditions.)

1. Push the front side of the door handle.
   
2. Pull the rear side of the handle.
   
3. Pull the handle.
   

Vehicle Stabilization

Use standard stabilization (cribbing) points, as shown. Always be sure to connect to a structural member of the vehicle and avoid placing cribbing under high voltage cables, fuel lines and other areas not normally considered acceptable.

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.

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. Drain the water from the vehicle. Use one of the methods described in sections to disable the vehicle.

• If severe damage causes high-voltage components to become exposed, responders should take appropriate precautions and wear appropriate insulated personal protective equipment.
• Do not attempt to remove a safety plug while in the water

Failure to follow any of these instructions may result in serious injury or death by electrocution.

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.

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 electrolyte that can vent, ignite, and produce sparks when subjected to temperatures above 300°F.
• May burn rapidly with a flare-burning effect.
• Even after the high-voltage battery fire appears to have been extinguished, renewed or delayed fire can occur.
  • Use a thermal imaging camera to ensure the high voltage battery is completely cooled before leaving the incident.
  • Always advise second responders that there is a risk of the battery re-igniting.
  • Fire, submersion or a collision that has compromised the high voltage battery, always store it in an open area with no exposures within 50 feet.
• A burning battery could release hydrogen fluoride, carbon monoxide, and carbon dioxide gasses. Use NIOSH/MSHA approved full-face self-contained breathing apparatus (SCBA) with full protective gear.
• If the fire spreads until the hydrogen tanks which are installed to rear floor of NEXO, you should not extinguish a fire. And wait until the vehicle to be burned at the place where you can conceal yourself.

Even if the high-voltage battery pack is not directly involved in a vehicle fire, approach the vehicle very carefully.

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. Do not extinguish fire with a small amount of water. Firefighters should not hesitate to pour large amounts of water on the vehicle.

If the temperature near the safety valve located at the rear under vehicle is over 110°C caused by a fire or other reasons, the safety valve will open to vent hydrogen gas. Venting the hydrogen gas makes a loud noise because the venting speed is very fast. Stay well away from the vehicle. This jet stream of hydrogen gas could ignite.

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.

• Cease all smoke, spark, flame activity around the vehicle.
• Electrolyte solution is a skin irritant.
• Do not touch or step on the spilled electrolyte.
• If electrolyte leak occurs, wear appropriate solvent resistant PPE and use oil, sand, or a dry cloth to clean up the spilled electrolyte. Be sure to adequately ventilate the area.

Irritant Substance Risk!

• Internal components of HV Batteries are irritants and sensitizers.
• To avoid contact with these irritants and sensitizers wear positive pressure self- contained breathing apparatus (SCBA) and other personal protective equipment (PPE) designed for use with these types of hazards.

Failure to wear proper SCBA and PPE can result in serious injury or death.

• Electrolyte solution is an eye irritant – If contact with eyes, rinse with plenty of water for 15 minutes.
• Electrolyte solution is a skin irritant. Therefore, if there is contact with skin, wash off with soap.
• Electrolyte liquid or fumes that have come into contact with water vapors in the air will create an oxidized substance. This substance may irritate skin and eyes. In these cases, rinse with plenty of water and see a doctor immediately.
• Electrolyte fumes (when inhaled) can cause respiratory irritation and acute intoxication

Move to a well ventilated location for fresh air and wash mouth with water. See a doctor immediately.

Roadside Assistance

Towing

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. The best way to tow the vehicle is to lift the whole vehicle using the tow truck. However, to tow the vehicle using the two wheels, use the flatbed or wheel dollies and lift the front tires as the vehicle is equipped with the front wheel drive motor.

Before towing the vehicle, release the parking brake and turn the vehicle off. Then, press the 「P RELEASE」 button and place the shift lever in N (neutral). Detail guidelines for towing the vehicle are as follows:

• Do not tow the vehicle backwards with the front wheels on the ground as this may cause damage to the vehicle.
• Do not tow with sling-type equipment. Use wheel lift or flatbed equipment.
• Never tow the vehicle with the front wheels on the ground (forward or backward), as this may cause damage to the vehicle.
• If the vehicle is equipped with the side air bag, make sure to turn the vehicle off. If the vehicle inclines while the vehicle is turned on, the system may detect it as a roll over and may deploy the side air bags.

To Jump Start the Car

1. Make sure the booster battery is 12-volt.
2. If the booster battery is in another vehicle, do not allow the vehicles to touch.
3. Turn off all unnecessary electrical loads.
4. First, separate the fuse box located on the left side of the fuel cell power module room. Then, connect one jumper cable to the positive (+) battery terminal of the discharged battery (1) and connect the other end to the positive (+) battery terminal for the jump start (2).
   

Connect the second jumper cable to the negative (-) battery terminal for the jump start (3) and connect the other end to an unpainted robust fixed metal (i.e., hood latch striker), away from the battery.

• Do not connect the cables to or near any part that moves when the vehicle is started.
• Do not allow the jumper cables to contact anything except the correct battery terminals or the correct ground.
• Do not lean over the battery when making connections.

5. To connect to a battery of an assisting vehicle, start the engine of the assisting vehicle and let it run for a few minutes.
6. Press the 「12V BATT RESET」 button.
   
7. Turn on the discharged vehicle within about 15 seconds. Remove the jumper cable after turning on the vehicle.
8. Disconnect the negative (-) cable terminal first, and then the positive (+) cable terminal.
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.

Documents / Resources

Download manual

Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

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