Hyundai IONIQ 5 User manual

Emergency Response Guide
IONIQ 5

Introduction ······································································································
IONIQ 5 Identification································································································
- General Vehicle Description ···········································································
- Identifying a Hyundai electric vehicle································································
IONIQ 5 main systems···························································································
- Vehicle Components ·····················································································
- Airbag system (SRS : Supplemental Restraint System) ········································
Emergency procedures ·························································································
- Initial response: Identify, Immobilize and Disable ···············································
- Extraction Operations ···················································································
- Submersion ·································································································
- Vehicle Fire ·································································································
- High-Voltage Battery Damage and Fluid Leaks ··················································
Roadside Assistance ··························································································
- Towing ·······································································································
- Jump Starting ······························································································
Contents
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1

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 IONIQ 5 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 system.
Vehicle Description
An electric vehicle is driven using a battery and an electric motor. While general vehicles use an
internal combustion engine and gasoline as fuel, electric vehicles use electrical energy that is
charged inside the high voltage battery. As a result, electric vehicles are eco-friendly in that they
do not require fuel and 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 range of the vehicle.
When the battery charge is not sufficient, normal charge, quick charge and trickle charge are
available.
Introduction 1

IONIQ 5 Identification 2
General Vehicle Description
The Hyundai IONIQ 5 is very similar to the existing five-door hatchback, but there are some
notable exceptions. Using the information provided in this section, responders will be able to
differentiate between the two.
Charging Port
The Charging Port is located on the side outer panel covered by the charging port cap and it has
one port for AC normal, fast and trickle charging.
How to open the charging port
1. Depress the brake pedal and apply the
parking brake.
2. Turn OFF all switches, shift to P (Park), and
turn OFF the vehicle.
3. Push the charging door where the icon is
located to open. The charge door opens only
when the door is unlocked until 2 minutes
after turn OFF.
4. Remove the charging inlet cover ①.
Identifying a Hyundai electric vehicle
Vehicle Underside
An orange-colored cable covered by the under cover is
also visible on the underside of the vehicle.
Open the Charging port in Emergency
1. Put your finger between the charge door and
the vehicle body.
2. Lift the charge door Panel
※ Please use only during discharge and failure

IONIQ 5 Identification 3
Electric Vehicle Cluster Instrument Panel
The Electric Vehicle Instrument Cluster Panel displays the electric vehicle specific features that
identify as an electric vehicle.
: Regeneration brake
/charge/power gauge
: SOC(high voltage battery)
Indicator indicates the charge
state of the high voltage
battery.
: The “Ready” Light indicates
the vehicle is ready for driving.
1 2
3
1
2
3

1
3
2
4
5
4
2
IONIQ 5 main systems 4
1 High voltage battery
Supplies electric energy to traction motor and
stores generated electric energy.
2High-voltage
Junction box (FRT, RR)
It supplies electricity from battery to the inverter,
LDC, air conditioner compressor, etc...
3ICCU
(OBC + LDC)
Integrated
Charging Control Unit (OBC + LDC)
OBC (On
-Board Charger)
: Battery charging equipment (AC→DC)
LDC (Low Voltage DC
-DC Converter)
: Charge 12V auxiliary battery
4Drive
System
Motor
When current flows through the coil,
it generates a
rotating magnetic field and generates motor torque.
EV
Transmission
Increases Motor Torque and increased Torque is
transferred to the wheels.
Inverter
DC
→ AC (from battery to traction motor)
AC
→ DC (charge using regenerative braking)
5 High-Voltage Cable
The high
-voltage cabling is orange per the SAE
standard.
Vehicle Components Location

IONIQ 5 main systems 5
High-Voltage Electrical Isolation
Unlike the 12V electrical system that is grounded to the vehicle’s chassis, the IONIQ 5’s high-
voltage electrical system is designed to be isolated from the vehicle.
Regulation of High-Voltage Electrical Current
The Power Relay Assembly (PRA) is mounted
rear 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 IONIQ 5. The system
that protects the High-Voltage Electrical
System is called the Battery Management
Unit (BMU). The BMU is located beside the
Power Relay Assembly and measures several
parameters to maintain the optimal
performance of the High-Voltage Battery. In
addition, if a system fault occurs, the BMU
turns off the PRA to protect the system.
PRA
BMU
•Never cut or disconnect the high voltage orange cabling and connectors without first disabling
the system by removing the High voltage cut-off Switch.
•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.
Electrocution Risk!

IONIQ 5 main systems 6
Airbag system (SRS : Supplemental Restraint System)
1. Driver’s front airbag
2. Passenger’s front airbag
3. Seat Belt Pretensioner (BPT)
4. Side Airbag (Driver, Passenger, Center)
5. Curtain Airbag (Driver, Passenger side)
6. Supplemental Restraint System Control Module
(SRSCM)
•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 IONIQ 5 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. 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 IONIQ 5 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. 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.
7

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 IONIQ 5 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
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.
Engage Parking Brake
* The actual image of vehicle may differ from the illustration
Press park (P)
position
8
Chock the Wheels

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.
Disabling the system –Smart Key System and EV START/STOP BUTTON
9
1. Check the status of the READY light on
the instrument panel. If the READY light is
illuminated, the vehicle is on.
a) If the READY light is NOT illuminated,
the vehicle is off, Do not push the
EV START/STOP button because
the vehicle may restart.
b) To turn off the system, put the shift
lever in the P (Park) position and press
the EV button beside the shift lever. EV START/STOP Button
Pressing
EV Start/Stop
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
EV Start/Stop
button
Button Position Vehicle condition
OFF Off
One time - Ready to drive
Without depressing the brake pedal

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
located in the PE room, to further prevent the risk
of accidental restart.
10
Smart Key
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.
NOTICE
4. Use the following procedure to isolate the high voltage of the battery.
4-1 . Remove the High voltage cut-off Switch located in the low voltage junction block.
a) Remove the Junction block upper cover
ⓐin the PE room a

b) Disconnect the High voltage cut-off Switch
using the following procedure :
①: Pull the label → ② : Disconnect
Emergency procedures 11
High voltage cut-off Switch
•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.
Electrocution 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.
Explosive Risk!
If this method of disabling system is unsuccessful, the vehicle is not secured from accidental
deployment of airbags and electric shock from high-voltage components.

Emergency procedures 12
Extrication Operations
The extrication operations for the IONIQ 5 is 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 in page 9 to 11.
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.
* The actual image of vehicle may differ from the illustration

Emergency procedures 13
Airbag High Voltage battery and Cables
Pre-tensioner Ultra High Strength Steel
(hot stamped steel)
Extrication procedure
When responding to an incident involving the IONIQ 5, 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 as below image to avoid
damage to parts which may increase the risks of explosion.
Yellow marked zone is Hot stamped steel. So this zone can not be cut with general tools.

•If severe damage causes high-voltage components to become exposed, responders should take
appropriate precautions and wear appropriate insulated personal protective equipment.
Failure to follow any of these instructions may result in serious injury or death by electrocution.
Submersion
Some emergency responses can involve a submerged vehicle. A IONIQ 5 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 of page 9 to 12 to disable the vehicle.
Emergency procedures 14

Emergency procedures 15
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 IONIQ 5 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
IONIQ 5, 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.
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.

Emergency procedures 16
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.
•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.
High-Voltage Battery Damage and Fluid Leaks
•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
Irritant Substance Risk!

•Do not lift vehicle by the tow fitting or
body and chassis parts. Otherwise the
vehicle may be damaged.
•Do not tow the vehicle with the rear 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.
Roadside Assistance 17
If any the loaded wheels or suspension components are damaged or the vehicle is being towed
with the rear wheels on the ground, use a towing dolly under the rear wheels.
When being towed by a commercial tow truck and wheel dollies are not used, the rear of the
vehicle should always be lifted, not the front.
Towing
If emergency towing is necessary, we
recommend having it done by an authorized
retailer or a commercial tow-truck service.
Proper lifting and towing procedures are
necessary to prevent damage to the vehicle.
The use of wheel dollies or flatbed is
recommended.
For 2WD vehicles, it is acceptable to tow the
vehicle with the front wheels on the ground
(without dollies) and the rear wheels off the
ground.
Towing procedures is continued on following page.

Roadside Assistance 18
•Don’t open the driver door while the vehicle stays in N after turned off. (The shift position will
be automatically changed to P (Park) position)
•Failure to shift to N (Neutral) may cause internal damage to the vehicle.
1. While depressing the brake pedal shift to the N (Neutral) position using gear shifter.
2. Stop depressing the brake pedal and press and hold OK button on the steering wheel when
you see the following pop-up message on the cluster.
3. Turn the vehicle off. The EV START/STOP button will be in the ACC position.
4. Release the parking brake.
Towing (continuous)
Press and hold
OK button on
the steering
wheel to stay in
Neutral