Hyundai Kona User manual

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.
•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.

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.
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE indicates a situation which, if not avoided, could result in vehicle damage.
•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.
Important Safety Information

Introduction ······························································································ 1
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) ········································
Emergency Procedures ···············································································
- Initial response: Identify, Immobilize and Disable ···············································
- Extraction Operations ···················································································
- Submersion ·································································································
- Vehicle Fire ·································································································
- High-Voltage Battery Damage and Fluid Leaks ··················································
Roadside Assistance
- Towing ·······································································································
- To Jump Start the Car ···················································································
Contents
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Important Safety Information

Document Purpose
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. 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 distance to empty.
When the battery charge is not sufficient, normal charge, quick charge and trickle charge are
available.
Introduction 1

KONA Electric Identification 2
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.
Identifying a Hyundai electric vehicle
Electric badge on Trunk and Blue Drive badge on side of Vehicle
The Hyundai KONA Electric can be easily identified by the ‘electric’ and the ‘KONA’ 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.

KONA Electric Identification 3
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].
XXXXXXXH/GXXXXXXX
8th digit

KONA Electric Identification 4
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. This cable runs from the center of the
vehicle to the motor compartment.

KONA Electric Identification 5
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
Unlock Charging Connector in Emergency
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 charging door opens only
when the door is unlocked.
4. Remove the charging inlet cover (1).
If the charging connector does not disconnect due
to battery discharge and failure of the electric
wires, open the hood and slightly pull the
emergency cable. The charging connector will
then disconnect.

KONA Electric Identification 6
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
/ECO/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
Charge Status Indicator
The battery charge status indicator, visible from
outside is illuminated when the vehicle is charging.

KONA Electric Main Systems 7
Key Specifications
Item Electric
Motor
Type
150kW 100kW
Permanent Magnet Synchronous
Motor
Max. Output (kW) 150 100
Max Torque (Nm) 395
Reduction Gear
Maximum
torque (Nm) 395
Gear Ratio 7.981
EPCU
Inverter Input Voltage(V) 245 ~ 421V
OBC
(On Board Charger)
Max. Output (kW) 7.2
Output density
(kVA/ℓ) 0.57
High Voltage
Battery
Type
Extended Economical
Lithium-ion polymer
Rated Voltage (V) 352.8 324
Capacity (Ah) /
Energy (kwh) 180 / 64 120 / 39.2
Number for Packs 98CELL 90CELL
Weight (kg) 445 325

KONA Electric Main Systems
Vehicle Components Location
High-voltage
Junction box
It supplies electricity from battery to the inverter, LDC, air
conditioner compressor, etc...
OBC
On
-Board Charger:
Battery charging equipment (AC→DC)
EPCU
Electric Power Control Unit
(Inverter + LDC + VCU)
LDC
Low Power DC
-DC Converter:
Charge 12V supplementary battery
Inverter
DC
→ AC (from battery to traction motor)
AC
→ DC (charge using regenerative braking)
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
Supplies
electric energy to traction motor and stores
generated electric energy.
8
High-Voltage Cable
High-Voltage Battery Assembly
Electric Drive Motor
On Board Charger (OBC)EPCU
Reduction Gear

•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 these instructions can lead to death by electrical shock.
Electrocution Risk!
KONA Electric Main Systems

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
(Electric Power Control Unit) which controls high
voltage current to main electronic systems like
the motor and high voltage junction box.
High-Voltage (HV) Battery
The Lithium-ion Polymer HV battery contains a
gel electrolyte and is made up of 98 (90) cells
wired in series for a nominal voltage of 352.4V
(328V) with 150 Ah (120 Ah) of capacity. The
battery is located below the underbody.
OBC (On-Board Charger)
The OBC is the battery charging equipment that
converts external AC to DC to charge the high
voltage battery.
9

•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 these instructions can lead to death by electrical shock.
Electrocution Risk!
KONA Electric Main Systems

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. The LDC converts high voltage
electricity to 12 volts to charge the 12V auxiliary
battery.
Electric Drive Motor
Mounted at 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.
10

•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 these instructions can lead to death by electrical shock.
Electrocution Risk!
KONA Electric Main Systems

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.
11
•Never cut or disconnect the high voltage orange cabling and connectors without first disabling the
system by removing the Service Disconnect 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.
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.
Failure to follow these instructions can lead to death by electrical shock.
Electrocution Risk!
KONA Electric Main Systems

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
12
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 KONA Electric. 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.
PRA
BMS

KONA Electric main systems 13
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.
* 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 Side airbag Driver / Passenger side
4 Curtain airbag Driver / Passenger side
5 Passenger Airbag Switch Passenger side