Hyundai SONATA hybrid User manual

Emergency Response Guide
SONATA hybrid

Contents
1. Identification / recognition 2
2. Immobilization / stabilization / lifting 6
3. Disable direct hazards / satety regulations 7
4. Access to the occupants 12
5. Stored energy / liquid / gases / solids 15
6. In case of fire 18
7. In case of submersion 22
8. Towing / Transportation / storage 23
9. Important additional information 26
1

1. Identification / recognition
Initial Response: Identify, Immobilize and Disable
2
Identify
The SONATA HEV is built on a conventional SONATA chassis and therefore the appearance
looks very similar to the internal combustion engine model.
Emergency responders should assume that any SONATA you respond to is a Hybrid vehicle
and respond to emergency scenarios involving the SONATA HEV accordingly, exercising
extreme care and caution to avoid contact with the high voltage system within the vehicle.
The following procedures should be used whenever you are dealing with a SONATA HEV at
an emergency scene. However, all operations should be consistent with your department's
standard operating procedures, guidelines, and any applicable laws. When an HEV is
damaged in a crash, the high voltage safety systems may have been compromised 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.

Engine Compartment and Underside
1. Identification / recognition
1.1 Identifying a HYUNDAI SONATA HEV
4
The SONATA HEV has a plastic cover with “Hybrid” clearly shown on it.
Additionally, there are orange colored high
-voltage electrical cables in the motor
compartment and underside

1. Identification / recognition
VIN Label
The VIN (Vehicle Identification Number) identifies
an electric car with a “4” displayed in the
8th position, as shown in the below picture.
The VIN can be found:
1) Driver’s side windshield cowl.
2) On the vehicle certification label attached to the driver’s side (or passenger) center pillar.
8th position
1.1 Identifying a HYUNDAI SONATA HEV
4
XXXXXXX4XXXXXXX

Step on brake pedal
to park the vehicle,
then position the
shift lever in park (P)
2. Immobilization / stabilization / lifting
The next step is to immobilize the vehicle to prevent any accidental movement that can
endanger responding emergency personnel or civilians. When the SONATA HEV is damaged in
a crash, the vehicle may appear to be shut off when it is not because the engine emits little to no
sound.
When the "READY" mode light is illuminated on the Instrument Panel, the vehicle can move
silently using the electric motor. Responders should approach the vehicle from the sides and
stay away from the front or rear as they are potential paths for vehicle movement. Be sure to
immobilize the vehicle in the following manner.
2.2 Vehicle Stabilization
Use standard stabilization(lift) points, as
shown to the right. Always be sure to connect
to a structural member of the vehicle and
avoid placing cribbing under high voltage
cables, and other areas not normally
considered acceptable.
Chock the Wheels
Engage Parking Brake
2.1 Immobilization
5

3. Disable direct hazards / safety regulations
The final step in the initial response process, conducted after immobilizing the vehicle, 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.
3.1 Disabling the System –Smart Key System and “POWER”
START/STOP Button
1.
Confirm the status of the READY light on the instrument panel. If the READY light
is illuminated, the vehicle is ON.
“POWER” START/STOP Button
a) If the READY light is NOT illuminated, the vehicle is off. Do not push the “POWER”
START/STOP button because the vehicle may start (go
into READY mode).
b) To turn OFF the system, press the 'P' (Park) button, and press the POWER button.
Case I
Case II
Fuse removal
(Fuse box)
12 volt battery
disconnection
High voltage
shut off
*In case of the vehicle cannot be disabled using the “power” button.
Power Off 12 volt battery
disconnection
High voltage
shut off
Position the shift lever in the Park (P)
6

3. Disable direct hazards / safety regulations
2. If necessary, lower the windows, unlock the doors and open the tail gate as required,
before disconnecting the 12 volt battery. Once the 12 volt battery is
disconnected, power
controls will not operate. (Refer to below “4.” for 12 volt battery disconnection)
3. Before disconnecting the 12 volt battery, remove the Smart Key at least 2 meters
away from the vehicle to prevent accidental restart.
4. Disconnect the 12 volt auxiliary battery Negative(
-) cable (B), located in trunk trim.
Without depressing
the brake pedal
Pressing
POWER button
Button
Position/LED Vehicle condition
One time ACC/AMBER Electrical accessories are operational.
Two times ON/BLUE The warning lights can be checked before the
vehicle is started.
Three times OFF Off
Pressing
POWER button
Button
Position/LED Vehicle condition
One time START/BLUE Ready to drive
While depressing the brake pedal
7

3. Disable direct hazards / safety regulations
•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!
•SRS components may remain powered and active for up to 3 minutes after the 12 volt electrical
system is shut off or disabled. Disconnect the battery 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!
8
5. Use the following procedure to remove the service disconnect plug from the High voltage
battery.
A
B
C
A. Locate the Service Disconnect inside Trunk
B. Release the Latch
C. Move the Lever Down and pull the service plug out.

3.2 Disabling the System
–IG (Ignition) Fuse Removal
3. Disable direct hazards / safety regulations
1. Open
the hood.
2. Remove the engine room fuse box cover.
3.
In the event the vehicle cannot be disabled
using the “Power” START/STOP Button, pull
the IG1 relay from the engine compartment
room fuse box. If the IG fuses cannot be
located, pull out all the fuses and relays in the
fuse box.
Engine room fuse box
9
4. Separate the negative(-) 12 volt battery
cable (B), located in trunk trim to further
prevent the risk of accidental restart.
AB
C

3. Disable direct hazards / safety regulations
10
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.
•Before engaging in any emergency response procedures, ensure the vehicle is disabled and
wait 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. Never touch the metal
chassis wires, cables, connectors, or any electric components before disabling the system,
and/or shorted to the vehicle chassis.
Failure to follow these instructions will lead to serious bodily injury or death by electrocution.
Electrocution Risk
5. Use the following procedure to remove the service disconnect plug from the High voltage
battery.
A
B
C
A. Locate the Service Disconnect inside Trunk
B. Release the Latch
C. Move the Lever Down and pull the service plug out

4.1 Extraction Operations
4. Access to the occupants
The SONATA is a Hybrid model. Because of the high voltage components contained therein,
first responders should exercise extreme caution when they extract occupants in the car.
Before performing any extraction operations, the first responders should
"Identify, Immobilize
and Disable"
the vehicle as discussed in sections on emergency procedures.
4.2 Vehicle Stabilization
Use standard stabilization(lift) points, as
shown to the right. Always be sure to connect
to
a structural member of the vehicle and avoid
placing cribbing under high voltage cables,
and other areas not normally considered
acceptable.
4.3 Extraction tools and procedure
When responding to an incident involving a SONATA HEV, we recommend that the first
responders follow their organization’s standard operating procedures for dealing with vehicle
emergencies.
When the first responders cut the vehicle, they should always pay special attention to the
airbag system, orange colored high voltage cables and other high voltage components so that
the parts are not damaged and to prevent a risk of electric shock or explosion..
11

4.4 Location of ultra-high strength steel
4. Access to the occupants
In these images, high strength steel is used in the areas colored in blue and ultra
-high strength
steel is used in the red colored areas. Depending on the tools used, ultra high strength steel can
be challenging or extremely difficult to cut. If necessary, use a workaround technique.
Mild steel
High
strength steel
Ultra
-high strength steel
12
확인 필요
(LF HEV 이미지)
차체설계3팀 채석준 파트장님께
9/9 차체 구조 이미지 요청, 미회신
Translated
Need to be confirmed(LF HEV image)
Dear Suk-Jun Chae, Part Manager of Body Design
Team 39/9 Body structure image request, no reply

4.5 Occupants rescue guide
4. Access to the occupants
When dealing with the emergency situation, check the components as below.
Supplemental Restraint Syst
em Control Module (SRSCM) Airbag Airbag Gas
Inflators
High voltage cable Air-conditioning line
12 volt Battery
OBC (On –Board Charger) Ultra-High Strength
Steel
High Voltage Battery Air-conditioning
component Seat belt pretensioner
13
Service Plug

5.1 High voltage system
5. Stored energy / liquid / gases / solids
14
HPCU Hybrid Power Control Unit
(Inverter + LDC + HCU)
LDC Low Power DC-DC Converter :
Charge 12 volt 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.
High voltage battery Supplies electric energy to traction motor and stores
generated electric energy .
High‐Voltage Battery Assembly
High‐Voltage Cable 12V Auxiliary Battery
Hybrid Starter Generator
(HSG)
Fuel Tank
Fuel Line
Electric AC Compressor
Electric Drive Motor
Hybrid Power Control Unit

5.1 High voltage system
5. Stored energy / liquid / gases / solids
High voltage battery
The High Voltage Lithium
-ion polymer battery supplies and stores electric energy, to the traction
motor, and is located behind the rear seat in the trunk area.
Motor
Type Permanent magnet synchronous motor
Max. Output (kW) 35
Max Torque (Nm) 205
HPCU Inverter Input Voltage(V) 200 ~ 310
LDC Max. Output (kW) 1.8
High Voltage Battery
Type Lithium-ion polymer
Rated Voltage (V) 270
Energy (Wh)1431
Quantity for Pack
(Cell / Module) 72 cells / 9 modules
※
Specification
15

5.2 High voltage orange cabling
5. Stored energy / liquid / gases / solids
The High Voltage cabling is orange,
per Society of Automotive Engineers (SAE) standards.
Cables run under the floor of the vehicle and connect the High Voltage Battery to the HPCU,
Motor, LDC, Inverter, A/C compressor
and other High Voltage components located towards
the front of the vehicle.
The presence of orange cables under the hood, in
the under-floor battery compartment, or
High Voltage cables under the car, identifies the vehicle as an electric vehicle.
•Never cut or disconnect the high voltage orange cabling and connectors without first
disabling the High Voltage system (refer to page 6 ).
•Exposed cables or wires may be visible inside or outside the vehicle. Never touch
the metal chassis wires, cables, connectors, or any electric components before
disabling the system, and; or shorted to the vehicle chassis.
Failure to follow these instructions will lead to serious bodily injury or death by electrical
shock.
16
1,2,3 : High voltage cable

5. Stored energy / liquid / gases / solids
16
Sonata HEV has a Gasoline engine. The fuel type is Gasoline stored in the fuel tank. When
dealing with an emergency situation, be careful not to cut the fuel line and tank.
5.3 Fuel (Gasoline)
Fuel Line
Fuel Tank

6.1 Firefighting Operations
6. In case of fire
Strict precautions must be taken while conducting firefighting operations due to following
Reasons:
•
Lithium-ion batteries contain electrolyte that can vent, ignite, and produce sparks when
subjected to temperatures above 300°F.
•
Vehicle 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 fellow emergency responders and civilians that there is a risk of the battery
re-igniting.
-In a fire, submersion or a collision that has compromised the high voltage battery, store the
vehicle in an open area with no exposure within 50 feet. Alternatively, a damaged vehicle or
battery pack may be stored in a barrier of earth, steel, concrete, or solid masonry.
•
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.
6.2 Extinguishers
•
Small fires that do not involve the high voltage battery should be extinguished using an ABC
fire extinguisher. (ex. Fire caused by wiring harnesses, electrical components, etc.)
•
Do not attempt to extinguish fires that involve the high voltage battery with small amounts
of water as this can result in electrocution. Fires that involve the high voltage battery should
be extinguished using large amounts of water (minimum 2,650 gallons) to cool the high
voltage battery. Fire fighters should not hesitate to pour larger amounts of water on the
vehicle in such scenarios. Make sure the battery is fully cooled to avoid fire re-ignition.
17

6.3.1 Vehicle fire
6.3 How to deal with the situation
6. In case of fire
Fire Extinguish the fire with a large amount of water.
Don’t use seawater or salt water. It can generate
toxic vapor or cause reignition.
Damaged
battery or
Fluid leak*
Disconnecting 12 volt Battery (-) terminal,
Disabling the high voltage system,
Neutralizing the battery by applying a large
volume of water. (It does not discharge the
battery)
*If electrolyte solution leakage, or any damage to the High Voltage battery casing is observed
Battery
discharging
18
•
You must use a large volume of water (minimum 2,650 gallons) to cool down the
battery.
•
If water is put into the high voltage battery casing, it will help to cool down the
battery. (But never attempt to penetrate the battery or its casing to apply water.)
•
Soaking the vehicle in a container filled with water can be an effective way to
extinguish the fire.