Hyundai Sonata Plug-in Hybrid User manual

NEW THINKING.
NEW POSSIBILITIES.
Plug-in
Emergency Response Guide

Introduction
Sonata Plug-in Hybrid Identification
- General Vehicle Description
- Identifying a Hyundai Plug-in Hybrid
Sonata Plug-in Hybrid main systems
- Key Specifications
- Vehicle Components Location
- Vehicle Components
- Plug-in Hybrid System Operation
- 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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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 Sonata Plug-in Hybrid 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 Sonata with additional information provided on dealing with the high-voltage
electrical system.
Vehicle Description
As with other plug-in hybrids, the Hyundai Sonata Plug-in Hybrid uses a conventional gasoline
powered internal combustion engine paired with a high-voltage electric motor to propel the
vehicle. The high-voltage battery is recharged by an external power source such as a charging
station through charging port. It is also recharged while the vehicle is being driven. This is
accomplished through the use of a generator that produces electricity during driving and braking.
Introduction 1

Sonata Plug-in Hybrid Identification 2
General Vehicle Description
The Hyundai Sonata Plug-in Hybrid is built on a conventional Sonata chassis and therefore the
four door sedan looks very similar to its conventional counterpart with a few notable exceptions.
The safest method is to assume that any Sonata you respond to is a Hybrid vehicle until proven
otherwise. Using the information provided in this section, responders will be able to differentiate
between the two.
Identifying a Hyundai Plug-in Hybrid vehicle
Plug-in Hybrid badge on Trunk and Blue Drive badge on side of Vehicle
The Hyundai Sonata Plug-in Hybrid can be easily identified by the Plug-in Hybrid badge located
on the trunk lid and the Blue Drive badge on the both sides of the vehicle, beside the charging
port cap 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.

Sonata Plug-in Hybrid Identification 3
VIN number
The Vehicle Identification Number (VIN) identifies the Plug-in Hybrid Vehicle with a “2” displayed
in the 6th position, as shown in the below drawing.
The VIN is punched on the floor under the passenger seat. The number 2 in the 6th character of
the VIN indicates that it is a Plug-in Hybrid with 2.0 gasoline engine.
XXXXX2XXXXXXXXX
6th position

Sonata Plug-in Hybrid Identification 4
Engine Compartment
Unlike the conventionally powered Sonata, the
Hybrid version has a plastic engine cover with
“hybrid” clearly shown on it.
Additionally, there are orange colored high-
voltage electrical cables in the engine
compartment.
Vehicle Underside
An orange colored cable covered by the under
cover is also visible on the underside of the
vehicle. This cable runs along the passenger
side from the rear of the vehicle to the engine
compartment.

Sonata Plug-in Hybrid Identification 5
Charging Port
The Charging Port is located on the front fender covered by the charging port cap and it has one
port for AC normal charging.
How to open the charging port
Unlock Charging Door in Emergency
1. Depress the brake pedal and apply the
parking brake.
2. Turn OFF all switches, move the shift lever to
P (Park), and turn OFF the vehicle.
3. Open the charging door by pressing it.
4. Open the charging inlet cover (1).
If the charging door does not open or the
charging cable is not disconnected, open the
hood and pull the emergency cable lightly as
shown left. The charging door will then open.

Sonata Plug-in Hybrid Identification 6
Plug-in Hybrid Vehicle Cluster Instrument Panel
The Plug-in Hybrid Vehicle Instrument Cluster Panel displays the Plug-in Hybrid vehicle specific
features that identify the Sonata as a plug-in hybrid vehicle. Also “plug-in hybrid” symbol is
located at the upper of the left side of the Instrument Cluster Penal.
: The Plug-in Hybrid Mode Gauge indicates the driving mode of the vehicle.
: The “Ready” Light indicates the vehicle is ready for driving.
: The charging cable indicator displays the cable is connected.
Charge Status Indicator
The battery charge status indicator, visible from
outside, at the center of the crash-pad, is
illuminated when the vehicle is charging.

Sonata Plug-in Hybrid main systems 7
Key Specifications
Item Plug-in Hybrid
Engine Displacement 2.0L GDI Hybrid Engine
Transmission Type 6speed Automatic Transmission
Fuel Tank Capacity
(U.S.gal / ℓ ) 14.5 / 55
Motor
Type Permanent Magnet Synchronous Motor
Max. Output (kW) 50
Max Torque (Nm) 205
Inverter Input Voltage (V) 240 ~ 413V
High Voltage
Battery
Type Lithium-ion polymer
Rated Voltage (V) 360
Capacity (Ah) /
Energy (kwh) 27.2 / 9.8
Number for Packs
(Cell / Module) 96CELL / 12MODULE

Sonata Plug-in Hybrid main systems
Vehicle Components Location
Hybrid Starter Generator
(HSG)
Electric AC Compressor
High-Voltage Cable
High-Voltage Battery Assembly
12V Auxiliary BatteryElectric Drive Motor
On Board Charger
(OBC)
OBC
On
-Board Charger :
Battery charging equipment (AC
→ DC)
HPCU
Hybrid
Power Control Unit
(Inverter + LDC + HCU)
LDC
Low Power DC
-DC Converter :
Charge 12V supplementary battery
Inverter
DC
→ AC (from battery to 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
and stores electric energy to traction motor.
HPCU
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Sonata Plug-in Hybrid main systems
Vehicle Components
12V Auxiliary Battery
The 12V Auxiliary Battery is located in the trunk
on the passenger side of the vehicle and is
accessed by removing a small cover. This
battery powers all of the standard electronics
like radio, air conditioner, etc. It also supplies
current to the high-voltage system relays,
which control the flow of high-voltage current.
High-Voltage (HV) Battery
The Lithium-ion Polymer HV battery contains a
gel electrolyte and is made up of 96 - 3.75V
cells wired in series for a nominal voltage of
360V with 27.2 Ah of capacity. The battery
consist of two parts located behind the rear
seat in the trunk area and under the trunk area.
High-Voltage Cabling
The high-voltage cabling in the Sonata Plug-
in Hybrid is orange per the SAE standard.
These cables run along the passenger side
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.
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Sonata Plug-in Hybrid main systems
Hybrid Power Control Unit
The Hybrid Power Control Unit (HPCU)
assembly consists of three components: a
Hybrid Control Unit (HCU), an Inverter (Motor
Control Unit (MCU)) as well as a Low-voltage
DC-DC Converter (LDC). The HPCU assembly
contains capacitors which take about 5-10
minutes to discharge after the high-voltage
system is shut down.
Electric Drive Motor
Mounted between the engine and transmission,
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.
Hybrid Starter Generator (HSG)
The HSG is mounted to the front of the engine
near the intake manifold. It cranks the engine
or starting and acts as a generator when the
HV battery needs charging. As this is one of
the major components of the HV system, its
electrical connection is clearly visible via an
orange HV cable.
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Sonata Plug-in Hybrid main systems
Air Conditioning Compressor
The Air Conditioning Compressor is mounted
to the engine directly below the HSG. It is also
powered by the high-voltage system, so its
electrical connection via an orange HV cable is
easily noticeable as well.
On-Board Charger (OBC)
The OBC is the battery charging equipment
that converts external AC to DC to charge the
high voltage battery.
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Sonata Plug-in Hybrid main systems
Plug-in Hybrid System Operation
Operating Parameters
The Plug-in Hybrid Sonata has two modes of using charged electricity. One is Charge Depleting
(CD) mode where the vehicle is propelled by the electric motor only until it depletes to the
predefined level of high-voltage battery. The other one is Charge Sustaining (CS) mode where
the vehicle is propelled by either the gasoline engine or the Electric Drive Motor, or a
combination of both.
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CD (Charge Depleting) MODE CS (Charge Sustaining) MODE Charging
Electric motor (Electric Vehicle
mode) Battery chargingChargingEngine+Motor
Motor
Startup/Low speed Startup/
Low speed
Acceleratio
nHigh speed Deceleratio nExternal charging
Hybrid
Plug-in Hybrid

Sonata Plug-in Hybrid main systems
High-Voltage Electrical Isolation
Unlike the 12V electrical system that is grounded to the vehicle’s chassis, the Sonata Plug-in
Hybrid’s high-voltage electrical system is designed to be isolated from the vehicle.
Regulation of High-Voltage Electrical Current
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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 located inside
the High-Voltage Battery Pack Assembly
and controls the high-voltage power circuit
between the High-Voltage Battery and the
Hybrid Power Control Unit.
High-Voltage Safety System
There are multiple safety systems
incorporated into the Sonata Plug-in Hybrid.
The system that protects the High-Voltage
Electrical System is called the Battery
Management System (BMS). The BMS is
located inside the High-Voltage Battery
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
Main BMS
Sub BMS

Sonata Plug-in Hybrid main systems 14
Airbag system (SRS : Supplemental Restraint System)
Airbag
Seven airbags are installed in the Sonata Plug-in Hybrid 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 Knee airbag Driver side

Sonata Plug-in Hybrid main systems
Seat Belt Pretensioners
The Sonata Plug-in Hybrid is equipped with driver’s and front passenger’s 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.
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1. Driver Airbag (DAB)
2. Steering Wheel
3. Clock Spring
4. Seat Belt Pretensioner (BPT)
5. Side Impact Sensor (SIS)
6. Side Airbag (SAB)
7. Passenger Airbag (PAB)
8. Front Impact Sensor (FIS)
9. Curtain Airbag (CAB)
10. Supplemental Restraint System Control
Module (SRSCM)
11. Airbag Warning Lamp
12, 14. Emergency Fastening Device (EFD)
13, 15. Pressure Side Impact Sensor
(PSIS)
•Unintentional deployment of SRS components can result in serious injury or death.
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.

Emergency procedures
Initial Response:
The following procedures should be used whenever you are dealing with a Sonata Plug-in
Hybrid at an emergency scene. All other operations should be consistent with your department’s
standard operating procedures or guides.
Identify
When dealing with a Sonata at the scene of an accident, emergency responders should always
assume that it is a hybrid 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.
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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 Sonata Plug-in
Hybrid has the ability to shut down the gasoline engine when it is not needed, 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 alone.
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.
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Chock the Wheels Engage Parking Brake Position the shift
lever in park (P)

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.
Ⅰ. Disabling the system – Smart Key System and “POWER” START/STOP BUTTON
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1. Check the status of the READY light on
the instrument panel. If the READY light is
illuminated, the vehicle is on.
(Refer to page 6)
a) If the READY light is NOT illuminated,
the vehicle is off, Do not push the
“POWER” 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 POWER button beside a shift lever.
Without depressing the brake pedal
“POWER” START/STOP Button
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