Kia e-niro User manual

Emergency Rescue Guide Manual

Introduction
Niro Identification
Identifying a Kia Niro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Niro Main Electronic Systems
Power Electronics Specification . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Airbag system (S S: Supplemental estraint System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Procedures
Initial esponse: Identify, Immobilize and Disable. . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . .
Extraction Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Fire .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Submerged or Partially Submerged Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Voltage Battery Damage and Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Roadside Assistance
Towing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Starting. . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
6
18
12
20
23
23
Contents
22
21
12
10
7
6
2
Document Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
19

Document Purpose
The purpose of this document is to familiarize first responders and the towing/roadside
assistance industry with the proper methods to handle the Niro EV in an emergency
situation. This guide gives a basic overview of key vehicle systems and instructions for
dealing with the different types of emergencies encountered by first responders. The
emergency response procedures for this vehicle will provide how to deal with the high
voltage electrical system.
1
Introduction
Within this Emergency esponse Guide you will find Cautions , Warnings
and Dangers which provide critical information and help you do your job safely and
efficiently. Below are the definitions of these terms. When you see a Caution ,
Warning or Danger , be certain you understand the message before you attempt to
perform any part of an emergency response procedure.
A Caution alerts you to a hazardous situation which, if not avoided, could result in minor or
moderate injury.
A Warning alerts you to a hazardous situation which, if not avoided, could result in death
or serious injury.
A Danger alerts you to a hazardous situation which, if not avoided will
result in death or serious injury.

2
Introduction
Vehicle Description
The Kia
Niro EV uses a high voltage battery and a electric motor to power the vehicle
without any fuel unlike a conventional vehicle that uses a standard combustion engine.
The
Niro EV is an eco friendly vehicle which does not produce any exhaust emissions.
Identifying a Kia
Niro
The Kia
Niro EV can be easily identified by the “Eco electric” logo attached on the tail gate.
Eco
electric” logo on tail gate
The eco electric logo may be missing or hidden after a crash due to damage to the vehicle.
Always be sure to utilize additional methods of identification before determining that the
vehicle is not a electric car.
Electrocution Risk

The VIN (Vehicle Identification Number) identifies
an electric car with a “G” or “H”
displayed in the 8th position, as shown in the below drawing.
The VIN can be found:
1) Underneath the front passenger seat (or driver seat).
2) On the vehicle certification label attached to the driver’s side (or passenger) center pillar.
3
Niro EV Identification
VIN Label
XXXXXXXGXXXXXXXXX
8th position (G or H)

The
Niro EV Cluster Instrument Panel displays the EV specific features such as high
voltage
battery SOC (State of Charge) as highlighted below.
4
Niro
EV Cluster Instrument Panel
Niro EV Identification
Charge Status Indicator
The
battery charge status indicator (3 separate lights), visible from outside on the center
of the dashboard is illuminated when the vehicle is charged with an AC charger. The
number of lights illuminated indicates the charge level of the battery.

The charging port is located on the front
left bumper.
Note : The doors must be un-locked to open the charge port door.
5
Charging Port
How to open the charging port
1.
Press the unlock door button, 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.
Unlock charging door in emergency
If the charging door does not open due to
battery discharge, open the hood and slightly
pull the emergency cable as shown left.
The charging door will then open.
Niro EV Identification

6
Niro EV Main Electronic Systems
High Voltage
System
High-voltage battery
EPCU
Motor
Motor
Type Permanent magnet synchronous motor
Max. Output HP(kW) 201 (150)
Max Torque lb-ft(Nm) 291 (395)
EPCU
Inverter Input Voltage(V) 200 ~ 310
LDC Max. OutputHP(kW) 2.4 (1.8)
High Voltage
Battery
Type Lithium-ion polymer
Rated Voltage (V) 356 327
Capacity (Ah) /
Energy (kWh) 180 / 64.0 120 / 39.2
Quantity for Pack
(Cell / Module) 64Cells / 4Modules

7
Niro EV Main Electronic Systems
Vehicle
components
12V
auxiliary battery
12V Auxiliary Battery
The 12V auxiliary battery is located in the left side of the electric motor room, and powers
all of the vehicle’s standard electronics like radio, lights, door locks, power windows, etc.
Also, it powers the EPCU (Electric Power Control Unit) which controls the high voltage
current to main electronic systems like the motor and high voltage junction box.

8
Niro EV Main Electronic Systems
Motor
The motor of the EV converts electrical energy into
motive force with a Max. power of 201Hp (150kW)
and Max. torque of 291lb
-ft (395Nm).
Electric Power Control Unit (EPCU)
The EPCU includes an Inverter and LDC (Low Power
DC
-DC Converter) 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
voltage to charge the 12V auxiliary battery.
High voltage battery
The HV Lithium ion polymer battery supplies and stores
electric energy, to the traction motor, and is
located under the
Niro EV chassis.
The
OBC is the battery charging equipment that
converts external AC to DC to charge the high voltage
battery.
On
-Board Charger (OBC)

9
Niro EV Main Electronic Systems
High Voltage Orange Cabling
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 EPCU,
Motor, LDC, Inverter, OBC, A/C compressor and other High Voltage components located
towards the front of the vehicle.
The presence of orange cables under the hood, on
the under-floor battery compartment,
or HV 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 HV system by removing the safety plug (refer to page 15).
 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.
Failure to follow these instructions will lead to serious bodily injury or death by
electrical shock.
High Voltage Cables

10
Niro EV Main Electronic Systems
Airbag
system (SRS: Supplemental Restraint System)
Air
bag
Seven(7) airbags are installed in the Niro EV, located in the areas shown in the image
below. Before performing any emergency procedure, make sure the vehicle ignition switch
is turned off and disconnect the negative connector from the 12V auxiliary battery (located
in the left side engine compartment) to prevent accidental deployment of undeployed
airbags.
Seat Belt Pretensioner
In the Niro EV, the driver's and front passenger's seat belts are equipped 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 down after they have been activated.
❈The actual air bags and seats in the vehicle may differ from the illustration.
(1) Driver front airbag
(2) Passenger front airbag
(3) Side airbag
(4) Curtain airbag
(5) Driver’s knee air bag

11
Niro EV Main Electronic Systems
Airbag system
components
To avoid injuries caused
by accidental deployment of undeployed airbags
 Do not cut the red colored part on the above layout.
 Make sure the vehicle ignition switch is turned off, disconnect the negative cable
from the 12V auxiliary battery(located in the right side of motor room, and wait 3
minutes or longer to allow the system to deactivate.
Failure to follow any of these instructions may result in serious injury or death from
accidental deployment of the airbag system.
Undeployed Airbags
1.
Driver Airbag (DAB)
2. Clock Spring
3.
Steering Wheel
4.
Seat Belt Pretensioner (BPT)
5. Passenger
Airbag (PAB)
6.
Side Airbag (SAB)
7. Curtain Airbag
(CAB)
8.
Front Impact Sensor (FIS)
9. Knee Airbag (KAB)
10. Pressure
Side Impact Sensor (PSIS)
11. ear Side Impact Sensor ( SIS)
12.
Supplemental estraint System Control
Module(S SCM)
13
. Emergency Fastening Device (EFD)
14. Occupant Classification System (OCS)

12
Emergency Procedures
Initial Response: Identify, Immobilize and Disable
Identify
The
Niro EV is an electric vehicle. Emergency responders should respond to emergency
scenarios involving the Niro EV 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
Niro EV at an
emergency scene. All other operations should be consistent with your department’s
standard operating procedures or guides. When an EV 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. emove all
metallic jewelry, including watches and rings.

13
Emergency Procedures
Immobilize
The next step is to immobilize the vehicle to prevent any accidental movement that can
endanger response personnel or civilians. When the Niro EV is damaged in a crash, the
vehicle may appear to be shut off when it is not due to no engine sounds.
When the " EADY" mode light is illuminated on the Instrument Panel, the vehicle
can move silently using the electric motor. esponders 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.
Chock the wheels Set the parking brake.
Put rotary shifter
dial in the P (Park)
position

14
Emergency Procedures
Disable
The final step in the initial response process, conducted after immobilizing the vehicle, is to
disable the vehicle, its S S 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
1. Confirm the status of the EADY light on
the instrument panel. If the EADY
light is illuminated, the vehicle is ON.
a) If the EADY light is NOT
illuminated, the vehicle is off. Do not
push the “POWE ” STA T/STOP
button because the vehicle may start
(go into EADY mode).
b) To turn OFF the system, put rotary shifter dial in the P (Park) position and press the
POWE button.
Without depressing the brake pedal
Pressing
POWER button
POWER button
LED color Vehicle condition
Off Off
One time Amber Electrical accessories are
operational.
Two times eddish orange The warning lights can be checked
before the vehicle is started.
Three times Off Off
While depressing the brake pedal
Pressing
POWER button
POWER button
LED color Vehicle condition
Off Off
One time Off eady to drive
POWER” START/STOP Button

15
Emergency Procedures
2. If necessary, lower the windows, unlock the doors and open the tail gate as required,
before disconnecting the 12V battery. Once the 12V battery is disconnected, power
controls will not operate.
3. Before disconnecting 12V battery, remove the Smart Key at least 2 meters away
from the vehicle to prevent accidental restart.
4. Use the following procedure to remove the safety plug
and disable the high voltage battery:
b) emove the service plug
cover (A)
after removing rear seat cushion assembly.
a)
Disconnect 12V auxiliary batter negative
(-) terminal.
c) emove the service plug (A).
5. In case of emergency, cut the service interlock connector
cable to isolate the high voltage of the battery.

16
Emergency Procedures
1. Open the hood.
II. Disabling the System – IG (Ignition) Fuse Removal
2. emove the motor room fuse box
cover.
3. If necessary, lower the windows,
unlock the doors and open the tail gate
as required, before disconnecting the
12V battery (located in the right side of
motor room). Once the 12V battery is
disconnected, power controls will not
operate.
4. In the event the vehicle is unable
to be disabled using the “Power”
STA T/STOP Button, using the fuse
puller located
in the Motor room fuse
box, pull both the IG1, IG2 Fuse
from the motor room fuse box.
If the
IG fuses cannot be located, pull out
all the fuses and relays in the fuse
box.
Motor room fuse box

17
Emergency Procedures
If previously mentioned methods of disabling the vehicle’s system are unsuccessful, any
emergency procedures involving the electric vehicle may cause the accidental
deployment of undeployed airbags and electric shock from high-voltage components.
5. emove the safety plug and disable the high voltage battery
( efer to No.4 procedure in page 15 and cut the HV interlock circuit wiring)
 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 wires or cables before disabling the system.
Failure to follow these instructions will lead to serious bodily injury or death by
electrocution.
Electrocution Risk

18
Emergency Procedures
Extraction Operations
Vehicle Stabilization
Use standard stabilization (cribbing) points,
as shown beside. 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
Niro
EV is an electric model. Because of the high voltage components contained therein,
first responders should pay special attention 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 page 12-17.
Extraction
tools and procedure
When responding to an incident involving a Niro EV, 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 the
airbag system, orange colored high voltage cables and other high voltage components so that
the parts are not damaged, to create a risk of explosion.
Location
of ultra-high strength steel
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 impossible to
cut. If necessary, use a workaround
technique.
Mild steel
High
strength steel
Ultra
-high strength steel