Kia EV9 User manual

Kia EV9
Emergency
Response Guide

Introduction
IMPORTANT INFORMATION
WARNING
A WARNING indicates a situation in which harm, serious bodily injury or death could result if
the warning is ignored.
The ERG (Emergency Response Guide) provided by Kia describes emergency response
operations, warnings, and precautions related to the vehicle. This publication is intended to
provide necessary information for vehicle accident rescue operations and for the training
and further education of first and second responders.
Please note that the guide may be updated by Kia on an ongoing basis. It is not intended for
retailers, end consumers, or any other readers not mentioned in the preceding sentence.
The provided guide applies only to the Kia EV9 vehicle and includes information about the
location and description of high-voltage components and the vehicle's structure. However, it
does not cover every scenario in emergency situations.
Failure to follow the recommended procedures during emergency response may result in
death or other serious injuries. It is important to read the guide in advance as it contains
necessary information about the vehicle's features and other provided content in the event
of an accident.
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Emergency Response Guide
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Contents
1. Identification / recognition
10. Explanation of pictograms used
2. Immobilization / stabilization / lifting
3. Disable direct hazards / safety regulations
4. Access to the occupants
5. Stored energy / liquids / gases / solids
6. In case of fire
7. In case of Submersion
8. Towing / transportation / storage
9. Important additional information
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1. IDENTIFICATION / RECOGNITION
Initial Response: Identify,
Immobilize and Disable
The following procedures should be used
whenever you are dealing with a EV9 at an
emergency scene. However, all operations
should be consistent with your
department’s standard operating
procedures, guidelines, and any applicable
laws. When an EV9 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.
WARNING
Identify
The EV9 is an electric vehicle. Emergency
responders should respond to emergency
scenarios involving the EV9 accordingly,
exercising extreme care and caution to
avoid contact with the high-voltage system
within the vehicle.
Identifying a Kia EV9
“EV9” Car name emblem on tailgate
• The EV9 can be easily identified by the
car name emblem attached on the tailgate
on the left side.
•The car name emblem may be missing or
hidden after a crash due to damage to the
vehicle. Always be sure to use other
identification methods in this section before
determining that the vehicle is not an
electric car.
Charging Port
The charging port is located on the rear
left side.
Note that the doors must be unlocked
to open the charge port door.
How to open the charging port
1. Press the unlock door button,
depress the brake pedal and apply the
Electric Parking Brake (EPB).
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, or press the “charging door open
button” in the crash pad.
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1. IDENTIFICATION / RECOGNITION
The VIN can be also found under the
driver’s seat (or passenger’s seat)
Identifying a EV9
VIN Label
The vehicle certification label attached on
the top of the dashboard through the front
windshield gives the VIN (Vehicle
Identification Number) as shown in the
below picture.
Charge Status Indicator
The battery charge status indicator (4
separate lights), located inside the
charging door, is illuminated when the
vehicle is charged. The number of
lights illuminated indicates the charge
level of the battery.
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1. IDENTIFICATION / RECOGNITION
EV9 Cluster Instrument Panel
The EV9 Cluster Instrument Panel displays EV specific features such as high-voltage
battery SOC (State of Charge) as below.
1. Speedometer
2. Distance to empty
3. Power/Charge gauge
4. Battery SOC (State of Charge) gauge
5. LCD display
6. Warning and indicator lights
7. Reduction gear shift indicator
8. Odometer
9. Regenerative braking level indicator
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2. IMMOBILIZATION / STABILIZATION / LIFTING
WARNING
• When installing a block or jack, avoid
high-voltage cable, high-voltage battery.
• If high-voltage components or cables
are exposed, do not place any support
on them.
2.1 Immobilization
The next step is to immobilize the vehicle
to prevent any accidental movement that
can endanger response personnel or
civilians. When the EV9 is damaged in a
crash, the vehicle may appear to be shut
off, even when it actually is not, due to a
lack of virtual engine sounds. 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. Put the vehicle in P (Park) position by
pressing the ‘P’ button.
3. Set the Electronic Parking Brake (EPB)
2.2 Vehicle Stabilization
Use standard stabilization (lift) points,
as shown beside. Always be sure to
connect to a structural component of
the vehicle and avoid placing cribbing
under high-voltage cables, and other
areas not normally considered
acceptable.
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3. DISABLE DIRECT HAZARDS / SAFETY REGULATIONS
Disabling vehicle
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.
Case 1:
1. EV off
2. 12 V battery disconnection
3. high-voltage shut off
Case 2*:
1. Fuse removal (Fuse box)
2. 12 V battery disconnection
3. high-voltage shut off
*In case of emergency
SRS : Supplemental Restraint System
3.1 Disabling the System –Smart
Key System and “EV”
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.
a) If the READY light is NOT illuminated,
the vehicle is off. Do not push the “EV”
START/STOP button because the vehicle
may start (go into READY mode).
b) To turn OFF the system, press the 'P'
(Park) button on the rotary shifter dial, and
press the EV button.
2. If necessary, lower the windows,
unlock the doors and open the trunk as
required, before disconnecting the 12 V
battery. Once the 12 V battery is
disconnected, power controls will not
operate.
3. Before disconnecting the 12 V
battery, remove the smart key at least 2
meters (7 feet) away from the vehicle to
prevent accidental restart.
4. Open the hood after pressing the
release button twice.
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3. DISABLE DIRECT HAZARDS / SAFETY REGULATIONS
WARNING
Wait more than 5 minutes for capacitor
of the high-voltage battery system to be
discharged completely.
* If the release button does not work, pull
the emergency lever twice after removing
the emergency open cover located on the
left hand side of the footrest.
4. Separate the 12 V auxiliary battery
negative terminal (A) after loosening the
nut.
5. Remove the PE room junction box cover.
6. Disconnect the high voltage service
interlock connector (A).
Before
After
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3. DISABLE DIRECT HAZARDS / SAFETY REGULATIONS
5. Remove the service interlock
connector and disable the high-voltage
battery.
• 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.
3.2 Disabling the system –IG
(Ignition) Fuse Removal
1. Open the hood.
2. Remove the PE (Motor) room fuse box
cover.
3. If necessary, lower the windows, unlock
the doors and open the tailgate as required,
before disconnecting the 12 V battery
(located in the left side of PE(Motor) room).
Once the 12 V battery is disconnected,
power controls will not operate.
4. In the event the vehicle is unable to be
disabled using the “EV” START/STOP
Button, using the fuse puller located in the
PE(Motor) room fuse box, pull both the IG1,
IG2 fuse from the PE room fuse box. If the
IG fuses cannot be located, pull out all of
the fuses and relays in the fuse box.
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3. DISABLE DIRECT HAZARDS / SAFETY REGULATIONS
WARNING
Electrocution risk
• 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.
Failure to follow these instructions will lead
to serious bodily injury or death by
electrocution.
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4. ACCESS TO THE OCCUPANTS
4.1 Extraction Operations
The EV9 is an electric vehicle. Because of
the high-voltage components contained
within, 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
emergency procedures.
4.2 Extraction Tools and
Procedure
When responding to an incident involving
the EV9, 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 explosion or electrocution.
4.3 Door open
When the door outer handle
doesn’t pop-up, push the front
side inwards.
When the door outer handle doesn’t
pop-up, push the front side inwards.
Push
Pull
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4. ACCESS TO THE OCCUPANTS
4.4 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.
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4. ACCESS TO THE OCCUPANTS
4.5 Occupants Rescue Guide
When dealing with an emergency situation, refer to the components as below.
Do not cut the body near the airbag, high-voltage cable, high-voltage system.
Supplemental Restraint System
Control Module (SRSCM) Airbag Airbag Inflator
High-voltage cable Air-conditioning line
Seat belt pretentioner
Cable Cut (with the service plug that
can disable the high-voltage system)
12 V battery
High-voltage Battery
Air-conditioning
component High-voltage
component
12 V battery (-) connector
High-voltage charge port
4WD, long-range model, 6P
Ultra-High Strength
Steel
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4. ACCESS TO THE OCCUPANTS
4.6 Occupants Rescue Guide
When dealing with an emergency situation, refer to the components as below.
Do not cut the body near the airbag, high-voltage cable, high-voltage system.
4WD, long-range model, 7P
Supplemental Restraint System
Control Module (SRSCM) Airbag Airbag Inflator
High-voltage cable Air-conditioning line
Seat belt pretentioner
12 V battery
High-voltage Battery
Air-conditioning
component High-voltage
component
12 V battery (-) connector
High-voltage charge port
Ultra-High Strength
Steel
Cable Cut (with the service plug that
can disable the high-voltage system)
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5. STORED ENERGY / LIQUIDS / GASES / SOLIDS
5.1 High-voltage System
1. Vehicle Charging Management System (VCMS)
2. Combo Charger Inlet Assembly
3. Integrated Charging Control Unit (ICCU)
4. Motor & Reduction Gear Assembly
5. Rear High Voltage Junction Box
6. Multi Inverter Assembly
7. Battery System Assembly (BSA)
8. 12 V Auxiliary Battery
9. Front High Voltage Junction Box
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5. STORED ENERGY / LIQUIDS / GASES / SOLIDS
High-voltage Battery System
Standard
Long-range
5.2 High-voltage Orange Cabling
The high-voltage cabling is orange, per
Society of Automotive Engineer standards.
Cables run under the floor of the vehicle
and connect the High-voltage Battery to
the ICCU, Motor, Inverter, Junction box,
A/C compressor and Voltage components
located towards the front of the vehicle.
You can identify the vehicle as an electric
vehicle with the presence of orange the
hood, in the under-floor battery
compartment, or HV cables under the car.
WARNING
High-voltage Cables
• Never cut or disconnect the high-
voltage orange cabling and connectors
without first disabling the HV system by
removing the service interlock
connector. (refer to page 7)
• 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.
Capacity (kwh) 76.2
Rate Voltage (V) 636
Composition 174 cell
(29 module)
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Capacity (kwh) 99.8
Rate Voltage (V) 552
Composition 152 cell
(38 module)

6. IN CASE OF FIRE
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(Max 100,000 liter) 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.
6.1 Firefighting Operations
Strict precautions must be taken while
conducting firefighting operations following
Reasons:
• Lithium-ion batteries contain liquid
electrolyte that can vent, ignite, and
produce sparks when subjected to
temperatures above 300 F (150 C).
• 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 second responders that
there is a risk of the battery re-igniting.
- In a 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 (15m).
• 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.
NIOSH: National Institute of
Occupational Safety & Health
MSHA: Mine Safety and Health
Administration
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6. IN CASE OF FIRE
6.3.2 High-Voltage Battery
Damage and Fluid Leaks
If electrolyte solution leakage, or any
damage to the Lithium ion battery
casing is observed, the first responders
should attempt to neutralize the battery
by applying a large volume of water to
the battery pack while wearing
appropriate Personal Protective
Equipment (PPE). The neutralization
process helps stabilize the thermal
condition of the battery pack but does
not discharge the battery.
• Do not put any smoke, spark, flame
around the vehicle.
• Do not touch or step on the spilled
electrolyte.
• If electrolyte leak occurs, wear
appropriate solvent resistant PPE and
use soil, sand, or a dry cloth to clean up
the spilled electrolyte. Be sure to
adequately ventilate the area.
6.3 How to Deal with the Situation
When there is a fire:
Extinguish the fire with a large amount of
water. Don’t use seawater or salt water. It
can generate the toxic vapor or cause the
re-ignition.
When damaged battery or fluid leak:
•Disconnect 12 V Battery (-) terminal
•Disable the high-voltage system
•Neutralize the battery by applying a
large volume of water. (Note: this
doesn’t discharge the battery)
•Discharge battery
6.3.1 Vehicle Fire
• Use a large volume of water (max.
100,000 liter). Water must cool down the
battery.
•Adding water to the high-voltage battery
casing can enhance the battery's cooling
process. However, it is crucial to avoid
attempting to penetrate the HV battery or
its casing in order to apply water.
•Introducing water into the high-voltage
battery can be difficult due to the battery
case.
• Introduce water into any openings that
may have resulted from the accident or fire.
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6. IN CASE OF FIRE
To prevent re-ignition, the first
responder and second responder need
to be aware of the risk of stranded
energy* which remains in the damaged
cells and lead to re-ignition.
*Thermal runaway: The originating
cause of thermal runaway is generally
short circuiting inside a battery cell and
a resulting increase in the cell’s internal
temperature.
Battery produces heat with thermal
runaway and it can spread from one
battery cell to many cells, in a domino
effect.
*Stranded energy : Energy remains
inside any undamaged battery cells
after the accident. That stranded
energy can cause a high-voltage
battery to re-ignite multiple times after a
fire has been extinguished.
How to Prevent Re-ignition
(Mitigating Stranded Energy
Risk)
1. 12 V battery (-) terminal
disconnection (To depower battery
management system)
2. High-voltage shut off
(refer to page 7~9)
3. Discharging the high-voltage battery
(refer to page 22)
WARNING
Electrolyte Irritation
The high-voltage battery contains
electrolyte solution. To avoid exposure to
electrolyte solution and serious personal
injury, always wear appropriate solvent
resistant PPE (Personal Protective
Equipment) and SCBA (Self-contained
Breathing Apparatus).
• Electrolyte solution is an eye irritant – In
the event of contact with eyes, rinse with
plenty of water for 15 minutes.
• Electrolyte solution is a skin irritant.
Therefore, in the event of contact with skin,
wash off with a soap.
• Electrolyte liquid or fumes coming into
contact with water will create vapors in the
air from oxidization. These vapors may
irritate skin and eyes. In the event of
contact with vapors, rinse with plenty of
water and consult a doctor immediately.
• Electrolyte fumes (when inhaled) can
cause respiratory irritation and acute
intoxication. Inhale fresh air and wash
mouth with water. Consult a doctor
immediately.
6.4 High-voltage Battery Re-
ignition by Stranded Energy
Damaged cells in the high-voltage battery
can experience thermal run away* and re-
ignition.
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