Kia Niro EV User manual

Emergency
Response
Guide
Version_1
1

1. Identification / Recognition
3
2. Immobilization / Stabilization / Lifting
7
3. Disable Direct Hazards / Safety Regulations
8
4. Access to the Occupants
13
5. Stored Energy / Liquid / Gases / Solids
16
6. In Case of Fire
1
9
7. In Case of Submersion
23
8. Towing / Transportation / Storage
24
9. ImportantAdditional Information
27
Contents
2

1. Identification / Recognition
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. However, all operations should be consistent with your department's
standard operating procedures, guidelines, and any applicable laws. 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. Remove all metallic jewelry, including watches and rings.
3

1. Identification / Recognition
1.1 Identifying a Kia NIRO EV
“Eco Electric” Logo on Tailgate
•
The Niro EV can be easily identified by the
“Eco electric” logo attached on the tailgate and
front charge port door on driver’s side.
•
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.
Charging Port
•
The charging port is located on the front left bumper.
#Note : The doors must be un
-locked 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.
Unlock
charging door in emergency
•
If the charging port door does not open due to
battery discharge, open the hood and pull the
emergency cable slightly as shown left.
•
The charging port door will then open.
4

1. Identification / Recognition
1.1 Identifying a Kia NIRO EV
VIN Label
The VIN (Vehicle Identification Number) identifies
an electric car
with a “G” or “H” displayed
in the 8th position, as shown in the below picture.
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) VIN Plate also can be seen through the windshield from outside.
XXXXXXXGXXXXXXXXX
8th position (G or H)
5

1. Identification / Recognition
1.1 Identifying a Kia NIRO EV
The
Niro EV Cluster Instrument Panel displays EV specific features such as high voltage
battery SOC (State of Charge) as circled below
.
NIRO EV Cluster Instrument Panel
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.
6

2. Immobilization / Stabilization / Lifting
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, even when it actually is not, due to a lack of 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.
Chock the wheels
Set the Electronic Parking
Brake (EPB)
Put the vehicle in P (Park)
position by pressing the ‘P’
button on the rotary shifter
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.
2.1 Immobilization
7
•
When installing a block or jack, avoid high voltage cable, battery and fuel system (exhaust
system).
•
If high voltage components or cables are exposed, do not place any support on them.

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.
8
Case I
Power
Off
12V battery
disconnection
High voltage
shut off
Case II*
12V battery
disconnection
Fuse removal
(Fuse box)
High voltage
shut off
*In case of emergency
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
“POWER” START/STOP Button
light is illuminated, the vehicle is ON.
a) I 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 on the rotary shifter dial, and
press the POWER button.

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 12V battery. Once the 12V battery is
disconnected, power
controls will not operate. (Refer to below “5.
– a” for 12V battery disconnection)
3. Before disconnecting the 12V battery, remove the
smart key at least 2 meters away
from the vehicle to prevent accidental restart.
4. In case of emergency, cut the service interlock connector cable to isolate the high
voltage of the battery.
9
While depressing the brake pedal
Pressing POWER
button
POWER button
LED color Vehicle condition
One time Off Ready to drive
Without depressing
the brake pedal
Pressing
POWER button
POWER button
LED color Vehicle condition
One time Amber Electrical accessories are operational.
Two times Reddish orange The warning lights can be checked
before the vehicle is started.
Three times Off Off

3.
Disable Direct Hazards / Safety Regulations
5. Follow the procedure below to remove the safety plug and disable the high voltage battery:
a)
Disconnect the 12V auxiliary battery
negative (-) terminal.
d) Remove the service plug (A) by sliding lever
and pulling up as shown below.
b) Remove the rear seat by
pulling "up" as shown.
10
*There are 2 locking hooks.
*Pull the front part of the seat.
c) Remove the service plug cover (A).

3.
Disable Direct Hazards / Safety Regulations
3.2 Disabling the System
–IG (Ignition) Fuse Removal
1. Open the hood.
2. Remove the PE (Engine) room fuse
box cover.
3. If necessary, lower the windows,
unlock the doors and open the tailgate
as required, before disconnecting the
12V battery (located in the left side of
PE (Engine) 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”
START/STOP Button, using the fuse
puller located in the PE (Engine) room
fuse box, pull both the IG1, IG2 fuse
from the PE (Engine) room fuse box.
If the IG fuses cannot be located, pull
out all of the fuses and relays in the
fuse box.
PE(Engine) room fuse box
11

3.
Disable Direct Hazards / Safety Regulations
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.
Disconnect the 12V battery and disable the high voltage battery by referring to page 9, 10.
•
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.
Electrocution Risk
12

4. Access to the Occupants
4.1 Extraction Operations
The
Niro
EV is an electric vehicle. 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 emergency procedures.
4.2 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.
4.3 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 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.
13

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.
14
Mild steel
High
strength steel
Ultra
-high strength steel

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, fuel system.
15
Supplemental Restraint Syst
em Control Module (SRSCM) Airbag Airbag Inflators
High voltage cable Air-conditioning line
12V Battery
Service Plug OBC (On –Board Charger) Ultra-High Strength
Steel
High Voltage Battery Air-conditioning
component Seat belt pretentioner
LHD

5. Stored Energy / Liquid / Gases / Solids
5.1 High Voltage System
Motor
EPCU
OBC
The EPCU is the main HV control unit & 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.
EPCU
The OBC is the HV battery charging equipment that converts externalAC to DC or direct DC to
DC, to charge the high voltage battery.
On
-Board Charger (OBC)
High voltage battery
The electric motor of the EV converts electrical energy into motive force with a Max. power of
201Hp (150kW) and Max. torque of 291lb-ft (395Nm).
Motor
16
Capacitor in EPCU
•
There is the capacitor inside the EPCU. Wait 5+ minutes for the capacitor to discharge
after removing the service plug.

5. Stored Energy / Liquid / Gases / Solids
5.1 High Voltage System
High Voltage Battery
The HV
lithium-ion
polymer battery supplies and stores electric energy from the traction motor,
and is located under the
Niro EV chassis.
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.
Motor
Type Permanent magnet synchronous motor
Max. Output (kW) Long-range : 150
Economy : 100
Max Torque (Nm) 395
EPCU Inverter Input Voltage(V) 245 ~ 421
LDC Max. Output (kW) 1.8
High Voltage Battery
Type Lithium-ion polymer
Rated Voltage (V) Long-range : 352.8 (240~412)
Economy : 324 (225~387)
Energy (kWh) Long-range : 64
Economy : 39.2
Quantity for Pack
(Cell / Module)
Long-range : 98 cells / 5 modules
Economy : 90 cells / 3 modules
※
Specification
17

5. Stored Energy / Liquid / Gases / Solids
5.2 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, in
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 10 ).
•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 electrical
shock.
High Voltage Cables
18

6. In Case of Fire
Strict precautions must be taken while conducting firefighting operations due to following
reasons:
•
Lithium-ion Polymer batteries contain gel 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 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.
•
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.
6.1 Firefighting Operations
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 10,000 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.
19

6. In Case of Fire
6.3 How to Deal with the Situation
Fire Extinguish the fire with a large amount of water.
Don’t use seawater or salt water. Use of such water
can generate toxic vapors or cause re-ignition.
Damaged
battery or
Fluid leak*
Disconnect 12V Battery (-) terminal,
Disable the high voltage system,
Neutralize the battery by applying a large volume
of water. (Process will not discharge the battery.)
*To be used if electrolyte solution leakage or damage to the high voltage battery casing is
observed.
Battery
discharging
6.3.1 Vehicle Fire
•
Use a large volume of water (max. 100,000 liter). Water must cool down the battery.
•
If water is applied directly onto the high voltage battery module inside the casing, it will
better cool the battery. (But, never attempt to penetrate the HV battery or its casing to
apply water.)
•
Putting water into the high voltage battery can be difficult due to the battery case.
•
Put water through the hole that might be made due to the accident or fire.
20