Kia OPTIMA PHEV User manual

Emergency Response
Guide
Version_1
1
OPTIMA PHEV
(JF PHEV)

1. Identification / Recognition
3
2. Immobilization / Stabilization / Lifting
8
3. Disable Direct Hazards / Safety Regulations
9
4. Access to the
Occupants
15
5. Stored
Energy / Liquid / Gases / Solids
18
6. In
Case of Fire
21
7. In
Case of Submersion
25
8. Towing / Transportation /
Storage
26
9. Important
Additional Information
28
Contents
2
OPTIMA PHEV

1. Identification /
Recognition
Initial Response: Identify, Immobilize and Disable
Identify
•
The OPTIMA PHEV is an hybrid electric vehicle. Emergency responders should
respond
to emergency scenarios involving the OPTIMA PHEV 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 OPTIMA
PHEV
at
an emergency scene. However, all operations should be consistent with
your
department's
standard operating procedures, guidelines, and any applicable laws. When
an
PHEV
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
OPTIMA PHEV
WARNING

1. Identification /
Recognition
1.1 Identifying a Kia OPTIMA PHEV
Charging Port
•
The charging port is located on the side of the vehicle.
#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, put the vehicle in
P(Park)
position and turn off the vehicle.
3.
Open the charging inlet door by pressing rear
center
edge of the charging inlet door
Unlock
charging door in emergency
4
Orange
Color Cable
Orange color cables run under the floor of the vehicle and under the hood. When opening
the hood, the orange color cable identifies a PHEV.
OPTIMA PHEV
•
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 port door will then open.

1. Identification /
Recognition
1.1 Identifying a Kia OPTIMA PHEV
VIN Label
The
VIN (Vehicle Identification Number) identifies the Plug-in hybrid with a “D”
displayed
in
the 8th position, as shown in the below drawing.
The VIN can be found:
1) VIN Plate can be seen through the windshield from outside.
2) Underneath the front passenger seat (or driver seat)
3)
On the vehicle certification label attached to the driver’s side center pillar
5
OPTIMA PHEV
XXXXXXXDXXXXXXXXX

1. Identification /
Recognition
1.1 Identifying a Kia OPTIMA PHEV
The
OPTIMA plug-in hybrid Cluster Instrument Panel displays the PHEV specific
features
such
as high voltage battery SOC (State of Charge) in the highlighted part.
OPTIMA PHEV Cluster Instrument Panel
6
OPTIMA PHEV

1. Identification /
Recognition
1.1 Identifying a Kia OPTIMA PHEV
Charge Status Indicator
The
High Voltage battery Charge Status Indicator is visible from outside the vehicle. It
is
seen
through the windshield at the center of the crash pad and is illuminated when
the
vehicle
is plugged-in and charging.
7
OPTIMA PHEV

2. Immobilization / Stabilization / Lifting
Chock the wheels
Set the Electronic Parking
Brake (EPB)
Put the vehicle
in P (Park) position
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
The next step is to immobilize the vehicle to prevent any accidental movement that can
endanger response personnel or civilians. When the OPTIMA PHEV 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.
8
OPTIMA PHEV
•
When installing a block or jack, avoid high voltage cable, battery and fuel system.
•
If high voltage components or cables are exposed, do not place any support on them.
WARNING

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, put the vehicle in ‘P' (Park) position, and press the
POWER
button
.
9
Case I
Power
Off
12V battery
disconnection
High voltage
shut off
Case II*
12V battery
disconnection
Fuse removal
(Fuse box)
High voltage
shut off
OPTIMA PHEV
*In case of emergency

3.
Disable Direct Hazards / Safety Regulations
2.
If necessary, lower the windows, unlock the doors and open the trunk as
required,
before
disconnecting the 12V battery. Once the 12V battery is disconnected,
power
controls
will not operate. (Refer to below “4. –b” 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.
10
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
OPTIMA PHEV

3.
Disable Direct Hazards / Safety Regulations
4. Follow the procedure below to remove the safety plug and disable the high voltage battery:
c) Remove the luggage cover board and the side luggage foam in the trunk.
d) Remove the safety plug cover (B) by removing the mounting (10mm) bolts (A).
11
OPTIMA PHEV
a) Turn the ignition switch OFF and remove the luggage side trim [RH] side cover.
b) Disconnect the battery negative (-) terminal.

3.
Disable Direct Hazards / Safety Regulations
12
e)
Unfasten the hook (A) to the direction of arrow.
f) Unfasten the lever (A) to the direction of arrow.
OPTIMA PHEV
g)
Remove the safety plug (A).

3.
Disable Direct Hazards / Safety Regulations
1. Open
the hood.
3.2 Disabling the System
–IG (Ignition) Fuse Removal
2.
Remove the engine room fuse
box
cover
.
3.
If necessary, lower the
windows,
unlock
the doors and open the trunk
as
required,
before disconnecting the 12
V
battery
(located in the right side
of
luggage
compartment). 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
“Power”
START/STOP
Button, using the
fuse
puller
located in the engine room
fuse
box,
pull both the IG1, IG2 and
IG3
fuse
from the engine room fuse
box.
If
the IG fuses cannot be located,
pull
out
all of the fuses and relays in
the
fuse
box.
13
OPTIMA PHEV
Engine room fuse box

3.
Disable Direct Hazards / Safety Regulations
If
previously mentioned methods of disabling the vehicle’s system are unsuccessful,
any
emergency
procedures involving the PHEV vehicle may cause the
accidental
deployment
of undeployed airbags and electric shock from high-voltage components.
5. R
emove the safety plug and disable the high voltage battery
•
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
14
OPTIMA PHEV
WARNING

4. Access to the
Occupants
4.1 Extraction Operations
The
OPTIMA PHEV is a eco friendly 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 OPTIMA PHEV, 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.
15
OPTIMA PHEV

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.
16
OPTIMA PHEV

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.
17
Supplemental Restraint Syst
em Control Module (SRSCM) Airbag Airbag Inflator
High voltage cable Air-conditioning line
Seat belt pretentioner
Service Plug
12V battery
Ultra-High Strength
Steel
High Voltage Battery Air-conditioning
component Gasoline fuel
tank & Line
OBC (On-Board charger)
12V battery (-) connector
High voltage charge
port
OPTIMA PHEV
LHD
High voltage component

5. Stored
Energy / Liquid / Gases / Solids
5.1 High
Voltage System
18
OPTIMA PHEV
OPTIMA(
JF)PHEV Specification
Capacity 27.4 Ah
Voltage 360 V
Energy 9.8 kWh
Power Cable
Transaxle
Hybrid Drive
Motor Assembly
Hybrid Starter Generator
(HSG)
Engine
Main High Voltage Battery System
Sub High Voltage Battery System

5. Stored
Energy / Liquid / Gases / Solids
5.1 High
Voltage System
19
Motor
The motor of the PHEV converts electrical energy
into motive force with a Max. power of 67Hp (50kW)
and Max. torque of 151lb-ft (205Nm).
HPCU
The HPCU 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 transfers high voltage
electricity to 12 voltage to charge 12V auxiliary
battery.
HSG (Hybrid Starter Generator)
The HSG restarts the engine in the ICE/HEV
modes, and also charges the high voltage battery
while driving, as this is the generator for hybrid
vehicle.
PHEV
–High Voltage Battery
High voltage battery modules supply and store
electric energy from traction motor and it is a
Lithium ion polymer battery with specifications,
360V / 27.4Ah / 9.8kWh.
On
-Board Charger (OBC)
The
OBC is the battery charging equipment
that
converts
external AC to DC to charge the high
voltage
battery
.
OPTIMA PHEV

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
HPCU,
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 PHEV 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 11 ).
•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.
High Voltage Cables
20
OPTIMA PHEV
WARNING