Kia SORENTO HEV User manual

Emergency
Response
Guide
Version_1
1
SORENTO HEV

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
20
7. In Case of Submersion
24
8. Towing / Transportation / Storage
25
9. ImportantAdditional Information
27
Contents
2
SORENTO HEV

1. Identification / Recognition
Initial Response: Identify, Immobilize and Disable
Identify
The
Sorento Hybrid is a hybrid electric vehicle. Emergency responders should respond
to
emergency
scenarios involving the Sorento HEV 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 Sorento Hybrid
at
an
emergency scene. However, all operations should be consistent with your
department's
standard
operating procedures, guidelines, and any applicable laws. When HEV 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), including high voltage safety gloves and boots. Remove
all
metallic
jewelry, including watches and rings.
3
SORENTO HEV
WARNING

1. Identification / Recognition
1.1 Identifying a Kia SORENTO HEV
4
SORENTO HEV
Orange Color Cable
Orang
e color cables run under the floor of the vehicle and under the hood. When opening
the hood, the orange color cable identifies a HEV.
“Eco hybrid” Logo on Tailgate
The
Sorento Hybrid can be easily identified by the
“Eco hybrid” logo attached on the tailgate.
The
eco hybrid 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 hybrid car.
Engine
room
“Hybrid”
is also specified on the engine room cover under the hood.
HYBRID

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

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

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 Sorento HEV 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.
•
If high voltage components or cables are exposed, do not place any support on them.
SORENTO HEV
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, press the 'P' (Park) button on the rotary shifter dial,
and
press
the POWER button.
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
SORENTO HEV

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

3.
Disable Direct Hazards / Safety Regulations
4. Follow the procedure below to remove the interlock connector and
disable the high voltage battery :
b)
Remove the auxiliary battery service cover (A).
a)
Open the luggage mat (A).
10
c)
Disconnect the auxiliary 12V negative (-)
battery terminal (A) after loosening the nut.
d)
Disconnect the service interlock connector (A).
If the service interlock connector
can not be disconnected, cut the
service interlock connector wire.
SORENTO HEV

3.
Disable Direct Hazards / Safety Regulations
1. Open
the hood.
3.2 Disabling the System
–IG (Ignition) Fuse Removal
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
12
V battery (located in the left side
of
PE(Engine)
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
“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
SORENTO HEV

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 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
SORENTO HEV
WARNING

4. Access to the Occupants
4.1 Extraction Operations
The
Sorento Hybrid is an hybrid 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 Sorento Hybrid, 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
SORENTO HEV

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
SORENTO HEV

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 System
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
12V battery (-) connector
LHD
SORENTO HEV

5. Stored Energy / Liquid / Gases / Solids
5.1 High Voltage System
Motor
The HPCU is the main high voltage 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 convertsAC to DC to charge the high voltage battery. The LDC converts high
voltage electricity to 12 voltage to charge the 12V auxiliary battery.
HPCU
HSG
High voltage
battery
The electric motor of the HEV converts electrical energy into motive force with a Max. power of
59.7Hp (44.2kW) and Max. torque of 194lb-ft (264Nm).
Motor
16
Capacitor in HPCU
•
There is the capacitor inside the HPCU. Wait 5+ minutes for the capacitor to discharge
after removing the service plug.
SORENTO HEV
HPCU
HSG
The
HSG is short for hybrid starter generator. It acts as a starter motor when a Sorento HEV
starts and also acts as a alternator as well.
High voltage
power cable
Engine
HSG
Motor + Transmission
WARNING

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
Sorento HEV chassis.
12V
Auxiliary Battery
The 12V auxiliary battery is located under the luggage, and powers
all of the vehicle’s standard electronics like radio, lights, door locks,
power windows,
etc. Also, it powers the HPCU (Hybrid 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) 44.2 kW
Max Torque (Nm) 264 Nm
HSG Max. Output (kW) 13 kW
Max Torque (Nm) 43.2 Nm
High Voltage Battery
Type Lithium-ion polymer
Rated Voltage (V) 270
Energy (kWh) 1.49
Quantity for Pack
(Cell / Module) 8 Cells X 9 Modules
※
Specification
17
SORENTO HEV

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, 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. (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
SORENTO HEV
WARNING

5. Stored Energy / Liquid / Gases / Solids
5.3 Fuel (Gasoline)
19
Sorento
HEV has a 1.6L 4-cylinder engine. The fuel type is gasoline that is stored in the
fuel
tank
and delivered through the fuel line. When dealing with an emergency situation,
be
careful
not to cut the fuel line and tank.
Fuel tank
Fuel line
Fuel tank
SORENTO HEV

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.
20
SORENTO HEV