Renault FLUENCE Z.E. User manual

FLUENCE Z.E. – Roadside assistance technician's guide
Network Development Division | February 2012 V3|
RENAULT PROPERTY
RENAULT FLUENCE Z.E.
ROADSIDE ASSISTANCE TECHNICIAN'S GUIDE

FLUENCE Z.E. – Roadside assistance technician's guide
RENAULT PROPERTY Network Development Division | February 2012 V3|
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INTRODUCTION
This document contains information for roadside technicians performing towing or
on-site breakdown repair operations.
This document describes the guidelines and precautions to be applied when
performing an operation on the Fluence Z.E. which has either broken down or been
damaged in an accident. These measures must be reviewed on a regular basis and
will be included in the final version of the roadside technician's guide.
This document must be read in full in order to understand the particularities of
these vehicles and thus prevent the risk of injury and electric shock during
operations.
As with any product that uses both high-voltage and low-voltage systems, it is
essential to follow specific procedures when carrying out work.
Vehicles which have broken down or been damaged in an accident must only be
towed or repaired by a qualified Electric Vehicle operative (with an authorization).
The few minutes spent reading this document will be very valuable in terms of the
information learnt concerning the safety, speed and quality of operations in order
to:
!prevent major mechanical and/or electrical damage during recovery
!better understand the possible and authorised towing configurations
!comply with the towing conditions defined by national legislation
!comply with the towing vehicle's payload
!act in a way that guarantees the safety of the occupants of the immobilised
vehicle.
"To identify the lockout methods in force according to the vehicle, consult the
Repair Methods on DIALOGYS or on INFOTECH on the internet.
(http://www.infotech.renault.com)

FLUENCE Z.E. – Roadside assistance technician's guide
RENAULT PROPERTY Network Development Division | February 2012 V3|
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INTRODUCTION….......................................................................................................................................2
CONTENTS…...............................................................................................................................................3
1 FLUENCE Z.E. IDENTIFICATION ....................................................................................……….............4/7
2 TECHNICAL DESCRIPTION OF THE FLUENCE Z.E. ..........................................................................8/10
3 BEHAVIOUR TO BE ADOPTED IN THE EVENT OF THE VEHICLE BEING SUBMERGED..............11/12
4 OPERATING PROCEDURE ON A VEHICLE DAMAGED BY FIRE.........................................................13
5 TOWING A FLUENCE Z.E. DAMAGED IN AN ACCIDENT.................................................................14/30
6 TOWING OR REPAIRING A BROKEN DOWN FLUENCE Z.E. ..........................................................31/32
7 REMINDER: TECHNICAL GUIDELINES FOR FLATBED/TOW DOLLY RECOVERY........................33/38
8 EQUIPMENTS, TOOLS AND SPARE PARTS TO CARRY ON-BOARD (Z.E. SPECIFIC) .................39/40
9 FLOW CHART FOR MAKING TOWING DECISIONS………………………………………………………41/43
Contents

FLUENCE Z.E. – Roadside assistance technician's guide
RENAULT PROPERTY Network Development Division | February 2012 V3|
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1. VEHICLE IDENTIFICATION:
Fluence Z.E. electric version differs from the internal combustion version by means of a design "signature"
with "blue-chrome" elements.
a. External identifying characteristics
Front view:
Main criteria:
#Blue chrome front logo
$Specific blue chrome upper air intake
aperture
%Blue-tinted front headlights
Secondary criteria:
&Lower air intake surround same colour
as car body
'Black registration plate surround
(Blue chrome fog lights or grained black
cover plates with 3 small ribs

FLUENCE Z.E. – Roadside assistance technician's guide
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Profile:
Charging flap closed Charging flap open
"The main external identifying characteristics of the electric vehicle are the 2 charging flaps
located on the front wings on each side of the vehicle as well as the absence of an exhaust
pipe.
"From the outside, a charging flap looks like a fuel filler flap.
"The name "FLUENCE" present on the rear strip of the vehicle is identical on internal
combustion vehicles and electric vehicles.
Rear view:
Main criteria:
#Z.E. badge
$Specific blue rear lights with internal
diamond-shaped mask
%Blue chrome rear diamond
&Blue chrome rear strip
Secondary criteria:
'Black strip above boot
(Absence of an exhaust pipe
)Absence of fuel filler flap on the right
rear wing

FLUENCE Z.E. – Roadside assistance technician's guide
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b. Identifying characteristics in the passenger compartment
Passenger compartment view:
#Specific instrument panel
$Blue Z.E. pictogram
On the instrument panel:
#Blue counter graphics
$Blue Z.E. pictogram
Warning lights specific to this electric vehicle
Fuel saver
Electro-technical fault
System temperature warning
Vehicle ready, traction active
Warning lights specific to this electric vehicle
Battery gauge
Battery discharged
Vehicle connected
Preconditioning

FLUENCE Z.E. – Roadside assistance technician's guide
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c. Identifying characteristics in the engine compartment
Engine compartment:
#Specific stickers on the accessible
400V components
$Orange 400V cables
1
2
1
2

FLUENCE Z.E. – Roadside assistance technician's guide
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2. TECHNICAL DESCRIPTION OF THE ELECTRIC VEHICLE
a. Power train and 400V electrical circuit
#Two electric charge
sockets
$Charger, connection unit
%Power electronics
&Electric motor
'Reducer
(Traction battery
)Reinforced suspension and
orange 400V cables
*Orange 400V cables and
connection zone between
cables and traction battery
b. Vehicle underbody
#Orange 400V cable
$Traction battery
%Aerodynamic casing
&Cutout switch
Traction battery
'Connection zone between the
cables and the traction battery
12
3
5
4
12
3
5
4

FLUENCE Z.E. – Roadside assistance technician's guide
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View from underneath, centre towards the front wheels:
Underbody Underbody without the aerodynamic casing,
orange 400V cable
c. 12V battery
The 12V battery on the electric vehicle is a standard 12V direct current battery - identical to the one used on a
conventional combustion engine vehicle. It is located in the engine compartment at the front of the vehicle.
The negative terminal is connected to the metallic chassis to create an electric earth.
Specifications of the 12 V battery
Voltage 12 V
Current intensity 70 A
Battery type Lead
Model L3 standard
d. 400 V traction battery
Specifications of the traction battery
Voltage 400 V
Current intensity 300 A
Capacity 24 kWh
Weight 295 kg
Battery type Lithium-ion
Dimensions 1200 x 750 x 800mm
"The vehicle’s battery is compatible with the Quick Drop system and must never
be removed outside approved stations or garages.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.

FLUENCE Z.E. – Roadside assistance technician's guide
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e. Energy transfer and isolation of the 400V circuit
All the 400V cables are ORANGE for identification purposes.
The 400V circuit, both positive and negative, is isolated from the vehicle's metal chassis.
400V circuit elements are related to the mass of the vehicle by an electrical link (ex: mass braids,..). These
links are a safety device for the occupants of the vehicle, the Emergency Services and stakeholders
roadsides against risk of electric shock.
Orange 400V cable Earth strap
"These connections must never be cut.
"These earth connections are a safety mechanism for the vehicle occupants,
the emergency services and roadside assistance technicians protecting
against the risk of electric shocks.
"The connections may be damaged in severe impacts. In this case, the
potential may no longer be equalised.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT
IN DEATH.

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3. BEHAVIOUR TO BE ADOPTED IN THE EVENT OF THE VEHICLE
BEING SUBMERGED
Case of a submerged vehicle:
For an electric vehicle, the reference of the electrical energy is the negative terminal of the traction battery.
The risk of electrifying only exists if a person comes into contact with the two electrical terminals of a circuit
supplied by the traction battery. There is therefore no danger involved in touching the water and the body of
the submerged vehicle.
The victims of an accident can be rescued, even if the vehicle is still in contact with the water
WARNING:
The vehicle can only be made secure after it has been removed from the water. If
an operation needs to be performed in a wet environment, you must comply with
the following recommendations.
"As a precautionary measure, during an operation on a vehicle which is partially
or entirely submerged, or more generally in a wet environment, do not touch the
orange 400V cables, the 400V components or the traction battery directly.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.

FLUENCE Z.E. – Roadside assistance technician's guide
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Securing the vehicle after it has been removed from the water
!Wear electrical safety gloves and a face shield (see page 40)
!Switch the ignition off
!Remove the traction battery cut-out switch (see pages 19 to 21), avoiding any skin contact with the
water pouring from the traction battery.
!Disconnect the 12V battery (see pages 22 to 23).
"After the vehicle has been removed from the water, it is essential to secure
the vehicle in order to prevent any risk of an additional accident in the
logistics chain (towing, storage, etc.)
"When removing the traction battery cut-out switch in a vehicle which has
been submerged, it is mandatory to wear insulating gloves and a face
shield.
"Always take care! Avoid all skin contact with the water pouring from the
traction battery when removing the cut-out switch
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.

FLUENCE Z.E. – Roadside assistance technician's guide
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4. OPERATING PROCEDURE ON A VEHICLE DAMAGED BY FIRE
"The procedures indicated in this chapter must be applied when handling a vehicle damaged
by fire.
"A vehicle in which the traction battery is smoking can quickly take fire. In this case, call the
fire service immediately, specifying that the vehicle involved is an electric vehicle then stand
away from the vehicle and wait for the emergency services to arrive.
Risks and protective equipment.
After the fire, the vehicle may still present an electrical risk due to the presence of live naked parts.
"Do not touch the damaged orange 400V cables or the 400V components
with your bare hands. Risk of serious injury and electric shock which may
result in death.
"If it is necessary to touch the damaged orange 400V cables or the 400V
components, it is mandatory to wear electrical safety gloves and a
face shield .

FLUENCE Z.E. – Roadside assistance technician's guide
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5. TOWING A FLUENCE Z.E. DAMAGED IN AN ACCIDENT
Any operation on a damaged electric vehicle requires the use of
protective equipment.
For any operation on a vehicle which has been damaged in an accident, the following must be worn:
•a face shield,
•electrical safety gloves of the correct size.
Electrical safety gloves
Face shield
No-voltage tester
The absence of voltage is measured using a device known as a NVT (no-voltage tester).
The measurement must be performed between the vehicle's metal chassis and the conductive core of the
damaged orange 400V cables.
This device must comply with the following standards:
European: EN 61 243-3
International: CEI 61 243-3
Insulating gloves for electrical work, class 00, test
voltage 2500V, operating voltage 500V.
Class III personal protective equipment, in
accordance with the following standards:
European: EN 60 903
International: CEI 60 903
Protects the face against projected liquids/solids and
short circuit electrical arcs.
Personal protective equipment in accordance with
European standards:
EN 166: personal eye protection, specification.
EN 170: personal eye protection, UV filter.

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a. Towing preparation procedure
All the steps described below are illustrated in the following pages:
"Put on high-visibility clothing before leaving the breakdown vehicle
"Make sure no-one is in the immediate vicinity of the vehicle involved in the accident
"Make sure the driver and passengers are in a safe place (e.g. behind safety barriers)
"Identify and immobilise the vehicle (see page 16)
"Wear electrical safety gloves and a face shield (see page 40)
"Disconnect the external voltage sources (e.g. charging lead, see page 18)
"Separate the supply sources (see pages 19 to 24)
"Lock the supply sources (see page 24)
"Verify the absence of voltage (see page 24)
""VEHICLE ELECTRICALLY SAFE" sign (see pages 25 to 27)
"The Fluence Z.E. must only be towed by a qualified electric vehicle operative
(with an authorization).
"Electrical safety gloves and a face shield must be worn when
working on the 400V circuit.
"Disconnect the vehicle's electrical circuits before carrying out any work on a
vehicle damaged in an accident (see page 19 to 24).
"A damaged component or cable on the 400V circuit may result in burns or
electrocution caused by electric shock.
"Do not touch the orange 400V cables or the 400V components if they are
damaged, without the use of electrical safety equipment.
"If the battery has been damaged, there is a risk of delayed battery fire; the
battery must therefore be monitored after the work is complete.
"A Fluence Z.E. which has been damaged in an accident must only be
transported on a flatbed (see page 29)

FLUENCE Z.E. – Roadside assistance technician's guide
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b. Immobilising the vehicle
"A stationary vehicle is silent. The motor may be running and there is a risk that the
vehicle may move.
"Only switching off the vehicle's ignition using the key will ensure that traction is
shut down.
Procedure:
!Apply the handbrake (image#).
11
!Switch off the ignition using the key, then
remove the key (image$).
22
!Place the gear selector lever in the P
(park) position. The drive wheels are then
locked mechanically (image%) (to unlock
the gear selector, see page 28).

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c. Procedure in case of electrolyte leakage from the 400V battery.
An electrolyte leak from the 400V battery is very unlikely.
However, if an electrolyte leak does occur, wear chemical safety gloves to protect against corrosion.
Distribute absorbent products and collect them for treatment using classic organic solvents.
The electrolyte in a lithium-ion battery is a clear fluid with a characteristic organic solvent odour.
The electrolyte is a flammable solution.
In case of leakage, ventilate the accident area if necessary.
Battery electrolyte is corrosive. Contact with the electrolyte will cause severe burns to the skin and eyes.
Do not breathe the fumes.
Wear safety gloves and goggles.
In case of ingestion, inhalation or contact with the skin or eyes, wash with plenty of water as soon as possible
and call a poison centre or a doctor.
d. Disconnecting a FLUENCE Z.E. damaged in an accident while charging
"Electrical safety gloves must be worn when disconnecting a charging
vehicle as part of this procedure.
Standard charging lead Charging lead for occasional use

FLUENCE Z.E. – Roadside assistance technician's guide
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Procedure:
!Wear electrical safety gloves and a face shield .
!If possible, cut the power supply to the charging socket to which the Fluence Z.E.is connected.
!Disconnect the charging lead on the power supply side.
!If the charging lead cannot be disconnected on the power supply side, disconnect the lead from
the vehicle.
zzzzzzzzzzzzzzz "The main power supply must be cut, if possible, before any work is carried out.
"Do not cut the charging lead. Risk of severe burns or electrocution.
"If the traction battery has been damaged, there is a risk of delayed battery fire; the
battery must therefore be monitored after the work is complete.
"If the vehicle is locked, an actuator prevents the charging plug from being removed
on the vehicle side. It is possible, though difficult, to pull the plug out. There is no
risk involved in this procedure, even in a wet environment, as long as electrical
safety gloves are worn.
"When the vehicle is locked, actuator prevents withdraw support decision-making side
vehicle. Pull this taking is possible but difficult. This operation is not risk of sur-accident,
even in a wet environment, as long as it is carried out with electrical protective gloves
and a face shield

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e. 400V circuit lockout
Procedure (refer to the Repair Manual for more details):
!Wear electrical safety gloves and a face shield .
!Position the "Warning: Danger" signs (see page 25)
!Locate the traction battery cutout switch (see illustration below).
!Remove the traction battery cutout switch and place it on the instrument panel
!Fit the lockout tool in place of the traction battery cutout switch.
!Fit the lockout padlock on the traction battery lockout tool
!Position the "Warning: Danger" signs (see page 26)
!Complete the lockout sheet (see page 27)
Locating the traction battery cutout
switch:
!The traction battery cutout switch is
located behind the vehicle's right
rear wheel.
!#The traction battery cutout
switch.
"Reminder: this operation must be carried out by a breakdown/recovery
operative qualified to work on electric vehicles

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Procedure for removing the traction battery cutout access safety cover:
Bottom view of the vehicle on the right rear
!To unlock the slide, press the clip and
slide the part.
Bottom view of the vehicle on the right rear
!Unlocked position.
Focus on the cover
!Push the cover to release the two lugs
from the panel support.