Sonata Hybrid - Electric Vehicle Safety Training
Contents
1. HYUNDAI Table of Contents introduction s a a e o a a 1 sonata Hybrid Identification sus aia tel 2 General Vehicle Description ssni A a Gare oe 2 Exterior Visual Identification r o nn Ea rt aes ssn ga aes eae cae ae are eee cheaters ER 2 Interior Visual Identification cst tig nolo tare eee eee eee oe et 6 Vehicle Systems Overview dd 8 Key Specifications ad E we Seek en Oe a cs ee id dd Vehicle Component Locations A er Say See ea cae Vehicle Components nextel re oo eas Hybrid System Operationerna Se cosas oes coke ence te eas Ot lt aa eee ae ane ees a 11 Operatine Parameters aat rea na co alee 11 High Voltage Electrical isolation renia r an a a A ae ee a a 12 Regulation of High Voltage Electrical Current s ssssessssesssssssessesessssess 12 High Voltage Safety System sree rresia de eiee a a AOS 12 Supplemental Restraint System SRS 2 ee ee ee ee eee eee 13 Emergency Response Procedures 0 ccc ccc ec cee ee ce eee e ete eee cence 15 initial Responses A is co ee ae coe eee eaten Se 15 CN E pa ar Serer tr tae ae eer ge ant en eer Smee aks E en anne eae aig te 15 MIMO A E cc teste A A O eras se meutar ede TON 16 BIS AIS OS we ae tae e o ee nie celo Le et Gah 17 ade fot d 6 eee eee eer mee Genre er ear an tao iMene eer ir Carer tant geen mar karan erat N E me army cree eae 21 Firenc MUNN real Comsat A RN tenet tae 22 SUI MESA hs Sere cet Fe cen tere teehee nee eee cs Anca oon ota Piensa dad 23 High Vol2. Density MSDS Page 6 of 8 Printed 10 11 4 Appendix Page A 6 HL Green Power MATERIAL SAFETY DATA SHEET 10 Stability and Reactivity Reactivity None Incompatibilities None during normal operation Avoid exposure to heat open flame and COITOSIVES Hazardous Decomposition Products None during normal operating conditions If batteries are damaged hydrogen fluoride and carbon monoxide may be released Conditions To Avoid Avoid exposure to heat and open flame Do not puncture crush or incinerate 11 Toxicological Information This product does not elicit toxicological properties during routine handling and use See es e Reproductive e Teratogenicity eee ty Acute toxicity If the batteries are opened through misuse or damage discard immediately Internal components of batteries are irritants and sensitizers 12 Ecological Information Some materials within the batteries are bioaccumulative Under normal conditions these materials are contained and pose no risk to persons or the surrounding environment MSDS Page 7 of 8 Printed 10 11 4 Appendix Page A 7 HL Green Power MATERIAL SAFETY DATA SHEET 13 Disposal Considerations California regulated debris RCRA Waste Code Non regulated Dispose of according to all federal state and local regulations 14 Transport Information UN No 3480 Class 9 Proper Shipping Name Lithium ion Batteries 15 Regulatory Information OSHA haza
3. 6 noted below Open the cover of 12V Auxiliary Battery in the trunk Make sure the booster battery is 12 volt and that its negative terminal is grounded If the booster battery is in another vehicle do not allow the vehicles to touch Turn off all unnecessary electrical loads Connect the jumper cables in the exact sequence shown in the illustration First connect one end of a jumper cable to the positive terminal of the discharged 12V Auxiliary Battery 1 Then connect the other end to the positive terminal on the booster battery 2 Connect one end of the other jumper cable to the negative terminal of the booster battery 3 Next connect the other end to a solid stationary metallic point such as the trunk latch striker away from the 12V Auxiliary Battery 4 Do not allow the jumper cables to contact anything except the correct battery terminals or the correct ground Do not lean over the battery when making connections Start the engine of the vehicle with the booster battery and let it run at 2 000 rpm Then start the engine of the vehicle with the discharged 12V Auxiliary Battery Turn the ignition to hybrid ready and the LDC will recharge the 12V Auxiliary Battery Note that the gasoline engine may start at any time when the ignition is in the ready position Hyundai Sonata Hybrid Ma e Keep all flames or sparks away from the battery The battery produces hydrogen gas that can explode if
4. The READY Indicator is visible when the ignition is ON and either the gasoline engine or the Electric Drive Motor is running Lastly the Energy Monitor can be seen when the ignition is ON EV Mode Indicator Hybrid Logo E o Ready Indicator Energy Monitor Page 6 Hyundai Sonata Hybrid Sonata Hybrid Identification High Voltage Battery Vents The battery venting is located inside the trunk Ambient air is drawn into the battery pack through an inlet on the top side of the pack The duct s inlet is on the rear package tray which is visible through the rear window Air is pushed out through a duct that exits to the exterior through a vent in the left rear wheelwell opening This vent is not easily seen or accessible to emergency responders Hyundai Sonata Hybrid Page 7 Vehicle Systems Overview Key Specifications Curb Weight 3578 pounds Gasoline Engine 166 hp 2 4L Hybrid Engine Fuel Tank 17 2 US gallons Electric Drive Motor 34 Kw 40 hp HV Battery Lithium ion polymer LiPB 270 Volt Transmission Automatic Seating Capacity 5 Vehicle Component Locations High Voltage Battery Assembly High Voltage Cable 12V Auxiliary Battery Hybrid Starter Generator HSG Fuel Tank Fuel Line Electric AC Compressor Hybrid Power Control Unit Electric Drive Motor Page 8 Hyundai Sonata Hybrid Vehicle Systems Overview The following components can be found in al
5. During overhaul operations it is important for responders to remember the dangers that are still present even after a fire has been extinguished Just as during a fire the same dangers exist They include but are not limited to e Harmful gasses e Reignition of fire e Electrical Burns Shock or Electrocution To protect oneself and others and to minimize potential risk resoonders should use appropriate Personal Protective Equipment PPE defined by the department s SOP s and ensure the vehicle s high voltage electrical system has been disabled The methods described at the beginning of the Emergency Response Procedures section page 17 should be followed Submersion Some emergency responses can involve a submerged vehicle A Sonata Hybrid that is submerged does not have high voltage potential on the vehicle s body or framework and is safe to touch whether it is in water or on land Procedure 1 Remove the vehicle from water 2 Drain the water from the vehicle 3 Disable the vehicle by using the methods described at the beginning of the Emergency Response Procedures section page 17 NOTE Once the vehicle has been removed from the water and drained the drained water that is surrounding the area will not be energized This is a benefit of the design of the Sonata Hybrid s high voltage electrical system It is designed to maintain its isolation from the vehicle s chassis and the surrounding area Hyundai So
6. Hybrid Page 25 Towing and Jump Starting Towing The Sonata Hybrid is no different from a conventionally powered gasoline engine vehicle with regard to towing If emergency towing is necessary Hyundai recommends having it done by an authorized Hyundai dealer or a professional tow truck service Proper lifting and towing procedures are necessary to prevent damage to the vehicle Because the vehicle has a front wheel drive powertrain using a flatbed or wheel dollies is recommended specific towing guidelines are described below A Towing via flatbed is the recommended method for transporting a Sonata Hybrid B If any of the loaded wheels or suspension components are damaged or the vehicle is being towed with the rear wheels off the ground use a towing dolly under the front wheels C The vehicle can be towed with the front wheels supported by the lifting equipment in most cases that do not involve damage to wheel tire or suspension components A CAUTION e Towing with sling type equipment or with the front wheels on the ground are not correct methods for towing this vehicle e To prevent damage to the vehicle always use wheel lift or flatbed equipment e Failure to use the proper towing methods will cause damage to the vehicle Page 26 Hyundai Sonata Hybrid Towing and Jump Starting Jump Starting Jump Starting the Sonata Hybrid is similar to conventional models Specific methods and warnings are 1
7. exposed to flame or sparks If these instructions are not followed exactly serious personal injury and damage to the vehicle may occur If you are not sure how to follow this procedure seek qualified assistance Automobile batteries contain sulfuric acid which is poisonous and highly corrosive When jump starting wear protective glasses and be careful not to get acid on yourself your clothing or on the car Do not attempt to jump start the vehicle if the discharged battery is frozen or if the electrolyte level is low the battery may rupture or explode Never attempt to check the electrolyte level of the battery as this may cause the battery to rupture or explode causing serious injury Page 2 7 Appendix A HL Green Power MATERIAL SAFETY DATA SHEET MATERIAL SAFETY DATA SHEET Model YF amp TF Battery Module Assembly 1 Chemical Product and Company Identification Product Identification HL Green Power Battery Module Assembly Manufacturer HL Green Power Ltd Sam dong Uiwang si Gyeonggi do 437 815 Korea Emergency Telephone Number 82 31 596 8214 2 Composition Information a Cell Composition Ingredients CAS Number Aluminum Foil 2 10 7429 90 5 Metal Oxide propietary 20 50 Polyvinylidene Fluoride PVDF lt 5 24937 79 9 Copper Foil 5 20 7440 50 8 Carbon proprietary 10 30 7440 44 0 Styrene Butadiene Rubber SBR lt 5 9003 55 8 CarboxyMethyl Cellulose CMC lt 5 Electrolyte proprietary 10 30 A
8. not remove this cover No cust i allo HYUNDAI 2011 Hyundai Motor America All rights reserved This document may not be altered without the written permission of Hyundai Motor America Document No YFHEV101_REV 0
9. age Battery It controls the battery cooling fan to ensure proper battery operation In addition if a system fault occurs the BMS turns off the PRA to protect the system Shown with back Seat Removed Page 12 Hyundai Sonata Hybrid Vehicle Systems Overview Supplemental Restraint System SRS Airbags The Sonata Hybrid is equipped with a total of six airbags for passenger protection These airbags are located in standard areas of the vehicle where emergency responders are accustomed to finding them Care should always be taken to secure any 12V power sources in the vehicle before extrication operations are initiated or emergency response personnel enter the vehicle This is critical in order to prevent any accidental deployment of the supplemental restraints Airbag Types and Locations Driver s Side Impact Frontal Curtain Side Impact Thorax Passenger Side Impact h Frontal Thorax Location Frontal Frontal Side Impact Thorax Side Impact Thorax Side Impact Curtain Side Impact Curtain Hyundai Sonata Hybrid Page 13 Vehicle Systems Overview Seatbelt Pretensioners The Sonata Hybrid has a total of four seatbelt pretensioners Two are located in the Driver s Side B pillar one is a Belt Pretensioner BPT and the other is an Anchor Pretensioner APT The other two are located in the Passenger s Side B pillar They also consist of a BPT and an APT Sensor and Control Module Locations T
10. dix A In an emergency refer to the manufacturer s MSDS For HV Battery Chemical Emergency Spill Leak Fire Exposure 1 800 424 9300 Accident Call CHEMTREC Day or Night Within USA amp Canada Disposal of Damaged HV Battery Pack Contact a local authorized Hyundai dealer Page 24 Hyundai Sonata Hybrid Emergency Response Procedures First Aid for Electrolyte Exposure The Sonata Hybrid HV battery pack is a self contained sealed unit and poses no electrolyte contamination hazards under normal conditions It is only under the rare instance of HV battery damage that the gel electrolyte would be exposed and a person could come in contact with it Follow these guidelines for electrolyte exposure If a victim has been exposed to electrolyte complete these steps first e Move victim to fresh air e Apply artificial respiration if victim is not breathing e Administer oxygen if breathing is difficult e Remove and isolate contaminated clothing and shoes e Ensure that other emergency responders are aware of the materials involved and take precautions to protect themselves Then treat the victim according to his her path of exposure Absorption Eye Contact Rinse eyes with water for 15 minutes Skin Contact Wash area thoroughly with soap and water Inhalation Remove the victim and leave the area immediately to avoid further exposure Ingestion Compel the victim to drink milk or water and induce vomiting Hyundai Sonata
11. elf contained and does not need to be recharged by an external power source such as a charging station The high voltage battery is recharged while the vehicle is being driven This is accomplished through the use of a generator that produces electricity during driving and braking Hyundai Sonata Hybrid Page 1 Sonata Hybrid Identification General Vehicle Description The Hyundai Sonata Hybrid is built on a conventional Sonata chassis and therefore the four door sedan looks very similar to its conventional counterpart The best approach is to assume that all Sonatas are Hybrids until proven otherwise Using the information provided in this section responders will be able to differentiate between the two Exterior Visual Identification Badging or Symbols The Sonata Hybrid can be identified by unique badging found on the exterior of the vehicle On the front of the vehicle is the Hyundai logo a slanted stylized H with a blue background there is a blue drive badge on each of the front fenders and on the passenger side of the trunk lid there is a hybrid badge Badging may become hidden after a crash due to damage to the vehicle Always be sure to inspect all sides of the vehicle before determining whether or not a badge is present Page 2 Hyundai Sonata Hybrid Sonata Hybrid Identification Vehicle Identification Number VIN The Vehicle Identification Number VIN is used to determine whether a vehicle is conve
12. en can be hidden by damage caused in a crash Responders must always be sure to inspect all sides of the vehicle as well as using the identifiers found under the hood and in the interior of the vehicle Hyundai Sonata Hybrid Page 15 Emergency Response Procedures Immobilize The next step is to immobilize the vehicle to prevent any accidental movement that can endanger the emergency response personnel and any crash victims Since the Sonata Hybrid has the ability to shut down the gasoline engine when it is not needed there will be instances where the vehicle appears to be off because of the absence of engine noise When in its ready mode the vehicle can move almost silently using the electric motor alone Responders should approach the vehicle from the sides and stay away from the front or rear as they are both potential paths of travel Instructions for immobilizing the vehicle are shown below OYF05902 Chock the Wheels Engage Parking Brake Place Vehicle in Park Page 16 Hyundai Sonata Hybrid Emergency Response Procedures Disable After the vehicle has been secured to prevent movement the final step in the initial response process is to disable the vehicle its SRS components and its high voltage electrical system This can be accomplished in one of two ways Primary Method Turn the vehicle off disconnect the 12V Auxiliary Battery and remove the Service Disconnect Plug 1 Determine if the vehicle is
13. he airbags and pretensioners are managed by the SRS Control Module or SRSCM which is located below the front of the center console In addition there are four side impact sensors two conventional accelerometer sensors in the B pillars and two pressure sensing sensors inside of the front door modules Their locations are illustrated in the image below SRS Component Locations Driver Airbag DAB Steering Wheel Clock Spring Seat Belt Pretensioner BPT Pressure Side Impact Sensor P SIS Side Impact Sensor SIS Side Airbag SAB Passenger Airbag PAB Front Impact Sensor FIS Curtain Airbag CAB Supplemental Restraint System Control Module SRSCM Airbag Warning Lamp Telltale Lamp Weight Classification System WCS Module Anchor Pretensioner APT Seat Track Position Sensor STPS 00 JDd0U0pswNA Page 14 Hyundai Sonata Hybrid Emergency Response Procedures Initial Response The following procedures should be utilized when working with a Sonata Hybrid at an emergency scene All other operations should be consistent with your department s SOPs or SOGs Identify When working with a Sonata at an accident scene emergency responders should always assume that it is a hybrid model until it can be proven otherwise using the identification features outlined at the beginning of this Emergency Response Guide ERG External badging will usually be the first indicator but it oft
14. he engine compartment fuse box cover lt oy A IA 3 gt T7 a EJ Bo W A Ay dy Engine Compartment Fuse Box Location Page 18 Hyundai Sonata Hybrid Emergency Response Procedures 3 Remove the IG1 relay tan Refer to the illustration for relay location If the correct relay cannot be recognized pull all of the fuses and relays from the fuse Y Mn Te a e ao 30 a ES pes box oe O ee oo PUMP 1 Oee E A HORN EJ RELAY EJ E 35 BOX Front WIPER THERN RELAY RELAY Engine Compartment Fuse Box 4 Disconnect the 12V Auxiliary Battery which is located in the trunk NOTE Before disconnecting the 12V Auxiliary Battery if necessary lower the windows and unlock the doors Once the 12V Auxiliary Battery is disconnected the window and door lock controls will not operate 5 Complete the steps shown below to remove the Service Disconnect Plug from the HV Battery Locate the Service Disconnect inside Trunk Release the Latch Move the Lever Down Pull the Plug Out Hyundai Sonata Hybrid Page 19 Emergency Response Procedures If neither of the preceding methods can be completed emergency responders must be aware of the potential for accidental SRS activation as well as understand that there is no guarantee that the high voltage system has been shut down PSTN AN HIGH VOLTAGE e Before any type of emergency service is performed on
15. ic Drive Motor During recharging the HPCU takes AC from the Electric Drive Motor and changes it to DC to charge the battery The HPCU assembly contains capacitors which take about 5 10 minutes to discharge after the high voltage system is shut down Electric Drive Motor Mounted between the engine and transmission the Electric Drive Motor is used for vehicle propulsion During deceleration or braking it acts as an alternator and charges the HV battery by converting the vehicle s kinetic energy into electrical energy Electric Drive Motor Automatic Transmission Hybrid Starter Generator HSG The HSG is mounted to the front of the engine A a near the intake manifold It cranks the engine for y starting and acts as a generator when the HV battery needs charging As this is one of the major components of the HV system its electrical connection via an orange HV cable is clearly visible Page 10 Hyundai Sonata Hybrid Vehicle Systems Overview Air Conditioning Compressor The Air Conditioning Compressor is mounted to the engine directly below the HSG It is also powered by the high voltage system so its electrical connection via an orange HV cable is easily noticeable as well Hybrid System Operation Operating Parameters The Hybrid Sonata is a full hybrid Depending upon acceleration needs and driving conditions it can be propelled by either the gasoline engine or the Electric Drive Motor o
16. ion Firefighting Operations If the high voltage battery pack is either involved in or at risk of being involved in a fire in a Sonata Hybrid strict cautions must be taken while conducting firefighting operations because of the following reasons e Lithium ion Polymer batteries contain gel electrolyte that can vent ignite and produce sparks when subjected to temperatures above 300 F e May burn rapidly with a flare burning effect e 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 Extinguishers To extinguish a small high voltage battery fire the following techniques can be used e Dry chemical e CO e Large amounts of water e Regular foam For a large high voltage battery fire use these types of extinguishing methods e Large amounts of water e Fog e Regular foam Placing Water on High voltage Electricity When approaching a vehicle fire on a Sonata Hybrid firefighters should not hesitate to extinguish the fire with water The vehicle s high voltage electrical system is well insulated and unlike the 12V electrical system it is not part of the vehicle s chassis Page 22 Hyundai Sonata Hybrid Emergency Response Procedures Overhaul Operations
17. l Sonata Hybrid vehicles 12V Auxiliary Battery The 12V Auxiliary Battery is located in the trunk on the passenger side of the vehicle and is accessed by removing a small cover This battery powers all of the standard electronics It also supplies current to the high voltage system relays which control the flow of high voltage current High Voltage HV Battery The Lithium ion Polymer HV battery contains a gel electrolyte and is made up of 72 3 75V cells wired in series for a nominal voltage of 270V with 5 3 Ah of capacity The battery is located behind the rear seat in the trunk area The battery pack weighs about 93 pounds Its dimensions are approximately 8 3 X 13 9 X 28 6 High Voltage Cabling The high voltage cabling in the Sonata Hybrid is orange per the SAE standard These cables run along the passenger side from the rear of the vehicle where they connect to the HV battery up to the front of the vehicle where they connect to the Electric Drive Motor and other HV components Hyundai Sonata Hybrid Page 9 Vehicle Systems Overview Hybrid Power Control Unit The Hybrid Power Control Unit HPCU assembly consists of four components a Hybrid Control Unit HCU an Inverter Motor Control Unit MCU and a Generator Control Unit GCU as well as a Low voltage DC DC Converter LDC This assembly takes Direct Current DC from the HV battery and changes it to alternating current AC to run the Electr
18. luminum Copper plate and inert materials Remainder N A MSDS Page 1 of 8 Printed 10 11 4 Appendix Page A 1 HL Green Power b Base Plate Pack Cover etc Composition Ingredients lron Manganese Carbon Ethylene vinyl acetate copolymer Phosphorus Sulphur 2 Ethylhexyl acrylate Ethyl acetate Silicon c Cell Module housing etc Composition Ingredients PA66 Talc PA6 Polybutylene terephthalate Copper PBT lron Polypropylene Polyvinylchloride d Wire Harness etc Composition Ingredients Copper PBT Polyvinylchloride 1 2 Benzenedicarboxylic acid di C8 10 branched alkyl esters C9 rich Limestone Polyamid 6 6 Hexanedioic acid polymer with hexahydro 2H azepin 2 one and 1 6 hex Polypropylene Zinc metal MSDS Page 2 of 8 Appendix Page A 2 MATERIAL SAFETY DATA SHEET 99 66 0 19 0 03 0 02 0 01 0 0077 0 005 0 005 0 005 40 60 24 96 17 30 6 96 4 44 1 49 1 21 0 63 0 40 60 56 11 64 8 51 7 09 6 86 2 08 1 1 0 48 0 17 CAS Number 439 89 6 439 96 5 440 44 0 24937 78 8 723 14 0 704 34 9 103 11 7 141 78 6 440 21 3 CAS Number 14807 96 6 26062 94 2 7440 50 8 439 89 6 9003 07 0 9002 86 2 CAS Number 440 50 8 9002 86 2 68515 48 0 1317 65 3 32131 17 2 24993 04 2 9003 07 0 440 66 6 Printed 10 11 4 HL Green Power MATERIAL SAFETY DATA SHEET 3 Hazards Identification Emergency Overview May explode in a fire which co
19. nata Hybrid Page 23 Emergency Response Procedures High Voltage Battery Damage Spills The HV Battery assembly is enclosed in a sturdy metal case that is rigidly mounted to structural components of the vehicle This construction helps prevent damage to the HV Battery assembly even in severe crashes This section provides emergency responders with information regarding how to mitigate the severity of a damaged HV Battery assembly or gel electrolyte spill however unlikely that might be Mitigation Procedures For a gel electrolyte spill or leak e Eliminate all ignition sources no smoking flares sparks or flames in the immediate area e Donot touch or walk through spilled material e Absorb electrolyte with earth sand or other non combustible material e Place leaking battery if removed from a vehicle and contaminated absorbant material in metal containers 4 WARNING Mos e Internal components of HV Batteries are irritants and sensitizers e To avoid contact with these irritants and sensitizers wear positive pressure self contained breathing apparatus SCBA and other personal protective equipment PPE designed for use with these types of hazards e Failure to wear proper SCBA and PPE can result in serious injury or death HV Battery Manufacturer Contact Information Emergency Phone Number HL Green Power Ltd 011 82 31 596 8214 Sam dong Uiwang si Gyeonggi do 437 815 Korea Material Data Safety Sheet MSDS See Appen
20. nect to a structural member of the vehicle and avoid placing cribbing under high voltage cables fuel lines and other areas not normally considered acceptable Cribbing Points Tire Deflation In some instances responders may determine the need to deflate the tires to stabilize the vehicle In this case note that this vehicle uses a Tire Pressure Monitoring System The sensors in the tires are mounted by means of a metal valve stem To rapidly deflate the tires it might be necessary to snap off the valve stem with pliers or remove the valve cap and Schrader valve Extrication Equipment and Techniques Standard extrication equipment can be employed on this vehicle and normal techniques and the dispatching unit s Standard Operating Procedures SOPs and Standard Operating Guidelines SOGs should be followed There are no high voltage cables or components in areas that are considered standard cut points Extrication personnel should always visually inspect the area being cut to ensure no SRS or high voltage components are compromised Hyundai Sonata Hybrid Page 21 Emergency Response Procedures Firefighting After Initial Emergency Response Procedures have been applied Firefighting Procedures may begin Hyundai recommends that each response team follow their own department s standard operating procedures for fighting vehicle fires in combination with the Sonata Hybrid specific details that are covered in this sect
21. ntional or hybrid The VIN is located on the driver s side windshield cowl and the driver s side door pillar The number 4 in the 8 character of the VIN indicates that it is a hybrid XXXXXXX4XXXXXXXXX 8th position Hyundai Sonata Hybrid Page 3 Sonata Hybrid Identification Engine Compartment Unlike the conventionally powered Sonata the Hybrid version has a plastic engine cover with hybrid clearly shown on it Additionally there are orange colored high voltage electrical cables in the engine compartment Page 4 Hyundai Sonata Hybrid Sonata Hybrid Identification Vehicle Underside An orange colored cable is also visible on the underside of the vehicle This cable runs along the passenger side from the rear of the vehicle to the engine compartment Other Notable Features Unlike the conventional Sonata the Hybrid has an Active Air Flap behind the front bumper This large black frontal area distinguishes the Hybrid from its conventional counterpart Hyundai Sonata Hybrid Page 5 Sonata Hybrid Identification Dashboard The Sonata Hybrid s instrument cluster contains several unique components that are not found ona conventional Sonata The hybrid logo is the most easily recognizable item in the instrument cluster It is visible no matter what the powertrain or ignition status may be The EV Mode Indicator is displayed when the Electric Drive Motor is being powered
22. ocation If the correct relay cannot be recognized pull all of the fuses and relays from the fuse box c D A Ser SPARE 254 a WMA Morada il wea la teu esc oiL cuts a DEICER RELAY 5 ES a a Tai amp wAn 3 Y jt ACC Wo tows aal ji S Cros lal a o VWF N Ml De ecu wan 9 sea laa al mou Pill FIPUMP PA RELAY RELAY E N EMS BOX Front RELAY Appendix Page B 3 A B Disconnect the 12V Auxiliary Battery which is located in the trunk NOTE Before disconnecting the 12V Auxiliary Battery if necessary lower the windows and unlock the doors Once the 12V Auxiliary Battery is disconnected the window and door lock controls will not operate Complete the steps shown below to remove the Service Disconnect Plug from the HV Battery Locate the Service Disconnect inside Trunk Release the Latch tic Move the Lever DownRelease the Latch Pull the Plug Out 44 WARNING Sooo High Voltage Labels AE IN High voltage labels are placed throughout the Sonata Hybrid on high voltage components These labels enable emergency responders to quickly identify potential electrical hazards REE CTURYEIEESITITNCMUE Ee RUG DWE DA PEGO IZA WARNING HIGH VOLTAGE BRAUN BA 228 HAAA OF BND T 2 You will be killed or hurt be Do
23. on or off by looking at the indicators on the instrument cluster see page 6 a If the vehicle is off move to step 2 b If the instrument cluster lights indicate the vehicle is on push the Engine START STOP power button located at the right of the steering column according to the conditions in the tables below Brake Pedal Not Applied START STOP Button START STOP Button Vehicle or BLUE N _ Brake Pedal Applied and Transmission in Park Press Engine LED Color on Engine START STOP Button START STOP Button Vehicle or Hyundai Sonata Hybrid Page 17 Emergency Response Procedures 2 If possible remove the proximity key from the vehicle Keep the key a minimum of 6 feet away to prevent accidental restarting of the vehicle until the 12V Auxiliary Battery is disconnected 3 Disconnect the 12V Auxiliary Battery which is located in the trunk NOTE Before disconnecting the 12V Auxiliary Battery if necessary lower the windows and unlock the doors Once the 12V Auxiliary Battery is disconnected the window and door lock controls will not operate 4 Remove the Service Disconnect Plug from the HV Battery by following the procedure shown below Locate the Service Disconnect inside Trunk Release the Latch Move the Lever Down Pull the Plug Out Secondary Method Remove fuse or relay disconnect the 12V Auxiliary Battery and remove the Service Disconnect Plug 1 Open the hood 2 Remove t
24. r a combination of both Charging is accomplished through regenerative braking during deceleration or by obtaining power from the HSG Driving conditions Driving state Driving Driving Acceleration Startu Deceleration Stoppage Low speed High speed Hill climbing ECOS Power Als Engine stops source automatically Motor Motor Engine Recharging the by ISG battery Hyundai Sonata Hybrid Page 11 Vehicle Systems Overview High Voltage Electrical Isolation Unlike the 12V electrical system that is grounded to the vehicle s chassis the Sonata Hybrid s high voltage electrical system is designed to be isolated from the vehicle Regulation of High Voltage Electrical Current Current from the High Voltage Battery is controlled by the Power Relay Assembly PRA which consists of Positive and Negative Main Relays a Pre charge Relay Pre charge Resistor and the Battery Current Sensor The PRA is located inside the High Voltage Battery Pack Assembly and controls the high voltage power circuit between the High Voltage Battery and the Hybrid Power Control Unit High Voltage Safety System There are multiple safety systems incorporated into the Sonata Hybrid The system that protects the High Voltage Electrical System is called the Battery Management System BMS The BMS is located inside the High Voltage Battery Assembly and measures several parameters to maintain the optimal performance of the High Volt
25. rd communication standard 29 CFR 1910 1200 v Hazardous Non hazardous MSDS Page 8 of 8 Printed 10 11 4 Appendix Page A 8 Hyundai Sonata Quick Reference Guide O g Ma A pa m a IA Ja E i ol SO ie de ef pa E E TA NA O Exterior Visual Identification e Badging or Symbols The Sonata Hybrid can be identified by unique badging found on the exterior of the vehicle On the front of the vehicle is the Hyundai logo a slanted stylized H with a blue background there is a blue drive badge on each of the front fenders and on the passenger side of the trunk lid there is a hybrid badge Badging may become hidden after a crash due to damage to the vehicle Always be sure to inspect all sides of the vehicle before determining whether or not a badge is present Vehicle Identification Number VIN The Vehicle Identification Number VIN is used to determine whether a vehicle is conventional or hybrid The VIN is located on the driver s side windshield cowl and the driver s side door pillar The number 4 in the 8 character of the VIN indicates that it is a hybrid Engine Compartment Unlike the conventionally powered Sonata the Hybrid version has a plastic engine cover with hybrid clearly shown on it Additionally there are orange colored high voltage electrical cables in the engine compartment Vehicle Underside An orange colored cable is also visible on the underside of the vehicle Thi
26. s cable runs along the passenger side from the rear of the vehicle to the engine compartment Other Notable Features Unlike the conventional Sonata the Hybrid has an Active Air Flap behind the front bumper This large black frontal area distinguishes the Hybrid from its conventional counterpart Py L mer vi roy Rennes A Ant fie tir Interior Visual Identificatio Dashboard The Sonata Hybrid s instrument cluster contains several unique components that are not found on a conventional Sonata EV Mode Indicator Hybrid Logo Energy Monitor Ready Indicator Hyundai Sonata Quick Reference Guide Vehicle Component Locations High Voltage Battery Assembly High Voltage Cable 12V Auxiliary Battery Hybrid Starter Generator HSG Fuel Tank Fuel Line Electric AC Compressor Hybrid Power Control Unit Electric Drive Motor Initial Response Disable After the vehicle has been secured to prevent movement disable the vehicle its SRS components and its high voltage electrical system This can be accomplished in one of two ways Primary Method Turn the vehicle off disconnect the 12V Auxiliary Battery and remove the Service Disconnect Plug 1 Determine if the vehicle is on or off by looking at the indicators on the instrument cluster see page 6 a If the vehicle is off move to step 2 b If the instrument cluster lights indicate the vehicle is on push the Engine START STOP power b
27. tage Battery Damage SpillS 2 2 oc ee cee eee eee eens 24 Mitigation Procedures ta nhc dO coe creator site a cts Gah leet Seen ican a nears 24 First Aldi fOr Electrolyte EXPOSURE tt O rail A 25 TOWINE JUMP Strung ae A A ced A ea ect AN ay nares ea ct lee 26 TOWN DAA repel A AU me NN A A NA 26 JUANA la cay haar Ra 27 APPEAR area rari A E e A o A 1 APPENA A A RA A RA A cae B 1 Hyundai Sonata Hybrid Introduction Foreword Hyundai has high standards and is dedicated to the safety of our customers and emergency responders alike Hyundai is providing this hybrid vehicle information as a result of our commitment to safety Document Purpose The purpose of this document is to familiarize emergency responders and the towing roadside assistance industry with the proper methods to treat the Hyundai Sonata Hybrid in an emergency situation This guide offers a basic overview of key vehicle systems and provides instructions for dealing with the different types of situations encountered by emergency responders The emergency response procedures for this vehicle are somewhat similar to a conventional Sonata with additional information provided on dealing with the high voltage electrical system Vehicle Description As with other hybrids the Hyundai Sonata Hybrid uses a conventional gasoline powered internal combustion engine paired with a high voltage electric motor to propel the vehicle The high voltage electrical system is completely s
28. the battery is incinerated Combustion products include but are not limited to hydrogen fluoride carbon monoxide and carbon dioxide Extinguishing Media Use extinguishing media suitable for the materials that are burning Special Firefighting Instructions If possible remove battery from fire fighting area If heated above 150 C Battery may explode vent Firefighting Equipment Use NIOSH MSHA approved full face self contained breathing apparatus SCBA with full protective gear Accidental Release Measures On Land Place material into suitable containers and call local fire police department In Water If possible remove from water and call local fire police department Handling and Storage Handling No special protective clothing required for handling individual batteries Storage Store in a cool dry place MSDS Page 5 of 8 Printed 10 11 4 Appendix Page A 5 HL Green Power MATERIAL SAFETY DATA SHEET 8 Exposure Controls Personal Protection Engineering controls Keep away from heat and open flame Store in a cool dry place Personal Protection Respirator Not required during normal operations SCBA required in the event of a fire Eye face protection Not required beyond safety practices of employer Gloves Not required for handling of batteries Foot protection Steel toed shoes recommended for large container handling 9 Physical and Chemical Properties Vapor density Deasy
29. this vehicle the high voltage system must be shut down Wait 5 10 minutes after shut down to allow high voltage capacitors to discharge sufficiently e Even after the high voltage system has been shut down and discharged all high voltage components should be treated as if they are still energized e Failure to shut down and disable the high voltage system prior to emergency operations can result in serious injury or death e SRS Components can be unintentionally deployed e To avoid unintentional deployment the 12V electrical system must be shut down Wait 3 minutes after the system is shut down or disabled to allow the voltage to discharge sufficiently Do not cut through any SRS Component e Failure to shut down and disable the SRS system prior to emergency operations or cutting through SRS Components can result in serious injury or death Page 20 Hyundai Sonata Hybrid Emergency Response Procedures Having addressed the general initial resoonse procedures for handling the Sonata Hybrid in an emergency the following sections will address specific types of emergencies Extrication Extrication operations for the Sonata Hybrid are almost the same as for a conventional vehicle but with some notable exceptions Utilize the Identify Immobilize and Disable model described in the previous pages prior to engaging in extrication operations Vehicle Stabilization Use standard stabilization cribbing points Always be sure to con
30. uld release hydrogen fluoride gas Use extinguishing media suitable for materials burning in fire Primary routes of entry Skin contact NO Skin absorption NO Eye contact NO Inhalation NO Ingestion NO Symptoms of exposure Skin contact No effect under routine handling and use Skin absorption No effect under routine handling and use Eye contact No effect under routine handling and use Inhalation No effect under routine handling and use Reported as carcinogen Not applicable MSDS Page 3 of 8 Printed 10 11 4 Appendix Page A 3 HL Green Power MATERIAL SAFETY DATA SHEET 4 First Aid Measures Inhalation Not a health hazard Kye contact Not a health hazard Skin contact Not a health hazard Ingestion If swallowed obtain medical attention immediately IF EXPOSURE TO INTERNAL MATERIALS WITHIN BATTERY DUE TO DAMAGED OUTER CASING THE FOLLOWING ACTIONS ARE RECOMMENDED Inhalation Leave area immediately and seek medical attention Kye contact Rinse eyes with water for 15 minutes and seek medical attention Skin contact Wash area thoroughly with soap and water and seek medical attention Ingestion Drink milk water and induce vomiting seek medical attention MSDS Page 4 of 8 Printed 10 11 4 Appendix Page A 4 HL Green Power MATERIAL SAFETY DATA SHEET 5 Fire Fighting Measures General Hazard Battery is not flammable but internal organic material will burn if
31. utton located at the right of the steering column according to the conditions in the tables below Brake Pedal Not Applied Press Engine f START STOP LED Color on Engine State o START STOP Button Vehicle Button po andtime ue ON OFF Brake Pedal Applied and Transmission in Park Press Engine f START STOP LED Color on Engine Stateo START STOP Button Vehicle Button o BLUE START 2 If possible remove the proximity key from the vehicle Keep the key a minimum of 6 feet away to prevent accidental restarting of the vehicle until the 12V Auxiliary Battery is disconnected 3 Disconnect the 12V Auxiliary Battery which is located in the trunk NOTE Before disconnecting the 12V Auxiliary Battery if necessary lower the windows and unlock the doors Once the 12V Auxiliary Battery is disconnected the window and door lock controls will not operate 4 Remove the Service Disconnect Plug from the HV Battery by following the procedure shown below A Locate the Service Disconnect inside Trunk B Release the Latch Hyundai Sonata Quick Reference Guide 4 5 C Move the Lever DownRelease the Latch D Pull the Plug Out Secondary Method Remove fuse or relay disconnect the 12V Auxiliary Battery and remove the Service Disconnect Plug 1 Open the hood 2 Remove the engine compartment fuse box cover 3 Remove the IG1 relay tan Refer to the illustration for relay l
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