NFPA ELECTRIC VEHICLE SAFETY FOR EMERGENCY RESPONDERS Module III : Vehicle Systems and Safety Features Module III : Vehicle Systems and Safety Features 3-1

NFPA ELECTRIC VEHICLE SAFETY FOR EMERGENCY RESPONDERS Module III : Vehicle Systems and SafetyFeatures Describe the operation of P/HEV and EV systems. Terminal Objective ●Define terms related to P/HEV and EV systems. ●Compare and contrast P/HEV’s and EV’s. ●List major components of P/HEV systems. ●List major components of EV systems. Enabling Objectives 3-2 Module III Objectives

Hybrid Electric (HEV) All hybrids use batteries and electric motors to reduce demand on the internal combustion engine (ICE). ●Allows better fuel economy. ●ICE can shut down when not needed. ●Some Hybrids can drive short distances on electric power only (silent movement hazard). ●For response purposes, treat all hybrids the same. 3-3 Toyota Prius Honda Civic Hybrid

Plug-In Hybrid Electric (PHEV) Increases battery charge Increases range Reduces dependence on the gasoline engine. A hybrid vehicle that allows the battery to be charged via an external power source Toyota Prius

Electric Vehicle Electric motors are the only means of propulsion. 3-5 Vehicle must be charged by an external power source. Nissan Leaf

Extended Range Electric Vehicle Electric motors provide the propulsion. When battery is low, gasoline generator provides the electricity for the motor. For emergency response, treat as a PHEV with… a gasoline engine high voltage battery electric propulsion possible external power. 3-6 Chevrolet Volt

High Voltage Battery Recharging Methods External Power (Plug In) Regenerative Braking Engine Power

Term: Regenerative Braking ●During braking, wheels turn the electric motor, making it act as a generator and produce electricity. ●Electricity routed to HV battery to increase charge. 3-8 Can damage HV system if towed with drive wheels on ground (fire hazard).

Video Vehicle Types 3-9

Video Vehicle Types 3-10

3-11 Response Breakdown ●Hybrids ●Plug-in Hybrids ●Extended Range EVs High Voltage and Fuel High Voltage Only ●Pure EVs Vehicle types by hazards

HEV / PHEV / EV VEHICLE COMPONENTS 3-12

Standard Components VDC battery can be located in various locations around vehicle. Common Locations: · Trunk / Cargo compartment · Under hood Internal Combustion Engine (Not in EVs) 12 Volt DC Battery Less Common Locations: · Front wheel well · Under 2 nd Row seats

High Voltage Batteries Battery Types Lithium Ion Various Materials NiMH Nickel Metal Hydride 3-14

High Voltage Batteries Nickel Metal Hydride (NiMH) Battery 3-15 ●Most common battery in HEVs. ●Electrolyte is caustic alkaline and may produce harmful fumes if exposed.

3-16 High Voltage Batteries Lithium Ion (Li-Ion) Battery ●Most common in PHEVs and EVs. ●Different from Li-Ion batteries in home electronics. ●Electrolyte may produce harmful, flammable fumes if exposed.

3-17 High Voltage Batteries Small Cells in Series ●High voltage batteries are made of many small, low- voltage cells. ●Small cells wired in series to multiply voltage. ●Ex: Four 1.5 VDC batteries in series equals 6 VDC.

High Voltage Batteries Location of Batteries in HEVs, PHEVs Generally located in rear of vehicle. Under 2 nd row seating in most SUVs and trucks, in trunk/ cargo area in most sedans. 3-18

High Voltage Batteries Location of Batteries in EVs ● EV Batteries are often larger and of higher capacity than P/HEV batteries. higher capacity than P/HEV batteries. ● Usually located under the floor of the vehicle. the vehicle. 3-19

Video 12 VDC and High Voltage Batteries 3-20

Video 12 VDC and High Voltage Batteries 3-21

High Voltage Batteries Service Disconnects ● Recommendations for use and required use and required safety equipment vary safety equipment vary by manufacturer. by manufacturer. Consult appropriate Consult appropriate ERG before using ERG before using service disconnect. service disconnect. ● Located on the HV battery. HV battery. ● Physically disconnects the HV battery from HV the HV battery from HV systems. systems Service disconnect will be addressed later in course.

Inverter/ Converter ● Found in vehicles using AC drive motors. ● Converts DC from HV Battery to AC to run motor. ● Converts AC from regenerative braking back to DC to charge HV Battery. DC to charge HV Battery Located under hood

Inverter/Converter ● Capacitors inside unit can store energy for a period of time. for a period of time. ● If damaged, capable of rapid energy discharge that can cause severe injuries. discharge that can cause severe injuries Located under hood Dangerous to penetrate cover with tools.

DC-DC Converter ● Provides same functions as alternator in conventional vehicles. conventional vehicles. ● Steps down high voltage DC from the HV battery to 12 VDC to run low voltage systems. battery to 12 VDC to run low voltage systems DC-DC Converter (APM) for Chevrolet Volt ● Serves as second 12V second 12V power supply power supply (in addition to (in addition to 12V battery). 12V battery).

DC-DC Converter ● In some models the DC-DC converter is housed in the inverter/converter module. housed in the inverter/converter module. 3-26

High Voltage Battery Relay 3-27 ● Located on HV Battery. ● Functions like a switch. ● Activated by 12v power from the low voltage from the low voltage system system ● Removal of 12v power causes the relay power causes the relay to open, stopping the to open, stopping the flow of HV current flow of HV current

Video The 12V System and the HV Relay 3-28

Video 3-29 The 12V System and the HV Relay

Video High Voltage Battery Relay Animation 3-30

Video High Voltage Battery Relay Animation 3-31

EV/ HEV Cabling 3-32 ●Low Voltage: <30 Volts Often Red or Black ●Intermediate: Volts Usually Yellow or Blue Usually Yellow or Blue ●High Voltage: >60 Volts Orange Color coded to SAE voltage levels

Medium/High Voltage Cabling Medium and high voltage should both be considered highly dangerous For safety, treat yellow and blue cables the same as high voltage orange.

Location 3-34 High Voltage Cabling ●Between the HV battery, HV components, and the electric motor. battery, HV components, and the electric motor. ●Typically routed along the underside of the vehicle and under hood.

Construction/Fault Protection If a cable is compromised or damaged, the system is designed to detect the damage and shut down For safety, ALL high voltage cable should be considered energized during response operations. High Voltage Cabling

Electric Motors Provide propulsion in EVs and some P/HEVs.Provide propulsion in EVs and some P/HEVs. Start and stop the ICE when not needed.Start and stop the ICE when not needed. Recharge HV battery through regenerative braking and ICE.Recharge HV battery through regenerative braking and ICE. Sometimes called Drive Motors or Traction MotorsSometimes called Drive Motors or Traction Motors 3-36

Safety Systems ●Crash Impact ●Airbag Deployment ●Cabling Damage ●Short Circuits P/HEVs and EVs have safety systems designed to automatically shut down the high voltage systems in the event of: 3-37 However, always treat HV systems as energized for maximum safety.

Charging Ports Connects charging cord to vehicle.Connects charging cord to vehicle. Charging components reside on the vehicle.Charging components reside on the vehicle. The charging unit is an interface between the power supply and the vehicle.The charging unit is an interface between the power supply and the vehicle. 3-38

Charging Stations Level I 120 VAC 8-16 hours Level II 240 VAC 3-8 hours DC Quick Charge 480 VDC min. 3-39

Level 1 Charging Station Level I 120 VAC 8-16 hours ● Utilizes 120VAC power. ● Uses standard household plug. ● Slowest rate of the three levels. ● Can accompany vehicle to charge it anywhere. 3-40

Level II Charging Station Level II 240 VAC 3-8 hours ● Utilizes 240VAC power. ● Can be a fixed installation or portable unit. ● Faster than Level I systems. Typically 3-8 hours depending on the size of the battery. 3-41

J1772 Plug and Receptacle ● SAE standardized for Level I and II charging. ● Multi-pin charging/ communication link between charger and vehicle ● Conducts current. ● Relays charge status. ● Shuts down charging when battery “full.” ● Prevents vehicle from moving when plugged in.

DC Quick Charge Station DC Quick Charge 480 VDC min. ● Currently provides 480VDC directly to the battery. ● New standards being developed, so this may change. ● Fastest charging system. ● Due to wiring requirements, availability, and expense, will likely be in commercial sites only. 3-43

3-44 Charging Stations

3-45 Charging Stations

You will be shown a series of slides, each with a picture of a component of a P/HEV or EV. You will be given a few moments to discuss and decide on the name of the component and its function. Be prepared to share your answer with the class. P/HEV, EV Components 3-46 Activity 3.1

? 3-47

High Voltage Battery The electrical storage system that provides power for vehicle systems. Component Function 3-48

? 3-49

High Voltage Cabling Wiring used to carry electric current from the high voltage battery to the electrical motor. Component Function 3-50

? 3-51

Inverter / Converter Devices which convert DC from the high voltage battery to AC to drive the motor. Component Function 3-52

? 3-53

Charging Ports Electrical connections on a vehicle for connecting the high voltage battery to a charging source. Component Function 3-54

? 3-55

Manual Service Disconnect Cuts off the battery from the high voltage system. Component Function 3-56 Refer to Manufacturer ERG before use!

? 3-57

J1772 Connector Multi-pin communication link between charger and vehicle. Component Function 3-58

There are several different types of P/HEVs and EVs. Each one has specific components related to its electrical identify. Familiarity with the types, components and differences will facilitate emergency operations Module Summary