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

3-3 HEV Hybrid Electric Vehicle A vehicle that has both an internal combustion engine (ICE) and electric motor(s). PHEV Plug-In Hybrid Electric Vehicle A vehicle that has both an ICE and electric motors, and can recharge its batteries to full charge from an external electric power source. EV Electric Vehicle A vehicle which uses only electric motor(s) for propulsion. Definitions

Video Vehicle Types 3-4

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. ●Full Hybrids can drive short distances on electric power only (silent movement hazard). ●For response purposes, treat all hybrids the same. 3-5 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 Ford Escape 2012 Toyota Prius

Electric Vehicle Electric motors are the only means of propulsion. 3-7 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. 3-8 Chevrolet Volt

HEV / PHEV / EV VEHICLE COMPONENTS 3-9

Standard Components VDC battery can be located in various locations around vehicle. Common Locations: · Trunk / Cargo compartment · Under hood Internal Combustion Engine 12 Volt DC Battery Less Common Locations: · Front wheel well · Under 2 nd Row seats

Video 12 VDC and High Voltage Batteries 3-11

High Voltage Batteries Battery Types Lithium Ion Various Materials NiMH Nickel Metal Hydride 3-12

High Voltage Batteries Nickel Metal Hydride (NiMH) Battery 3-13 ●Most common battery in existing hybrids. ●Less common in newer vehicles. ●Electrolyte is alkaline.

3-14 High Voltage Batteries Lithium Ion (Li-Ion) Battery ●Most common in electric vehicles. ●Will be used more in future hybrids. ●Many different chemical variations. ●Different from Li-Ion batteries in home electronics.

Video High Voltage Battery Construction 3-15

3-16 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. 3-17

High Voltage Batteries Location of Batteries in EVs ● EV Batteries are larger and of higher voltage than P/HEV batteries. voltage than P/HEV batteries. ● Usually located on the underside of the vehicle. the vehicle. 3-18

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 battery. battery. ● Cuts off the battery from the high voltage from the high voltage system. system 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 voltage 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 ● Takes the place of the alternator. ● Converts DC from high voltage battery to 12 VDC to run vehicle’s low voltage systems. to run vehicle’s low voltage systems. ● In some models the DC/DC converter is housed in the inverter/converter module. in the inverter/converter module DC-DC Converter (APM) for Chevrolet Volt

Video High Voltage Battery Relay 3-23

EV/ HEV Cabling 3-24 ●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 the purposes of this program, treat blue cables the same as high voltage orange.

Location 3-26 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 some models.Provide propulsion in some models. 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. P/HEVs EVs Provide propulsion and recharge HV battery through regenerative braking.Provide propulsion and recharge HV battery through regenerative braking. 3-28

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. A process used to capture energy from braking and help recharge the high voltage battery Can damage HV system if towed in overhaul.

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: 3-30 Always treat HV systems as energized for maximum safety.

Charging Ports Used to connect a charging cord to the vehicle.Used to connect a charging cord to the vehicle. The charging components reside on the vehicle.The 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. 3-31

3-32 Charging Stations

Level I 120 VAC 8-16 hours Level II 240 VAC 3-8 hours DC Quick Charge 480 VDC min. 3-33

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. 3-34

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. 3-35

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. 3-37

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 3-38 Activity 3.1

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High Voltage Battery The electrical storage system that provides power for vehicle systems. Component Function 3-40

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High Voltage Cabling Wiring used to carry electric current from the high voltage battery to the electrical motor. Component Function 3-42

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Inverter / Converter Devices which convert DC from the high voltage battery to AC to drive the motor. May also house DC-DC converter to step down high voltage DC to 12VDC to run standard vehicle systems. Component Function 3-44

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Charging Ports Electrical connections on a vehicle for connecting the high voltage battery to a charging source. Component Function 3-46

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Manual Service Disconnect Cuts off the battery from the high voltage system. Component Function 3-48 Refer to Manufacturer ERG before use!

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J1772 Connector Multi-pin communication link between charger and vehicle. Component Function 3-50

End of Activity 3-51 Activity 3.1

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