Holden Volt Emergency Response Guide 9/11/12 1
Course Overview Duration: 2 hours Course Content: Vehicle Introduction Battery and Electrical Technology Emergency Operations Response to the Incident 2
Course Overview The intent of this guide is to provide information to help you respond to emergency situations involving Holden Volt vehicles in the safest manner possible This guide contains a general description of how the Holden Volt vehicle systems operate, identifies the location of the unique badging, and includes illustrations of the unique components The guide also describes methods of disabling the high voltage system and identifying cut zones. 3
4 Vehicle Introduction
Holden Volt The Holden Volt is a front-wheel drive, four-passenger electric vehicle with extended-range capability The Volt is propelled exclusively by electric motors The Volt uses high voltage energy that is stored in the high voltage battery as its primary power source Once the battery capacity is reduced, the petrol engine drives a generator which produces electricity to power the Volt 5
Volt Badging The Holden Volt badging is one method of identifying the vehicle The vehicle's Volt logo is located on the right-front and left-front fenders as well as the hatch lid A Charge Port is located on the left hand side of the vehicle below the A pillar 6
Volt Identification Another method to identify a Holden Volt is by the unique Liquid Crystal Display (LCD) Instrument Panel Cluster and Energy Display. To be updated 7
Volt Propulsion The Volt propulsion system is composed of the following components and systems: High Voltage Lithium-Ion battery (360V) Absorbent Glass Mat (AGM) low voltage battery (12V) Power Inverter Module (PIM) Accessory Power Module (APM) High Voltage Battery Charger 1.4 Litre Engine 4ET50 transmission 8
Petrol Engine and Transmission The 4ET50 transmission is a fully automatic, front-wheel drive transaxle, variable-speed, electronic controlled transmission. The transmission contains two electric motor / generators that are utilised to: Propel the vehicle Generate / recapture energy Start the internal combustion engine The Volt uses an internal combustion 1.4L engine. The engine does not directly propel the vehicle, but operates only to spin the drive motor / generator. 9
System Operation The Holden Volt is an Extended Range Electric Vehicle (EREV) that uses an electric propulsion system to drive the vehicle Stored electrical energy is used in electric mode to propel the vehicle The vehicle operates up to 87 km until the battery has reached a low state of charge Once the stored electrical energy is reduced, the vehicle automatically enters extended-range mode The petrol engine drives the generator which produces electricity for vehicle propulsion 10
11 Battery and Electrical Technology
High and Low Voltage Systems There are two separate electrical systems, low voltage and high voltage The low voltage system is similar to a conventional vehicle The high voltage electrical system distributes 360 Volts Direct Current (DC) between the high voltage components, and 3-phase Alternating Current (AC) to the transmission. The high voltage cables are orange in colour to easily identify the potential existence of high voltage High voltage cables that are routed through non-orange conduit are identified with high voltage warning labels 12
13 Component Overview
High and Low Voltage Batteries The High Voltage Battery, also known as the Drive Motor Battery, is a system of many components that operate together to provide the energy required for vehicle propulsion High voltage contactors turn on and off to control the output of the high voltage battery The battery is enclosed in a dust sealed container 14
15 High Voltage Battery
Battery with Casing Removed MSD Port Protective Shield 16
Battery Components A battery section comprises of multiple cell groups Each group is connected together using coolant plates, separator plates and a frame Coolant plates allow for coolant to flow between the cells Each coolant plate and frame has impregnated seals, that when clamped together, form an inlet and outlet manifold for coolant to flow through There are inlet and outlet coolant hose connections on each end of the battery section 17
Battery Cell Each battery cell contains a carbon anode (negative electrode), manganesebased cathode (positive electrode), and a safety reinforced separator Safety reinforced separator provides the medium to transfer electrical charge ions between the anode and the cathode inside of the battery cell There are 288 lithium ion battery cells Tabs at top of each cell are welded together in parallel groups of three 96 cell groups Each group is rated at 3.7 volts Connected in series to form three sections, totaling 355 nominal volts 18
Low Voltage Battery The Volt s low voltage system (12V) utilises an AGM lead acid battery The battery is located in the rear compartment underneath the load floor The low voltage energy is utilised by vehicle modules to control the high voltage battery contactors Severing the low voltage cables is designed to cause the high voltage battery contactors to open The low voltage (12V) positive cable cut location is found behind the left rear closeout panel in the rear compartment of the vehicle 19
Power Inverter Module (PIM) The Power Inverter Module (PIM) is located on the passenger s side of the engine compartment and is mounted on top of the transmission The module changes the high voltage direct current into 3 phase alternating current This 3-phase electrical energy is provided to the motors within the transmission for vehicle propulsion 20
Accessory Power Module (APM) The Accessory Power Module (APM) is located in the rear compartment beneath the load floor The APM replaces the belt-driven generator common to conventional vehicles The module converts high voltage DC electrical energy into low voltage DC electrical energy to provide the energy needed for the vehicle systems 21
Charging System The Holden Volt features an onboard high voltage charging system that recharges the high voltage battery The system utilises a SAE J1772 receptacle. This receptacle is used by many manufacturers. The high voltage charger is located behind the driver side headlamp assembly and bumper fascia 22
Charging System The high voltage charger converts household AC into DC voltage to charge the onboard battery In the event that a Volt is involved in an incident while the Volt is plugged in for charging, disconnect the charge cord using the charge cord handle at the charge port If the charge cord cannot be disconnected, the electrical power to the charge cord should be terminated at the source 23
Charging System High Voltage Charger shown with bumper removed 24
Volt Air Bags The Volt is equipped with eight air bags to protect the occupant in front, rear, side and rollover crashes The Volt is one of the few vehicles with knee air bags, which help reduce injuries to the front occupant s legs There are dual pretensioner seatbelts that work together with the air bag system to protect the occupant in the event of a crash 25
Air Bag Deployment The contactors within the high voltage battery are commanded open whenever one or more airbags deploy. This interrupts the 360 volt electrical system and discontinues current flow through the high voltage cables. The Volt is equipped with dual-stage air bags Depending on the severity of the accident one or two stages of the airbag deployment may occur. Be aware that if stage one has deployed stage two may still be live. Disabling the 12 volt power is essential to ensure personal safety even if the airbags in the vehicle appear to have been deployed After disabling the 12 volt power, wait 1 minute to allow any un-deployed air bag reserve energy to dissipate 26
High Strength Steel The Volt has been designed to protect the occupant(s) during a collision The body structure is nearly 80% high strength steel 27
28 High Strength Steel
High Voltage Labels The emergency / service personnel warning labels affixed at the front of the engine compartment provide specific procedures for emergency personnel. 29
High Voltage Labels HV cables under the vehicle are protected by a metal sheath with orange HV labels attached. HV Cables 30 Battery Protective Plate
Labels in Rear Load Compartment Area Under Load Floor Accessory Power Module 12V Battery Cooling Fan 31
First Responder Labels The cable cut tag is yellow and wraps around the low voltage positive cable to indicate where emergency personnel must cut the cable Important: Cut through the low voltage cable on each side of the tag to remove a section of the cable to ensure the cables cannot inadvertently reconnect 32
33 Emergency Operations
First Responder Scenarios On arrival, emergency responders should follow their standard operating procedures for vehicle incidents. Standard Operating Procedures : Size-Up, Approach, Immobilize, Extinguish Vehicle on Fire NO increased risk to first responders Vehicle in Water NO increased risk of shock hazard 34
Personal Protective Equipment Class 0 Gloves Follow Emergency Service Standard Operating procedures. Leather outer glove Rubber inner glove 35
Personal Protective Equipment Eye protection when within 50 feet of vehicle Rubber soled shoes create grounding barrier 36
Safety Precautions Remove jewellery and watches Remove metal objects from clothing 37
Approaching the Vehicle Additional Information SAFETY Anticipate that the vehicle may well be turned on and/or be in Run mode No audible electrical or mechanical noise does not indicate that the vehicle is switched off If the bonnet is open or is opened while the vehicle is in Run mode this will start the petrol run generator engine - This is a safety feature as you should expect to hear a running generator engine 38
To Disable Volt if Airbags have NOT Deployed 1. Assess accident situation for hazards such as spilt fuel or unstable vehicle 2. Identify vehicle as Holden Volt by checking its badging 3. Immobilise Chock the wheels, engage Emergency Brake and place vehicle in Park 4. Press the Start button on the centre instrument panel to turn OFF the ignition 5. Confirm that both LCD displays are not illuminated 6. If the airbags have NOT deployed then pressing the Power button is all that is required to turn the Volt off 39
To Disable Volt if Airbags HAVE deployed 1. Assess accident situation for hazards such as spilt fuel or unstable vehicle 2. Identify vehicle as Holden Volt by checking its badging 3. Immobilise Chock the wheels, engage Emergency Brake and place vehicle in Park. Note: When airbags are deployed the hazard lights may be flashing and a Service Vehicle Soon message will be displayed on the Driver Instrument Centre 4. Ensure that the ignition is OFF by confirming that both LCD displays are not illuminated 5. If the ignition is ON press the Start button on the centre instrument panel to turn OFF the ignition 6. Cut the12v positive battery cable at the yellow tag cut position a. The cable is identified by the yellow First Responder tag b. The tag is located behind the left rear closeout panel in the rear compartment of the vehicle Note: After disabling 12V power, wait 1 minute to allow any un-deployed air bag reserve energy to dissipate. 40
To Disable 12V System (continued) If you can not access the 12 Volt cable in the rear compartment area. o Locate the fuse box in the dash by the front passenger s door o Pull all fuses in the fuse box o The airbags will now be disabled Dash Left Hand Fuse Box 41
To Disable 12V System (continued) If you can not access the 12 volt cable in the rear compartment area or the fuse box, there is also a secondary cut zone to access the 12 volt cable. The secondary cut zone is located between the B and C post in the rocker panel on the passenger side. o The cable is coloured RED but is surrounded by a black sheath o Always remove interior trim before cutting cables Passenger Rear Seat Door Sill 42
Disabling the High Voltage System In the event of an Airbag deployment, the Volt Safety System is designed to disable the high voltage contactors in the battery pack. If Emergency Responders are still concerned that the contactors were not disabled during airbag deployment, the Manual Service Disconnect (MSD) may be removed. 43
Accessing the Manual Service Disconnect (MSD) Step 1 Remove the centre console trim (clicks in place) 44 Step 2 The MSD is located under a white protective pad Step 3 Remove the MSD
Removing the Manual Service Disconnect (MSD) The MSD has a two stage removal process. MSD in place Step 1 Depress the holding clip while pulling the MSD up until it stops Step 2 Press the clip in for a second time to fully release the MSD 45
High Voltage Cables - DO NOT CUT ZONES The high voltage cables in the Volt are highly protected and should not interfere with any extraction procedures. Performing the disabling procedure prior to starting any work (to isolate the 360V battery), eliminates the electrical current flow through the 12 volt system and disables the high voltage electrical system. No further action is required. 46
High Voltage Cables - DO NOT CUT ZONES DO NOT CUT ANY UNDERBONNET ORANGE CABLES 47
Vehicle - DO NOT CUT ZONES Do NOT cut the: Centre tunnel area or the area under the rear seats. The 360 volt battery is installed in this area. Roof rails near the lift gate hinge. Side curtain air bag inflators and lift gate hold open struts are located in this area. Front seat back on the outboard area as this area contains the side air bags. B pillar near the rocker as this area contains the seat belt retractor pretensioner. Note: The outboard area of the front seat lower frame, houses an additional seat belt pretensioner. 48
Vehicle - DO NOT CUT ZONES Do not cut in either the centre tunnel area or below the rear seat as the HV battery is located in this area. WARNING: Do NOT cut into the vehicle until the 12V electrical system has been disabled. Cutting into the vehicle prior to disconnecting and isolating the 12V electrical energy sources may cause air bag deployment resulting in serious injury. 49
50 Vehicle CUT ZONES
51 Vehicle CUT ZONES
52 Vehicle CUT ZONES
First Responder Considerations Approaching a vehicle that is plugged in Upon arriving at a location with the Volt plugged in for charging, you should first unplug the vehicle. If access to unplug the vehicle is unavailable turn the power off to the charge station. 53
First Responder Considerations Fire Fire will not cause the battery to explode If battery cells reach high enough temperature, they will vent and release electrolyte Battery electrolyte is flammable Gas being vented directly from battery vents may be flammable, however unlikely to combust as once mixed with the surrounding atmosphere the concentration level is too low 54
First Responder Considerations Use copious amounts of water to cool the battery and extinguish the fire. Do not attempt to disconnect the battery if there is a fire Use of water to cool the battery will avoid further thermal runaway Extinguish the flame first First Priority Once fire is extinguished, battery can be disconnected if safe to do so Standard operating procedures must be followed Extremely low risk of electrocution due to battery being isolated from chassis ABC dry chemical extinguisher will not extinguish a battery fire. 55
First Responder Considerations Water The high voltage battery is isolated from the vehicle chassis. If the vehicle is immersed in water, you will not be electrocuted by touching the vehicle. Locate and review the Lithium-Ion Battery Chemistry Material Safety Data Sheet for more information. 56
Volt Emergency Response Quick Reference Guides Volt Emergency Response quick reference guides will also be available to download and are available in A4 and A5 size The guides can be used utilised by responders should they encounter a vehicle and can be carried in response vehicles for easy future reference. Downloadable PDF s will be made available in the members only, Vehicle Emergency Response Guides Library at www.arro.org.au 57
Perceived Volt Issues Concern: High voltage batteries will leak dangerous amounts of fluid if damaged. Reality: HV Batteries are not lead acid Li-Ion are dry cell batteries Electrolyte is absorbed in a medium A few drops of electrolyte may be produced if cell is crushed 58
Perceived Volt Issues Concern: Do I risk electrocution by touching a Volt involved in a crash or if it is submerged? Reality: High voltage system is completely isolated from chassis Integrated safety systems and basic electrical theory protect occupants and responders 59
Perceived Volt Issues Concern: The Volt may roll away down hill while connected to a high voltage charger. Reality: To turn the Volt off the vehicle must be placed in PARK To charge the Volt the vehicle must be placed in PARK The Volt is designed not to roll away while set in the PARK setting 60
Perceived Volt Issues Concern: It will be difficult to disable the HV electrical system. Reality: Automatically integrates shutdown procedures of the HV electrical system in the event of a crash Shutting off the vehicle s ignition will shut down the high voltage system 12V battery disconnection automatically disconnects the HV electrical system 61
Perceived Volt Issues Concern: Extrications will be hampered by HV wiring Reality: HV wiring is placed in areas not typically considered cut points Concern: Special equipment is needed for vehicle fires Reality: Fires are extinguished with standard firefighting procedures 62
Further Information - ARRO Website ( www.arro.org.au ) will host the following Volt Emergency Responder reference material : Volt Emergency Responder presentation ( At the completion of Volt Training in mid December 2012 ) Volt Emergency Response Quick Reference Guides MSDS for Volt lithium battery Further vehicle information on Volt can be found on www.holden.com.au 63
Conclusion Holden is committed to making your job as safe as possible We are confident the information contained in this guide will prove useful as you prepare to assist those involved in an emergency event 64
65 Questions