TM TM The all-electric car from an all-electric car company CODA 2012 TM Emergency Responder’s Guide Technical Assistance Center 888-718-5046 or techinfo@codaautomotive.
Copyright 2012 CODA Automotive, Inc. Information in this document is the confidential property of CODA Automotive, Inc. and, shall not be disclosed, disseminated, copied, duplicated, or used except for purposes authorized by contract or agreement or otherwise expressly authorized in writing. Products and services referred to in this document may be either trademarks and/or registered trademarks of the respective owners. CODA Automotive, Inc. makes no claim to these trademarks.
Table of Contents 1. ABOUT THIS MANUAL .................................................................................................. 1 INTRODUCTION .................................................................................................................... 1 IMPORTANT INFORMATION ABOUT THIS MANUAL .............................................................................. 1 2. ABOUT THE CODA VEHICLE ..........................................................................................
1. About this Manual Introduction This manual describes first responder operations, related warnings and cautions for this vehicle. This vehicle is powered by a HIGH VOLTAGE battery pack. Improper contact with a high voltage battery pack or other high voltage components MAY RESULT in serious injury or DEATH. Please fully read this manual in advance to understand the technology of this vehicle and to help you safely respond to an incident involving this vehicle.
2. About the CODA Vehicle TM CODA is a plug-in electric vehicle that uses two types of batteries: • High voltage traction battery – a 333-volt Lithium ion battery pack (Lithium Iron Phosphate technology) to power drive motor and other high voltage components. • Low voltage accessory battery - a standard 12-volt lead acid battery (Absorbed Glass Mat (AGM) technology) to power select vehicle electrical equipment.
Vehicle Identification Number (VIN) The Vehicle Identification Number can be located in the lower left side of the dashboard as seen through the windshield. Example of the VIN numbering: 53G1U4A4XCBXXXXXX Figure 2: Location of Vehicle Identification Number Figure 3: Example of Vehicle Identification Number on dashboard The VIN is also displayed on the vehicle certification label on the driver’s side b-pillar. 2.
Interior Component Location Interior controls and locations in this manual are shown below in Figure 4: Figure 4: Interior Component Location 1. Instrument panel illumination 2. Exterior lights and turn signals 3. Instrument Panel 4. Wiper and Washer 5. Trunk release 6. Hazard warning flashers 7. Passenger Airbag status indicator 8. Touch-screen (Entertainment and navigation system) 9. Heating and Ventilation Controls 10.Gear selector 11.Starter switch 12.Steering column adjust 13.Horn 14.Hood release 15.
3. Electrical System Information High Voltage and 12-Volt Component Locations and Descriptions Main components of CODA’s electrical system are shown in Figure 5-7. Table 1 presents description of the components shown in Figure 5-7. High voltage battery specifications are shown in Table 2. Figure 5: High Voltage and 12-Volt Component Location 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
7 (AC Compressor), 6(PTC Heater) 10 (Main Service Disconnect) Figure 6 Figure 7 Table 1: Electrical System Components Component Location Description 1 On-Board Chargers and DC/DC Converter Rear compartment, floor pan area Two independent on-board chargers convert standard 110/220 volt AC wall plug power into DC power to charge the high voltage battery. The DC/DC converter reduces the voltage of the high voltage battery to provide power to the 12-Volt accessory components (i.e.
Main Service Disconnect (MSD) Under vehicle on the front of the battery pack This service disconnect plug is a high voltage interconnect loop and is used to manually disconnect the high voltage between the battery and the vehicle. High voltage is still present inside the battery pack even if the MSD is disconnected. 11 Propulsion Motor Under hood, mounted below high voltage inverter Permanent magnet brushless DC motor uses three-phase high voltage current to propel the wheels via transaxle.
4. Electric Vehicle Safety Rules The CODA vehicle is powered by a HIGH VOLTAGE electrical system. Failure to follow these instructions will result in death or serious injury from high voltage electrical shock. 1. Never attempt any repairs if you are not familiar with any of the affected systems or how electric vehicles operate. 2. Never approach or attempt any high voltage disconnects or repairs without Class O gloves, safety glasses/shield, non-synthetic clothing, and personal jewelry removed. 3.
5. Emergency Procedure STEP 1: ASSESS DAMAGE AND PREPARE EMERGENCY EQUIPMENT Before attempting any emergency procedures, verify that the high voltage battery is disconnected and use appropriate protective equipment (PPE). Failure to disable the high voltage electrical system before the Emergency Response Procedures are performed will result in serious injury or death from high voltage electrical shock.
Battery Charge READY Indicator Lamp Figure 9: Location of READY and CHARGE Indicators READY Lamp Flashes green to indicate that the vehicle is performing pre-drive system checks. Illuminates continuously when the vehicle is in Drive mode and is ready to be driven. Charge Indicator Illuminates yellow to indicate that the vehicle is charging. The indicator will turn off when charging is completed. If a fault is detected, the indicator will turn off. 5.
Before beginning any work on the vehicle, ensure that you have the following PPE.
• Set the parking brake (Figure 10) Lift up on handle and firmly apply parking brake. Handle should move at least 6 clicks. Figure 10: Parking Brake • Use a minimum two wheel chocks of wooden blocks to prevent the vehicle from rolling. Do not stabilize the vehicle with wooden blocks under the Li-ion battery pack. To avoid electrical shock, do not put air lift equipment and wheel chocks under the high voltage components and harnesses.
STEP 3: DISCONNECT HIGH VOLTAGE BATTERY Read and follow all Danger and Warning messages covered in Section 3“Electric Vehicle Safety Rules” before disconnecting the high voltage battery. Failure to disable the high voltage electrical system before the Emergency Response Procedures are performed will result in serious injury or death from high voltage electrical shock. NEVER APPROACH OR WORK ON HIGH VOLTAGE WITHOUT WEARING PPE.
5 4 3 2 1 Figure 13 High Voltage Shutdown System – Component Location Table 5: High Voltage Shutdown System Components 1 High Voltage Interlock High Voltage In-Line (HVIL) interlock system is a continuous loop connecting all high voltage components. If any of the high voltage connectors are separated, the main high voltage battery relay opens, disconnecting the battery from the vehicle. High voltage is still present inside the battery pack, but all vehicle components are disconnected.
High Voltage System Shutdown When Vehicle Is Connected to Charger There are many manufacturers of Electric Vehicle Service Equipment (EVSE). For exact disconnect procedure follow specific manufacturer’s instructions. General instructions are: 1. 2. 3. 4. Press the unlock release button on lever on the J1772 charge connector handle. Pull the charge connector handle to remove it from charge port connector. Replace connector handle to EVSE charging station. Never place high voltage charge connector on ground.
High Voltage System Shutdown- 12 Volt Disconnect Perform the following steps: Disconnect 12-Volt battery to disable airbag systems and shut-off high voltage battery. Disconnecting 12 volt battery in most cases will disconnect the high voltage battery, but it is possible that high voltage may still be present in the vehicle. Use proper PPE and observe the high voltage safety rules in this guide while disconnecting the 12V battery. 1.
5. Before proceeding with any emergency procedures including extrication of occupants, wait 2 minutes for high voltage and SRS system to fully power down. High Voltage System Shutdown- Main Service Disconnect Perform the following steps: 1. Unlatch the orange plastic cover on the skid plate to access the MSD. Connector Unlock Tool 2. Insert connector unlock tool. 3. Unplug the MSD plug. 4. Wait 2 minutes to ensure that the high voltage is fully disconnected. 5.
High Voltage System Shutdown- Rear Service Disconnect Disconnecting the RSD is the only shutdown method that fully disconnects the vehicle from the high voltage battery. Perform the following steps: 1. Remove rear seat cushion. Remove 13mm mounting bolts Remove rear seat cushion 2. Remove access panel on the rear left floor. Remove the cover screws Open the cover 3. Unplug the Rear Service Disconnect plug.
5. Secure the battery connector terminals with electrical tape. High Voltage System Shutdown- Front Power Distribution Box (FPDB) Perform the following steps: 1. Lift and pull orange latch connector handle. 2. Completely unplug connector and move away from FPDB. 3. Wait 2 minutes to ensure that the high voltage is fully disconnected. 4. Secure the battery connector terminals with electrical tape. 5.
STEP 4: Thermal Event Containment In case it is necessary to extinguish a fire involving the high voltage battery pack, large amounts of water from a fire hydrant (if possible) must be applied. Small amounts of water could produce a combustible or explosive gas mixture via electrolysis or from a chemical reaction between the Li-ion battery and water.
STEP 5: Accessing Vehicle Occupants DO NOT cut the Li-ion battery and/or case to avoid possible exposure to the high voltage battery and possibility of electrocution and or battery pack damage leading to electrocution. DO NOT cut high voltage harness wires (ORANGE) to avoid possible exposure to the high voltage battery and possibility of electrocution and or battery pack damage leading to electrocution. DO NOT touch the high voltage parts or the insides of the exposed ORANGECOLORED high voltage cables.
A Front Airbags Driver Steering Wheel Passenger Front Instrument Panel B Side Curtain Airbags Driver’s, Front Passenger’s & Outer Rear Passenger’s roof line C Seat Airbags Driver’s Seat Outer Trim Panel Passenger’s Seat Outer Trim Panel D Seat Belt Pretensioners Driver’s and Passenger’s Seat Belt Retractors E Side Curtain Inflators B Post, Above roof line Figure 16 shows safe cutting area. There are no high voltage harnesses in the top of the vehicle, above the belt line.
There are various fluids that could possibly leak in the event of a collision. Primary fluid leak would be coolant from the cooling system. Avoid this fluid to avoid possible burns from hot liquid. Other fluids that could possibly leak are brake fluid and/or transaxle oil. High voltage battery cells contain a small amount of flammable electrolyte. Major electrolyte leaks are unlikely as it is largely absorbed in the cell material.
