ION C Zero User Manual
iOn / C-Zéro
Passengers rescue manual
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Foreword
Ion/C-Zero are electric cars equipped with high voltage
battery.
This manual provides safety instructions that need to be
followed after vehicle breakdown or when rescuing the
passengers from the vehicle after an accident.
It describes how to deal securely with the incident
involving the vehicle.
It is not intended to describe how to repair the vehicle.
See the after-sales manual to find this information.
Failure to follow these instructions and especially the
warnings and cautions may result in death or serious
injury.
Please read and understand this manual carefully for
your and the passengers safety.
Throughout this manual the words WARNING, CAUTION and NOTE appear.
These serve as reminders to be especially careful. Failure to follow instructions could result in personal injury or
damage to your vehicle.
Indicates a strong possibility of severe personal injury or death if instructions are not followed.
Means hazards or unsafe practices that could cause minor personal injury or damage to your vehicle.
NOTE: gives helpful information.
*: indicates optional equipment.
It may differ according to the sales classification; refer to the sales catalogue
PSA Peugeot Citroen reserves the right to make changes in design and specification and/or to make additions
to or improvements in this product without obligation to install them on products previously manufacturers
Please note that the contents of this manual may not fit completely with actual vehicle due to the change of
vehicle specification.
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Table of contents
1. About the iOn / C-Zéro.................................................................................................................................4
(1)
Main features.........................................................................................................................................4
(2)
Exterior and interior features to identify iOn / C-Zéro............................................................................4
2. High Voltage System and 12V system Information ..................................................................................6
(1)
High voltage-related and 12V-related component Locations and descriptions.....................................6
(2)
Li-ion Battery Pack Specifications .........................................................................................................7
(3)
High voltage safety measures ...............................................................................................................8
(4)
Warning label.........................................................................................................................................8
(5)
High voltage Circuit Shut-off System.....................................................................................................8
3. Safety precaution for handling high voltage.............................................................................................9
(1)
Required tools and equipment ..............................................................................................................9
(2)
Precautions when rescuing passengers................................................................................................9
4. Steps of Emergency Response ................................................................................................................10
(1)
Identify the vehicle...............................................................................................................................10
(2)
Use Personal Protective Equipement (PPE).......................................................................................10
(3)
Precautions at the accident site ..........................................................................................................10
(4)
Preparation: Vehicle Immobilization and Stabilization ........................................................................11
(5)
Checking the state of the vehicle ........................................................................................................11
5. The procedure to handle a damaged vehicle at an accident scene......................................................12
(1)
Actions if there is no visible damage...................................................................................................12
(2)
Actions to perform in case of Emergency............................................................................................13
(3)
Vehicle fire...........................................................................................................................................14
(4)
Submerged vehicle..............................................................................................................................15
6. The procedure to the transportation of a vehicle ...................................................................................16
(1)
Re-inverting a rolled vehicle ................................................................................................................16
(2)
Transportation of a damaged vehicle ..................................................................................................16
(3)
Precaution for a vehicle transportation................................................................................................17
7. Detail working procedure..........................................................................................................................19
(1)
Procedure to turn OFF the contact with contact key...........................................................................19
(2)
Procedure to disconnect auxiliary battery ...........................................................................................19
(3)
Procedure to remove the fuse .............................................................................................................19
(4)
Procedure to remove service plug.......................................................................................................20
(5)
Procedure to verify absence of tension...............................................................................................21
8. Safety for vehicle environment.................................................................................................................23
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1. About the iOn / C-Zéro
(1) Main features
This vehicle uses two types of battery. One is a 12V battery that is the same as the battery in vehicles powered
by internal combustion engines, and the other is the Lithium-ion (Li-ion) battery (high voltage) for the traction
motor which propels the vehicle. The Li-ion battery is encased in steel and mounted underneath the vehicle.
The iOn / C-Zéro is a rear-wheel drive vehicle.
The vehicle must be plugged-in in order to the Li-ion battery to be recharged. Additionally, the vehicle system
can recharge the Li-ion battery by converting driving force into electricity while the vehicle is decelerating or
being driven downhill. This is called regenerative deceleration. This vehicle is considered to be an
environmentally friendly vehicle because it does not emit exhaust gases.
(2) Exterior and interior features to identify iOn / C-Zéro
Here are given the exterior features that will allow you to identify the vehicle:
1. iOn / C-Zéro logos
2. 2 lids : Regular and Quick charging
3. Absence of exhaust pipe
4. Chassis number
1. Logos
Mark and “Full Electric” Logo
The logo « Full Electric » is located on both sides of the iOn / C-Zéro vehicle
2. Regular and quick charging lid
Quick charge Regular charge
Left side Right Side
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AUTOMOBILES
PEUGEOT
AUTOMOBILES CITROEN
3. Absence of exhaust pipe
iOn / C-Zéro does not have an exhaust pipe :
4. Chassis number
The Chassis number is stamped on the “Manufacture’s Plate” and “Quarter trim”.
The Model code is stamped on the “Vehicle information code plate”.
・Vehicle information code plate
The chassis number is stamped on this plate.
iOn / C-Zéro includes "NZKZZ" in the Chassis number.
VF31NZKZZBU8xxxxx
1450 KG
- - - - KG
1 – 640 KG
VF71NZKZZBU9xxxxx
2 – 820 KG
1450 KG
- - - - KG
1 – 640 KG
2 – 820 KG
Example of Chassis number stamp:
For iOn : VF31NZKZZBU8xxxxxx
For C-Zéro : VF71NZKZZBU9xxxxxx
・Manufacture’s Plate (Caution plate)
(Centre pillar, passenger side)
The chassis number is stamped on this plate.
iOn / C-Zéro includes "NZKZZ" in the Chassis number.
Example of Chassis number stamp:
For iOn : VF31NZKZZBU8xxxxxx
For C-Zéro : VF71NZKZZBU9xxxxxx
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Vehicle Identification Number (Chassis number)
1
2
4
5
8
3
6
7
9
(Inside of quarter trim in luggage area)
The chassis number is stamped on the quarter trim lower panel.
iOn / C-Zéro includes "NZKZZ” in the Chassis number.
For iOn : VF31NZKZZBU8xxxxxx
For C-Zéro : VF71NZKZZBU9xxxxxx
2. High Voltage System and 12V system Information
(1) High voltage-related and 12V-related component Locations and descriptions
High voltage cables
10
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Component Location Description
1 Traction motor On the rear axle Converts three-phase AC power to drive power (torque) which
propels the vehicle
2 On board charger
/
DC/DC Converter
On the rear axle This component includes a DC/DC converter and an on board
charger :
- The DC/DC converter reduces the voltage of the Li-ion battery
to provide power to the 12V battery in order to operate the
vehicle's electric components (headlights, audio system, etc.)
- The on board charger converts single-phase AC power from a
home power outlet to DC power and increases the voltage in
order to charge the Li-ion battery
3 Inverter On the rear axle Converts the DC power stored in the Li-ion battery to the three-
phase AC power and controls motor torque (revolution) by
regulating the motor current
4 Electric
Under hood Air conditioner compressor
compressor
5 PTC heater Under hood This is the electric heat source for the cabin heater. It heats the
interior of the vehicle (PTC : Positive Temperature Coefficient)
6 Regular Charge
lid
6 Quick Charging
lid
7 12V Battery (or
Right side of the
Connecting port for EVSE (Electric Vehicle Supply Equipment)
vehicle
Left side of the
Connecting port for quick charge
vehicle
Under hood A lead-acid battery that supplies power to the low voltage devices
auxiliary battery)
8 Li-ion (Lithium
ion) Battery (or
Undercarriage Stores and outputs DC power (Maximum voltage 330V) needed
to propel the vehicle
HV battery)
9 High voltage
cables
10 Service plug Under Left Front
Undercarriage and
Under hood
Orange-coloured power cables carry high direct current (DC)
voltage between each of the high voltage components
Used to disable the high voltage system
seat
(2) Li-ion Battery Pack Specifications
Li-ion battery voltage 325,6V
Number of Li-ion battery modules in the
pack
Li-ion battery dimensions 1383 x 672 x 219 mm
Li-ion battery weight (pack) 236 kg
88 cells of 3,7V each, divided on 10 modules of 8 cells and 2
modules of 4 cells
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(3) High voltage safety measures
The following safety measures are set against high voltage system:
Circuit insulation The high voltage circuit is insulated from the vehicle body.
Reducing the risk of electrocution All of high voltage components are covered up by cases/cover and high
voltage wiring cables can be distinguished from normal wiring harness
by their orange coloured insulation.
Identification The high voltage components are labelled “WARNING” as shown below.
All high voltage harnesses are coated in orange.
Cases of high voltage components are insulated from high voltage
circuit inside
Communication In case of crash, the vehicle communicates to the assistance that the
vehicle contains High Voltage inside.
(4) Warning label
(5) High voltage Circuit Shut-off System
The high voltage can be shut off by the following methods:
Service plug Positioned under the left front seat, this plug shuts off output high voltage when
manually removed.
Contact key The contact key can shut off the high voltage from the Li-ion battery.
Emergency shut-off system In the case of a collision (airbag deployment, etc.) or certain system malfunctions
this system shuts off the high voltage from the Li-ion battery.
Charging connector Some of the high voltage components are activated during charging. Remove the
charging connector to deactivate theses components.
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3. Safety precaution for handling high voltage
Since iOn / C-Zéro has a high voltage circuit with 330V Lithium-ion battery for the electric motor unit and other
components, it is necessary to ensure “isolation” and “cut off” from the high voltage circuit in order to prevent
the risk of electric shock before handling the vehicle.
(1) Required tools and equipment
Items Specification Purpose
Insulating Personal
protective equipment
1. Rubber insulating gloves
2. Helmet
3&4. Pants and jacket
(recommended)
5. Rubber sole insulating
shoes
Wrench
Organic mask, Solvent
resistance gloves (or heavyduty rubber gloves) and
eyes protector.
Absorption mat, sand.
Fire extinguisher Type ABC Fire extinguisher that is suitable
Insulating plastic tape
Minimum 400V
voltage resistance
Size 10 mm
Size 12mm
Prevention of electric shock
while working on high voltage
circuit/s.
To be used to loosen :
The 2 nuts (12mm) fastening
service lid to access and
unplug the service plug.
To disconnect the auxiliary
battery negative terminal
(10mm).
For use when the electrolyte is
leaking from the traction
battery.
For absorbing the electrolyte
leakage.
An absorption mat (that is
effective to absorb fuel and/or
oil) and/or sand need to be
available.
for flammable liquid and
electrical equipment fires is
required.
For insulating the electric circuit
and tools if these are damaged.
(2) Precautions when rescuing passengers
WARNING:
Please handle the vehicle in accordance with the instructions provided throughout this manual to reduce the
risk of injury from electric shock
Points to note are:
This vehicle uses 325,6V high voltage circuit.
1) Traction battery uses an electrolyte made of flammable “Carbonate ester solution of lithium salts”.
When reacting with moisture in the air, this electrolyte generates acidic organic vapour which is harmful
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