Emergency Response Guide
Honda Fuel Cell Vehicle
Prepared for Fire Service, Law Enforcement, Emergency Medical, and Professional
Towing Personnel by American Honda Motor Co., Inc.
Contents
Key Components ................................................................................................................... 2
Vehicle Description ................................................................................................................ 3
Vehicle Type, Size, and Materials .............................................................................. 3
Identifying the FCX Clarity ......................................................................................... 3
Fuel Cell Stack ............................................................................................................ 3
Hydrogen Tank ............................................................................................................ 4
High-Voltage Electric Motors ...................................................................................... 4
Power Drive Unit ......................................................................................................... 4
High-Voltage Battery ................................................................................................... 5
High-Voltage Cables ................................................................................................... 5
12-Volt Battery ............................................................................................................ 5
Occupant Protection Equipment .................................................................................. 6
Built-In Safety Features ......................................................................................................... 7
Crash Detection System .............................................................................................. 7
Hydrogen Tank Safety Valves ...................................................................................... 7
Hydrogen Detectors ..................................................................................................... 8
Potential Hazards .................................................................................................................. 9
Flammable Fluid .......................................................................................................... 9
Hydrogen Properties and Potential Hazards ................................................................ 9
Electric Shock Potential ............................................................................................. 10
High-Voltage Battery Contents ................................................................................... 11
Emergency Procedures ....................................................................................................... 12
Incidents Involving Fire .............................................................................................. 12
Submerged or Partly Submerged Vehicle .................................................................. 12
Shutting Down the High-Voltage, Hydrogen & Airbag Systems ................................. 13
Preferred Method................................................................................................ 13
Alternate Method ................................................................................................ 14
Extricating Occupants ................................................................................................ 16
Emergency Towing ..................................................................................................... 16
1
Key Components
High-Voltage DC-DC Fuel Cell High-Voltage
AC Compressor Cables Converter Stack Battery
Power Drive Unit
(PDU)
Air Pump
Unit
Drive Motor/
Gearbox
12-Volt
Battery
Underhood
Fuse Box
Electric Fuel Cell Battery Voltage Hydrogen Supply & Hydrogen
Heater Contactor Control Unit Humidifier Systems Tank
Fuel Cell Hydrogen Supply &
DC-DC Stack Humidifier Systems
Air Pump Electric Converter
Underhood Unit Heater
Fuse Box
12-Volt
Battery
Power Drive
Unit (PDU)
AC
Compressor
Drive Motor/
Gearbox High-Voltage Fuel Cell Battery Voltage High-Voltage Hydrogen
Cables Contactor Control Unit Battery Tank
2
Vehicle Description
Vehicle Type, Size, and Materials
The Honda FCX Clarity is a 4-door, 4-passenger
sedan that uses fuel cells to convert hydrogen and
oxygen into electrical power. The chassis and most
components are made of steel and aluminum. Some
parts are made of plastic.
Identifying the FCX Clarity
The Clarity can be identified by the logo containing
the words FCX and Clarity located on the lower
part of both rear passenger doors, and to the left of
the license plate on the rear of the vehicle.
Fuel Cell Stack
The FCX Claritys main power source is a fuel cell
stack housed in a metal box in the lower center of
the vehicle. The stack contains layers of individual
fuel cells that combine hydrogen from an onboard
tank with oxygen brought into the vehicle from air
Fuel Cell Stack intakes to produce electricity. The only by-products
of this process are heat and water. Some of the
water is used by the humidifier, and excess water is
vented through the exhaust pipe.
The fuel cell stack is well protected in the lower center of the vehicle,
shown here with the underbody covers removed.
3
Vehicle Description
Hydrogen Tank
The hydrogen used to generate electricity is
compressed to 5,000 psi and stored in a strong,
refillable tank located behind the rear seats. The
tank is made of nonflammable materials, and has
passed the same rigid impact tests for tanks in cars
fueled by compressed natural gas (CNG). Tank
capacity is 171 liters.
The hydrogen tank is securely strapped to the FCX Claritys frame.
High-Voltage Electric Motors
Electricity generated by the fuel cell stack powers
the drive motor, an air pump motor, and an air
conditioning motorall located under the hood.
Other high-voltage components include a fuel cell
contactor, forward of the fuel cell stack; a battery
voltage control unit, under the drivers seat; a DC-
DC converter; a power drive unit; and an electric
Removing the underbody covers that protect components from dirt heater. (See page 2 for component locations.)
and damage reveals the drive motor, located between the front
wheels.
Power Drive Unit
The power drive unit (PDU) controls the high-
voltage electric motor power. While the PDU
contains high-voltage components, it is located out
of sight and reach, under other components.
The Power Drive Unit (PDU) is located under other components and
can be reached only by their removal.
4
Vehicle Description
High-Voltage Battery
A lithium-ion battery stores power generated by the
fuel cells and regenerated by the drive motor. It
provides extra current when needed, such as during
acceleration. The battery is housed under the rear
seat and just forward of the hydrogen tank. Its
voltage is nominally 288 volts.
High-Voltage Battery Location
High-Voltage Cables
Electricity from the fuel cell stack and the high-
voltage battery is delivered to the motors through a
number of cables. Most are located inside or behind
enclosed high-voltage components. Those located
underneath the vehicle are protected by the
underbody covers. Any that might be visible under
the hood can be easily identified by distinctive
The distinctive orange color makes it easy to identify the location of orange protective covers.
high-voltage cables, shown here with the underbody covers
removed.
12-Volt Battery
A conventional 12-volt battery is located under the
hood on the drivers side. This battery powers the
lights, the audio system, and other standard
electrical components. It is also used to start the
drive system.
12 Volt Battery
5
Vehicle Description
Occupant Protection Equipment
The FCX Clarity has lap/shoulder belts in all
seating positions, dual front airbags, side airbags in
front, and side curtain airbags. The front seats are
equipped with pyrotechnically activated seat belt
pretensioners. As with conventional automobiles, it
takes about 3 minutes for the airbags and
pretensioners to be disabled after the ignition switch
is turned off or the 12-volt negative battery cable is
cut.
6
Built-In Safety Features
The FCX Clarity is designed with a number of built-
in features to protect users, bystanders and
emergency responders.
Crash Detection System
The vehicle is equipped with sensors that can detect
a serious impact to the vehicle. If the impact is
severe enough to deploy any airbag, the system
controller will automatically shut off the flow of
hydrogen and electric current. While the hydrogen
flow stops immediately, it takes about 3 minutes
before the high-voltage system is completely shut
down.
Hydrogen Tank Safety Valves
The hydrogen tank contains an internal solenoid
valve with three safety valves. One prevents
backflow during refueling. Another stops the flow of
hydrogen when signaled by the system controller.
The third is a pressure relief valve that releases
Hydrogen Pressure Relief Tube Location
hydrogen if temperature inside the tank exceeds
about 226oF (108oC).
If the pressure relief valve opens, hydrogen will be
routed through a metal line and out a pressure relief
tube under the trunk on the passenger side of the
vehicle. The hydrogen will make a hissing noise as
it escapes, and it will continue releasing and
dissipating up into the atmosphere until the tank is
empty. It could take up to 5 minutes if the tank is
Hydrogen Pressure Relief Outlet
full.
7
Built-In Safety Features
Hydrogen Detectors
In addition to the safety valves, several hydrogen
sensors are located throughout the vehicle. If a
potentially hazardous leak is detected, the system
controller will automatically stop the flow of
hydrogen from the tank.
8
Potential Hazards
The FCX Clarity does not appear to present any
greater hazards than a conventional gasoline-
powered, hybrid, or electric car. The vehicle
performed well in all standard crash tests, with no
damage to the high-voltage or hydrogen
components.
Flammable Fluid
The only flammable fluid used by the FCX Clarity
is transmission oil. The capacity is 1.2 liters.
Hydrogen Properties and Potential
Hazards
Flammability in Air Explosivity in Air The hydrogen used in the FCX Clarity is a nontoxic
(Volume %) (Volume %)
and odorless gas. Unlike gasoline and oil, it cannot
80
4 to 74.5% spill and it cannot harm humans, wildlife, or the
70 environment.
60 However, like other fuels, hydrogen is flammable
18.3 to 59% and explosive. Compared to gasoline, for example,
50
when mixed with air, hydrogen has a much larger
40 range of flammability, and its explosive range is
also much larger.
30
Emergency responders should also know that
20
hydrogen flames are invisible. In addition,
1 to 7.6 %
10 hydrogen burns very quickly and radiates less heat
1.1 to 3.3 %
than gasoline or other fuels.
0
Gasoline To limit the chance of a hydrogen leak, the FCX
Hydrogen
Clarity has many built-in safety features (see pages
7-8). And, since hydrogen is 14 times lighter than
air, a leak occurring outdoors would quickly
dissipate into the atmosphere.
9
Potential Hazards
Electric Shock Potential
Unprotected contact with any electrically charged
or hot high-voltage component can cause serious
injury or death. However, receiving an electric
shock is highly unlikely due to these facts:
Following the instructions on pages 13-15 after
an incident will shut down the high-voltage
system (in about 3 minutes).
All high-voltage components are insulated from
the rest of the vehicle, so touching the body or
other vehicle parts cannot result in an electric
shock.
Contact with high-voltage components (shown in
orange in the illustrations on page 2) can occur
only if these items are damaged and someone
deliberately touches the contents.
Contact with any of the high-voltage motors or
other components can occur only after one or
more components are removed, or the vehicle is
cut outside the cut zone shown on page 16.
10
Potential Hazards
High-Voltage Battery Contents
The lithium-ion battery is contained in a strong
metal box and should present no hazard in normal
circumstances. Also, if the box is engulfed in flames
or temperatures above 212oF (100oC), a pressure
relief valve will open and release pressure, so the
battery should not explode.
However, the contents of the battery are flammable
and will burn if the box is broken open, giving off
gases that can cause irritation if inhaled. To
extinguish a burning battery, the manufacturer
recommends CO2 or an abundance of water.
The electrolyte in the battery is a non-aqueous liquid
which is less hazardous than the electrolyte in the
12-volt battery. If the battery box is broken and the
electrolyte leaks out, appropriate skin and eye
protection are recommended.
11
Emergency Procedures
Based on discussions with rescue professionals, we
recommend that emergency response personnel
follow standard procedures developed by their own
organization for assessing situations and dealing
with potential hazards. Given our knowledge of the
FCX Clarity, we also recommend the procedures
outlined in this section.
Incidents Involving Fire
If an FCX Clarity is involved in a fire, follow
standard fire-fighting procedures, but with this
reminder:
Keep away from the rear of the vehicle until the
fire is completely out. If the temperature inside the
hydrogen tank exceeds about 226oF (108oC), the gas
in the tank will be released through a pressure relief
tube at the right rear of the vehicle. You may hear a
hissing sound as the hydrogen escapes, and it can
take up to 5 minutes for a full tank to empty.
Although pure hydrogen flames are invisible, you
will see colored flames if other parts of the vehicle
are burning.
Submerged or Partly Submerged
Vehicle
Pull the vehicle out of the water, then proceed with
the emergency procedures on the following pages.
12
Emergency Procedures
Shutting Down the High-Voltage,
Hydrogen & Airbag Systems
If it becomes necessary to shut down the high-
voltage, hydrogen and airbag systems (such as after
the vehicle has been involved in a collision), follow
one of the two procedures described below and on
the following pages.
Preferred Method
This method is recommended for situations where
the responder can safely reach the ignition key.
Turn the ignition key to the off (O) position
and remove the key.
Turning the ignition switch off immediately shuts
Ignition Switch Off (O) Position
down the flow of hydrogen. In about three minutes,
the high-voltage system and any undeployed
airbags and front seat-belt pretensioners will also be
shut down.
Removing the key prevents the high-voltage and
occupant protection systems from restarting while
you assist the vehicles occupants.
13
Emergency Procedures
Alternate Method
This method is recommended for situations in
which responders cannot reach the ignition key but
can reach under the hood and have access to a
Phillips screwdriver.
Remove the 120 amp main fuse from the
underhood fuse box, THEN cut the negative
12-volt battery cable.
Removing the main fuse shuts down the high-
voltage and hydrogen systems, and cutting the
negative 12-volt battery cable shuts down power to
the airbags and pretensioners. (Remember, it will
take about 3 minutes for these systems to shut
down.)
To use this method:
1. Raise the hood and locate the underhood fuse
box and the 12-volt battery.
Underhood 12-Volt
Fuse Box Battery
14
Emergency Procedures
2. Remove the underhood fuse box lid and locate
the 120 amp main fuse.
3. Using a Phillips screwdriver, unscrew and
remove the main fuse assembly.
120 Main Fuse Screws
4. Cut the negative 12-volt battery cable.
Negative 12-Volt Battery Cable
15
Emergency Procedures
Extricating Occupants
If you need to cut into the body, or use other Jaws of
Life type of equipment to remove occupants, be sure
to stay within the cut zone indicated in the
illustration below.
Cut Zone
Side Curtain
Airbag Inflators
Cutting into these components can result Cutting into these components should not
in high-voltage electric shock result in electric shock
Emergency Towing
If a damaged or disabled FCX Clarity needs to be
moved a short distance, such as to the side of the
road, and the car can still roll on the ground, shift
the transmission to neutral, then manually push the
car. If the vehicle needs to be towed away from the
area, the preferred method is by flatbed truck.
16
Copyright 2008, American Honda Motor Co., Inc.
Reorder Number Y0804
