PHEV Conversion Kit User Manual
Contents
1. Inc Michigan USA Web www enginer us Toll Free 877 886 8897 Address 1562 Hamlet Drive Troy MI 48084 USA Made By Enginer Inc Shanghai Web www enginer us Address Suite 901 Building 28 Lane 111 7580 Humin Road Shanghai China 201102 Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius Preparing and Assembling the PHEV Conversion Kit Please carefully read and understand these instructions before opening the product box Installation and Use l Prepare a flat area of at least a 7x7 feet on the ground near the end of your Prius and cover the floor with 5x5 feet soft and flat cloth or cardboard The equipment is heavy and should be removed and handled by at least two adults As industry standard it is suggested that the system should be lift by lifting machine Knock open the wooden box if there is one and then open the cardboard box in side Take out accessories and place them in a place not impeding your later installation Take out the foam plastic cover from the cardboard box and pull out the steel box this requires at least two people with both hands carefully and steadily move out the entire steel box and place it gently on the floor Do not tilt or turn over the equipment The equipment weights about 165 lbs Enginer strongly suggests you use professional lifting equipment or operators that are strong enough to lift this much weig2. Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius 11 PHEV switch panel operation ON Turn on PHEV DC DC Converter LED Green On Red Battery Low OFF Turn off PHEV DC DC Converter LED Green Off Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius Connecting Enginer PHEV Conversion Kit to your Prius Installation Time 1 hour by professionals Before installation please be advised to login to Toyota Technical Website techinfo toyota com for Reference Instructions 15 for two day usage as of June 2009 Preparation tools Required Screw shell M6 M14 Crosshead screwdriver Electric drill Installation Procedure 1 Stop your Prius engine completely by taking away your car key 2 Remove trunk interior cover on the back of the back seat to gain access to OEM stock battery orange service plug and unplug it 3 Remove auxiliary battery negative terminal 4 Remove back seat and gain access to the OEM stock battery output terminals Reference RM000002XNWOOLX for 2010 Prius Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius Enginer Inc Shanghai September 2010 Edition User Manual for 2010 Prius Enginer Plug in Hybrid Electric Vehicle Conversion Kit Enginer Inc Shanghai Septemb
3. a high current fault Steel enclosure Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius How the System Works 110VAC USA household electricity gt Enginer PHEV conversion kit gt Prius OEM stock battery gt Prius electric motor Capacity Average Gas Mileage EV Mixed Range Charge time Batteries Lithium lon 85mpg p OV m Use 110V AC source USA or other AC source matching PHEV charger only Warranty Two year limited parts warranty applies If equipment defect occurs in normal use conditions Enginer shall repair the equipment or change the defective component in this conversion kit only Use this information at your own risk Other than as specified above there is no additional warranty expressed nor implied and Enginer shall not be liable for any of your past present nor future actions Even if you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle By utilizing these ideas and instructions in an attempt to enhance national security reduce gas consumption vehicle emissions your carbon footprint or smog you do so at your own risk amp peril Contacts US Distributor Enginer
4. if there is some problem A Charger fuse The fuse block of the charger is inserted into the AC plug You can use a flat screw driver to pivot the block in the middle edge above the fuse sign and pull it outward Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius l B Converter fuse The fuse block is connected to the high voltage wire You can open the block by hand and replace the fuse Product Overview The Enginer Plug in Hybrid Electric Vehicle Conversion Kit PHEV is a rechargeable battery set that is supplementary to prius OEM battery It supplies electricity which is charged from an AC wall socket stored in PHEV kit providing for 40 miles of electrically assisted driving per charge sufficient for most normal daily commutes It is safe reliable and user and environment friendly What is Included in this Product AKWH Lithium lon batteries BMS monitoring and balancing battery voltages to avoid over or under charges to individual cells This can extend battery life by a factor of 3 110VAC 48VDC 15A high power charger 5000W DC DC converter and controller Fire extinguisher will be activated once the inside temperature exceeds 221F First of all please remove the cover and pull out the blue insulative inserter Automatic DC circuit breaker to disconnect high voltage equipment operation in the event of
5. style on Enginer Prius PHEV have shown way better than 100MPG or 100KM 2 83L with the best factory field test outcome of 160MPG or 100KM 1 7L for accumulated test drive distance of 165KM Attention 1 Please read instructions before installation 2 Never connect wires improperly Do recheck wires at least 3 times before switch on power 3 New batteries should be re charged to full and balanced before driving 4 Please check the batteries voltages and balance regularly for the first few times you drive the vehicle 5 To extend battery life equipment must be recharged especially when it will not be used for over one week using the 110VAC for USA or the right voltage in other countries watching the label on Enginer charger household electricity powered charger provided to full each time and the cells need to be fully balanced after charging 6 The circuit breaker on the right hand side of the enclosure box is set to be switched off automatically if the current exceeds a pre set limit 125A In the event this breaker switches off you will then need to manually switch it back on before use 7 Please switch the equipment off immediately if damage or defect is found 8 Please do not disassemble the components if the equipment is working normally and if you are not a qualified profeesional 9 Please disconnect BMS to batteries if not used for over 10 days to avoid battery failure 10 You can replace the charger and converter fuse
6. Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius Enginer PHEV Conversion Kit User Manual for 2010 Prius Warning You are strongly recommended to have a qualified professional to undertake this installation High Voltage HV Direct Current DC Warning Traction battery packs motors chargers and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such high voltage direct current sources Please note that anyone attempting to install this conversion kit and modify their vehicle is doing so at their own discretion and risk Warranty In performing some of these modifications it is possible though unlikely to void your warranty with the vehicles manufacturer Please check with your original vehicle manufacturer dealer for confirmation Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius This is a patent pending technology Driving Techniques for Maximizing Enginer Prius PHEV Mileage 1 Maintain steady speed as frequently as you can 2 When attaining the speed you desire on the road feather the accelerator or lifting your foot off entirely then very lightly easing back in to maintain a steady speed of under 34 miles or 70km per hour That motion activates your Prius EV feature that merely consumes stock and Enginer batteries Tests in this driving
7. eaker mounted on top of charger Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius Left Pack Right Pack Converter ans Circuit Breaker Figure 1 Component Layout 7 Wiring Check CD Make sure circuit breaker is in the OFF position BMS interfaces off 2 Charger and converter connections are connected firmly 8 Connection between black wires from batteries and circuit breaker are connected firmly and correctly as shown follow Breaker Figure 2 Connection of batteries 4KWH 8 Wiring Connect two pair Anderson plugs to batteries should be R to R and L to L R means Right pack and L means Left pack Connect the two 9 pins and two 4 pins white connectors to the BMS also should be R to R and L to L Then connect the 8 pin wire to BMS Connect the high voltage core red and black core with blue bullet connectors to the converter output connectors E Connect the 6 pin phone wire to the converter 9 The conversion kit assemble is completed and ready to be installed into the vehicle 10 Bumper outlet for charger connection Black wire Live line L White wire Null Line N Green wire Ground Line E Take the wire of charger through the back panel and reach to bumper outlet You need to get your hand in from under the car and tighten the silver ring of bumper plug Enginer Inc
8. er 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius e P S ds I in a a i a me o ff 225 RO DET ud eam LL esi Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius 5 Connect the conversion kit s power cable to positive and negative terminals of the stock battery output power cable 6 Install on off switch panel A Take off the blank panel on the left hand side of your meter board B Loosen the switch bolt place it on through the panel hole and tighten it on the panel Before replace panel After replace panel rcm WM 7 Hook up ECU Ignition Ready signal to on off switch panel Reference X387000000801LD for 2010 Prius SMRG L5 2 Yellow Ignition Ready Connect to the Green wire of PHEV switch panel E01 L5 5 White Red Ground Connect to the Brown wire of PHEV switch panel e White wire shall not be connected for 2010 Prius Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius POWER MANAGEMENT CONTROL ECU 8 Hookup 6 Pin on off switch panel cable to your Enginer battery box 9 Drill a hole and mount Bumper AC Outlet 10 Re Install back seat and trunk panels Reposition tightly Service Plug Grip otherwise electric power can not be started Enginer Inc Shanghai Septemb
9. er 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius Your Enginer PHEV Conversion Kit installation is now complete Please test the equipment in the following steps 1 Turn the the Enginer circuit breaker off 2 Disconnect the converter high voltage output to the OEM battery red and black wires with blue bullet connectors 3 Turn on the car 4 If the car can t start and has check engine light do step 5 8 5 Check Toyota battery orange high voltage service plug to make sure it is plug in correctly and secured 6 Check splice wires to make sure the connectivity is not compromised and the wire is correct Sometime the splice could cut off the original wire 7 Use scan tool to reset error code or disconnect the 12V battery and wait for 15 minutes to reset the error code 8 re check the car to make sure it is operational 9 Turn on Enginer circuit breaker But keep HV output wires disconnected 10 Turn on the car 11 Check if only the green light on Enginer PHEV switch panel is on when the switch is ON Also check the light on the converter output panel in the battery box 12 If the green light is not on use a meter to check if the Ignition 12V signal is 12V on the PHEV switch panel Also check the phone cable connector on the converter side to make sure pin 5 6 has 12V signal 13 Check OEM battery high voltage Play attention to the polarity of the wire 14 Check PHEV converter ou
10. ht Slowly handle the equipment to avoid physical injury or equipment damage After popping up the cover firmly and checking that it is being safe with no risk of dropping down take out all insulating foam gently and check inside component and accessory bags against the following list mM ECU signal wires green brown and white One switch panel with on off switch red and green LED lights 6 pin phone wire Converter high voltage core red and black core with blue bullet connectors Power core for charger input 2 sets of equipment mounting screws size M8 One charger input bumper socket One double sized spanner One thread for converter and charger 4pcs plastic clamps for connecting ECU signal wires to Prius Two black rubber blanket longer one for left hand side shorter one for the right hand side 1 1 mounting hole positions template Stainless steel box and cover 833 x 505 5 x 152mm Batteries 2 packs 4KWH Please make sure batteries match your order One converter mounted back left connecting batteries with one red and one black power inlet wires with a pair of Anderson plug It also contains one red and one black power outlet and a 6 pin cable M One charger mounted on right back connecting black power inlet cable with left hand side one red and one black cable with an Anderson plug B BMS fixed upon the charger the side close to your body M wo ventilation fan fixed on the converter at left corner mM One circuit br
11. lid you are now Safe to drive your Enginer Plug in Hybrid Electric Vehicle Please dial Enginer Assistance Hotline at 877 886 8897 if you encounter difficulty or risk during and after installation Enginer very much appreciates your effort to save the earth and wishes you enjoy your driving with your PHEV Enginer Inc Shanghai September 2010 Edition User Manual for 2010 Prius Enginer Plug in Hybrid Electric Vehicle Conversion Kit Bri AOL L os iff JS DE OLA oF ref eag VOOL LS eot uid AS GNO AZ uomnubBi Les sIeje gene euoug azrH 28ds ELT Lo AAOOOF ANDOOE Jape AOD OO OO ARP S NE bo JayeAu OF BIGE TD JeAO Aes OFE Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius NOTE Enginer Inc Shanghai September 2010 Edition
12. tput high voltage Play attention to the polarity The voltage should be higher 5 10V higher than the OEM battery voltage 15 Turn off the car connect converter high voltage to the OEM battery 16 Turn on the car in Park check PHEV battery voltage it should drop 1 5V when it charges the OEM battery 17 If the PHEV voltage drops more than 5 volt check the individual cell voltages to see if any cell is weak and significantly lower than the peer 18 Charging batteries 19 Wait overnight for the cell to be balanced At last Mount your Enginer PHEV Conversion Kit A Mark eight mounting holes according to size and dimension of the Kit s mounting brackets Remove one screw on the right side of truck avoiding bumping against brackets B Drill eight 13mm holes on the truck floor plate C Put the rubber blankets under the brackets the long one for left bracket the short one for the end of right bracket D Tighten eight mounting screws with washer and spring ring E Remove implements on the left side of trunk and put the vent pipe for circulating air inside PHEV F Then you may tighten buckles on two sides of the enclosure box to mount the entire equipment Enginer Inc Shanghai September 2010 Edition Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 2010 Prius Remove this plastic tool box Once all the above steps are completed and no defect occurs so tighten two screws on both sides of the steel
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