Hybrid Plug-in Conversions - EAA-PHEV
Contents
1. m m a m TE i EM EN i_at Figure 1 Component Layout Wiring Check CDMake sure circuit breaker is in the OFF position Anderson plugs from charger and converter are disconnected balancers interfaces are pulled off charger and converter connections are connected firmly SConnection between black wires from converter and circuit breaker is connected firmly Connection between circuit breaker and another black wire is connected firmly positive and negative of each group of batteries are connected firmly 16 cells in series two 16 cell packs in parallel shown in FIG1 terminal plastic covers are in position User Manual H Ts s u s ONENEO Figure 2 Connection of one row batteries 2KWH Connection of two rows of batteries AKWH Connection between balancers and batteries are normal and firm Figure 3 Balancer Connection 10 Wiring out the protection cap of the batter terminals positive and negative 11 between two battery packs use red black short jumper cable to put them in series as shown in Figure 2 If it is 4KWH model connect two str2. dimension of the Kit s mounting brackets B Drill and tap 10 screw on the truck floor plate C Tighten four mounting screws with washier and spring ring Enginer Plug in Hybrid Electric Vehicle Conversion Kit 5 Remove back seat and gain access to the OEM stock battery output terminals Prius 2000 2003 Model Reference HV 4 HYBRID VEHICLE CONTROL HV BATTERY A Pull up the seat cushion pad front edge toward back B Remove back cushion screws and pull it up C Remove battery carrier catch bracket to access to power cable terminal The upper terminal is positive the lower is negative 7 9 81 70 in Ibf 2 Hog Ring M72 Seat Cushion Cover 2 Seat Cushion 3 Lock Hook ka Seat Cushion Pad N m kgf cm ft Ibf Specified torque Non reusable part 2000 2003 Model Shown User Manual 18 185 13 18 185 13 Battery Bracket Blower Motor Control C onneeotor 18 185 13 ___ LH Battery Bracket Power Cable soar e Battery Carrier Catch Bracket 2000 2003 Model Shown c a he Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual 2004 2009 Model Reference 21 54 HYBRID CONTROL SYSTEM HV BATTERY Hear Floor Board Mo 3 Hear Floor Board Mo 2 Deck Floor Box Rear Li 1 457 Luggage Hold Bek Striker E La ct
3. Enginer Plug in Hybrid Electric Vehicle Conversion Kit Plug in Hybrid Electric Vehicle Conversion Kit User Manual You are strongly recommended to have a specialist to undertake the task HV High Voltage DC Direct Current 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 you may void your warranty with the vehicles manufacturer This is a patent pending application Product Overview Plug in Hybrid Electric Vehicle Conversion Kit PHEV is a rechargeable battery set sup plementary to a Hybrid vehicle It supplies electricity charged from AC wall socket for 20 to 40 mile mixed drive per charge sufficient for normal daily commute is safe reliable cost saving and user and environmental friendly Product Specifications 16 32 cells for 2KWH 4KWH LiFePO4 batteries Battery balancers one for every 8 cells monitoring and balancing battery voltage to avoid over or under charge individual cells extending battery life by 3 times 48V 15A high power charger 3000W DC DC Converter and Controller Automatic circuit breaker to discontinue equipment operation at abnormal hig
4. Kit Please read carefully and comprehend this instruction before moving out the product Installation and Use gt Prepare at least 2X2 meter flat ground near the end of your hybrid vehicle and cover the floor with 1 5X1 5 meter soft and flat cloth or cardboard The equipment must be removed by two adults Knock open the wooden box and then open the cardboard box in side Take out accessory bags and check against the following list to see whether com ponents are complete One 48cm lid supporting pole One plastic holding bracket Two 3cm red and black jumper wires with ring terminal One red and one black parallel connection bars Optional 4KWH batteries ECU signal wires red black and white One switch panel with on off switch red and green LED lights 4 sets of equipment mounting brackets and screws Two screws with handle One double sized spanner A set of two fire extinguisher holders and mounting screws Place the above accessories in a place not impeding the installation Take out the foam plastic cover from the cardboard box and pull out the stainless steel box by two people with both hands carefully and steadily move out the entire equipment and place it gently on the floor Do not incline or turn over the equipment avoid scratch ing the product The equipment weighted 55 80 kg Enginer strongly suggests you use professional lifting equipment or operators should be strong e
5. al F Cable To Irregrtar Poe JS Phoma Gable 3 a Pin Pana Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual NOTE 16
6. as Luggage Hold Bek Sinker I LI I 7 m ze AT UE Fleer Floor Board 1 6 0 61 53 in Ibf Service Plug Grip Fear Sent Cushion Assy Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual Bettery Flower Melay Mo 1 Rear Side Side Sack Frame Deok Trim Side Panel Assy Luggage Hold Belt Striker Assy Enginer Plug in Hybrid Electric Vehicle Conversion Kit w OE p Beater Carrier Panel 6 PE Negative 2010 Prius Model Reference RM000002XNWOOLX User Manual User Manual Enginer Plug in Hybrid Electric Vehicle Conversion Kit Ts xo r 2f SLAMA Pa DY AN NS 4 JAA A 67 H i Wess Ws 10 Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual 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 Drill three holes for the switch and the 2 LED lights to fit in 6mm for the switch 3mm for each LED light C Loosen the switch bolt place it on through the panel ho
7. h current Easy installation simple to use User Manual Equipment work procedure 110VAC household electricity Enginer PHEV conversion kit Hybrid vehicle OEM Stock battery Hybrid electric motor Batteries Type ed Average Gas EV Mixed Charge time Mileage mpg Range hour 20 16 Cells LiFePO4 40AH Use 110V AC source only Balancers monitoring and balance battery cells Each controls 8 cells Press LiPo LiFe to select battery type LiFe mode should be set for this equipment at all times After setup press Start Stop to initiate balancer The balancer s screen will show in order data of Total voltage of the 8 cells Voltage of individual cell Standard deviation of voltage A red dot flashes during balancing and turns off when voltage difference is less than 0 01V The balancer will alert if any cell voltage drops below 2 8V or is charged above 3 75V Attention 1 Please read instructions before installation 2 Never wrongly connect wires 3 New batteries should be re charged to full before use 4 Please check the batteries voltage regularly at the first few times of usage 5 Equipment must be recharged at 110VAC household electricity to full each time and fully balanced to extend battery life after charged 6 Circuit breaker in the enclosure box shall be automatically switched off if the current is over the limit 100A You will then need to resume the switch before use 7 Please sw
8. ings of the 2KWH battery packs in parallel positive to positive negative to negative terminals Connect the DC DC converter 11 to the end terminals of the battery pack red to positive and black for negative Connect the white connectors to the balancers Connect the gray Anderson connector to the charger Remove the lid supporting bar close the cover and tighten two screws on both side of the cover 12 The conversion kit assemble is completed and ready to be installed into the vehicle Enginer Plug in Hybrid Electric Vehicle Conversion Kit 13 Bumper outlet for charger connection 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 User Manual Connecting Enginer PHEV Conversion Kit to a Toyota Prius Installation Time 2 3 hours by professionals 6 hours or longer by first timers 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 Installation Procedure 1 Stop your Prius engine completely by removing t car key 2 Remove truck 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 Mount your Enginer PHEV Conversion Kit to the truck A Mark four mounting holes according to size and
9. itch the equipment off if defect is found during driving 8 Please do not disassemble components if the equipment is in normal working condi tions Enginer Plug in Hybrid Electric Vehicle Conversion Kit Warranty 2 year limited parts warranty applies If equipment defect occurs in normal use conditions Enginer shall repair the equipment or change defect components in this conversion kit only Use this information at your own risk There is no warranty expressed nor implied and we are not liable for any of your past present nor future actions Even should 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 attempting 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 AutomationTech Inc www automationtechinc com Toll Free 877 886 8897 1562 Hamlet Drive Troy MI 48084 USA Made By Enginer EnvironmentTech Co Ltd Web www enginer us Address 1010 1701 Beijing Xi Road Shanghai 200040 China User Manual Enginer Plug in Hybrid Electric Vehicle Conversion Kit Preparing and Assembling the PHEV Conversion
10. le and tighten it on the panel 7 Hook up ECU Ignition Ready signal to on off switch panel 11 Enginer Plug in Hybrid Electric Vehicle Conversion Kit 2000 2003 Model Reference 01 20 Terminals of ECM 2 H12 2 Grey Ignition Ready Connect to the Red wire of PHEV switch panel GND1 H14 31 White Black Ground Connect to the White Black wire of PHEV switch panel White wire is not connected for 2000 2003 Model HV ECU Terminals 6 514312 1 1211110191817 151419 1110 12 User Manual Cowl Side Trim Front Door Scuff Plate Enginer Plug in Hybrid Electric Vehicle Conversion Kit 2004 2009 Model Reference 05 408 DIAGNOSTICS HYBRID CONTROL SYSTEM 2 H16 2 Green Ignition Ready Connect to the Red wire of PHEV switch panel GND1 H14 1 White Black Ground Connect to the White Black wire of PHEV switch panel EV H14 27 Blank Pin EV Mode Connect to the White wire of PHEV switch panel 13 User Manual Add EV switch wire Reference http www calcars org prius evbutton install pdf EV Button Modification for 04 Americas Prius Transmission ECU Transmission Shift Assembly Key Slot You will need to insert a receptacle amp wire into hole 27 Tamparan Lock Postion Please note that anyone attempting to do this modification is doing so at their own discretion and risk Enginer Plug in Hybrid Elect
11. nough Slowly handle the equip User Manual ment to avoid injury or equipment damage Take the supporting pole from accessories and hold it with your right hand Open the enclosure box cover and stick the pole in the hole at right hand side close to your body and prop up the cover on the other end Take out a white small plastic bracket holder from accessories and push it hard to a small hole on right side to rest the pole after use After popping up the cover firmly take out all insulating foams gently and check in side component against the following list Stainless steel box and cover 796 4x520 0x180 0mm Batteries 2 sets of 8 cells 2KWH or 4 sets of 8 cells 4KWH depending on your or der Please make sure batteries match your order Two battery mounting frames to fix the two rows of batteries Balancers fixed on the rear battery frame two 2KWH kit or 4 for 4KWH kit black each linking 8 cells with wires One converter connected 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 One charger connected on right back connecting black power inlet cable with left hand side one red and one black cable with an Anderson plug One circuit breaker mounted on right lower conner Enginer Plug in Hybrid Electric Vehicle Conversion Kit gt
12. ric Vehicle Conversion Kit 2010 Prius Model Reference X387000000801LD Power Management Control ECU SMRG L5 2 Yellow Ignition Ready Connect to the Red wire of PHEV switch panel E01 L5 5 White Red Ground Connect to the White Black wire of PHEV switch panel White wire is not connected for 2010 Prius 14 User Manual POWER MANAGEMENT _ CONTROL ECU Enginer Plug in Hybrid Electric Vehicle Conversion Kit 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 Your Enginer PHEV Conversion Kit installation is now complete Please test the equipment in the following steps 1 Charging batteries 2 Wait overnight for the cell to be balanced 3 Turn on circuit breaker 4 Turn off PHEV switch 5 Turn vehicle ignition key 6 Turn on PHEV switch Power LED should turn green and Battery Low LED should be off Once all the above steps are completed and no defect occurs you are safe to drive your Enginer Plug in Hybrid Electric Vehicle now Please dial Enginer assistance hotline on 877 886 8897 if you encounter difficulty or risk during and after installation Enginer very much appreciates your action of saving the earth and wishes you enjoy your driving with the new PHEV 15 au DC E 1 A Bor B1 1004 User Manu
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