PHEV Add-on System User Manual
Contents
1. black with an Anderson plug m BMS is mounted on the right side of the battery holding tray m A Circuit breaker main switch mounted next to the converter m Fire extinguisher is attached on the middle of converter Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Fire Extinguisher Converter Figure 1 4KWH System Structure Layout Upper 4K WH Batteries and BMS Figure 2 8KWH System Structure Layout 5 Wiring Check O Make sure circuit breaker is in the OFF position BMS interfaces off Charger and converter connections are appropriate solid and firm Red cores from batteries and to circuit breaker are connected correctly and firmly as shown below Left Pack Right Pack Figure 3 Connection of batteries 4KWH Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Figure 4 Connection of batteries BK WH 6 Bumper outlet for charger connection Black wire Live line L White wire Null Line N Green wire Ground Line E Take the charger cord through the back panel and reach to bumper inlet You need to get your hand in from under the car and tighten the silver ring of bumper plug 7 Install the Charger LED into the tail light this LED shows charger operation Red LED Charging at about 15A Green LED Fully charged 8 PHEV s2. contact your installer or Enginer customer service via Contact Us page on www Enginer us If your vehicle and PHEV switch are both on but green light is off please check the System circuit breaker by pressing it off and on again to make sure it is engaged If problem persists please seek support from Enginer or your installer Enginer Battery Management System BMS stores diagnostics information on an SD card inside and displays instant performance data on the dash LCD monitor Please refer to BMS User Manual for details and when making inquiry provide Enginer or your installer with your SD card data To charge the system it is recommended to use a Gauge 14 extension cord 15A and plug it into a standard 120VAC 220VAC power outlet with a 20A circuit breaker Its average current is 10A 120VAC or 5A 220VAC Once it is plugged in the external dual color LED indicator should turn solid red It turns green when batteries are fully charged and the charger stops automatically No hand shut off is necessary It takes about 5 hours to charge up from drained Lithium lon batteries should be charged as often as possible even if they have not been used up If the indicator is not on or flashing red please check the charger fuse or contact your installer or Enginer for advice Lithium battery needs to be charged above freezing temperature 32F 0C If ambient temperature is under freezing point such batteries should be warmed up before charging to avo
3. to maintain a steady speed of under 34 miles or 70km per hour That motion activates your Prius EV feature to consume battery power only Tests in this driving 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 Consumption Teme 77 F 50Wh Regenerated d ND MPG 75 50 ES e xu lt gt C lt gt amp 30min 25 20 15 10 5 Current AVERAGE Energy 99 OMPG 22 miles Reset S 1 Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius User Guide Enginer Add on System is designed for PHEV blended mode operation and therefore EV mode switch is not required although it is an option This PHEV technology minimizes possible impact on your hybrid vehicle to preserve your original warranty The primary goal of the system is to improve fuel efficiency reduce gasoline consumption The PHEV switch should be in the ON position most of the time unless the PHEV red light is ON which indicates low PHEV battery level or unless you wish to preserve battery energy for later use When your vehicle and Enginer PHEV switch are both on the green indicator should also be on meaning the System is operational If the red light is on as well it means low battery or System error If the red light stays on all the time please
4. with four bolts installed Mark up the mounting holes on the floor 12 Drill three holes each on the two sides of the cover plate for mounting purpose 20 Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius 13 Place battery packs into the battery tray in the spare tire well Optionally inject spray foam on the bottom of the battery tray for additional support and safety 14 Wiring Insert the R battery 9 pins white plug into the R port on BMS and the L one to L port Turn on the BMS to make sure the green light is on If not the R and L BMS harness could be in reverse position X3 15 Put the cover plate on and connect the Anderson plug labeled R to the R Right battery pack and L to the L Left pack Don t mount the cover plate until the system is verified Use a 1 foot 2x4 stick to hold the cover plate in 45 degree angle for easy diagnostics 16 Turn on the BMS to make sure the green light is on and the remote display shows data 17 Plug the 8 pin and 2 pin wires into BMS and the 6 pin phone wire to the converter but do not connect the high voltage cable yet 18 Hook up the 12V auxiliary Battery 19 Insert the orange service plug into the stock battery pack Slide the handle to lock the service plug If the service plug is not inserted correctly it could trigger a trouble code in the vehicle and disable the car
5. 012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Battery Blower Relay No 1 Quarter Vertilation Inner Duct No 2 o 2 es 20 208 21 4 0 47 25 in Ib Jy g enm Connector Reinforcement Clip Battery Bracket F u _J3 Quarter Ventilator Duct Battery Carrier Bracket 16 Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius cor AER e Umm mom mcm m dla N i 2 F Lal 19 194 14 AJ Junction Tarminzal SM 19 194 14 19 194 14 14 Battery Comer Pane No 6 T S 76 66 iumn Ibf P Junction Terminal 5 Connect the HV power cable to positive and negative terminals of the stock battery output power cable 17 Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System 6 Install On Off switch panel User Manual for 2004 2009 Prius a Pull off left side vent remove 2 screws unsnap lower panel can unhook wires amp cable for more room BU Np Z4 Uk we g e Loosen the switch bolt place it on through the panel hole and tighten it on the panel as shown below Before replacing the panel After replacing the panel a Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius 7 Hook up the car s ECU Ignition Ready s
6. 20 Start your vehicle Use a digital volt meter to measure the high voltage cable that is going to the converter to verify the voltage and polarity of the hook up If there is no voltage or the polarity is wrong check the connection again 21 Turn off the vehicle Firmly connect the high voltage cable red and black wires with yellow bullet connectors with the converter output connectors 22 Turn on the vehicle Turn on the circuit breaker and then the Enginer PHEV switch Verify the green light on the switch panel and green light on the converter output panel If there is no green light check the ECU hookup The green wire should have 12V and the brown wire is ground Also measure the voltage between pin 5 and pin 6 of the 6 Pin phone connector going into the converter There should be 12V between the pins 23 Review remote LCD display for Vo output voltage lo output current Vi input voltage and li input current 23 Once the converter output is verified turn off the vehicle and fasten the battery pack and the cover plate 24 Put back all the removed panels 25 Recover back seat and trunk panels 21 Enginer Inc May 1 2012 User Manual for 2004 2009 Prius Enginer Plug in Hybrid Electric Vehicle Add on System uid A3 ONS Azi voui LZE oct aeey 6 aqep euoug SZH O9d3 JeyeAu OF eig Jano EL LO EE ET A zE DFE gs rer su A oL azg EnH Jj wAOLL j L gpp Ja reyg l Lo 18 4J9HEH OLAS L E MOORS Hy4Belg
7. 4 2009 Prius Preparing and Assembling Enginer PHEV Add on System Please carefully read and understand these instructions before opening the product container Installing and Use p leu x Prepare a flat area near the end of your Prius and cover the floor with a 5x5 feet soft and flat cloth or cardboard The equipment components are heavy and should be handled by two adults Knock pull open the wooden or carton boxes carefully Take out all insulating foam and check inside component and accessory bags against the following list m ECU signal wires green brown and white m One switch panel with On Off switch red and green LED lights m A 6 pin phone wire m Converter high voltage cable red and black cable with yellow bullet connectors m Power cord for charger input m 2 sets of mounting screws size M8 m 1 charger bumper inlet m 1 spanner m 1 thread for converter m 3 pieces plastic clamps for connecting ECU signal wires to Prius m 1 metal mounting panel and square battery holding tray s m Batteries 4KWH in 2 packs 8KWH in 4 packs Please make sure batteries match your order m DC DC converter is mounted on the right hand side with a pair of red and black power cables linking an Anderson plug to connect battery packs A pair of HV wires red and black and a 6 pin cable at the other end m Battery charger is mounted under the metal panel left side of the batteries with a gray power cable and a pair of cord red and
8. Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius i Enginer PHEV Add on System User Manual for 2004 2009 Prius Warnings You are strongly recommended to hire a qualified professional 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 System 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 vehicle manufacturer Please check and confirm with your original vehicle manufacturer dealer This is a patent pending technology Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Attention 1 Please read this manual carefully and follow the instructions before and during installation 2 Please never connect wires improperly and do carefully check them against the instruction for at least 3 times before switching the power on 3 New system batteries should be charged to full and well balanced before driving 4 Please monitor individual cell voltages and balance them regularly 5 Please check carefully to make sure the voltage as lab
9. H YOOL LS sa CGE Lf MODOR MODE Jape Avo THI ZXIASE 22 Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Your Enginer PHEV Add on System installation is now complete Please test the equipment in the following steps 1 Turn the Enginer circuit breaker off 2 Disconnect the converter high voltage output to the OEM battery red and black wires with yellow bullet connectors 3 Start your vehicle 4 If the vehicle does not start with the Check Engine light on do step 5 8 5 Check Toyota battery orange high voltage service plug to ensure it is plug in correctly locked and secured 6 Check splice wires to make sure the connectivity is not compromised and the wire is correct Splice may occasionally 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 your vehicle and confirm it is operational 9 Turn on Enginer PHEV circuit breaker while keeping HV output wires disconnected 10 Start your vehicle 11 Check if Enginer PHEV switch panel is only green light on when the switch is at ON position 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 have 12V
10. e plug It is a 3 step process do in reverse to re insert i raise handle straight up about 1 4 1 ii flip handle down 90 degrees to vertical position iii Pull plug out horizontally EMEN m Que 9 7 US gym Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius 3 Disconnect 12V auxiliary battery positive terminal record radio stations first if necessary 4 Flip down the back seat and open the panels to gain access to the OEM stock battery output terminals zin lt Bea i E SJE z 911 PM 12 Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Reference 21 54 HYBRID CONTROL SYSTEM HV BATTERY for 2004 2009 Prius Rear Floor Board No 3 Deck Floor Box Rear service Plug Grip Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Deck Trim Cover Rear Tonneau Cover Assy dy Luggage Hold Belt Striker i i i i i Rear Seat Cushion Assy 14 Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius anel Assy RH Deck Trim Side P Rear Floor Board Mo 4 1 amp Curiker ASSY Hold Belt Luggage Rear Side eat Side Back Frame RH Rear Side Seat Side Back Frame LH Enginer Inc May 1 2
11. eled on the charger matches your input electricity source 6 To extend battery life the System should be charged to full each time especially before the System is to be left unused for over 10 days 7 To avoid possible battery failure please turn off the BMS if the System is not to be used for over 10 days 8 The main switch circuit breaker on the right hand side of the metal panel will be switched off automatically whenever current exceeds the pre set limit 125A In the event that this switch is turned off you need to manually press it back on before use You are suggested to report such errors to Enginer or your installer if this keeps happening 9 Please switch the equipment off immediately if any damage or defect occurs 10 Please do not disassemble the System if it is working properly and if you are not a qualified professional 11 Charger and DC DC converter fuses can be replaced if blown A Charger fuse Fuse block of the charger is inserted in 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 May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Driving Techniques for Maximizing Enginer PHEV Mileage 1 Maintain steady speed at all times if possible 2 When your desired driving speed is achieved feather the accelerator or lifting your foot off entirely then very lightly easing back in
12. id permanent battery damage With a working PHEV System the Prius Energy Monitor should stay in seven 7 green bars most of the time If it often shows eight 8 green bars or only six 6 or fewer blue bars please contact your installer or Enginer for advice It is recommended to have access to a scan tool such as Scangauge and a wattage monitor like Kill A Watt device to monitor and optimize your driving experience with this PHEV System Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Product Overview The Enginer PHEV Add on System is a rechargeable battery set that supplements Prius OEM battery The System supplies stored electricity which was previously charged from an AC wall socket providing 40 miles of electrically assisted driving distance per charge sufficient for most daily commutes It is safe reliable and user environment friendly What ts Included in this Product 4KWH Lithium lon batteries BMS monitoring and balancing batteries to avoid individual cells over charge discharge extending battery life 48VDC 15A high power charger 5KW DC DC converter Fire extinguisher will be activated once the inside temperature exceeds 221F First of all please remove the cover and pull out the blue isolation insert Automatic DC circuit breaker to disconnect high voltage equipment operation in the event of a high current fault e Metal mounting panel and ba
13. ignal Ground and EV optional wires to PHEV On Off switch panel a Create access to ECU by removing vent lower glove box and plastic piece to right of glove box c Connect the PHEV wires to the car s ECU as indicated below CON2 H16 2 Green Ignition Ready Connect to the Green wire of PHEV switch panel GND1 H14 1 White Black Ground Connect to the Brown wire of PHEV switch panel EV H14 27 Blank Pin EV Mode Connect to White wire of PHEV switch panel Optional Attention Disconnect all ECU wires in car before connecting Blank Pin to PHEV switch panel s White wire 17 Tm mm mm th bal 13 JEN hahahahaa pilale 7 M P m s R e e E E Gat al Bs EEE E u Tis ps eu 2322 21520 aha hz 35534 ce n ieee GEIL mud its 18 NOTE The ECUs are actually positioned vertically with H17 at TOP RIGHT H14 at BOTTOM RIGHT 1 O Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius EV Button Modification for 04 Americas Prius You Will need Lo insert a recepiaele amp wire mio hole 27 Bate ect Ic Pee 8 Lay the 6 Pin cable and the USB cable along the side of the vehicle from front dash board to the trunk area 9 Remove the spare tire from the spare tire well 10 Position the battery tray in the spare tire well Use foam material to raise the bottom if necessary 11 Lay the large cover plate on top of the battery tray
14. ner Plug in H YOU INSTALLATION NOTE US Distributor Manufactured By ybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Contacts Enginer Inc Michigan USA Web www Enginer us Email CS Enginer us Toll Free 877 886 8897 P O Box 3 Troy MI 48099 USA Enginer Inc Shanghai 151 Keyuan Road Zhangjiang High Tech Zone Pudong District Shanghai 201203 China 24 Enginer Inc May 1 2012
15. signal 13 Check OEM battery high voltage Pay attention to the polarity of the wire 14 Check PHEV converter output high voltage Pay attention to the polarity The voltage should be 5 10V higher than the OEM battery voltage 15 Turn off the car before connecting the converter high voltage to the OEM battery 16 Turn on the car in Park check PHEV battery voltage which should drop 1 5V when charging the OEM battery 17 If the PHEV voltage drops more than 5 volts check individual cell voltages to locate weak cell s that is are significantly lower than the peer 18 Charging batteries 19 Wait overnight for the cells to be charged and balanced Final Stage Mounting Your Enginer PHEV Add on System A Mark six mounting holes on the car according to size and dimension of the System s mounting brackets B Drill six 14mm holes on the marked places C Put the well nuts in the holes D Put the PHEV kit on the car and then tighten six 8mm mounting screws with washer and spring ring Once all the above steps are completed and no defect occurs so tighten two screws on both sides of the steel 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 during and after installation Enginer appreciates your efforts to save our environment and wishes you safe and enjoyable driving with your new PHEV Enginer Inc May 1 2012 Engi
16. ttery holder s How the System Works 110VAC USA household electricity gt Enginer PHEV Add on System gt Prius OEM stock battery gt Jointly drive Prius electric motor pee Capacity Average Gas Mileage EV Mixed Range Charge time _ Batteries ype Capacity Average Gas Mileage EV Mixed Range Charge time Lithium lon D 40 5 hours Warranty Two year part limited warranty applies unless extended warranty is purchased If equipment defect occurs in normal use conditions Enginer shall repair or replace the components 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 latter you could still damage any number of components in your vehicle causing it to no longer functional 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 gasoline consumption vehicle emissions your carbon footprint or smog you do so at your own risk amp peril Certifications Enginer PHEV Add on System has been certified by FCC CE and C TICK Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 200
17. witch panel operation ON Turn on PHEV DC DC Converter LED Green On Red Low Battery OFF Turn off PHEV DC DC Converter LED Off Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius Connecting Enginer PHEV Add on System to your Prius Installation Time 4 hours by professionals Before installation please login to Toyota Technical Website techinfo toyota com for Reference Instructions 15 for two day usage as of June 2009 Installation Tools Required Screw Shell M6 M14 Phillips Screwdriver Electric Drill Installation Procedure 1 Turn off your Prius 2 Remove trunk interior cover on the back of the back seat to gain access to and unplug the orange service plug a Remove unbolted rear parts and lay seats down Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius b Remove Deck Trim Cover Rear c Remove Rear floorboard no 4 and Deck Floor Box LH d Remove bolts from Deck Trim Side Panel Assy LH DON T REMOVE SIDE PANEL YET e Remove bolts from Rear Floor Board No 1 10 Enginer Inc May 1 2012 Enginer Plug in Hybrid Electric Vehicle Add on System User Manual for 2004 2009 Prius g Pull out upper portion of Rear Side Seat Side Back Frame LH Mode Saou i Unplug the orange OEM stock battery servic
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