PHEV Conversion Kit User Manual
Contents
1. 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius NOTE 14 Second Edition 2009 Enginer GreenTech Co Ltd2. Plate 9 Hookup 6 Pin on off switch panel cable to your Enginer battery box 10 Drill a hole and mount Bumper AC Outlet 11 Re Install back seat and trunk panels 11 Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius 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 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 12 Second Edition 2009 Enginer GreenTech Co Ltd User Manual for 1997 2003 Prius Enginer Plug in Hybrid Electric Vehicle Conversion Kit Bn AOL L os iff sBrey 5 OLA oF ref Hesg VOOL LS ect uid A3 GNO AZ uomnubB siepe E 3989 auoug ELF Lor Sef 398 L AAOOOF ANDOOE Jape AOD COJ OCOASE S NE bo JayeAu OF SIGE JeAO Aes OFE 13 Second Edition
3. assisted driving per charge sufficient for most normal daily commutes It is safe reliable saves money and is user and environmentally friendly What is Included in this Product 16 32 cells for 2KWH 4KWH Lithium lon batteries Battery balancers one for every 8 cells monitoring and balancing battery voltages to avoid over or under charges to individual cells This can extend battery life by a factor of 3 48V 15A high power charger 3000W DC DC Converter and Controller Fire extinguisher for protecting when the temperature is over 105 C First of all please open the cover and take out the blue insulative inserter to let it work Automatic DC circuit breaker to disconnect high voltage equipment operation in the event of a high current fault Easily installed enclosure simple to use system How the System Works 110VAC household electricity gt Enginer PHEV conversion kit gt Hybrid vehicle OEM Stock battery gt Hybrid electric motor Capacity Average Gas Mileage EV Mixed Range Charge time F 40 AH 85mpg 10 20 3 hours 16 Cells L ithium lon 32 Cells Use 110V AC source only Balancers Each balancer controls 8 cells After setup press Start Stop to initiate the balancer to start balancing Balancer screen will show in order the following data Total voltage of the 8 cells Voltages of each individual cell Standard deviation of voltage A red dot flashes during balanc
4. steel box this requires two people with both hands carefully and steadily move out the entire stainless steel box and place it gently on the floor Do not tilt or turn over the equipment The equipment weights about 65 Ibs without batteries or 115 Ibs 2KWH to 165 Ibs 4KWH with batteries Enginer strongly suggests you use professional lifting equipment or operators that are strong enough to lift this much weight Slowly handle the equipment to avoid physical 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 small white plastic bracket holder from accessories and push it hard into a small hole on the right side of the steel box to rest the pole after use After popping up the cover firmly and checking that it is safe with no risk of dropping down take out all insulating foam gently and check inside component against the following list Stainless steel box and cover 833 x 505 5 x 157 mm Batteries 4 sets of 4 cells 2KWH or 8 sets of 4 cells 4KWH depending on what you ordered Please make sure batteries match your order Two battery mounting frames to fix the two rows of batteries O Balancers fixed on the rear the side close to your body battery frame two balancers for 2KWH kit or 4 for 4KWH kit black each linking 8 cell
5. Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius Enginer PHEV Conversion Kit User Manual for 1997 2003 Prius Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius Attention 1 Please read instructions before installation 2 Never connect wires improperly 3 New batteries should be re charged to full and balanced before use 4 Please check the batteries voltage and balance regularly for the first few times you drive the vehicle 5 To extend battery life equipment must be recharged using the 110VAC household electricity powered charger provided to full each time and the cells need to be fully balanced after charging 6 The circuit breaker in the enclosure box is set to be switched off automatically if the current exceeds a pre set limit 100A 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 a defect is found while driving 8 Please do not disassemble the components if the equipment is working normally Product Overview The Plug in Hybrid Electric Vehicle Conversion Kit PHEV is a rechargeable battery set that is supplementary to a Hybrid vehicle battery It supplies electricity stored in the supplementary battery which is charged from an AC wall socket which provides for 20 to 40 mile of electrically
6. ble part Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius Contral Connector i LH Battery Bracket B 0 80 71 inibi 5 0 50 44 in Ib Battery Carrier Catch Bracket Positive Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius 6 Connect the conversion kit s power cable to positive and negative terminals of the stock battery output power cable 7 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 Oand 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 hole and tighten it on the panel 8 Hook up ECU Ignition Ready signal to on off switch panel Reference DI 20 Terminals of ECM for 2000 2003 Prius CON 2 H12 2 Grey Ignition Ready Connect to the Green wire of PHEV switch panel GND1 H14 31 White Black Ground Connect to the Brown wire of PHEV switch panel e White wire is not connected for 2000 2003 Model HV ECU Terminals 10 Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius ECU Cover ECU Bracket 6 0 60 53 in Ibf Cowl Side Trim Front Door Scuff
7. hanghai 200040 China Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 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 at least a 7x7 feet flat area on the ground near the end of your hybrid vehicle and cover the floor with 5x5 feet soft and flat cloth or cardboard The equipment is heavy and should be removed and handled by two adults Knock open the wooden box if there is one and then open the cardboard box inside Take out accessory bags and check against the following list to count whether components are complete One 48cm lid supporting pole One plastic holding bracket Six red and black jumper wires with ring terminal Two long wires for connecting the batteries in parallel ECU signal wires green brown and white One switch panel with on off switch red and green LED lights 2 sets of equipment mounting brackets and screws Four screws for mounting the box cover One double sized spanner A set of two fire extinguisher holders and mounting screws One thread for converter and charger One 0 2m corrugated pipe 1 1drawing for making mounting holes on car Place the above accessories in a place not impeding your later installation Take out the foam plastic cover from the cardboard box and pull out the stainless
8. ime 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 the 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 dimension of the Kit s mounting brackets B Drill and tap 10 screw on the truck floor plate C Tighten six mounting screws with washer and spring ring 5 Remove back seat and gain access to the OEM stock battery output terminals Reference HV 4 HYBRID VEHICLE CONTROL HV BATTERY for 2000 2003 Prius 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 Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius MET T 7 9 81 70 in Ibf Seat Cushion Cover 2 Hog Ring Seat Cushion Lock Hook Seat Cushion Pad Nem kgf cm ft Ibf Specified torque Non r usa
9. ing and disappears when voltage difference is less than 2 Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius 0 01V The balancer will alert if any cell voltage drops below 2 8V or is charged above 3 75V Warranty Two year limited parts warranty applies If equipment defect occurs in normal use conditions Enginer shall repair the equipment or change defective components 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 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 Web www automationtechinc com Toll Free 877 886 8897 Address 1562 Hamlet Drive Troy MI 48084 USA Made By Enginer EnvironmenTech Co Ltd Web www enginer us Address 1010 1701 Beijing Xi Road S
10. on 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius Connection between balancers and batteries are normal and firm Figure 3 Balancer Connection 10 Wiring Pull off the protection cap of the battery terminals positive and negative between two battery packs use red black short jumper cable to put them in series as shown in Figure 2 If it is a 4KWH model connect two strings 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 grey Anderson connector to the charger 11 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 13 Bumper outlet for charger connection Black wire Live line L White wire Null Line N Green wire Ground Line E 14 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 Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius Connecting Enginer PHEV Conversion Kit to a Toyota Prius Installation T
11. s with wires L 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 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 shared with converter One ventilation fan on left lower corner Second Edition 2009 Enginer GreenTech Co Ltd Enginer Plug in Hybrid Electric Vehicle Conversion Kit User Manual for 1997 2003 Prius O One circuit breaker mounted on top of charger j te Se Thread for Charger Mounting 4 Fire extinguisher m7 Brakets amp amp holders Screws ECU Signal Wires Figure 1 Component Layout Wiring Check Make sure circuit breaker is in the OFF position Anderson plug from charger converter is disconnected balancers interfaces are pulled off Charger and converter connections are connected firmly Connection 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 Figure 2 Connection of one row batteries 2KWH Connection of two rows of batteries 4KWH Second Editi
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