xcel
09-14-2009, 10:53 AM
You can view the Enginer FAQ (Frequently Asked Questions) (http://www.enginer.us/faq/) in its entirety as linked.
Enginer - Frequently Asked Questions (synopsis)
What is the difference between your conversion kit and others?
To lower the kits cost, Enginer did not pursue maximum EV. If you travel 20 + miles daily, the result is the same whether you use the battery power at the beginning under an all-EV scenario or release it in a controlled manner over a longer period and at higher speeds.
The kit does not pursue a high SOC (80%) on the Prius’ OEM NiMH battery but instead injects additional electric energy into the OEM battery pack in a controlled manner. Forcing the Prius into a continuous pure EV mode may not be good for the OEM NiMH battery or motor(s) longevity.
The Enginer System does not “spoof” the Prius into thinking it has more battery power, it simply replaces the energy consumed by the NiMH pack from the kits Li-ion auxiliary battery pack.
In practice, the kit continuously charges the stock battery to higher SOC leveraging the ability of the system to improve fuel economy at higher speeds well above the Prius’ stock EV mode threshold.
Can I use the kit for other hybrids?
Yes. The conversion kit is programmable and can be reconfigured for any hybrid vehicle by adjusting output voltage and current settings. However, the battery box may have to redesign to fit into donor vehicles.
Does the kit include a smart charger or one that that automatically lowers the current when it's getting close to full and shuts off by itself?
Yes. It is a smart charger made by the same company that produces the Li-ion battery.
Does the kit adjust the voltage as the temperature fluctuates?
Yes. There is temperature compensation for summer and winter conditions.
It appears to sit on top of the spare. Is there some sort of spring that facilitates moving the pack up to access the spare?
No. Defer to a future release. You can however easily remove four screws, lift up the kit and gain access to the spare tire when necessary.
Does it come with all the necessary instructions? Will it work in EV mode only up to 34mph, or will it go up to 50mph? When the gasoline engine is on, will it behave like a regular hybrid, or will the gas mileage still improve (ie. even when the gas engine is running)?
As listed in the user manual, Enginer does not pursue maximum EV only driving but instead simplified the design and installation to preserve the OEM control algorithm for emission control and prolong battery life.
The PHEV Auxiliary Li-Ion battery charges the stock OEM battery so that ICE does not need to. The PHEV Auxiliary battery assists so that ICE doesn't need to work that hard. This improves fuel economy dramatically.
Can you provide full install instructions so I can get an estimate from a local mechanic on how much it would cost to install?
Installation instructions are available at our website. It is very straight-forward once you gain access to the battery module. Only two high voltage wires and three low voltage wires (ignition, ground and EV mode) need to be connected. If your mechanic is familiar with the Prius’ high voltage pack layout, it would take 2-3 hours to install.
How does the low-speed EV mode work? Most use the integrated Prius functionality, which frequently locks you out and automatically exits when needed. The plug-in power PHEV uses a different system that forces EV and goes up to 52MPH.
Although Enginer does connect the EV mode switch, the kit does not attempt to maximize EV. Our control strategy is to releases energy in a controlled manner prolonging battery life/safety and minimizing impact to existing systems. The final gas mileage over longer range is the same as other PHEV kits. The result is significant reduction in conversion kit cost.
How many amps does the charger pull (my garage has a small breaker)?
Approximately 7 Amps @120VAC
How does the modified hybrid mode work? Does the lithium pack power the motor directly, or does it charge the traction battery?
Yes and Yes. It supplements battery electric power when the electric motor is used and charges the battery to a higher SoC when it is not.
Are the electronics in the Prius 'fooled' into thinking that the battery is more charged than it is (resulting in more electric power being used)?
No. The OEM NiMH battery has more power because the Enginer kit continuously charges it to a higher SoC.
Can you recommend an installer?
A list of installers can be found at the following: Enginer – PHEV Conversion – Registered Installers (http://www.enginer.us/installers/).
Do I keep my spare tire? If so, how accessible is it after the install?
Yes. If you release four mounting screws with a handle, you can lift the pack enclosure up and stand it on its side allowing access to the spare tire.
Will the kit damage my hybrid?
The Enginer PHEV conversion kit will not harm your hybrid since it only connects to the OEM NiMH battery’s output in parallel. The stock HV controller will maintain the SoC of the original battery but use more electricity with SoC nearing 80% SOC. The Kit does not force EV mode by spoofing CAN messages like other conversion kits. It also includes both voltage and current limiter to make sure the OEM NiMH battery is not over charged.
Will the auxiliary Lithium-Ion battery cause a fire?
No. Enginer uses the latest and safest Lithium Phosphate batteries with low cell voltages (3.2V). Additionally, very low internal resistance results in very little heat build-up. The Enginer PHEV Conversion kit limits current output to further reduce heat build up and prolong battery life. The pack is only warm to the touch while under load. The Li-Ion battery packs chemistry is designed in such a way there is no chance for thermal-run-away like other Lithium chemistries (Cobalt oxide, Manganese Oxide).
However, a fire could occur when a connection is loose or if the kit were improperly wired. Safety is a high priority and an automatic fire extinguisher is installed in all kits.
How is this kit comparing to Calcars' design?
The kit is a simplified and improved vs. Calcars' in the way it is connected and releases energy. The PHEV battery pack does not connect directly to Prius’ OEM NiMH pack. It uses a customized isolated DC/DC converter to control the release of energy to the inverter and OEM NiMH battery. It does charge and assists the stock battery during driving when vehicle is booted up. It does not have the 100 MPG capability of Calcars' over short ranges and at slower speeds. At higher speeds over 20 miles (2KW)/40 miles (4KW), the Enginer kit is equivalent to Calcars'. The controlled release of energy (constant output current of ~10A and set max voltage range 320V for Prius-I, 240V for Prius-II) results in lower power requirements for all components and longer battery life and reduces cost dramatically.
The kit eliminates the need for CAN View or other control circuit boards so that the same design can be ported to other hybrid vehicles like Ford Escape, Fusion or Honda Insight.
Do you use a fan to keep the battery pack cool?
No. With limited current output and very low internal resistance in this type of battery compared with a NiMH battery pack, no fan is needed. With the Auxiliary pack assisting for less than one hour, no significant heat builds up.
Is there an interlock to prevent the car from being stated while the car is plugged in?
No. It is not really needed since it is isolated DC/DC converter. You can even use a roof top solar panel to charge the battery while it is running.
It is recommended that you drape the charging cord over the drivers side mirror to prevent an inadvertent drive-off with the cord still plugged in.
Is the 3,000 W DC-DC converter significantly underpowered to support extended EV mode?
The Enginer kit makes compromises between cost and short range EV performance. This design still relies on the ICE for higher speeds and harder acceleration, which the ICE was designed for. However, 3,000 W is adequate for cruise at speeds less than 25 MPH on flat ground. This significantly reduces the cost of the kit and discharge current to prolong battery life.
How do I order?
You can order directly through Enginer’s Ebay store (http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MESELX:IT&item=200344551230) or for higher volume order, use the Contact Us (http://www.enginer.us/contact/) form.
How long does the battery last?
The Lithium-ion battery is rated for 2000 cycles when using 80% of the packs total capacity and 3000 cycles using just 70%. If you charge it daily, you would normally have six to eight years of use. This kind of battery will not completely die like a lead-acid battery, it will simply stores and provide less power.
What is the warranty?
The manufacturer of the battery provides a two year warranty and Enginer provides a two year limited warranty on the kit.
Will the kit void my warranty?
The Magneson-Moss Warranty Act prohibits Toyota from voiding your warranty unless they can show that the PHEV conversion damaged your car. Our kit is less likely to affect the original design of the vehicle because the interface is simpler and far less intrusive than other PHEV conversion kits and methods.
How much does it cost?
The DIY version starts at $995 including all accessories minus the battery. You can use any type of batteries as long as it fit into the battery box.
The 2KWH kit is $1,995 with sixteen 40AH Lithium-ion battery cells.
The 4KWH kit is $2,995 with thirty 40AH Lithium-ion battery cells.
How long does it take to install one?
It takes approximately two hours for a professional installer and six to eight hours for DIY.
Should I wait for GM Volt or Toyota PHEV?
It could be a two to three year wait and will be much more expensive than Enginer’s PHEV conversion kit. The best way to reduce oil consumption is to retrofit existing hybrids on the road today.
Is this qualified for any tax credit?
The aftermarket Enginer PHEV conversion qualifies for the 10% federal tax credit.
We are also working with major automakers to pre-install the kit so that it qualifies for $2,500 federal tax credit under the Recovery Act.
Additionally, some individual states provide tax credits for PHEV conversions.
What happen if PHEV battery runs out?
The converter will shutdown the kits output and the vehicle will return to its normal non-PHEV mode.
How do I recharge the battery pack?
You can plug in the included charger into any standard 110 volt, 7 amp AC outlet using a 3 wire, 14 gauge extension cord. The conversion kit includes a charge inlet receptacle for mounting on rear bumper or the opposite side of the fuel refill cap.
I do not live near one of your dealers; can I still buy a PHEV conversion system?
Yes. You can install the PHEV Conversion kit yourself by following the instructions or we can recommend an installer visit to your residence to install the conversion system for an additional charge.
Where can I find more information regarding Plug-in conversions?
Lithium Ion Batteries (http://www.batteryuniversity.com/partone-5A.htm)
Prius Plugin Conversions (http://www.eaa-phev.org/wiki/Prius_PHEV)
Cal Cars (http://www.calcars.org/)
BMS (http://www.mpoweruk.com/bms.htm)
Am I going to get 100 MPG once I install the Enginer Kit?
Enginer never advertises 100 MPG performance like its competitors. There are many factors affecting fuel efficiency including temperature, terrain, driving speed and charge frequency. Enginer made trade offs between short range fuel efficiency and total ownership cost. You should receive a 30 to 50% fuel efficiency improvement with the Enginer kit. You can get higher MPG if you charge it more frequently (charging at work) or drive exclusively in the city.
How do I know if my cells are balanced?
The Enginer kit includes balancers to keep the Li-Ion battery cells balanced. By pressing the right Start button, you can read individual cell voltage one by one, sequenced from right to left. The balanced cells are within 0.01 V difference. If the cells are significantly different (>0.1V), you can charge the cells and let them sit for half day then check it again. You can still drive it even it is not perfectly balanced but do not drain the battery below 3.0 V per cel. Turn the Enginer PHEV kit off if you hear a balancer alert beep(s).
How do I get higher MPG with Enginer kit?
Here are a few techniques to take full advantage of Enginer PHEV Conversion kit.
1. Use ICE to accelerate to a desired speed, release the pedal and re-engage to drive the car on EV only. In Enginer’s testing, the kit can maintain cruise under 25 MPH. You can use the same technique on highway at slightly decelerating speed.
2. Keep your A/C in Auto if you need it. Turn the A/C off and open your window for cooling.
3. Accelerate and brake gently if possible.
4. Turn the kit off a mile or two before you begin a long descent.
Enginer - Frequently Asked Questions (synopsis)
What is the difference between your conversion kit and others?
To lower the kits cost, Enginer did not pursue maximum EV. If you travel 20 + miles daily, the result is the same whether you use the battery power at the beginning under an all-EV scenario or release it in a controlled manner over a longer period and at higher speeds.
The kit does not pursue a high SOC (80%) on the Prius’ OEM NiMH battery but instead injects additional electric energy into the OEM battery pack in a controlled manner. Forcing the Prius into a continuous pure EV mode may not be good for the OEM NiMH battery or motor(s) longevity.
The Enginer System does not “spoof” the Prius into thinking it has more battery power, it simply replaces the energy consumed by the NiMH pack from the kits Li-ion auxiliary battery pack.
In practice, the kit continuously charges the stock battery to higher SOC leveraging the ability of the system to improve fuel economy at higher speeds well above the Prius’ stock EV mode threshold.
Can I use the kit for other hybrids?
Yes. The conversion kit is programmable and can be reconfigured for any hybrid vehicle by adjusting output voltage and current settings. However, the battery box may have to redesign to fit into donor vehicles.
Does the kit include a smart charger or one that that automatically lowers the current when it's getting close to full and shuts off by itself?
Yes. It is a smart charger made by the same company that produces the Li-ion battery.
Does the kit adjust the voltage as the temperature fluctuates?
Yes. There is temperature compensation for summer and winter conditions.
It appears to sit on top of the spare. Is there some sort of spring that facilitates moving the pack up to access the spare?
No. Defer to a future release. You can however easily remove four screws, lift up the kit and gain access to the spare tire when necessary.
Does it come with all the necessary instructions? Will it work in EV mode only up to 34mph, or will it go up to 50mph? When the gasoline engine is on, will it behave like a regular hybrid, or will the gas mileage still improve (ie. even when the gas engine is running)?
As listed in the user manual, Enginer does not pursue maximum EV only driving but instead simplified the design and installation to preserve the OEM control algorithm for emission control and prolong battery life.
The PHEV Auxiliary Li-Ion battery charges the stock OEM battery so that ICE does not need to. The PHEV Auxiliary battery assists so that ICE doesn't need to work that hard. This improves fuel economy dramatically.
Can you provide full install instructions so I can get an estimate from a local mechanic on how much it would cost to install?
Installation instructions are available at our website. It is very straight-forward once you gain access to the battery module. Only two high voltage wires and three low voltage wires (ignition, ground and EV mode) need to be connected. If your mechanic is familiar with the Prius’ high voltage pack layout, it would take 2-3 hours to install.
How does the low-speed EV mode work? Most use the integrated Prius functionality, which frequently locks you out and automatically exits when needed. The plug-in power PHEV uses a different system that forces EV and goes up to 52MPH.
Although Enginer does connect the EV mode switch, the kit does not attempt to maximize EV. Our control strategy is to releases energy in a controlled manner prolonging battery life/safety and minimizing impact to existing systems. The final gas mileage over longer range is the same as other PHEV kits. The result is significant reduction in conversion kit cost.
How many amps does the charger pull (my garage has a small breaker)?
Approximately 7 Amps @120VAC
How does the modified hybrid mode work? Does the lithium pack power the motor directly, or does it charge the traction battery?
Yes and Yes. It supplements battery electric power when the electric motor is used and charges the battery to a higher SoC when it is not.
Are the electronics in the Prius 'fooled' into thinking that the battery is more charged than it is (resulting in more electric power being used)?
No. The OEM NiMH battery has more power because the Enginer kit continuously charges it to a higher SoC.
Can you recommend an installer?
A list of installers can be found at the following: Enginer – PHEV Conversion – Registered Installers (http://www.enginer.us/installers/).
Do I keep my spare tire? If so, how accessible is it after the install?
Yes. If you release four mounting screws with a handle, you can lift the pack enclosure up and stand it on its side allowing access to the spare tire.
Will the kit damage my hybrid?
The Enginer PHEV conversion kit will not harm your hybrid since it only connects to the OEM NiMH battery’s output in parallel. The stock HV controller will maintain the SoC of the original battery but use more electricity with SoC nearing 80% SOC. The Kit does not force EV mode by spoofing CAN messages like other conversion kits. It also includes both voltage and current limiter to make sure the OEM NiMH battery is not over charged.
Will the auxiliary Lithium-Ion battery cause a fire?
No. Enginer uses the latest and safest Lithium Phosphate batteries with low cell voltages (3.2V). Additionally, very low internal resistance results in very little heat build-up. The Enginer PHEV Conversion kit limits current output to further reduce heat build up and prolong battery life. The pack is only warm to the touch while under load. The Li-Ion battery packs chemistry is designed in such a way there is no chance for thermal-run-away like other Lithium chemistries (Cobalt oxide, Manganese Oxide).
However, a fire could occur when a connection is loose or if the kit were improperly wired. Safety is a high priority and an automatic fire extinguisher is installed in all kits.
How is this kit comparing to Calcars' design?
The kit is a simplified and improved vs. Calcars' in the way it is connected and releases energy. The PHEV battery pack does not connect directly to Prius’ OEM NiMH pack. It uses a customized isolated DC/DC converter to control the release of energy to the inverter and OEM NiMH battery. It does charge and assists the stock battery during driving when vehicle is booted up. It does not have the 100 MPG capability of Calcars' over short ranges and at slower speeds. At higher speeds over 20 miles (2KW)/40 miles (4KW), the Enginer kit is equivalent to Calcars'. The controlled release of energy (constant output current of ~10A and set max voltage range 320V for Prius-I, 240V for Prius-II) results in lower power requirements for all components and longer battery life and reduces cost dramatically.
The kit eliminates the need for CAN View or other control circuit boards so that the same design can be ported to other hybrid vehicles like Ford Escape, Fusion or Honda Insight.
Do you use a fan to keep the battery pack cool?
No. With limited current output and very low internal resistance in this type of battery compared with a NiMH battery pack, no fan is needed. With the Auxiliary pack assisting for less than one hour, no significant heat builds up.
Is there an interlock to prevent the car from being stated while the car is plugged in?
No. It is not really needed since it is isolated DC/DC converter. You can even use a roof top solar panel to charge the battery while it is running.
It is recommended that you drape the charging cord over the drivers side mirror to prevent an inadvertent drive-off with the cord still plugged in.
Is the 3,000 W DC-DC converter significantly underpowered to support extended EV mode?
The Enginer kit makes compromises between cost and short range EV performance. This design still relies on the ICE for higher speeds and harder acceleration, which the ICE was designed for. However, 3,000 W is adequate for cruise at speeds less than 25 MPH on flat ground. This significantly reduces the cost of the kit and discharge current to prolong battery life.
How do I order?
You can order directly through Enginer’s Ebay store (http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MESELX:IT&item=200344551230) or for higher volume order, use the Contact Us (http://www.enginer.us/contact/) form.
How long does the battery last?
The Lithium-ion battery is rated for 2000 cycles when using 80% of the packs total capacity and 3000 cycles using just 70%. If you charge it daily, you would normally have six to eight years of use. This kind of battery will not completely die like a lead-acid battery, it will simply stores and provide less power.
What is the warranty?
The manufacturer of the battery provides a two year warranty and Enginer provides a two year limited warranty on the kit.
Will the kit void my warranty?
The Magneson-Moss Warranty Act prohibits Toyota from voiding your warranty unless they can show that the PHEV conversion damaged your car. Our kit is less likely to affect the original design of the vehicle because the interface is simpler and far less intrusive than other PHEV conversion kits and methods.
How much does it cost?
The DIY version starts at $995 including all accessories minus the battery. You can use any type of batteries as long as it fit into the battery box.
The 2KWH kit is $1,995 with sixteen 40AH Lithium-ion battery cells.
The 4KWH kit is $2,995 with thirty 40AH Lithium-ion battery cells.
How long does it take to install one?
It takes approximately two hours for a professional installer and six to eight hours for DIY.
Should I wait for GM Volt or Toyota PHEV?
It could be a two to three year wait and will be much more expensive than Enginer’s PHEV conversion kit. The best way to reduce oil consumption is to retrofit existing hybrids on the road today.
Is this qualified for any tax credit?
The aftermarket Enginer PHEV conversion qualifies for the 10% federal tax credit.
We are also working with major automakers to pre-install the kit so that it qualifies for $2,500 federal tax credit under the Recovery Act.
Additionally, some individual states provide tax credits for PHEV conversions.
What happen if PHEV battery runs out?
The converter will shutdown the kits output and the vehicle will return to its normal non-PHEV mode.
How do I recharge the battery pack?
You can plug in the included charger into any standard 110 volt, 7 amp AC outlet using a 3 wire, 14 gauge extension cord. The conversion kit includes a charge inlet receptacle for mounting on rear bumper or the opposite side of the fuel refill cap.
I do not live near one of your dealers; can I still buy a PHEV conversion system?
Yes. You can install the PHEV Conversion kit yourself by following the instructions or we can recommend an installer visit to your residence to install the conversion system for an additional charge.
Where can I find more information regarding Plug-in conversions?
Lithium Ion Batteries (http://www.batteryuniversity.com/partone-5A.htm)
Prius Plugin Conversions (http://www.eaa-phev.org/wiki/Prius_PHEV)
Cal Cars (http://www.calcars.org/)
BMS (http://www.mpoweruk.com/bms.htm)
Am I going to get 100 MPG once I install the Enginer Kit?
Enginer never advertises 100 MPG performance like its competitors. There are many factors affecting fuel efficiency including temperature, terrain, driving speed and charge frequency. Enginer made trade offs between short range fuel efficiency and total ownership cost. You should receive a 30 to 50% fuel efficiency improvement with the Enginer kit. You can get higher MPG if you charge it more frequently (charging at work) or drive exclusively in the city.
How do I know if my cells are balanced?
The Enginer kit includes balancers to keep the Li-Ion battery cells balanced. By pressing the right Start button, you can read individual cell voltage one by one, sequenced from right to left. The balanced cells are within 0.01 V difference. If the cells are significantly different (>0.1V), you can charge the cells and let them sit for half day then check it again. You can still drive it even it is not perfectly balanced but do not drain the battery below 3.0 V per cel. Turn the Enginer PHEV kit off if you hear a balancer alert beep(s).
How do I get higher MPG with Enginer kit?
Here are a few techniques to take full advantage of Enginer PHEV Conversion kit.
1. Use ICE to accelerate to a desired speed, release the pedal and re-engage to drive the car on EV only. In Enginer’s testing, the kit can maintain cruise under 25 MPH. You can use the same technique on highway at slightly decelerating speed.
2. Keep your A/C in Auto if you need it. Turn the A/C off and open your window for cooling.
3. Accelerate and brake gently if possible.
4. Turn the kit off a mile or two before you begin a long descent.