PHEV Conversion Kit User Manual
Contents
1. Acrel PHEV Conversion Kit User Manual For 2004 2009 Prius Aerel Warning You are strongly recommended to have a qualitied professional to undertake tnis installation High Voltage HV Direct Current DC Warning Traction battery packs motors chargers and other HVsources could cause serious Injury or death H proper precautions are not taken while working on or around auch high voltage direct current sources Please note hat anyone attempting o instali this conversion kit and modify their vehicle is doing so at er own discretion and risk Warranty In performing some ofthese modifications it is possible though unlikely to Vold your warranty with the vehicles manufacturer Please check with your original vehicle manutacturr dealer tor confirmation This is patent pending technology Driving Techniques for Maximizing Acrel Prius PHEV Mileage 1 Maintain steady sped as requenty as you can 2 When thing the speed you desire on the road feather the accelerator or ting your foot oft entirely then very laie easing back nto maintain a steady speed of under 34 milas or 704m per hour That motion activates your Prius EV feature that merely consumes stock and Acrel batteries Tests in thia driving style on Acrel Prius PHEV have shown way better than 100MPG or 100KM2 BL with the best actor feld test outcome of 1SOMPG ar 10DKM 1 7L for accumulated test dive distance of 185KM Attention 1 Please read Instruc2. White wira Nu Line N Green wire Ground Line E Take the wire of charger hough the back panel and reach to bumper tel You need to get your hand in from under the car and tighen the siver ring ot bumper plag 11 Install Charge LED into the tai gn tis LED shows the performance of Charger Red on Charge by about A Green on Fuly charged 12 PHEV swich panel operation ON Tum on PHEV DCIDC Converter LED Green On Red Batty Low OFF Tum of PHEV DC DC Converter LED Green Of Aer Pin ntc Vehicle Conversion n eer Maras tor 2001 2008 pre Connecting Acrel PHEV Conversion Kit to your Prius Intataton Time 1 hour by profesionais Before stan please be advised to login to Toyota Technical Website echinfo oyota com for Reference Instructions 1818 for wo day usage a of June 2009 Preparation tools Required Screw shen MEM etre at Installation Procedure 1 Stop your Prius engine compl y by taking away your car key 2 Remove trunk Interior cover on the back of he back seat to gain access to OEM stock battery orange service lug and uopug t 3 Remove say banery negative terminal 4 Remove back seat and gain access to the OEM stock batery output terminals Mere Pin rd ee Vehicle Conversion n eer Ma tor 2001 2009 pre Aer Pin ntc Vehicle Conversion Ki eer Manor 200200 pre Install ono sen panel A Take off h blank panel an the e
3. a pair at Anderson plug I also contains one red and one black power outlet and a 6 pin cable 11 One charger mounted on right back connecting black power Inlet cable wih left hand side one red and one black cable vith an Anderson pg a BMS ed upon the chargerine side cose ta your bay Two venation fan fed on the converter at iett corner a One creuit breaker mounted on top of charger One fre extinguisher is fned at he middle ot he box on batteries Aca Pt Htc Vehicle Conversion n eer Maras or 200200 pre Figure 1 Component Layout 7 wring Check Make sure circuit breaker a in the OFF positon EMS Interfaces o 2 Charger and converter connections are connected im Connection between black wires tom batarias and cet breaker are connected femly and conc as shown falow Tem Right o o Figure 2 Connection of batteries KWH swing Connect wo pair Anderson plugs to batteries shouid be R 1o A and L KV R means Right pack and L means Lol pack Connect the tn 9 pins and two 4 pins white connectors 1o the BMS also should be HR aV KV Then connect the amp pin wire to BMS Connect th high voltage core red and lek core wih blue bullet connectors K the converter output connectors Connect the 6 pin phone wire to Ihe convener The conversion kit assemble is completed and ready to be installed into the vice 10 Bumper out tor charger connection Black we Live bne L
4. wire Product Over You can open the black by hand and replace the use The Ace Plug in Hybrid Electric Vehicle Conversion Kt PHEV is a rechargeable battery set that is supplementary 10 Prius OEM battery supples elect which is charged from an AC wal socket sored in PHEV kt providing for 40 miles of electrically assisted diving per charge suficient for most normal day commutes His safe reta and user and environment tiendy What is Included in this Product ko Lita on bari BMS monto and balancing battery voltages to avoid over ar under charges 10 individual el Soya factor of 3 HIOYAG 48VDG 15A high power charger 4000W DC DC converter and controller Fire extinguisher wil be activated once the inside temperature exceeds 221F First of al please remove the cover and pull out tre blue insulative inserter This can extend battery Automatic DO cru breaker K disconnect high voltage equipment operation in the event of a high current a Stee enne Ac pin Mina nce Vice Conversion Ki eer Mami tor 887 pre How the System Works 110VAC USA household electricity Acrel PHEV conversion kit OEM stock battery Prius electric motor Type Capacity Te rma Range Chargetime Batteries venen soan asmoa 2040 Sours Use 110V AC soure USA other AC source matching PHEV charger only Warranty Two year ited parts waranty applies I equipment detect o
5. ccurs in normal use conditions Acrel shall repair the equipment or change the defective component in tis conversion kl only Use his Information at your own risk Other than as spelie above there Is no addtional waranty expressed nor Impled and ere shali not be lable for any ot your past present nor future atona Even I you perform these macs to the letter you ou stil damage any number of components in your vehicle causing it to a longer funcion Even ift appears to funci n propery your actons may cause i to self destruct with colateral damage to surrounding properties other you re your vehicle By izing ese ideas and instructions in an ateo enhance national security reduce gas consumption vehicle emissions your carbon op or smog you do so at your own risk amp peri Preparing and Assembling the PHEV Conversion Kit Please carefully read and understand these instructions before opening the product box Installation and Use 1 Prepare a flat area of at least a 7x7 feet on the ground near the end of your Prius so and fat cioth or cardboard 2 The equipment is heavy and shouid be removed and handed by at least two adute As Industry standard itis suggested that he system should be Ift ing machine 3 Knock open the wooden box If there Is ane and then apen the cardboard box in side 4 Take out accessories and place them In a place nat Impeding you later Installation Take out the foam plastis cover rom the cardboard box and
6. connectivity is not compromised and Te wire is corect Sometime he pice could cut ofi the orginal wre 7 Use scan tool 1o reset error code or disconnect the 12V battery and walt for 15 minutes 1o reset the error code 8 peoe the car to maka sure fis operational 9 Tum on Acrel circuit breaker But koop HV output wires disconnected 10 Tum on the car 11 Checkit oniy the green light on Acrel PHEV such panel is on when the switch is ON Also check the ight On the convener output panel In the battery box 12 Ifthe graen ight ia nat on use a meter 10 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 S 6 has 12V signal 13 Check OEM battery high voltage Play attention to the poarty ot t 14 Check PHEV convener ouput high voltage Play attention othe platy The voltage shouid be higher 10V Toner nan he GEM banery voltage 15 Tum off he car connect converter high voltage to the OEM battery 18 Tum on the car in Park check PHEV battery voltage i shouid drop 1 5V when it charges Ihe OEM battery 17 be PHEV votage drops more than 5 vot check the indvidual cell votages to see if any cellis weak and signicantly lower an ie peer 18 Charging bates 19 Walt overnight for the cell to be balanced Al Mount your Acrel PHEV Conversion Kit A Mark eight mounting hoes according to size and dimension of he Kits mounting brackets Re
7. hand side ot your meter board R Loosen ho switch bol place ion tough re panel hole and tighten on the panel Batore epace panel Ater replace panet 7 Hook up ECU ignition Ready signal to ono switch panel Reference 05 408 DIAGNOSTICS HYBRID CONTROL SYSTEM for 2004 2009 Prius CON H16 2 Green Iron Ready Connect to the Green wire of PHEV switch panei GND H141 Whte Back Ground Connect to ne Brown wire ot PHEV swich panal n me m ma er Pin Htc Vehicle Conversion Ki eer Maras tor 2001 2008 pre EV Button Modification for 04 Americas Prius Power Management Control ECU 8 Hookup amp Pln ono switch panel cable I your Acrel battery box 1 Dia hole and mount Bumper AC Outet 10 Re instal back seat and nk panels posan tight Service Plug Grip oiherwise sect power cannot be started Your Acrel PHEV Conversion Kit installation is now complete Please test the equipment in the following steps 1 Tum the Acrel ost breaker of 2 Disconnect he converter igh vage output tothe OEM battery ed and black wires wih blue bulet connectors 3 Tum on the car A tbe car cart start and has check engine Ig do step 5 8 5 Check Toyota battery orange high voltage servi plug to make sure it is plug in correctly and secured 6 Check splice wires 10 make sure the
8. move one screw lan the right side of truck avoiding bumping against brackets 8 Dril eight 13mm holes on the ruck lor piate Put the rubber blankets under the brackets he long ane for left bracket the short ane for he end af right bracket D Tahan eight mounting seraws wih washer and spring ring E Remove implements on the ide of uni and put the vent pipe for culating sir inside PHEV F Then you may tighten buckles on two sides ot he enclosure sto mount the entre equipment Once ali the above steps are completed and no detect occurs so tighten two screws on bath sides of the steel lid you are now safe to drive your Acrel Plug in Hybrid Electric Vehicle Acrel y Aer Pin rt Bac Vehicle Conversion n Contacts Shanghai Acrel Power Management System Co Lid Address 2 40 Raad Madang ni Park ling Website pe verer Tel ann Fang Deputy General Manage mal roae
9. pull out th steet box tis requires at least tuo people with botn hands caretuly and steadily move ou the ente see box and place gently on the Hoo Do not tit ortum avere equipment 5 The equipment weights about 165 bs Acrel strongly suggests you use professional ing equipment or operators hat are tong enough tot vs much weight low hande Ihe equipment o avoid physical nur or equipment damage After popping up the cover mi and checking that itis being safe with no risk of dropping down take out al insulating foam ent and check inside component and accessory bags against the folowing lst ECU signal wres green brown and white One switch panel with ant wich red and green LED lighis 8 pin phone we a Converter high votaga core fred and black core with bive bullet connectors a Power core for charger input a2 sets of equipment mounting serews size M a One charger Input bumper socket a One double sized spanner a One esa for converter and charger pes plastic clamps for connecting ECU signal wires to Prius Two black rubber blanketa longer one tor iett hand side shorter one for the right hand side a One Som long vent pipe for left hand size comer ventilation fan lt T mounting hole postions template Stainless steel box and cover 833x505 x 152mm Sates 2 packs KWH Please make sure batteries math your order One converter mounted back laf connecting batteries wih one red and one black power net wires wih
10. tions before installation 2 Naver connect wires improperly Do recheck wires at last times before switch on power 3 Naw batarias shouid be re chargad 10 tul and balanced before driving 4 Please check the bateo votages and balance regulari for the frst few tmas you drive the vehicle 5 To extend battery Ife equipment must be recharged especialy when It wil not be used for over one week using the 110VAG fr USA or the right lage in other countries watching the tabel on Acrel charger household electricity powered charger provided to a each bme and 1e cat need to be fully balanced after charaing 6 The circuit breaker on the right hand side of the enclosure box is set to be switched off automaticaly if the curent exceeds a pre set it 125A in the event this breaker suche cit you wil then need to manualy switch it back on before use 7 Piease such he equipment otf immediately damage or detect is found 8 Please do no disassemble he components if tne equipment is working normaly and it you are not a qualiled professional 9 Please disconnect BMS to batteries If not used for over 10 days to avoid battery tae 10 You can replace the charger and converter us If there is some probem A Charger fuse The fuse block of the charger Is inserted into the AC plug You can use a Ha crew driver to pivot ne block In the male edge above I use Sgn and pu card 8 Convener tuse The tuse black is connected to the high voltage
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