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Plug-In Hybrid Electric Vehicle (PHEV) FAQ's
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Yes. The conversion kit is programmable and can be reconfigured for most hybrid vehicles by adjusting output voltage and current settings. However, the battery box may have to be redesigned to fit into the donor vehicle.
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To lower the cost, we don't pursue the maximum pure EV range. Since the battery capacity is limited by financial constraints and space, for trips over a couple miles (or speeds over 34 mph) the internal combustion engine (ICE) will be used. If you travel 20+ miles daily, at the end of the day, the result is the same whether you use the battery power at the beginning or release it in a controlled manner for longer periods.
Our kit uses a less complex system than other expensive kits. We don't trick the hybrids into thinking there is more battery power, rather we keep it powered with the additional batteries. We keep the stock battery charged via the same mechanism as the brake regen motor when idle, and supplement the power when the battery is in use. We don't interfere with the stock battery state of charge (SOC) calculation.
We don't force EV mode. The kit continuously charges the stock battery to maintain a higher SOC so that the computer can remain in EV mode. The kit also assists EV drive so that the EV drive can operate for longer periods of time. We are not pursuing maximum EV drive, but the net effect over 20-40+ miles is the same as other kits that utilize complicated computer modifications.
Your hybrid will perform exactly the same way that it did prior to the PHEV conversion except that its EV only range will be extended due to the extra battery pack. This kit uses a simplified design to preserve the OEM control algorithm for emission control and prolong stock battery life. The PHEV battery charges the stock OEM battery so that the ICE doesn't need to. In addition, the PHEV battery assists driving power so that the ICE doesn't need to work as much. All these will improve gas mileage.
Yes. It is a smart charger made by the Li-ion battery manufacturer.
Yes. There is temperature compensation for summer and winter conditions.
Although we do connect the EV mode switch, our kit doesn't go after maximizing pure EV drive. Our control strategy is releasing the energy in a controlled manner to prolong battery life and increase safety while minimizing the impact to the existing system. The final gas mileage over longer ranges (20+ miles) is the same as other methods. The result is a significant reduction in the conversion kit cost.
The lithium pack does both . It supplements electric drive power when the electric motor is used and charges the battery when it is not.
No. The stock battery does have more power because our kit keeps it at a higher charge.
Yes. However, it becomes harder to access.
It will not hurt your car since we only connect parallel to the stock battery module output. The stock HV controller will maintain the SOC of the original battery by using more electricity if it is close to 80% SOC. We don't force EV mode by spoofing CAN messages like other conversion kits do. We also have voltage and current limits to make sure the original battery is not overcharged.
No. We use the latest and safest Lithium Phosphate batteries with low cell voltage (3.2V). The batteries have a very low internal resistance, resulting in little heat build-up. Also our kit limits the output of the current to further reduce heat build up and prolong battery life. There is no thermal-run-away situation like other Lithium chemistries (Cobalt oxide, Manganese Oxide).
This is an improved and simplified method. The PHEV battery pack doesn't connect to the stock pack directly. It uses a customized isolated DC/DC converter to control the release of energy to the inverter and the stock battery. It charges and assists the stock battery during driving (only when the engine is already on). It may not achieve 100 MPG performance over shorter ranges. But over 20 miles (2KW) and 40 miles (4KW), it is equivalent to the Calcars system. The controlled release of energy (constant output current ~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. This design reduces cost dramatically. We also eliminate the need for CAN View and other control circuit boards so that the same design can be easily ported to other hybrid vehicles like Ford Escape, Fusion or Honda Insight.
No. There is limited current output in our kit and very low internal resistance in this type of battery compared to the Nickel Metal Hydride chemistry. And it only lasts for one hour. No significant heat builds up.
No. This design relies on the ICE for high speed and hard acceleration, which the ICE does best. However, 5kW is adaquate for cruising at speeds less than 45 MPH. Being able to use this smaller sized DC-DC converter significantly reduces the cost of the kit and the lower discharge current prolongs the overall battery life.
Our Lithium-ion battery is rated at 2000 cycles at 80% discharge and 3000 cycles at 70% discharge. If you charge it daily, you can expect six to eight years usage.
We provide a two year limited parts warranty (including the batteries) on the kit. A five year warranty is available for an additional cost.
The Magnuson-Moss Warranty Act prohibits Toyota from voiding your warranty unless they can show that the conversion damaged your car. Our kit is less likely to affect the original design of the vehicle because the interface is very simple and less intrusive than other conversion methods.
It could be two to three years of waiting and cost much more than our conversion kit for a similar result.
The converter will shut down the conversion kit output and the hybrid vehicle will return to the normal non-PHEV mode.
You can plug 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 the rear bumper or the opposite side of the fuel tank refill cap.
There are many factors affecting fuel efficiency, such as temperature, terrain, driving speed, charge frequency. We made some tradeoffs between short range fuel efficiency and total ownership cost. You should get 40-100% fuel efficiency improvement with this kit. You can get higher MPG if you charge more frequently, and drive at lower speeds.
Our kit includes balancers to keep the Lithium Ion battery cells in balance. 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 0.01V difference. If the cells are significantly different (>0.1V), you can charge the cells and let them sit for half a day then check it again. You can still drive it even if it is not perfectly balanced.
Here are a few tricks to take advantage of your PHEV kit.
1. Use the ICE to accelerate to a desired speed, release the pedal and re-engage it softly to drive the car on EV only. The kit can maintain cruise speeds under 45 MPH. You can use the same technique on the highway at slightly decelerating speed.
2. Keep your A/C in Auto if you really need A/C. Otherwise turn the A/C off and open your window for cooling.
3. Accelerate and brake gently.
4. Turn the kit off if you are going downhill for a long time.
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Call Luc with any further questions about the Hybrid Conversion Kit.
720-373-7613
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