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Difference between revisions of "Prius PHEV"

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{{Prius PHEV Options Summary}}{{TOCright}}
 
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This is an Initial Page for the '''EAA-PHEV''' Projects page, which will now be dispersed about the new website...
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To this date there have been a number of successful [[Toyota Prius|Prius]] [[PHEV]] conversions beginning with [[User:Rgremban|Ron]] of [[:Category:CalCars|CalCars]] [http://www.CalCars.org] [http://groups.yahoo.com/group/calcars-news] [[PriusPlus History|Original]] [http://groups.yahoo.com/group/priusplus] and current [[PriusPlus]] projects.
There are other PHEV projects on the [[History]] and [[PriusPlus]] pages.
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Other small startups include the [[PiPrius]] [http://www.PiPrius.com] [http://www.manzanitamicro.com] and [[Hybrids-Plus]] [http://hybrids-plus.com] [http://energysense.com] projects.
CalCars has a great [http://www.calcars.org/calcars-phevtalkingpoints.pdf PHEV talking points] to bring you up to speed regarding Plug-in Hybrids.<br>
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[[EnergyCS]] [http://energycs.com/] and their European partner [[Amberjac]] [http://www.amberjac-projects.co.uk/] as well as Canadian [[Hymotion]] [http://www.hymotion.com] have converted numerous Prius PHEVs to this point.  [[EDrive]] [http://www.edrivesystems.com] will be offering conversion soon.
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The tenth conversion of [[PriusBlue]] was undertaken in public April of 2006 at the [[Inaugural Maker Faire]] to help enhance the documentation and help promote PHEVs in the pacific northwest and midwest.
  
==Maillist==
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At this time there are two common conversion methods for the Prius.
{{Maillist Archives}}
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The '''[[#Original CalCars Method]]''' used in Rons [[PriusPlus History]], [[EnergyCS]], [[Amberjac]], [[EDrive]], and [[Hybrids-Plus]] conversions replace the stock battery with a new [[Battery Pack Configurations#Simple|simple string]].
{{Maillist Subscriptions}}
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The second '''[[#Hybrid-Pack Method]]''' is used in the new [[PriusPlus]], [[PiPrius]], and by the [[Hymotion]] conversions.
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This second method should be easily adapted from the '04+ [[Toyota Prius|Prius]] to the ''Classic'' '00-'03 Prius, [[Ford Escape Hybrid|Escape]], and other [[Hybrid]]s as they use a [[Battery Pack Configurations#Hybrid|hybrid battery pack configuration]] which uses both a new simple string and the original stock batteries.
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The new PriusPlus and the PiPrius projects moved to the '''[[#Hybrid-Pack Method]]''' in order to remedy the [[State Of Charge Manipulation#Charge Limit Conundrum|CCL Conundrum]].
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Both types, of course, use a [[Battery Chargers]] to recharge from the grid.
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Toyota has warned that such conversions may adversely affect your [[Warranty]].
  
==Disclaimer==
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The [[Prius PHEV TechInfo]] page has a lot of technical information on the Prius which may be useful when designing a PHEV conversion.
{{Template:Disclaimer}}
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See the [[Template:Terms|Terms]] page if you aren't familiar with some of the underlying principals or acronyms used through the documentation.
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Also be aware of the [[Template:Disclaimer|Disclaimer]] should you be considering a conversion yourself.
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This [http://www.airlabcorp.com/Prius/priusdisman.pdf PriusDisMan.pdf] ''([[Media:Priusdisman.pdf]] from http://www.airlabcorp.com/Prius/priusdisman.pdf)'' might be handy for its dismantle and safety warnings
  
==Terms==
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==Prius Conversions Chronology==
{{Template:Terms}}
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For a more detailed chronology of Prius ''(and other vehicle)'' conversions completed since CalCars' first one in November 2004, including pictures, locations and contact information of the owners, see [http://www.calcars.org/where-phevs-are.html where-phevs-are] at CalCars.org.
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The Google http://rechargeit.org site has a map of PHEV vehicles, this http://www.frappr.com/phev was an early attempt at mapping PHEV's and EV's,  and the http://www.pluginmap.org site has charging stations.
  
==EV-Mode==
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=== Add A Vehicle ===
=== Enabling EV-Mode Button ===
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Chris Ewert has generously volunteered to collect and organize these lists.  Please send him information in the format listed below. Send corrections and updates to chris [at] infolaunch.com (Chris Ewert) and copy to info [at] calcars.org.
* Enabling the [[SEVA:User:Rjf/Prius_Modifications#Enabling_EV-mode_Button_.22H14_.2327_to_ground.22|EV-Mode Button]]
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* OWNER/SPONSOR Name and URL by CONVERTER
EV-only mode is auto canceled outside of the following limits:
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* MONTH/YEAR
* >=180V
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* CITY/COUNTY/STATE
* >=45% SOC (mode cannot be entered unles SOC is >=50%)
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* Contact email address *
* Accelerator pedal position <=120 (out of 255), corresponds to approx. 120A or 24kW
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: ''*(if the contact wants an anti-spam email address like info [at] name.com, please indicate that, or if the contact wants to be unlisted but is still willing to provide that info to CalCars (you won't regret it), please send it with that notation.''
* Vehicle speed <34 mph (55 kph)
 
* Defrost not selected (and possibly some other control selections)
 
Notes:
 
* The ICE will start 7 seconds after vehicle startup unless EV-only mode is entered during that time.
 
* Once the ICE starts the first time during a trip, it will not stop until it has warmed up.
 
* The A/C compressor is electric, and the A/C will work while in EV-only mode.
 
* When the EV-only mode is entered, the hybrid model screen will show.  A beep will be heard only if that screen wasn't already showing.
 
* Three beeps are heard whenever EV-only mode is requested but not allowed, and when it is auto canceled.<br>One must wait around five seconds before a new EV-only request is acknowledged.
 
Regenerative braking is limited by all of the following:
 
* 120A
 
* ~30A if SOC is >=80%
 
* HV 250-270V (progressively greater limitation)
 
None of the above voltage limits have been tested for temperature-based variations.
 
  
===SOC Spoofing===
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Please also feel free to edit this page right now with additions or corrections and we'll be sure to forward those changes on the Chris and CalCars.
Note: More information is now available in [[PriusPlus]] ([[Media:EAA-PHEV-PRIUS-.doc|.doc]]) and the [[EAA-PHEV_Maillist:]].
 
  
The Prius' battery management computer (BMS, called the Battery ECU) communicates to the main hybrid computers via the CAN busIt indicates battery voltage, current, temperature, and its estimates of state-of-charge (SOC), and maximum allowable charge and discharge current.
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=== Current Vehicles ===
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per http://www.calcars.org/where-phevs-are.html
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:-1. Historic - [[History]] of this website, the EAA, Hybrids, CalCars, Plug-in Hybrids, and more...
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:0. 1993-present - [[Dr. Andrew Frank]] from the University of California, Davis and his Team Fate.
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# Fall 2004 - CalCars [[PriusPlus History|PRIUS+/Ron Gremban]] by [[User:Rgremban|Ron Gremban]], [[EnergyCS]] and CalCars team
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# Mar. 2005 - [[EnergyCS]] by Greg Hanssen, Pete Nortman and team
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# May 2005 - Energy CS/Clean-Tech by [[EnergyCS]]
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# Sept. 2005 - Amberjac Projects Ltd UK, by ([[Amberjac]]/[[EnergyCS]])
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# Feb. 2006 - [[Hymotion]] by Hymotion
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# Mar. 2006 - Electro Energy by CalCars and [http://www.electroenergyinc.com/ Electro Energy]
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# Mar. 2006 - South Coast Air Quality Management District by [[EnergyCS]]
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# Apr. 2006 - CalCars/Felix Kramer by [[EnergyCS]]
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# Apr. 2006 - Sacramento Municipal Utility District by [[EnergyCS]]
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# Apr. 22-24 - [[User:Rjf|Ryan Fulcher]] of the [[SEVA:|Seattle EVA]] by CalCars and the [[Inaugural Maker Faire|Maker Faire team]]
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# May 2006 - City of Santa Monica by [[EnergyCS]], (Los Angeles County, contact rick.sikes [at] smgov.net)
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# July 2006 - Pacific Gas & Electric/Bay Area Air Quality Management District by [[EnergyCS]], (San Francisco County, contact sxtg [at] pge.com
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# Aug. 2006 - Hourcar by [[Hymotion]], (Twin Cities, MN, contact info@hourcar.org)
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# Aug. 2006 - Southern California Edison by [[EnergyCS]], (Los Angeles County)
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# Aug. 2006 - South Coast Air Quality Management District #2, by [[EnergyCS]] (Los Angeles County)
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# Sept. 2006 - '06 Prius for [http://www.state.co.us/oemc/ State of Colorado, Energy Office] (Denver CO) by [[Hybrids-Plus]] ([http://hybrids-plus.com hybrids-plus.com])
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# Sept. 2006 - Manitoba Hydro by [[EnergyCS]], (Winnipeg, Manitoba)
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# Sept. 2006 - Veridian Corp. by [[Hymotion]], (Ajax, Ontario, contact dhillsmilligan [at] veridian.on.ca)
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# Oct. 2006 - Chelan County (WA) [http://www.ncwctc.com/205.html Advanced Vehicle Initiative]'s "[[WhiteBird]]" was converted with the second [[PiPrius]] kit, (Contact Ron Johnston-Rodriguez: info [at] plugincenter.com or (509) 663-5159)
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# Oct. 2006 - Costar Corporation by [[Hymotion]], Annapolis, MD contact kliestenfeltz@costar.com
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# Nov. 2006 - Todd Dore of the [http://www.fveaa.org/ Fox Valley EAA chapter], Prius [[GrayPearl]] was converted with the third [[PiPrius]] kit.
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# Nov. 2006 - CalCars new [[PriusPlus]] conversion of Sven Thesen's 2005 Prius
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# Nov. 2006 - Fairfax County, VA by [[Hymotion]]
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# Nov. 2006 - Idaho National Laboratory of US Department of Energy by [[EnergyCS]]
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# Nov. 2006 - Idaho National Laboratory of US Department of Energy by [[Hymotion]]
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# Dec. 2006 - [http://www.lipog.org/PHEV%20PowerPoint.htm DUAL PWR-PHEV] by Horacio Calvento, Long Island, NY (contact: mrbigh at gmail.com)
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# Jan. 2007 - [[User:JimFell|Jim Fell]], Peterborough, England PFC40 conversion with 56 x 90ah Thundersky cells named [[FellUK]].
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# Feb. 2007 - Bay Area company by [[Hymotion]] (first car)
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# Feb. 2007 - Bay Area company by [[Hymotion]] (second car)
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# Feb. 2007 - GreenTomato Cars, ([[Amberjac]]/[[EnergyCS]]), London UK
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# Mar. 2007 - Southwestern utility by [[Hymotion]] (first car)
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# Mar. 2007 - Southwestern utility by [[Hymotion]] (second car)
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# Mar. 2007 - EcoFys, ([[Amberjac]]/[[EnergyCS]]) Maastricht Netherlands
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# Mar. 2007 - Jim Tech Ltd, ([[Amberjac]]/[[EnergyCS]]) London UK
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# Apr. 2007 - [[User:Cewert|Chris Ewert]], Wheaton, IL - first individual PriusPlus conversion with modified mounting method (contact: chris at infolaunch.com)
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# Apr. 2007 - Private early adopter, ([[Amberjac]]/[[EnergyCS]]) Bradford
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# May. 2007 - Philippi Family, Houston, TX - PriusPlus conversion with hinged battery box for access to spare tire. [[PriusPlus]] type conversion. [[2007 Maker Faire]] Team [http://HybridPlugs.com HybridPlugs.com]
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# May. 2007 - Northern California water agency by Hymotion, contact info to come#
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# May. 2007 - '07 Prius for [http://www.lithiumtech.com/ Lithium Technologies] (Plymouth Meeting, PA ) by [[Hybrids-Plus]] ([http://hybrids-plus.com hybrids-plus.com])
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# May. 2007 - '07 Prius for private individual (Seattle, WA ) by [[Hybrids-Plus]] ([http://hybrids-plus.com hybrids-plus.com]) [http://hybrids-plus.com/pmwiki/index.php?n=Ext.Conversion3 Conversion3 gallery] PHEV-30
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# May 2007 - Private early adopter, ([[Amberjac]]/[[EnergyCS]]) through Toyota dealer, Kent UK
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# May 2007 - eacon Energy, ([[Amberjac]]/[[EnergyCS]]) Loughborough UK
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# May 2007 - Ecordis/Spinnovation, ([[Amberjac]]/[[EnergyCS]]) Amsterdam Netherlands
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# May 2007 - [http://www.nilar.com/index.php?pageID=42&languageID=1 Nilar]s' in house [[PriusPlus]] type conversion.
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# July 2007 - [http://www.anl.gov/ Argonne National Labs] - Prius by [[Hybrids-Plus]] ([http://hybrids-plus.com hybrids-plus.com]) [http://hybrids-plus.com/pmwiki/index.php?n=Ext.Conversion5 Conversion5 gallery] PHEV-30
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# July 2007 - Private individual in Rifle Colorado - Prius by [[Hybrids-Plus]] ([http://hybrids-plus.com hybrids-plus.com]) [http://hybrids-plus.com/pmwiki/index.php?n=Ext.Conversion6 Conversion6 gallery] PHEV-30
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# July 2007 - Raleigh NC, [http://www.progress-energy.com Progress Energy Corporation] - 2005 Prius converted by [http://www.avrc.com Advanced Vehicle Research Center] with [[Hymotion]] hardware. (contact: Mike.Ligett (at) pgnmail.com)
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# Sept 2007 - Hybrids Plus in Boulder Colorado - Prius by [[Hybrids-Plus]] ([http://hybrids-plus.com hybrids-plus.com]) [http://hybrids-plus.com/pmwiki/index.php?n=Ext.Conversion8 Conversion8 gallery] PHEV-30
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# Sept 2007 - The [[Green Car Company]] delivered their first [[PiPrius]] conversion to King County.
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# Oct 2007 - Private individual in Charleston SC - Prius by [[Hybrids-Plus]] ([http://hybrids-plus.com hybrids-plus.com]) [http://hybrids-plus.com/pmwiki/index.php?n=Ext.Conversion17 Conversion17 gallery] PHEV-15
  
The BMS' estimate of SOC is critical, as the hybrid controller keeps SOC within 40-80% (the lower and upper limits of the (nonlinear) display graph), and tries to keep it around 60%.  When the SOC is above 60%, the hybrid controller works to discharge the battery by using battery power (and less gasoline) even during normal cruise.  This increases to around 30A (~6kW) at 70% and above.
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=== Newest Vehicles ===
  
When the SOC is below 60%, the hybrid controller works to charge the battery by making the ICE work extra hard even during normal cruise. Below 40% SOC, stranger things happen and it is difficult to get the engine to put out much power at all.
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* http://www.autobeyours.com/PHEV.htm - Steves salvaged "imwoody36 special" PHEVs Prii conversion is still a work in progress.
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* http://priuschat.com/My-official-Prius-Plus-mods-thread-t26951.html, Jim the latest CalCars conversion done at the [[2007 Maker Faire]].
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* http://www.ew.usna.edu/~bruninga/APRS-SPHEV.html Bob Bruninga, WB4APR, APRS Solar PHEV
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* http://www.phevprius.blogspot.com Kent's salvaged special by www.autobeyours.com
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* http://www.eVehicle.co.nz SynECO eVehicle Systems PRIUS PlugIN-2-GO!! (tm) PHEV upgrade
  
For a PHEV, the object of SOC spoofing is to keep the BMS's indicated SOC at 80% or above until the battery is discharged enough to accept significant regenerative braking current; then between 70-80% -- to force less gasoline use even during non-EV-only mode -- until the battery's real state-of-charge has come near its lower limitAt that point, the BMS's indicated SOC should hover around 60% to keep the battery's real state-of-charge from trending further downward (bad for the battery) or upward (thereby wasting gasoline).
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==Original CalCars Method==
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{{Disclaimer|baronly=1}}{{Clear}}
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{|
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| valign=top |
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This conversion method was originally demonstrated by CalCars which replaces the OEM battery with a new higher capacity [[Battery Pack Configurations#Simple|simple string]] of batteries.  Ron's first [[PriusPlus History]] conversion used early proprietary [[EDrive]] technology.  A later version of this method by CalCars attempted to exploit the [[State Of Charge Drift]] portion of the vehicles battery management routines in order to accomplish [[State Of Charge Manipulation]] with the use of a [[Battery Tap Emulator]]However this attempt was unsuccessful due to the [[State Of Charge Manipulation#Charge Limit Conundrum|CCL Conundrum]].  As such further development of the Original CalCars method has been postponed while perusing the [[#Hybrid-Pack Method]] which has now been successfully implemented.
  
Dan Kroushl did some experiments with higher voltage batteries that proved that the BMS's indicated SOC can be spoofed (Thanks, Dan!)That led me to do enough further experimentation to discover that it is definitely possible to do what I indicated in the above paragraph, and generally how to do itHowever, the circuitry and programming to do so is still in development. It generally involves, as needed, providing a higher voltage to the BMS than the actual battery voltage.
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A number of companies such as [[EnergyCS]], [[Amberjac]], [[EDrive]], and [[Hybrids-Plus]] use this method with custom hardware which replaces the OEM battery management computer in order to dictate the [[SOC]] which is communicated to the rest of the vehicles computersIn doing so these conversions report a higher than normal SOC while in [[Charge-depleting]] mode in order to raise mileage by increasing the electric contribution to motive powerThis higher than normal SOC also encourage more stealth mode and enables longer operation in [[Prius EV Mode]]. Once the new higher capacity battery pack is sufficiently depleted the system reports normal SOC values causing the vehicle to return to the normal [[Charge-systaining]] mode of operation just like a stock Prius.
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| valign=top |
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<center>'''[[Prius PHEV Schematics-CalCars]] are Dormant.'''</center>
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{{PriusPlus Schematics Small}}
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|}
  
Toyota's BMS also checks the voltage of 13 taps on the OEM battery.  These voltages must be equal to each other or the BMS will indicate a faultSince few PHEV battery packs, unlike the OEM pack, are divisible into 14 equal subpacks, these tap voltages must be spoofed, tooFortunately, it has been found that a fairly simple voltage divider can accomplish this.
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==Hybrid-Pack Method==
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{{Disclaimer|baronly=1}}
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The Hybrid-Pack method employs a [[Battery Pack Configurations#Hybrid|Hybrid Battery Pack Configuration]] which has been used in the past as a solution which combines two battery banks in order to mask weaknesses in one or both resulting in a robust overall system.  For example a high energy/low capacity and high capacity/low energy battery might be combined resulting in an overall high energy and high capacity resource.  [[Hymotion]] was the first to employ this type of configuration followed by the new [[PriusPlus]] and [[PiPrius]] projects.  These conversions mask the low capacity characteristics of the OEM battery with a higher capacity batteryWhile this higher capacity battery also has higher energy, keeping the OEM battery and it's support systems in place eliminates the need for a replacement Battery Management Computer capable of communicating with the rest of the Prius systemsFor more core ideas surrounding this method see [[Prius PHEV Battery Options]] for more specific battery information.  
  
Because of all of the above, CalCars' overall PRIUS+ circuit diagram is still in flux, and definitive answers about it are as yet unavailable.
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This method exploits the [[State Of Charge Drift]] portion of the OEM battery management routines in order to accomplish [[State Of Charge Manipulation]], but does not utilize a [[Battery Tap Emulator]].  The result is the ability to effectively change the target [[SOC]] from the normal ~60% to higher values which are more useful for [[PHEV]] applications.  The [[Prius EV Mode]] can also be utilized for longer durations because SOC Drift is capable of maintaining an acceptable SOC value.  A [[CAN]] device is required to acts as a [[Prius PHEV User Interfaces|Prius PHEV User Interface]] and management device.  <s>Such hardware/software will need to follow logic similar to that laid out by [[Prius PHEV Pseudo Code]].</s>  The Latest [[PriusPlus]] and [[PiPrius]] conversions  use [http://www.hybridinterfaces.ca hybridinterfaces] [[CAN-View]] Scantool device which is currently available for 2004 and newer Prius, and may eventually be used in other Hybrids such as the [[Ford Escape Hybrid]].  You can take a look at [[Prius PHEV Photos]] which are available to help visualize parts of the conversion process.
  
===SOC management===
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===Contactor Based===
Note: More information is now available in [[PriusPlus]] ([[Media:EAA-PHEV-PRIUS-.doc|.doc]]) and the [[EAA-PHEV_Maillist:]].
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Ron and CalCars have demonstrated a working contactor and resistor based configuration in a number of vehicles.
  
Here is the minimum needed in terms of a computer for spoofing the Prius' built-in BMS:
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'''See [[PriusPlus]] for the documentation of this type of conversion.'''
* CAN message reading and parsing (CAN bus writing is NOT necessary or even desirable)
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* [[Prius PHEV Battery Options#Contactor Based]]
* '''The ability to separately close and open two reed switch contacts based on CAN information'''
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* [[State Of Charge Manipulation#Contactor Based]]
** one to set EV-only mode, based on it not already being set, speed <34 mph, power request <120 (out of 200), SOC >49%, and a few other parameters.
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* [[Prius PHEV Schematics#Contactor Based]]
** one to set a voltage boost (to be explained later) to keep perceived SOC within a given range until the battery is sufficiently depleted
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* Documents from 2004 with information and considerations regarding various configurations.
* Amp-hour integration and display from the appropriate CAN bus messages
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** http://www.forsites.com/CalCars/EAA-PHEV/PriusPlusConfigurations040817rdg.pdf
* HV battery voltage and current display (both analog and digital desirable) from the appropriate CAN bus messages
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** http://www.forsites.com/CalCars/EAA-PHEV/PriusPlusConfigurations040817rdg.xls
* Display of trip info (since reset): # of CAN errors (important for debugging), odometer, milligallons of gasoline used, Amp-hr and/or kWh used, trip milligallon/mi, Wh/mi, and mpg, highest peak charge and discharge currents, highest and lowest HV battery voltages, and the battery's internal resistance (beginning, current, and end)
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* '''Good news: a hybrid-battery solution to the CCL conundrum'''<br>Ron Gremban - [[EAA-PHEV_Maillist:2006./5./5]] & [http://autos.groups.yahoo.com/group/eaa-phev/message/187 Y:187]
  
Additional displays, desirable but not necessary:
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===PFC Based===
* Not strictly necessary, but SUPER desirable:  storage of CAN trip running data on a removable medium (like a CompactFlash card) for later analysis.
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Rich Rudman of [[Manzanita Micro] (http://www.manzanitamicro.com) and [[User:Rjf|Ryan]] have implemented a conversion using an upgraded [[MM-PFC]]-30, named the PFC40H, as a DC-DC converter and charger.  Rich has developed and is offering conversion kits.
* Small graphical engine tachometer (but see rectangular suggestion below)
 
* Gasoline use rate (milligallon/min and/or milligallon/mi (inverse of mpg), or just a binary for gasoline being used
 
* Tiny graphical brake cylinder pressure (sum of that for each wheel), to indicate amount of non-regenerative braking being used
 
  
A very cool display would be two rectangular graphs indicating engine and electric power:
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===Enginer Based===
* Engine power (e.g. blue for combustion):  vertical: RPM, horizontal: torque
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Jack Chen has implemented a conversion using a special designed DC-DC converter and controller made by [[Enginer]] (http://www.enginer.us), which monitors stock and PHEV battery SOC to determine conversion kit's discharge rate without CAN interface. This method can support both Gen 1 and Gen 2 Prius as well as other hybrids by adjusting output voltage and current. The interface (5 wires) to the stock vehicle is very minimum resulting in significant cost savings. AutomationTech Inc is offering complete conversion kits under $2000 in US.
* Electric (e.g. red for discharge, green for charge):  vertical: HV battery voltage; horizontal:  HV battery current (absolute value)
 
The areas can be calibrated so that they show the relative power being produced by the electric motor vs. the engine. The same pair of rectangles could display and compare the power going into regenerative braking vs. that being wasted in the friction brakes.
 
  
==Batteries==
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'''See [[PiPrius]] for more details.'''
Any battery which meets the minimum requirements could be used to replace the [[SEVA:Prius Battery Specs|Stock Prius]] [[SEVA:Ni|NiMH]] battery pack.  The stock battery does not necessarily need to be removed, but should be disconnected while in PHEV mode due to serious problems that can occur from paralleling this sort of battery.  Adding more than 300 lb to the vehicle's weight is not recommended, at least without beefing up the suspension; removing the OEM battery pack removes around 80 lb.
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* [[Prius PHEV Battery Options#PFC Based]]
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* [[State Of Charge Manipulation#PFC Based]]
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* [[Prius PHEV Schematics#PFC Based]]
  
This application is on the edge of the capabilities of lead-acid (PbA) batteries.  CalCars' PbA conversion works, but just barely.  The battery pack's internal resistance, though O.K. at high states-of-charge (SOC) is twice as high at low SOC.  As this is what ultimately limits discharge, it also means that ordinary hybrid operation is compromised, too, once this low SOC is reached.  Additionally, and possibly most important, low temperature operation is very compromised.  Range is reduced at least 20% at 50 vs. 70+ degrees F, and '''at freezing temperatures CalCars' PRIUS+ wouldn't drive at all on the PbA pack!'''
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'''Electro Energy''' has successfully demonstrated a PFC based setup with [[SEVA:Ni|NiMH]] during CalCars trip to DC.
* '''CalCars''' has used 18 EVP20-12B B&B 20Ah 12v SLA [[SEVA:PbA|PbA]] batteries from [http://www.electricrider.com/batteries.htm ElectricRider.com] (~270 lb and 12Ah at 2C rate) for a total of <!--14.4vpc?-->3.1 kWh.  These PbA batteries have exceptional high power capabilities, cost $750 total, and deliver 10 miles of pure EV driving or 20 miles of doubled gasoline mileage in mixed driving per charge.  CalCars' first set lasted 200 cycles or $0.35/mile -- but see RonG's further information under '''Charging''' below.
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* 2006.05.26 - financialnewsusa.com - [http://www.financialnewsusa.com/release.php?rlsid=5262 Electro Energy Participates in Plug-In Hybrid Vehicle Demonstration in Washington, D.C. and Power Air Lists on Frankfurt Stock Exchange]
* Another PbA possibility is the Odssey PC625 by EnerSys Inc.  They are slightly lighter for the same high rate capacity and may have longer cycle life than the EVP20-12B.  I believe these are what used to be the much-touted Hawker brand.  More info on these batteries, where to get them, and for how much will be forthcoming -- and, again, see RonG's further information under '''Charging''' below.
 
* CalCars has nearly completed a project with Electro Energy Inc. using a custom pack of their specialized NiMH batteriesThough more expensive, it will weigh the same as the EVP20-12's but provide more than double the range, better performance, probable low temperature operation, and much longer expected lifetime. We are hoping that Electro Energy will make these available for conversions later this year (2006).  Stay tuned.
 
* '''EDrive''' plans on using 18 ''exotic'' 12V U-1 U-charge 40Ah @C/5 Li-ion batteries from [[SEVA:Li#Valence|Valence]] for a total of 9.9 kWh.
 
* Useful files by Ron Gremban:
 
** Feb 17, 2006 [http://www.forsites.com/CalCars/calcars-phev-batteries18feb06-rdg.xls New spreadsheet of projected battery performance in PHEV conversions] [http://www.forsites.com/CalCars/calcars-phev-batteries18feb06-rdg.pdf .pdf]
 
** Jul 21, 2005 [http://groups.yahoo.com/group/priusplus/message/468 Battery evaluation and production cost summary]
 
* You may want to use some [http://www.andersonpower.com/ Anderson] high power connectors for the DC connections.
 
  
===Minimum Requirements===
+
==Kits and Conversions==
We will focus on the Voltage requirements, as the AmpHour capacity of the pack may vary depending on who's implementing it and for what type of useage for various ranges from 5 to 50 or more miles.  While a PbA pack may only deliver about 1/2 its nameplate capacity (due to Peukert's Law, which does not affect other chemistries) a Lithium pack may be able to deliver all of it's nameplate capacity.  It all depends on how the battery's capacity is rated.  The Prius consumes about 1 Ah or 300 Wh per mile.
+
{{Prius PHEV Options}}
  
* The 6.5Ah '''Stock NiMH pack''' consists of 168 cells (28 modules) in series.
+
==Maillist Resources==
** 60% nominal to 45% minimum SOC => 15% of 6.5 Ah is 1 Ah for 1 mile EV-only range.
+
{{Maillist Archives}}
** 80% maximum to 45% minimum SOC => 35% of 6.5 Ah is 2.2 Ah for > 2 miles EV-only range.
 
** Nominal Voltage is 201.6V, ranging from 180V to 270V durring use.
 
* The 20Ah '''CalCars PbA pack''' (12Ah at 2C rate)
 
** Delivers ~10 miles EV-only or 20 miles [[Mixed-mode]] driving PHEV range.
 
** Nominal Voltage is <!--12.0vpc-->216V, still ranging form 180V to 270V durring use (range set by Toyota's hybrid system).
 
* The 40Ah '''EDrive Li-ion pack'''
 
** Delivers ~30 miles EV-only or 60 miles [[Mixed-mode]] driving PHEV range.
 
** Nominal Voltage is <!--12.8vpc-->230V.
 
 
 
CalCars' published chemistry-neutral PRIUS+ battery spec is reproduced below.  We have found 18 12V PbA modules or 180 NiMH cells in series to be near optimum.
 
 
 
Note: our PRIUS+ gets approx. 1 mile of pure EV range (or 2 miles of [[Mixed-mode]] driving range, with double normal gasoline mileage) per Amp-hr expended from the battery.  Therefore, a 30Ah battery, used to 70% depth-of-discharge (DOD) would provide 24 miles of EV-only range or 48 miles of [[Mixed-mode]] driving PHEV range.
 
 
 
* California Cars Initiative PRIUS+ Project - Preliminary Public Chemistry-neutral Battery Pack Specification
 
* Subject to Change 6/17/05 By Ron Gremban
 
** Voltages:
 
*** Maximum (during regenerative braking, 120A or max for SOC):  260V
 
*** Minimum (during 120A discharge at minimum normal SOC):  180V
 
*** Nominal:  210-230V (depends on the chemistry)
 
** Amp-hr at 60A rate: 30-50 (5.5-10.0 kWh)
 
** Max intermittent discharge rate: 200A
 
** Max intermittent charge rate (when SOC is low enough to accept this full rate): 120A
 
** DC internal resistance*, over normal range of SOC: Less than 0.25 ohm (0.20 ohm desired)
 
** Charge equalization: Please indicate requirements and provisions for charge equalization
 
** Thermal management: Please indicate requirements and provisions for thermal management
 
** Min cycle life*: At least 1000 cycles between normal SOC limits; 2000 cycles or more highly desired
 
** Max battery pack weight*: 300 lb (136 kg); 170 lb (77 kg) desired (replaces 70 lb hybrid battery)
 
** Max price*: $800/kWh or less to CalCars, including charge balancing, cooling, thermal management, and SOC monitoring
 
** Projected high-volume auto manufacturer's cost in two years*: $0.40 or less per kilowatt-hr lifetime throughput
 
* *The values of these parameters should be maximized (or minimized, as appropriate), given a reasonable cost of doing so
 
 
 
===Battery analysis by Richard===
 
per [[EAA-PHEV_Maillist:2005./12./2]]:<br>
 
I have completed my analysis for the battery pack and am attaching it. The first attachment explains the analysis and the second is a spread sheet of some of the data I ran.
 
* [[:Image:Minimum_cost2.doc]]
 
* [[:Image:Bmax.xls]]
 
 
 
==Chargers/Charging==
 
[[Image:Prius Charger.jpg|thumb|100px|right|[http://groups.yahoo.com/group/2004-prius/message/40720 THS Charger]]]
 
* CalCars uses a Brusa NLG5 charger from MetricMind.com.  This is a $4000, 4kW charger capable of being reprogramed for any chemistry and any voltage output up to 520V.  It is invaluable for our experimentation, especially since, for our world's first PRIUS+, we didn't know what would be necessary.  A less flexible, lower power, less expensive charger may be more suitable for subsequent conversions.
 
* CalCars believes that most PHEVs need only a 1-1.5 kW charger, able to plug into ordinary 120V, 15A GFI circuits.  Since gasoline is available as a range extender, charging need be no faster than overnight.
 
* [http://www.delta-q.com Delta-q] is taking a strong interest in PHEVs.  They are the charger supplier for EDrive Systems' conversions and have begun working with CalCars on creating chargers for both our PbA and Electro Energy NiMH conversions.
 
* [http://groups.yahoo.com/group/ev-list-archive/message/51581 PFC-20 Running off Prius HV Pack] [http://groups.yahoo.com/group/ev-list-archive/message/51660] Charging a BEV. This charger could run in both directions.
 
** charging from the grid to the additional pack
 
** charging from the additional pack to other EV's
 
** charging from the Prius ICE/Gas to other EV's (up to 10kW)
 
RonG:  Important new PbA charging information from Tony Goulet at [http://www.odysseybatteries.com West Coast Batteries Inc.] re. Odyssey (and all PbA) batteries (after nearly 40 years of working with PbA batteries off and on, I am still learning more about them):
 
 
 
Sulfation of PbA plates does not only happen at low states-of-charge (SOC) as I used to believe.  Sulfur is deposited on the battery's negative plates corresponding to its depth of discharge (DOD).  After three days or so this sulfur becomes crystalized and can no longer be removed from the plate by charging.  This means that any portion of a PbA battery's capacity that is left in an uncharged state for three days is permanently lost, and the battery now has less capacity!  This can happen repeatedly, causing increasing loss of capacity.  (Of course, as I already knew, if a PbA battery is left in a very low SOC for long, the sulfur may grow crystal trees that often permanently short out a battery right through its separators.)
 
 
 
The second piece of this tale is that unless a PbA battery has been held at a constant-voltage absorbtion charging stage for 8-12 hours, SOC is less than 100%.  If e.g. 97% charge is achieved and the battery is not charged more completely for three days, the uncharged 3% of the capacity will probably be permanently lost to sulfation!  It is therefore very important to charge a PbA battery to 100% at least every other day -- and less than a quite long absorbtion charge period (including ~3% overcharge on new batteries, or 10-20% overcharge on older ones) will not suffice!
 
 
 
* [http://www.forsites.com/CalCars/PbAAdvancedChargeAlgorithm.pdf Charging Algorithms for Increasing Lead Acid Battery Cycle Life for Electric Vehicles] is an interesting (though confusing unless read carefully) paper of NREL research indicating the possibility of greatly extending AGM/VRLA PbA cycle life via unusual charge algorithms.
 
 
 
==User Interfaces==
 
===CAN-View Scanner===
 
[[Image:Inimech.jpg|thumb|right|One of the graph screens<br>'''See the [http://www.hybridinterfaces.ca Official Website]''']]
 
 
 
This is a MFD Integrated CAN Scanner, named CAN-View.<br>
 
The Official Website is http://www.hybridinterfaces.ca
 
 
 
* http://priuschat.com/index.php?showtopic=11644 [http://groups.yahoo.com/group/Prius_Miniscanner_MarkIII/message/614 yahoo] [http://priuschat.com/CAN-VIEW-monitor-t12077.html Lost] [http://www.google.com/search?q=cache:9yflkBICdmIJ:priuschat.com/index.php%3Fshowtopic%3D12077 C1] [http://www.google.com/search?q=cache:OQWcUZ8AF-kJ:priuschat.com/page-2-t12077-s20.html C2] [ C3]
 
* http://priuschat.com/index.php?showtopic=2281 hardware level display hijacking, unrelated?
 
* Now available at http://www.priuschat.com/shop/
 
** Help installing it : [https://www.metrotpn.com/documents/PDF%20Files/Prius/Eddie's%20XMRadio%20Install/PriusXMradio3.2.pdf] [http://www.chrisdragon.com/downloads/Stereo%20Accessory%20Install%20Guide,%2004%20Prius,%20v1.03.pdf]
 
 
 
'''Additional accessories'''<br>
 
These additional features are supported by the 2nd version of the CAN-View, some require additional hardware.
 
*Aftermarket Navigation System Interface ''([http://www.google.com/search?q=Pioneer+AVIC-88 Pioneer's AVIC-88])''
 
*Serial MFD touch screen coordinates are outputted from the CAN-View via a serial DB9 RS232 port.
 
*SCART Plugs and cables. [http://cpc.farnell.com/jsp/endecaSearch/searchPage2.jsp?Ntt=scart+sockets&Nty=1&N=411&Ntk=gensearch]
 
*A $110 CC2RGB converter from http://www.threedoubleyou.com/otherconverters.htm outputs composite NTSC video via the CAN-View.
 
** per [http://priuschat.com/index.php?showtopic=11644&view=findpost&p=206535], This may be another option for  [http://www.tkk.fi/Misc/Electronics/circuits/vga2rgbs.html VGA to RGB + composite sync converter]
 
* Field Programming - http://priuschat.com/index.php?showtopic=11644&st=40#
 
** The Silabs development kit C8051F310DK (available on the DigiKey website at US$99)
 
*A $99 BOBIII device from http://www.decadenet.com outputs clean RGBs to the MFD via the CAN-View, it uses serial input to create color text.
 
 
 
===My CAN Project===
 
[[Image:Www.vassfamily.net-Others.jpg|thumb|right|[http://www.vassfamily.net/ToyotaPrius/CAN/cindex.html Vass] Software on the left]]
 
OK, not ''"My"'' Can Project, but some very nice software none the less.
 
*http://www.vassfamily.net/ToyotaPrius/CAN/cindex.html
 
: May Required Linux ''and all that that entails''
 
: '''Open Source''' courtesy of Attila Vass!
 
 
 
===Other CAN scanners===
 
*http://www.ecrostech.com/Products/MiniScanner/Intro.htm [http://home.earthlink.net/~graham1/Prius/MiniScanner/MiniScanner.htm]- Classic Prius (2000-2003)
 
*http://groups.yahoo.com/group/Prius_Miniscanner_MarkIII - THS Prius (2004+)
 
*http://www.hemdata.com/Products/Dawn - Another CAN scanner, with HEV screenshots.
 
* [http://babelfish.altavista.com/babelfish/trurl_pagecontent?lp=ja_en&trurl=http%3a%2f%2fpriusdiy.fc2web.com%2findex.html priusdiy.fc2web.com/index] - Translated from Japanese to English
 
*http://www.ecrostech.com/prius/original/PriusFrames.htm
 
*http://www.carplugs.com - Source for OBD2 connectors.
 
 
 
==Schematics and Documentation==
 
See [[Prius PHEV Schematics]]
 
  
==Management Pseudo Code==
+
[[Category:Prius]]
See [[Prius PHEV Pseudo Code]]
+
[[Category:PHEV]]
  
==Installation Photos==
+
[[Category:Amberjac]]
See [[Prius PHEV Photos]]
+
[[Category:CalCars]]
 +
[[Category:EDrive]]
 +
[[Category:EnergyCS]]
 +
[[Category:Hybrids-Plus]]
 +
[[Category:Hymotion]]
 +
[[Category:PiPrius]]
 +
[[Category:PriusPlus]]
 +
[[Category:Plug-In Conversions]]
 +
[[Category:Enginer]]

Latest revision as of 12:22, 14 June 2020

Click show for a short list of the current PHEV conversion and kit options for the Toyota Prius.

For Prius conversion details see the Prius PHEV article and comparisons table.

  1. Ron's Original PriusPlus History and current Contactor Based PriusPlus documentation for DIY projects.
  2. Ryan's PriusBlue is the testbed for DC-DC PFC Based PiPrius kits and documentation for DIY projects.
  3. Toyota OEM Prius PHEV and Prime Could use some work on this page
  4. Enginer China. But the rest of these appear to all be defunct as of 2020?
  5. |~- Hybrids-Plus USA/Colorado/Li -~|~- EnergyCS USA -~|~- Hymotion USA/Canada -~|~- Amberjac UK. -~|~- EDrive USA -~| Peter mentioned Plug-In Conversions |~-
Calcars-logo-large.png
Pluginpartnerslogo.gif

To this date there have been a number of successful Prius PHEV conversions beginning with Ron of CalCars [1] [2] Original [3] and current PriusPlus projects. Other small startups include the PiPrius [4] [5] and Hybrids-Plus [6] [7] projects. EnergyCS [8] and their European partner Amberjac [9] as well as Canadian Hymotion [10] have converted numerous Prius PHEVs to this point. EDrive [11] will be offering conversion soon. The tenth conversion of PriusBlue was undertaken in public April of 2006 at the Inaugural Maker Faire to help enhance the documentation and help promote PHEVs in the pacific northwest and midwest.

At this time there are two common conversion methods for the Prius. The #Original CalCars Method used in Rons PriusPlus History, EnergyCS, Amberjac, EDrive, and Hybrids-Plus conversions replace the stock battery with a new simple string. The second #Hybrid-Pack Method is used in the new PriusPlus, PiPrius, and by the Hymotion conversions. This second method should be easily adapted from the '04+ Prius to the Classic '00-'03 Prius, Escape, and other Hybrids as they use a hybrid battery pack configuration which uses both a new simple string and the original stock batteries. The new PriusPlus and the PiPrius projects moved to the #Hybrid-Pack Method in order to remedy the CCL Conundrum. Both types, of course, use a Battery Chargers to recharge from the grid. Toyota has warned that such conversions may adversely affect your Warranty.

The Prius PHEV TechInfo page has a lot of technical information on the Prius which may be useful when designing a PHEV conversion. See the Terms page if you aren't familiar with some of the underlying principals or acronyms used through the documentation. Also be aware of the Disclaimer should you be considering a conversion yourself. This PriusDisMan.pdf (Media:Priusdisman.pdf from http://www.airlabcorp.com/Prius/priusdisman.pdf) might be handy for its dismantle and safety warnings

Prius Conversions Chronology

For a more detailed chronology of Prius (and other vehicle) conversions completed since CalCars' first one in November 2004, including pictures, locations and contact information of the owners, see where-phevs-are at CalCars.org. The Google http://rechargeit.org site has a map of PHEV vehicles, this http://www.frappr.com/phev was an early attempt at mapping PHEV's and EV's, and the http://www.pluginmap.org site has charging stations.

Add A Vehicle

Chris Ewert has generously volunteered to collect and organize these lists. Please send him information in the format listed below. Send corrections and updates to chris [at] infolaunch.com (Chris Ewert) and copy to info [at] calcars.org.

  • OWNER/SPONSOR Name and URL by CONVERTER
  • MONTH/YEAR
  • CITY/COUNTY/STATE
  • Contact email address *
*(if the contact wants an anti-spam email address like info [at] name.com, please indicate that, or if the contact wants to be unlisted but is still willing to provide that info to CalCars (you won't regret it), please send it with that notation.

Please also feel free to edit this page right now with additions or corrections and we'll be sure to forward those changes on the Chris and CalCars.

Current Vehicles

per http://www.calcars.org/where-phevs-are.html

-1. Historic - History of this website, the EAA, Hybrids, CalCars, Plug-in Hybrids, and more...
0. 1993-present - Dr. Andrew Frank from the University of California, Davis and his Team Fate.
  1. Fall 2004 - CalCars PRIUS+/Ron Gremban by Ron Gremban, EnergyCS and CalCars team
  2. Mar. 2005 - EnergyCS by Greg Hanssen, Pete Nortman and team
  3. May 2005 - Energy CS/Clean-Tech by EnergyCS
  4. Sept. 2005 - Amberjac Projects Ltd UK, by (Amberjac/EnergyCS)
  5. Feb. 2006 - Hymotion by Hymotion
  6. Mar. 2006 - Electro Energy by CalCars and Electro Energy
  7. Mar. 2006 - South Coast Air Quality Management District by EnergyCS
  8. Apr. 2006 - CalCars/Felix Kramer by EnergyCS
  9. Apr. 2006 - Sacramento Municipal Utility District by EnergyCS
  10. Apr. 22-24 - Ryan Fulcher of the Seattle EVA by CalCars and the Maker Faire team
  11. May 2006 - City of Santa Monica by EnergyCS, (Los Angeles County, contact rick.sikes [at] smgov.net)
  12. July 2006 - Pacific Gas & Electric/Bay Area Air Quality Management District by EnergyCS, (San Francisco County, contact sxtg [at] pge.com
  13. Aug. 2006 - Hourcar by Hymotion, (Twin Cities, MN, contact info@hourcar.org)
  14. Aug. 2006 - Southern California Edison by EnergyCS, (Los Angeles County)
  15. Aug. 2006 - South Coast Air Quality Management District #2, by EnergyCS (Los Angeles County)
  16. Sept. 2006 - '06 Prius for State of Colorado, Energy Office (Denver CO) by Hybrids-Plus (hybrids-plus.com)
  17. Sept. 2006 - Manitoba Hydro by EnergyCS, (Winnipeg, Manitoba)
  18. Sept. 2006 - Veridian Corp. by Hymotion, (Ajax, Ontario, contact dhillsmilligan [at] veridian.on.ca)
  19. Oct. 2006 - Chelan County (WA) Advanced Vehicle Initiative's "WhiteBird" was converted with the second PiPrius kit, (Contact Ron Johnston-Rodriguez: info [at] plugincenter.com or (509) 663-5159)
  20. Oct. 2006 - Costar Corporation by Hymotion, Annapolis, MD contact kliestenfeltz@costar.com
  21. Nov. 2006 - Todd Dore of the Fox Valley EAA chapter, Prius GrayPearl was converted with the third PiPrius kit.
  22. Nov. 2006 - CalCars new PriusPlus conversion of Sven Thesen's 2005 Prius
  23. Nov. 2006 - Fairfax County, VA by Hymotion
  24. Nov. 2006 - Idaho National Laboratory of US Department of Energy by EnergyCS
  25. Nov. 2006 - Idaho National Laboratory of US Department of Energy by Hymotion
  26. Dec. 2006 - DUAL PWR-PHEV by Horacio Calvento, Long Island, NY (contact: mrbigh at gmail.com)
  27. Jan. 2007 - Jim Fell, Peterborough, England PFC40 conversion with 56 x 90ah Thundersky cells named FellUK.
  28. Feb. 2007 - Bay Area company by Hymotion (first car)
  29. Feb. 2007 - Bay Area company by Hymotion (second car)
  30. Feb. 2007 - GreenTomato Cars, (Amberjac/EnergyCS), London UK
  31. Mar. 2007 - Southwestern utility by Hymotion (first car)
  32. Mar. 2007 - Southwestern utility by Hymotion (second car)
  33. Mar. 2007 - EcoFys, (Amberjac/EnergyCS) Maastricht Netherlands
  34. Mar. 2007 - Jim Tech Ltd, (Amberjac/EnergyCS) London UK
  35. Apr. 2007 - Chris Ewert, Wheaton, IL - first individual PriusPlus conversion with modified mounting method (contact: chris at infolaunch.com)
  36. Apr. 2007 - Private early adopter, (Amberjac/EnergyCS) Bradford
  37. May. 2007 - Philippi Family, Houston, TX - PriusPlus conversion with hinged battery box for access to spare tire. PriusPlus type conversion. 2007 Maker Faire Team HybridPlugs.com
  38. May. 2007 - Northern California water agency by Hymotion, contact info to come#
  39. May. 2007 - '07 Prius for Lithium Technologies (Plymouth Meeting, PA ) by Hybrids-Plus (hybrids-plus.com)
  40. May. 2007 - '07 Prius for private individual (Seattle, WA ) by Hybrids-Plus (hybrids-plus.com) Conversion3 gallery PHEV-30
  41. May 2007 - Private early adopter, (Amberjac/EnergyCS) through Toyota dealer, Kent UK
  42. May 2007 - eacon Energy, (Amberjac/EnergyCS) Loughborough UK
  43. May 2007 - Ecordis/Spinnovation, (Amberjac/EnergyCS) Amsterdam Netherlands
  44. May 2007 - Nilars' in house PriusPlus type conversion.
  45. July 2007 - Argonne National Labs - Prius by Hybrids-Plus (hybrids-plus.com) Conversion5 gallery PHEV-30
  46. July 2007 - Private individual in Rifle Colorado - Prius by Hybrids-Plus (hybrids-plus.com) Conversion6 gallery PHEV-30
  47. July 2007 - Raleigh NC, Progress Energy Corporation - 2005 Prius converted by Advanced Vehicle Research Center with Hymotion hardware. (contact: Mike.Ligett (at) pgnmail.com)
  48. Sept 2007 - Hybrids Plus in Boulder Colorado - Prius by Hybrids-Plus (hybrids-plus.com) Conversion8 gallery PHEV-30
  49. Sept 2007 - The Green Car Company delivered their first PiPrius conversion to King County.
  50. Oct 2007 - Private individual in Charleston SC - Prius by Hybrids-Plus (hybrids-plus.com) Conversion17 gallery PHEV-15

Newest Vehicles

Original CalCars Method

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) 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.

Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should 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 & peril.

Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer.

See also our My wiki:General disclaimer

This conversion method was originally demonstrated by CalCars which replaces the OEM battery with a new higher capacity simple string of batteries. Ron's first PriusPlus History conversion used early proprietary EDrive technology. A later version of this method by CalCars attempted to exploit the State Of Charge Drift portion of the vehicles battery management routines in order to accomplish State Of Charge Manipulation with the use of a Battery Tap Emulator. However this attempt was unsuccessful due to the CCL Conundrum. As such further development of the Original CalCars method has been postponed while perusing the #Hybrid-Pack Method which has now been successfully implemented.

A number of companies such as EnergyCS, Amberjac, EDrive, and Hybrids-Plus use this method with custom hardware which replaces the OEM battery management computer in order to dictate the SOC which is communicated to the rest of the vehicles computers. In doing so these conversions report a higher than normal SOC while in Charge-depleting mode in order to raise mileage by increasing the electric contribution to motive power. This higher than normal SOC also encourage more stealth mode and enables longer operation in Prius EV Mode. Once the new higher capacity battery pack is sufficiently depleted the system reports normal SOC values causing the vehicle to return to the normal Charge-systaining mode of operation just like a stock Prius.

Prius PHEV Schematics-CalCars are Dormant.
EAA-PHEV-PRIUS-Combined.png

Navigation Image

Hybrid-Pack Method

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) 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.

Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should 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 & peril.

Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer.

See also our My wiki:General disclaimer

The Hybrid-Pack method employs a Hybrid Battery Pack Configuration which has been used in the past as a solution which combines two battery banks in order to mask weaknesses in one or both resulting in a robust overall system. For example a high energy/low capacity and high capacity/low energy battery might be combined resulting in an overall high energy and high capacity resource. Hymotion was the first to employ this type of configuration followed by the new PriusPlus and PiPrius projects. These conversions mask the low capacity characteristics of the OEM battery with a higher capacity battery. While this higher capacity battery also has higher energy, keeping the OEM battery and it's support systems in place eliminates the need for a replacement Battery Management Computer capable of communicating with the rest of the Prius systems. For more core ideas surrounding this method see Prius PHEV Battery Options for more specific battery information.

This method exploits the State Of Charge Drift portion of the OEM battery management routines in order to accomplish State Of Charge Manipulation, but does not utilize a Battery Tap Emulator. The result is the ability to effectively change the target SOC from the normal ~60% to higher values which are more useful for PHEV applications. The Prius EV Mode can also be utilized for longer durations because SOC Drift is capable of maintaining an acceptable SOC value. A CAN device is required to acts as a Prius PHEV User Interface and management device. Such hardware/software will need to follow logic similar to that laid out by Prius PHEV Pseudo Code. The Latest PriusPlus and PiPrius conversions use hybridinterfaces CAN-View Scantool device which is currently available for 2004 and newer Prius, and may eventually be used in other Hybrids such as the Ford Escape Hybrid. You can take a look at Prius PHEV Photos which are available to help visualize parts of the conversion process.

Contactor Based

Ron and CalCars have demonstrated a working contactor and resistor based configuration in a number of vehicles.

See PriusPlus for the documentation of this type of conversion.

PFC Based

Rich Rudman of [[Manzanita Micro] (http://www.manzanitamicro.com) and Ryan have implemented a conversion using an upgraded MM-PFC-30, named the PFC40H, as a DC-DC converter and charger. Rich has developed and is offering conversion kits.

Enginer Based

Jack Chen has implemented a conversion using a special designed DC-DC converter and controller made by Enginer (http://www.enginer.us), which monitors stock and PHEV battery SOC to determine conversion kit's discharge rate without CAN interface. This method can support both Gen 1 and Gen 2 Prius as well as other hybrids by adjusting output voltage and current. The interface (5 wires) to the stock vehicle is very minimum resulting in significant cost savings. AutomationTech Inc is offering complete conversion kits under $2000 in US.

See PiPrius for more details.

Electro Energy has successfully demonstrated a PFC based setup with NiMH during CalCars trip to DC.

Kits and Conversions

This div does not appear withing the page but is used to define the references used below. If multiple ref tags were to appear within the table only the text from the first would be displayed. Thus we pre-define them here, the only side effect being that the first "a" backlink does nothing.

<ref name=ev_range> EV range [mi] or All Electric Range (AER) Assuming <35 mph, 210 Wh/mile (260 Wh/mi from grid) per http://www.greencarcongress.com/2005/08/solarpoweraugme.html, 1.5 miles is approximately the range with a fully charged stock battery pack</ref>

<ref name=phev_range> PHEV range [mi] or Blended mode Range (BMR) During which the mileage is on the order of 100 mpg. Shows range as stated by organization.</ref>

<ref name=safety> Safety in case of major accident

  1. Many Lithium cells will burst in flames if penetrated. However, phosphate cathode LiIon cells (such as Valence and A123) are flame-proof.
  2. SLA batteries contain lead and sulphuric acid but are spill-proof</ref>

<ref name=charge_time> Charge time [hours] From discharged to the point the pack will no longer be used in PHEV, to fully charged.

(per Orbital, SLA require 8 hr taper -- done at least once every 3 days -- after near full charge, to reach 100% and prevent sulfation)</ref>

<ref name=energy> Available energy [KWh] Because the DOD of the stock pack is limited by the Prius, only about 0.3 KWh of its energy is available (used). It is assumed that additional batteries are limited to a DOD range of:

  1. SLA: 0% down to 50%, due to Wikipedia:Peukert's law much of the nameplate capacity is unavailable.
  2. Lithium: 0% down to 90%, has far less Peukert losses and can be safely deep discharged.</ref>

<ref name=spare_tire> Spare Tire access

  • No the original tire well is covered or occupied by the new battery pack and must be secured and stowed in the rear cargo space.
  • Yes the original tire well is accessible.
  • Opt Optionally the battery box may be implemented in such a way to preserve access.</ref>

<ref name=convert_service> Conversion service: done by the PHEV conversion company, at their location. Conversion kit: done by the owners in their hometown.</ref>

<ref name=status> Project Status:

  • Doc: Open Source Documentation in progress.
  • Dev: Development: Working vehicles on the road but some features still under development.
  • Unknown: Unknown: No public news the last 12 months
  • Prod: Production: Working vehicles on the road, performing conversions or supplying kits.</ref>

<ref name=topology_type> Topology Type:

  • New New Battery Pack and BMS, the OEM NiMH battery and BMS are replaced with a simple string.
  • Hyb OEM NiMH battery and additional battery are both utilized in a hybrid battery pack configuration, OEM BMS continues to manage OEM battery.
    • Con Contactors are used to parallel the OEM and PHEV batteries.
    • DC A DC to DC converter is used to move power forward from the PHEV to the OEM Battery.
    • CV The CAN-View is used to manage the PHEV systems operation.</ref>
Comparison table: PHEV conversion and kit options for the Toyota Prius
Organization :Location Websites (Products)
Conv. service
<ref name=convert_service/>

Conv. kit
<ref name=convert_service/>

Status
<ref name=status/>

# done so far
EV range [mi]
<ref name=ev_range/>

PHEV range [mi]
<ref name=phev_range/>

AC power
Charge time [hours]
<ref name=charge_time/>

Safety
<ref name=safety/>

Added weight [kg]
Spare Tire
<ref name=spare_tire/>

Cost [US$]
Warr. [years]
Type
<ref name=topology_type/>
Pack energy [KWh]
DOD energy [KWh]
<ref name=energy/>

Bat type
PriusPlus:CA<ref>CalCars is based in California, however locations where progress is being made and help is available now include CA, CT, CO, IL, and TX.</ref> CalCars (Pb
NiMH)
No Yes Dev Doc 5
<ref>CalCars completed the 1st ever Prius PHEV conversion 11/04, With six by 5/07 (One which became the test bed for the PiPrius project, two of which uses NiMH, and the latest which retains the spare tire.)</ref>
10-12
20-25
20+
40+
100 to 240 Vac 4+
5
<ref name=charge_time/>
Flame Spill proof 130
100
Opt $3-$9K +Labor
<ref>CalCars Batteries: ~$1K ($3-$5K for NiMH) Charger: $0.9-$2K Total: $3-$4K + labor for PbA conversions and an additional $3 to $5K for NiMH</ref>
0 Hyb Con CV 4.8
6.5
2.4-3.8 +0.3 stock
5
PbA (Ni, Li)
<ref>CalCars uses 20 * BB Battery EVP20-12B SLA (Sealed Lead-Acid). Have used Electroenergy NiMH in EEEI Prius and Nilar NiMH in Nilar Prius, evaluating Lithium.</ref>
PiPrius:WA Manzanita Micro, PiPrius, AVI, Green Car Co. No Yes Unknown 4
<ref>PiPrius vehicles include PriusBlue, WhiteBird, and GrayPearl.</ref>
10 20-30 90 to 300 Vac Vdc 0.4-3+
<ref>PiPrius Charges in about 3 hours @ 120v & 15a or can be charged in as little as 0.4 hours (24 minutes) @ 240v & up to 40amps with manual current control from 0 to 40amps.</ref><ref name=charge_time/>
Flame Spill proof 150 no $10K +Labor
<ref>PiPrius Batteries: $0.8K~$1.2K Charger/DC-DC: $3K Target: ~$10K</ref>
0 Hyb DC CV <ref>PiPrius notes:
  1. The PiPrius PFC40H charger doubles at the DC-DC converter between the OEM and added battery packs.
  2. BMS consists of a Mk 3 Reg on every battery, which fully protected each battery on charge and discharge mode.
  3. The BMS is programmable with a laptop, with no security locks (open source).</ref>
4.7 4+0.3 stock PbA (Ni, Li)
<ref>PiPrius uses 15 * Hawker EP26 SLA (Sealed Lead-Acid), 24 * 20Ah SLA., Evaluating Lithium, or users choice of chemistry, voltage and capacity.</ref>
EnergyCS:CA EnergyCS Yes No Unknown 11 30 50 120 Vac 9.0 Flame Spill proof 83 no $40K 0 New 9
<ref>EnergyCS has 9kWh of battery capacity from a 230v 40Ah pack</ref>
8 Li
<ref>EnergyCS uses Valence Saphion phosphate cathode LiIon cells extracted from U-Charge packs</ref>
Amberjac:UK Amberjac EnergyCS partner <ref>Amberjac uses the EnergyCS system electronics but a different battery manufacturer.</ref> Yes No Dev 7 30 60-70 110 to 230 Vac 9.0 Flame Spill proof 83 yes $40K 0 New 9
<ref>Amberjac has 9kWh of battery capacity from a 230v 40Ah pack</ref>
8 Li
<ref>Amberjac works closely with EnergyCS but uses a different battery system and manufacturer though the same (LiFePO4) chemistry</ref>
EDrive:CA EDrive Systems ? ? Unknown 0 32? 60? 100 to 240 Vac 9.0 via cell sep
<ref>EDrive Through cell separation</ref>
? yes $12K 0 New 9.5 8.5? Li
<ref>EDrive uses Laptop Cobalt LiIon 18650 cells</ref>
Hymotion:ON Canada Hymotion /A123 (PHEV-L5) Yes, fleets No Prod 18 15
<ref>In the past, Hymotion has stated 50 km (30 miles) pure EV range. Yet 4.3 KWh calculates out to 15 miles. The specs on their new website say "Up to 100 mpg for 30-40 miles", which means blended mode, and is indeed consistent with the energy stored in the battery</ref>
30 100 to 240 Vac 5.5 / 4.0 Spill proof 72 no $10K
<ref>Hymotion $10K may or may not include installation, depending on source</ref>
3 Hyb 5.0 4+0.3 stock Li
<ref>Hymotion uses Lithium polymer (future: A123 LiIon)</ref>
Plug-In Conversions:CA Plug-In Conversions Yes Yes Prod 15 25 50 120/240 Vac 6/2 Flame Spill proof 100 no $12.5K<ref>Plug-In Conversions High capacity chargers extra</ref> 3 New CV 6.1 5.1 NiMH
<ref>Plug-In Conversions Uses Gold Peak NiMH 10GP30EVH</ref>
Plug-In Supply:CA Plug-In Supply Yes Yes Prod 140 40-50 80-100 110 Vac 8 Flame Spill proof 220 Yes $13K 3 Hyb 10 10.6 LiFePO4
OEMtek:CA OEMtek Yes No Unknown ? 30 50 100/240 Vac 4/6 Flameproof 95 Yes $12K 0 Hyb 9 8 Li
3Prong Power:CA 3Prong Power Yes No Prod 12 10-12 20+ 110 Vac 4 Flame Spill proof 130 Yes $6.7K 1 Hyb 4.8 2.4 PbA
Enginer:MI Enginer No Yes Prod 795 10-20 20-40 110 Vac 3-5 Flame Spill proof 75-90 Yes $2-3K 2 Hyb 2-4 1.6-3.2 LiFePO4
MD-Tech:China MD-Tech No Yes Prod 200 25-30 35-40 110/230 Vac 3-5 Flame Spill proof 75-90 Yes $3K 2 Hyb 4 1.6-3.2 LiFePO4


Notes: <references/>

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