MD-Tech PHEV Operating manual

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 111. November. 2013
User and Installation Manual
MD-Tech
PHEV Conversion Kit Version 7 with
BMS Version 1.0

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 211. November. 2013
DECLARATION OF CONFORMITY
Table of Contents
1 For your safety ...............................................................................................................................4
1.1 Guarantee from Plug-in Autos................................................................................................5
2EU Declaration of Conformity......................................................................................................6
3 Overview of the conversion kit.......................................................................................................8
4 Installation......................................................................................................................................8
4.1 The kit contains the following parts .......................................................................................9
4.2 PHEV Box Wiring...................................................................................................................12
4.3 Connecting the PHEV Conversion Kit to your Prius...............................................................13
4.3.1 Required Tools for the installation ...............................................................................13
4.4 Remove Interior Trim from the rear compartment –Step 1 ................................................15
4.5 Remove Rear Floor Panels - Step 2.......................................................................................16
4.6 Remove Battery Covers - Step 3 ...........................................................................................17
4.7 Hybrid Vehicle Battery Wire connection ..............................................................................18
4.8 Install Communication cables...............................................................................................19
4.9 Install on/off switch panel. ...................................................................................................20
4.10 Switch connection to Vehicle HV ECU ..................................................................................21
4.11 Install the Bumper plug ........................................................................................................22
4.12 Mount the Kit Box ................................................................................................................23
4.13 Connect the Cables...............................................................................................................23
4.14 Install Charger's LED light .....................................................................................................23
4.15 Re-install Battery Service Plug ..............................................................................................24
4.16 Test the Kit Installation.........................................................................................................26
5 The BMS .......................................................................................................................................29
5.1 Basic Operation ....................................................................................................................29
5.1.1 Switch on the BMS........................................................................................................29
5.1.2 To switch off the BMS...................................................................................................29
5.2 The BMS Monitor .................................................................................................................29
Bottom: reset the touch screen. To reset the display update pushing data, see the
section. BMS Module Right side Buttons ....................................................................................29
5.3 The Battery System Monitor Module ...................................................................................30
5.3.1 BMS Module Left side Buttons - Balancing ...................................................................30

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
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5.3.2 BMS Module Right side Buttons ...................................................................................30
5.4 The BMS SD Card Data..........................................................................................................31
6 Operation .....................................................................................................................................32
6.1 Switch On .............................................................................................................................32
6.2 EV driving..............................................................................................................................32
6.3 PHEV Kit Battery empty ........................................................................................................33
6.4 Battery life............................................................................................................................34
7 Troubleshooting Installation ........................................................................................................34
8 Care and Maintenance .................................................................................................................36
9 Circuit Diagram.............................................................................................................................36

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 411. November. 2013
1For your safety
Read these simple guidelines. Not following them may be dangerous or illegal.
Read the complete user and installation guide for further information.
ROAD SAFETY COMES FIRST
Obey all local laws. Always keep your hands free to operate the
vehicle while driving. Your first consideration while driving should
be road safety.
QUALIFIED SERVICE
Only qualified personnel may install or repair this product.
Symbols Used in this Manual
Heavy object, should be handled by two persons or lifting gear.
Take care to follow advice in these steps .
High Voltage (HV) Direct Current (DC) 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. Electrical safety
gloves should be worn. Personnel who are not trained in HV safety
should be clear of the working area. To avoid electrical shock do not
open the kit box when the system is running, (especially children).
Please refer to the video on the installation CD for general fitting,
removal of panels and cable routing. Online videos are also
available at www.plughybrid.de
This is a patent pending technology.
Read this guide carefully before having the car kit professionally installed and using it.
Check www.plughybrid.de/support for the latest version of the user and installation guide, additional
information, and downloads related to your MD-Tech product.
This product may contain small parts. Keep them out of the reach of small children.
The car kit should only be installed by a qualified service technician using the original MD-Tech parts
supplied in the sales package.

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 511. November. 2013
1.1 Guarantee from Plug-in Autos.
The battery has a 3 year guarantee or 1500 deep cycles, whichever comes first, other parts have a two-
year limited parts guarantee.
A deep cycle is defined as discharge from a greater than 90% SOC to 0% SOC. Over the lifetime of the
battery (1500 cycles) it is accepted that there will be a reduction in battery capacity. The battery
guarantee is limited to a condition where there has been a failure of the battery where the battery fails to
hold a useable charge.
If equipment defect occurs under normal use, the faulty part with and purchase document must be
presented to Plug-in Autos, for replacement or repair.
Damaging the battery seals or deleting data from the SD card will void your battery guarantee.
Terms and Conditions apply:
Please download the terms and conditions at the time of purchase; they can be downloaded at
www.plughybrid.de
Failure to follow the Operation and Battery Management System procedures and instructions will void
your guarantee.
If you are going to leave the car for more than 10 days make sure the batteries are fully
charged and the BMS is switched off. See section 3, BMS.

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 611. November. 2013
2 EU Declaration of Conformity
According to UN Transport regulation 010 for a type of electrical/electronic sub-assembly with regard
to electromagnetic compatibility for vehicle use.
For the following equipment
Product: PHEV Kit
Type Description: PH04N2010C
Manufacturer’s Name: Shanghai Fountainhead Electronics Co., Ltd.
Manufacturer’s Address: No. 2028, Tingwei highway, Jinshan District, Shanghai City, 201508.
P.R.China
Is hereby confirmed to comply with the requirements set out in UN Transportation regulation 010 for
electrical/electronic sub-assembly and 2006/95/EC LVD.
The product is marked with an E Mark performed with the involvement of a Notified Body: TüV SÜD
Czech s.r.o.
Directive UN Transportation 010:
Person Responsible for making this declaration is the Authorised representative established within
the EU,
Name, Surname: Sushil Parab
Position: General Manager
Place: 64347 Griesheim Date: 15 April 2013 Signature:

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 711. November. 2013
Contact
Contacts
Shanghai Fountainhead Electronics Co., Ltd.
Address: No.2028.Tingwei Road, Jinshan District,
Shanghai, 201508,
http://www.21ftd.com
Tel:[phone]
Email: [e-mail]
[email protected]
European Distributor
UK:
Plug-in Autos Ltd.
Woodlands View
Heol Eglwys, Pen-y-fai,
Bridgend CF31 4LY
UK
Company Number 8735180
Germany:
Plug-in Autos UG (haftungsbeschänkt)
Friedrich Ebert Str 9
64347 Griesheim
Germany
Registered: Amtsgericht Darmstadt HRB 90838
Web: www.plughybrid.de
Tel [phone]
email: [email protected]

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 811. November. 2013
3Overview of the conversion kit
The PHEV kit adds a battery and a power management system to the vehicle
Hybrid to Plug-in Hybrid, PHEV Conversion
Overview of the Power Flow:
Charging: 220-240V AC (EU) household electricity → MD-Tech PHEV conversion kit
Driving:MD-Tech PHEV conversion kit →OEM stock traction battery →Prius electric
motor
The PHEV conversion kit supplies power to the Prius traction battery. This extra power increases the
distance that the car can travel using electric power.
4Installation
Prepare a flat area of at least a 7x7 feet on the ground near the end of your Prius, and cover
the floor with 5x5 feet of soft material or cardboard.
The equipment is heavy and should be moved and handled by at least two adults or lifting
gear.
Remove the kit from the packaging box.
4. Take out the kit parts place them in a suitable location away from your immediate working area:
Take out the foam plastic cover from the cardboard box and pull out the steel box, this requires at
least two people, carefully and steadily remove the entire steel box and place it gently on the floor.
Do not tilt or turn over the equipment.

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 911. November. 2013
5. The equipment weights about 165 lbs (74kgs). MD-Tech strongly suggests you use
professional lifting equipment. Slowly handle the equipment to avoid physical injury or
equipment damage.
6. After propping up the cover firmly, with no risk of dropping down, gently remove all the insulating
foam gently and check inside component and accessory bags against the following list:
4.1 The kit contains the following parts
Cable with three wires for the ECU signal wires (green, brown and white) see Kit figure 7 F
One dashboard panel on/off switch with red and green LED lights see Kit figure 7 H
6-pin phone wire (Converter to dash panel switch) see Kit figure 7 G
Converter high voltage orange cable bundle (red & black wires with bullet connectors for the
converter) see Kit figure 7 A
Charger power cable see Kit figure 7 E
2 sets of equipment mounting screws (size M8) see Kit figure 7 B
External power input bumper socket
One double-sized spanner
One Wire harness with four Anderson plugs for connecting the Batteries L and R, converter
and BMS see Kit figure 10.
Two black rubber blankets, longer one for left hand side see Kit figure 7 D.
Template 1:1 for marking the kit box mounting hole positions see Kit figure 9
Stainless steel box and cover (833 x 505.5 x 152mm), see Kit figure 1
Batteries: 2 packs (4kWh). Please make sure batteries match your order, see Kit figure 2
One 4000W converter, Connections: one red and one black power inlet cables attached to an
Anderson plug. A two pin wire and connector (fits to the BMS) see Kit figure 3
One charger mounted on right back connecting black power inlet cable, with left hand side
one red and one black wire with an Anderson plug. see Kit figure 6
Battery Management System is fixed on top of the charger (near right side).
One circuit breaker mounted to the side of the box.
One fire extinguisher is fixed at the middle of the box, on batteries. see Kit figure 12
M8 size Blind Rivet Nuts for mounting the kit to the car. see Kit figure 8
One Bluetooth OBDII scanner device. see Kit figure 14

MD-Tech Plug-in Hybrid Electric Vehicle Conversion Kit User Manual for 2009-2013 Prius
Version 1.0 ©2013 Plug-in Autos P a g e | 10 11. November. 2013
Kit figure 4-1. PHEV Steel Container Box
Kit figure 2. Pair of Battery packs
Kit figure 3. DC:DC Converter
Kit figure 4.Battery System Monitor
Kit figure 5. Battery Management System, BMS
Anderson plugs connect to Battery cable bundle and
the Charger
Kit Figure 6. Charger
Kit Figure 7. Cables and Screws