Bad BMS, Look ashamed!

I had my Daughter, Erin, verify the wiring on the BMS, and it was right. I packed it up, and sent it to Jack for replacement / repair. /sigh/.

E-mail to Jack

Jack,

I have my kit installed, but it doesn't seem to be working.

When I plug the unit in overnight, the BMS module shows a green light on the left connector, and a red light on the right.

When I plug in the BMS Monitor, every field reads 0 except TM 1 - TM4 which read as -40.

when I drive, the Green LED is on, and the Red LED is on for about 10 Min, then they go out.

What should I do next?

Thanks,

Mark Scanlon

Working ?

I think I connected the 12V lead this time, and its all connected together. I expected the battery status indicator to always be "full" for the first 10 - 20 miles, but I got a "battery low" red light after 6 miles.

I'll do a real charge and drive tomorrow. Here are the photos from the install.

interesting Observation

While the LED Lights aren't working on the Enginer panel switch, when I press the button to ON while driving, the Prius MFD display says " Cannot enter EV Mode at this Time". This tells me two of the three wires I connected under the dash must be connected properly.

My problem seems to be the connection to the 12V lead.

Day Two - Still not long enough!

After charging (I think) the batteries overnight, John and I installed the unit in the trunk, and began to test operation. John re-assembled the undercarriage covers, etc. so that I could drive the car if needed.

I was able to see the car operating normally with the new kit disconnected. Unfortunately, the lights from the new switch were not lighting. Something was wrong.

I verified as best I understood the wiring connecting to the car's ECU connector. Still no lights.

I connected to power output from the kit to the drive battery, and I got a error warning from the car's computer. I looked at the connectors to the drive battery, and compared them to the instructions. Molded on the Toyota terminal were little + and - symbols, exactly reverse of what the instructions indicated. So, I re- wired according to the instructions.

Trying again I still had no lights on the switch. I don't know what is wrong. My best guess is the wiring at the ECU isn't making a good connection, or the instructions were wrong / mis- understood by me.
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I have a trip to NYC, and won't be back to continue diagnosing until Friday at the earliest.

Sadness.

Day one - Long, but not long enough!

I began the actual conversion at 12:30 yesterday. The documentation, including the video, were weak. I was helped for part of the time by my friend, John Steigauf. His auto mechanical knowledge was most helpful!

By about 6:00, we were ready to put the unit into the trunk, and bolt it in. The dashboard cables were run, the power connectors to the drive battery connected. It was a good time to rest.

Install Fest Scheduled!

This coming Saturday, I'll get together a few friends and actually install the Enginer 4K system!

Look for lots of Pictures and videos after.

Its All Here!

The enclosure and the rest of the parts arrived. I'll schedule an Installation party in the next couple weeks. Until then, I'll be watching the installation video, and reading the updated (I hope) manual.

Yea! - Oh, that's different?

My batteries arrived yesterday! I joyously unpacked them, and discovered instead of 30 individual cells, I have two stainless steel sealed battery assemblies. Good news: simple installation, fewer chances for me to mess up the install. Bad news: I won't be able to diagnose and repair failed cells individually.

I'll e-mail Jack and ask for updated instructions, and when the rest arrives, schedule an installation party!

Finally, Shipping dates!

Here is what Jack said:

Mark,

Due to some production issue, the shipment is delayed. The cargo is heading LA right now. We expect ship date in the week of Oct 4th (battery) and Oct 11th (electronics).

Sorry for the delay.

Jack Chen
AutomationTech Inc
www.enginer.us

I guess I'll get the components in two shipments, and I must still wait.

Sadness

Still, "End of September" is the best information I have on the delivery of my Enginer kit.

Requested an update.

I sent Jack Chen at Enginer an e-mail, asking if he has a specific delivery date for my kit.

Sigh.

Mn EAA Meeting - Air Conditioning

I went to a Minnesota Electric Automobile Association monthly meeting last night. I got to see a Tesla Roadster, and a couple "brute Force" electric upgrade projects.

The speaker was discussing air conditioning basics, and how to adapt them for electric cars. I'm surprised to say, I was interested.

ReGo Visit

I stopped by the open house of ReGo, the local Prius upgrade company. I thought it was funny that they didn't want to disclose who's kit they were modifying, so outside they were not opening the cover on the enclosures, but the Enginer logo was visible on the dashboard switch, AND inside the shop area, they had units open, and the Enginer logo was everywhere! I was a little surprised Jack Chen wasn't invited.

I got a glimpse of their insulation methods (simple pink styro sheets), and got to meet the principals at the Company. I also ran into the President of the Mn. Electric Car Association, Jukka Kukkonen. Really sharp guy!

I hope ReGo is very successful as an enterprise!

BUMMER!

Jack Chen just advised me that "Due to shortage of battery, the shipment is postponed to end of September. Let me know if you have any questions. Sorry for the delay."

I am sad.

ReGo Open House

A local company is taking the Enginer 4K kit, adding some insulation and a few other accessories, and selling it installed for $5,000 with a 2 year warranty. They have an open house on the 19th, and I'm planning on stopping by.

Of course, I'll still install my own kit, and save half the cost!

A like- minded group

I attended a get together for the MN. Electric Auto Association Conversion Interest group. I had a chance to chat with guys and a gal who've been there, and done it!

Two cars that were "hoods up" were at the extreme end of the cost spectrum; a no holds barred $40k conversion of a classic Corvette, which exhibits the same drag racing performance characteristics as the original vehicle, and a SUV conversion where the owner took out the engine, etc. of a brand new vehicle!

There was a very practical conversion of a moderately costed VW, too!

I will have a lot of support and camaraderie from this group!

Plug In Kit Plan

I had two plans for building an electric car. The first was to buy some interesting and simple old car, such as a VW Thing, for as little as possible, and convert it to all electric. The second plan was to get a plug in kit for my Prius. My approach was to allow my "Toy Account" grow in value, and whichever I could afford first, I would do.

I looked at a Thing, and decided I didn't want one. I was watching VW Cabriolets, and the costs for EV conversions. Still, higher than my savings.

Plug in kits for Priuses started around $12K, then $8K, then 6K.

Finally, I came across a company called Enginer. They had a kit for about $2,500, which I had in savings. By the way, they had a 2K kit for less than $2,000 as well.

I drove to Milwaukee to see a Enginer upgraded Prius, and meet with the founder of Enginer, Jack Chen. After talking though all my questions and concerns, I gave Jack a deposit for a kit for my car.

To see what I bought, check out the Enginer.us website:

http://www.enginer.us/products/conversion_kit.php

Now, I need to wait for the kit to arrive, expected some time towards the end of August.

In the meantime, I joined the Minnesota Electric Auto Association, and look forward to attending their August meeting, conveniently held in Bloomington!

http://www.mneaa.com/

Prior Hacks

The first hack, absolutely necessary, was to disable the annoying "truck back up beep" played loudly when the car is moving backwards. It can't be heard outside the car, where it might do some good. Nope, it just frightens the passengers. Instructions I followed can be found here:

http://priuschat.com/forums/knowledge-base-articles-discussion/12677-list-hacks-easter-eggs.html

Second, I installed a Coastal E Tech EV Mode kit. The EV Mode is a Toyota factory capability around the world. It allows you to drive your Prius at low speeds for relatively short distances without using the ICE (Internal Combustion Engine. I really haven't used it much, but it gave me practice working in the dashboard area of my car. Info on that kit can be found at:

http://www.coastaletech.com/electric_only_mode.htm

Introduction

I proudly own a 2008 Toyota Prius, fulfilling my green desires. I have made a couple minor tweaks, but I'm about to make it a Plug In Hybrid Vehicle, using a 4 KV kit from Enginer.us (no typo).

I will post pictures, and descriptions as I go.