PHEV System Controls and Operation

Notice: The content on this page applies to our previous system design. On the current design, EV Mode is automatic. This page will be updated soon.

Modes of Operation

The Plug-In Supply PHEV conversion has three modes of operation:

  1. Standard Mode
  2. Blended Mode (Enhanced Mode)
  3. Manual EVTM (MEV) Mode
1. Standard Mode

Standard Mode means the car functions the same as an un-modified Prius car. The Owner's Manual describes how to operate the car in Standard Mode.

2. Blended Mode (Enhanced Mode)

Blended Mode (Enhanced Mode) is what we call the mode that can deliver over 100 miles per gallon (MPG).

Blended Mode uses the Toyota Electric Vehicle Mode (TEV Mode) found on Prius cars sold outside of North America and enhances it by adding an auxiliary battery pack and additional software. Our Blended Mode minimizes the use of the gas engine and maximizes the use of the electric drive.

You may also hear this mode called "Try EV Mode." In this mode the gas engine continues to operate from time to time whenever the car's computer determines it is needed.

Cars that come from Toyota equipped with the TEV Mode have an on-off push button switch to the left of the steering wheel labeled "EV."

Other companies also sell products to provide TEV Mode. Our TEV Mode will continue to work if a second manual TEV switch is installed in the car.

TEV Mode is meant to be used when stuck in traffic jams and other situations where slow, start and stop progress is desired without the gas engine running. This reduces vehicle emissions.

Our Blended Mode improves on TEV Mode by providing more power for the electric drive.

Limitations of Blended Mode
Blended Mode operation will be reduced or denied under these conditions:

  • When the car speed exceeds 34 MPH (55 KPH)
  • Pressing too hard on the accelerator pedal
  • Climbing a steep hill
  • Too cold outside, typically 50° F (10° C)
  • When prohibited by the Toyota computer. This can appear to be random.
3. Manual EVTM (MEV) Mode

Manual EVTM Mode is a completely electric mode of operation. In MEV Mode the gas engine will not operate. Only the electric drive is used to propel the car.

Our PHEV controller can be programmed to allow Blended Mode or MEV Mode or both modes of operation.

System Controls and Selecting the Mode of Operation

The PHEV system is controlled by two switches:

  • PHEV on-off power switch
  • EV switch

The PHEV on-off switch is a two position rocker switch that is lighted when "on."

The EV switch is a push button switch that turns off the gas engine.

These switches are used to turn the PHEV system on and off and to select the mode of operation.

Note: If you are concerned about the safety of the PHEV system or you do not want to use the PHEV system, turn the PHEV power switch "off."

The PHEV power switch is in the "off" position when the red LED in the switch is not lighted. The switch is in the "on" position when the red LED is illuminated.

1. Selecting Standard Mode

The car is in Standard Mode when the PHEV power switch is "off" and the EV switch has not been pressed.

To enter Standard Mode:

  • Turn the PHEV power switch off. Do not press the EV switch.
2. Selecting Blended Mode

Blended Mode is "on" when the PHEV power switch is "on" and the EV switch has not been pressed.

To enter Blended Mode:

  • Turn the PHEV power switch on

To leave Blended Mode:

  • Turn the PHEV power switch off
    or
  • Press the EV switch to enter EV Mode
3. Selecting Manual EVTM Mode

MEV Mode is "on" whenever the EV Switch is pushed.

To enter MEV Mode:

  1. Turn "on" the PHEV power switch.
  2. Turn "on" the car by pressing the car's "Power" switch. Wait for the car's green "Ready" light to illuminate on the dash then
  3. Press the EV Switch. When pressing the EV Switch, give it a solid, deliberate push. Do not do a partial depression of the switch.

The PHEV power switch must be "on" when the EV Switch is pressed.

If the PHEV power switch is "off" when the EV Switch is pressed warning lights will appear on the dash display. The car will drive with the warning lights illuminated and MEV Mode is still entered. To erase these warning lights turn "on" the PHEV power switch and re-press the EV Switch.

You can enter MEV Mode (press the EV Switch) when the car is stopped or in motion. Caution! The car speed must be less than 53 MPH (84 KPH) when entering MEV Mode. You will damage the car if you enter MEV Mode at high speed.

To leave MEV Mode:

  1. Stop the car. When safe to do so, bring the car to a complete stop. Consider your immediate surroundings and traffic conditions. Keep your foot on the brake pedal after the car has stopped.
  2. Put the car in Park. Push the park button on the dash. Keep your foot on the brake pedal.
  3. Turn the car off. Push the power button on the dash to turn the car off. Keep your foot on the brake pedal.
  4. Turn the car on. Push the power button on the dash to turn the car on. Keep your foot on the brake pedal. The car will restart in Standard Mode and typically the gas engine will start.
  5. Place the car in drive. You can now continue driving. You are in Standard Mode when you leave MEV Mode.

Low Power Warning Buzzer
When in MEV Mode, a buzzer will sound when the car has about 1 mile of electricity left. Stop driving the car in MEV Mode when you hear the buzzer.

CAUTION! Stop using MEV Mode as soon possible when you hear the buzzer. When the electricity is all gone the car will stop moving. You have less than 1 mile (1.6 km) to find a safe place to stop your car and leave MEV Mode. Don't panic or rush when leaving MEV Mode. It takes about 5 seconds to perform the 5 steps listed above to leave MEV Mode. Practice the procedure in quiet surroundings before doing it in traffic.

Multi-Function Display and Battery State of Charge

The multi-function display (MFD) provides an indication of how much electricity remains in your battery pack. The amount of electricity in the pack is called State Of Charge (SOC).

Normally the MFD will show the battery SOC fluctuating between green bars (full) and blue bars (half full). This fluctuation reflects the auxiliary battery pack charging up the Toyota NiMH battery pack.

You will know the auxiliary pack is running out of electricity when the MFD stops showing green bars and the number of blue bars slowly decreases.

With a gas powered car you re-fill your gas tank before you run out of gas. The same concept applies to an electric car. You should not run the battery pack all the way down to zero. Stop using the PHEV system when you are on the last blue bar. Switch the PHEV power switch off then charge the battery pack as soon as possible. This will help the battery pack last a long time.

In Blended Mode the PHEV system will stop discharging when the SOC reaches 40%. The system will still absorb regenerative power after it has reached this point.

In MEV Mode it is possible to drive the car until the pack is completely exhausted. Do not do this.

Driving Tips

  1. Use your charge when it best suits your drive.
    You can use your electricity when you want to by turning the PHEV power switch on and off as needed. For example, you can save the charge for city streets to minimize pollution in densely populated areas.
  2. Go slow.
    Driving slow uses less power than driving fast. You will go further on a charge when driving slow.
  3. Coasting.
    Ride the brake slightly when coasting to produce more regen electricity.

Charging

To charge the car, use a 3 wire, 14 gauge extension cord, up to 50 feet (15 meters) long. A 3 wire, 12 gauge extension cord is better than 14 gauge for long lengths. Never use a 16 gauge extension cord to charge the car.

Don't coil the extension cord when charging. It will over heat and the plastic jacket will melt.

Use an in-line GFI circuit breaker with the extension cord. Put the GFI at the end that plugs into the house.

Keep the PHEV power switch on (red LED lighted) when charging.

Do not charge the car with the windows closed when it is parked in the sun. Move it into the shade or roll down the windows slightly. The battery charger may over-heat and turn off.

Keep the area around the charger clear when it is charging. It gives off heat and needs to cool itself. If it gets too hot it will shut-off.

The PHEV system will sound a warning buzzer if you start the car when it is plugged into house power. To stop this buzzer, unplug the extension cord at the car.

Don't leave the car plugged in for extended periods of time. Once it is charged unplug it.

Don't leave the car with a discharged lead-acid battery pack. Charge it soon.

It is OK to leave or store a car with a lithium battery pack discharged.

Do recharge the pack every time the PHEV system is used, so it is ready to go next time.

Charger Operation

We supply three different brands of charger with your system. They are all automatic. No adjustments are needed.

One brand of charger displays output voltage and output current. Typically 4A max and 288VDC.

The car is fully charged when the charger display indicates .25 amps or less.

Normal charge time is 6 hours or less.

Accessing the spare tire

Follow this procedure when changing a flat tire.

To access the spare tire remove the 4 finger screws holding the PHEV battery pack down. There are two finger screws on each side of the pack. After the finger screws have been removed grasp the right and left corners of the pack near the gas spring attachment points and lift upwards. The pack will rise slowly, being assisted by the gas springs. Check to ensure no wires are being pinched behind the pack while it is rising. When the pack reaches an angle of 50 degrees it is fully open. The PHEV pack will stay in the fully up position and in the fully down position. If it does not stay up or tends to sink, lift it again to a point a little more open than before.

When you have finished changing the flat tire make sure you lower the PHEV pack and replace the finger screws holding the PHEV pack in the down position. Be careful you do not cross thread the finger screws when replacing them.

Caution! It is dangerous to drive the car without the finger screws in place. Without finger screws the PHEV pack could come loose in a collision and cause injury or death.