Specifications, Features, and Warranty

Plug In Conversion System Specifications

For Prius Gen 2, Prius Gen 3 (2004 and newer) and Lexus CT200h

Product 4 KW 7 KW 10 KWp
Usable Capacity 3.9 kWh 7.3 kWh 9.72 kWh
Range Per Charge 20 mi
(32 km)
37 mi
(47 km)
50 mi
(81 km)
Charge Time
@ 120V (@ 240V)
2.6 hours
(1.6 hours)
5.0 hours
(3.0 hours)
10.0 hours
(5.0 hours)
J1772 Capable Yes Yes Yes
Number of Modules 4 4 4
Weight of Module 29 lb
(13 kg)
48.5 lb
(22 kg)
72 lb
(37 kg)
Weight of Battery 116 lb
(52 kg)
194 lb
(88 kg)
289 lb
(131 kg)
Size of Module 30 x 6.25 x 3.5 in
762 x 159 x 89 mm
31.5 x 7.5 x 4 in
800 x 191 x 102 mm
35 x 8 x 5 in
889 x 203 x 127 mm
Cell Type Headway
8 Ah cylindrical
152 Cells
Headway
15 Ah cylindrical
152 Cells
Headway
40 Ah prismatic
Battery Chemistry LiFePO4 LiFePO4 LiFePO4

For Prius Plug-in (2012 and newer)

Product 3.3 KW 6.2 KW
Usable Capacity 3.3 kWh 6.2 kWh
Range Per Charge 15 mi
(24 km)
30 mi
(48 km)
Charge Time
@ 120V (@ 240V)
2 hours
(1 hour)
6.5 hours
(3.2 hours)
J1772 Capable Yes Yes
CHAdeMO Capable Yes Yes
Number of Modules 4 4
Weight of Module 24 lb
(11 kg)
48 lb
(22 kg)
Weight of Battery 95 lb
(43 kg)
190 lb
(86 kg)
Size of Module 24 x 6.25 x 3.5 in
610 x 159 x 89 mm
24 x 6.25 x 7 in
610 x 159 x 178 mm
Cell Type 8 Ah cylindrical 8 Ah cylindrical
Battery Chemistry LiFePO4 LiFePO4

For Prius C, Auris, Yaris (2012 and newer)

Product 3.3 KW 6.2 KW
Usable Capacity 3.3 kWh 6.2 kWh
Range Per Charge 19 mi
(31 km)
36 mi
(58 km)
Charge Time
@ 120V (@ 240V)
3 hours
(1.5 hours)
6 hours
(3 hours)
J1772 Capable Yes Yes
CHAdeMO Capable Yes Yes
Number of Modules 4 4
Weight of Module 24 lb
(11 kg)
48 lb
(22 kg)
Weight of Battery 95 lb
(43 kg)
190 lb
(86 kg)
Size of Module 24 x 6.25 x 3.5 in
610 x 159 x 89 mm
24 x 6.25 x 7 in
610 x 159 x 178 mm
Cell Type 8 Ah cylindrical 8 Ah cylindrical
Battery Chemistry LiFePO4 LiFePO4

No Range Anxiety!

When the add-on lithium battery pack in your Plug-In Supply plug-in hybrid conversion is empty your car reverts to being a normal hybrid vehicle. You will not be stranded by an empty battery. This feature is standard on all Plug-In Supply plug-in hybrid conversion systems.

100% Efficient

Plug-In Supply uses high power contactors to connect the add-on battery pack to the factory battery pack. This results in 100% efficient energy transfer to the car. Other designs use inefficient and unreliable DC to DC converters that turn the electricity into waste heat instead of increasing mileage.

Fail Safe Design

Our controller monitors the contactors for failure. If a failure occurs, the system is turned off and the car becomes a normal Prius. With this system the add-on battery pack and the factory battery pack cannot be overcharged.

Modular Design

Our plug-in hybrid conversion system is a modular design. This allows individual components to be upgraded and repaired quickly. The battery box, software, controls, and charger are separate components that are designed to work together. Customers can choose from several manufacturers of lithium iron phosphate cells and different sizes of chargers.

Easier Installation

No more engine hoist! You no longer need an engine hoist to install our 10 KW plug-in hybrid conversion system in a Prius.

Capacity

We name our lithium battery packs after the usable energy they deliver per discharge cycle. We call our large Prius pack "10 KW" because it delivers 10 kW-hr of usable energy from each charge cycle. Leaving some energy in the pack after a complete discharge is good for the pack and ensures a long service life. The amount of energy left is described as Depth of Discharge. Plug-In Supply systems are designed for 80% to 90% Depth of Discharge. The actual capacity of the 10 KW pack is 11 to 12 kW-hr depending on which cells are in the pack. The service life of a Plug-In Supply lithium iron phosphate battery pack is many thousands of cycles.

The current generation of hybrid cars have large gas engines and small battery packs. Think of it as the gas engine being the primary drive while the electric motor is the secondary drive. We believe that, over time, this will reverse. Traction batteries will grow more and more powerful while the gas engine will shrink in size, until finally, it disappears altogether.

You can drive the future today. Plug-In Supply plug-in hybrid conversion systems add a large battery pack to your hybrid car and our software makes the electric motor the primary drive and the gas engine the secondary drive.

Do It Yourself (DIY)

Now you can safely assemble your own high-power battery packs using our advanced components and designs. Our modular design lends itself to many applications from electric cars to stand-by power packs for off-grid use.

Cells

Customers can specify which lithium cells are used to build their plug-in conversion battery pack. We use lithium iron phosphate (LiFePO4) cells from CALB, GBS, Headway, Thundersky, and Winston. All have excellent quality and long service life. Price may vary depending on availability.

Discharge Power

Our 10 KW plug-in hybrid conversion system injects up to 200 amps into the Prius electric drive system. During normal operation it typically injects 100 to 135 amps continuously. Compare this to the 14 amps a Hymotion or Enginer system injects into the Prius. Plug-In Supply delivers ten times the power of Hymotion and Enginer. This allows our plug-in conversion system to keep the car in EV mode for extended periods of time.

Battery Management System (BMS)

A battery management system (BMS) is an essential part of a lithium iron phosphate (LiFePO4) battery pack. Without one the cells will eventually destroy themselves. We use our own Plug-In Supply designed BMS.

Software

Plug-In Supply customers receive free software upgrades.

EV Mode

Plug-In Supply developed a pure EV mode for the Gen 2 Prius. From our first lead-acid systems onwards we gave customers the ability to drive in pure EV mode faster than 34 MPH.

Automatic EVTM: When the system is on the car operates in EV mode, automatically, whenever possible. When you need more power — to climb a hill or pass a car — the gas engine comes on to provide that power. When the need for more power is gone, the gas engine turns off. When it's not needed the gas engine is in hot stand-by mode. This means the gas engine is off but warm and available to provide power instantly without high emissions due to a cold engine start.

Max RegenTM

Max RegenTM stands for maximum regenerative energy capture. This means electricity produced by the vehicle during braking is fed back into the add-on lithium battery pack where it's saved for future use. This can increase your range by 10%. Competitors like Hymotion and Enginer use a DC to DC converter that cannot capture regen.

Charging

With our modular design customers can choose from several different battery chargers. Some offer faster charging of the add-on lithium iron phosphate battery pack.

High Quality

Our products are made using the highest quality components that are rated for Industrial Service (I-temp). Established sub-contractors make our sub-assemblies and wire harnesses. Final assembly and test is done by Plug-In Supply.

Made in America

Whenever possible we use parts made in the USA and American-based suppliers. Final assembly and test is done in America by Plug-In Supply. You get what you pay for. The best.


Plug-In Conversion System Warranty

Plug-In Supply provides a 3 year warranty on parts made by Plug-In Supply, a 2 year warranty on the lithium iron phosphate (LiFePO4) cells from the cell manufacturer, and a 1 year warranty on the charger from the charger manufacturer. This warranty does not cover the cost of labor to make repairs. If you do the conversion yourself, when your DIY plug-in hybrid conversion is complete you will have the same 3 year warranty that the factory-built systems have.