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Making a difference -
where it matters
V3.0 - 2018.10.15
www.elintamotors.com
OWNER‘S MANUAL
IVECO DAILY PHEV-80/120
2018
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TABLE OF CONTENTS ......................................... 2
STARTING THE VEHICLE ..................................... 2
EV MODE DRIVING ............................................ 2
SWITCHING TO HYBRID MODE .......................... 2
HYBRID MODE DRIVING .................................... 2
HYBRID MODE POWER ...... Error! Bookmark not
defined.
CRUISE CONTROL .............................................. 2
ECO MODE ........................................................ 2
EV DRIVING RANGE ........................................... 2
IMPROVE DRIVING RANGE ................................ 2
LiFePo4 BATTERY LIFE ........................................ 2
PRECAUTIONS ON HIGH VOLTAGE .................... 2
SAFETY DISCONNECTOR .................................... 2
CHARGING WARNINGS ..................................... 2
CHARGING ......................................................... 2
METERS AND GAUGES ....................................... 2
FLEET MANAGEMENT ........................................ 2
SAFETY ............................................................... 2
SERVICE INFORMATION ..................................... 2
CLIMATE CONTROL ............................................ 2
POWER LIMITATION .......................................... 2
MAINTENANCE .................................................. 2
WARRANTY ........................................................ 2
HCU STATUS VALUES ......................................... 2
FUSE BOX ........................................................... 2
Terminalo st. 3 Biruliskiu km.
LT-54469, Lithuania
www.elintamotors.com
TABLE OF CONTENTS
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ev@elinta.lt
+370 37 351 987
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1. Check if gear is in neutral position
2. Depress the brake pedal
3. Turn ignition key to MAR-1 position
4. Check that the green speed limiter light on the
dashboard [2] to start driving in EV mode.
NOTE:
While in EV mode – speed will be limited to 70-80 km/h
depending on a vehicle type.
NOTE:
Do not turn the ignition key to AW-2 it will start the
diesel engine and vehicle will be running on hybrid mode.
When starting the vehicle for the first time – PHEV
monitor will load up within 10 seconds. Further startups
within 3-5 hours will be instant.
STARTING THE VEHICLE
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Forward on EV mode
1. Check if gear is in neutral position
2. Release the parking brake
3. Depress the accelerator to start driving forward
Reverse on EV mode
1. Stop fully and hold brake pedal depressed
2. Push “REVERSE GEAR” button on the HCU dashboard
3. Check that “REVERSE GEAR” lights up in red,
“Reverse Gear” message is on the LCD and sound is
audible
4. Start driving in reverse by depressing accelerator
5. To switch back to forward – repeat steps 1 and 2
6. Check that R light is OFF and no message is displayed
7. Depress the accelerator to start driving forward
NOTE:
It is important to stop fully when switching from forward
to reverse and back. If vehicle is still rolling, driving
direction might not be changed.
NOTE:
While driving on EV mode – gears and clutch is not used
at all. Unless switching to hybrid mode is required.
Turning off the vehicle
1. Fully stop the vehicle
2. Hold brake pedal depressed
3. Switch key to STOP-0 position
4. Pull the handbrake
NOTE:
Using handbrake is necessary. Electric motor does not
provide braking while vehicle is off.
EV MODE DRIVING
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There are 2 ways to switch to hybrid mode:
1. Depressing the clutch will start the engine and the
vehicle will switch to hybrid mode
2. Pushing HEV, SAVE, or CHG mode buttons will swicth
vehicle to selected hybrid mode.
Swithcing to hybrid mode can be done while standing still
or while driving. If the vehicle is moving - after switching
to hybrid mode use the correct gear to continue driving.
The gear switch number [1] will appear on the dashboard
after switched to hybird mode while driving. Also autostart icon [2] will be shown while starter runs.
Different hybrid modes provide different output power,
acceleration and fuel economy. This chart shows the level
of electric power assistance to the diesel engine.
POWER MODE – Driving in power mode will slowly
deplete the battery while driving - giving maximum power
and efficiency. Fuel consumption in power mode will be
reduced by 30% - 35%.
Power mode is available from 100% to 20% SOC.
SWITCHING TO HYBRID MODE
HYBRID MODE DRIVING
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SAVE MODE – Driving in SAVE mode, the battery capacity
will be maintained. Fuel consumption will be reduced by
15% - 20%.
SAVE mode is available from 95% to 10% SOC.
CHARGE MODE – Driving in charge mode will charge
battery. The electric motor assistance will not be
activated.
CHG mode may increase fuel consumption by 0.4 - 0.7 l /
100 km due to additional load on the diesel engine.
Charge mode is available below 90% SOC.
To switch back to EV mode:
1. Drive slower than 65 km/h (in some vehicle models
switching to EV mode only works while standing still).
2. Switch to neutral gear
3. Push EV mode button
4. Check if EV mode light is on and diesel engine shuts
down.
NOTE:
SOC – Battery State Of Charge
To turn on the cruise control – use standard cruise control
handle. Cruise control is only available in hybrid modes.
While driving on cruise control – vehicle will be using
diesel engine and saving electric power.
CRUISE CONTROL
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- The ECO mode helps reduce energy and fuel
consumption by reducing acceleration when compared to
the same accelerator pedal position.
– The ECO mode reduces the power of diesel engine.
– The ECO mode increases electric motor assist level.
To switch on ECO mode - push „E“ button on a dashboard.
Yellow indication LED should light up and message on
dashboard unit „ECO mode ON“ should appear.
ECO switch in EV mode should be used in traffic jams or
low speed driving. Acceleration will be smoother and
energy will be saved.
Vehicle range depends on a number of factors.
- Speed – Most efficient speed is up to 70 km/h.
- Cargo load – Do not overload the vehicle to maintan
EV range.
- Tyres – Tyre pressure must be checked frequently.
Winter tyres with higher rolling resistance will
decrease driving range up tp 20 %. For best results use
A or B efficiecy class tyres.
- Weather conditions – Heavy rain or snow will decrease
driving range compared to dry roads.
- Temperature – Make sure to keep vehicle plugged in
at low temperatures to keep battery system heated.
- Location topography – Driving in hilly areas will depete
the battery faster. It is recommended to use hybrid
modes driving long or steep hills.
ECO MODE
EV DRIVING RANGE
IND
LED
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- Use ECO mode (if vehicle is equipped) to reduce
power.
- Accelerate slowly and smoothly.
- Use SAVE mode to maintan SOC while on hybrid mode.
- Use free rolling when possible.
- Brake gently and use regeneration
- Observe power meter [1] Indicates regeneration; [2]
indicates power.
Driving range dependency of vehicle load (20 kWh)
IMPROOVE RANGE IN HYBRID MODES
- When driving in HEV mode – battery will deplete and
pure EV range will be reduced. If EV range will be
needed – use SAVE mode.
- If more EV range will be needed – use CHG mode.
- When in hybrid mode – do not brake with gear. Try
braking in neutral gear as much as possible.
- Use SAVE mode to maintan SOC while on hybrid mode.
- Avoid frequent stopping and braking. Maintain a safe
distance.
IMPROVE DRIVING RANGE
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The battery’s ability to hold a charge, like all batteries,
decreases with battery age and usage which results in
decreased vehicle range when compared to the vehicle
range when the vehicle was new.
This is normal and expected, and does not indicate a
malfunction of the vehicle or battery.
The battery’s ability to hold a charge can be affected by
how you drive the vehicle, store the vehicle, how you
charge the battery and battery temperature during vehicle
operation and charging.
- Avoid storing a vehicle in temperatures below -25°C
for over 7 days.
- Allow the battery charge to be below at least 80%
before charging.
- Do not leave the vehicle discharged with less than 30%
SOC for over 14 days.
- If the vehicle is not to be used for an extended period
of time (1 moth or more), charge the lithium battery
fully, disconnect service plug and 12V battery.
- If vehcile is stored for even longer period. Disconnect
the service plug and 12V battery.
- Failure to observe these requirements will void the
battery warranty.
Please read warranty policy for more information about
battery and other systems warranty conditions.
Elinta Motors ESS 20.3
LiFePo4 BATTERY LIFE
SAFETY
DISCONNECTOR
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Vehicle is equipped with high voltage system components.
All components and wires powered by high voltage are
marked orange color or special warning stickers.
Failure in observing these instructions may result in
electric shock, personal injury or death.
Locate safety disconnector on the back of left side of the
battery system.
It may be hard to access it without the vehicle lifter.
Make sure the vehicle is dry and no water or foreign
materials will reach the safety disconnector when its
pulled out.
To unplug safety disconnector:
Safety disconnector has 500A fuse inside the plug. In case
of any failure – check the fuse using multimeter.
PRECAUTIONS ON HIGH VOLTAGE
SAFETY DISCONNECTOR
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PRECAUTIONS ON CHARGING
NOTE:
Failure to observe these requirements will void the
warranty.
CHARGING WARNINGS
• Make sure there is no water or foreign materials in
the charge port, charge connector or electrical plug,
and that they are not damaged or affected by rust
or corrosion. If any of these conditions are
noticeable, do not charge the battery. This may
result in a short circuit or electric shock and could
cause a fire which may result in serious personal
injury or death.
• Do not touch the metal contacts of the charge port,
charge connector or electrical plug.
• Do not touch the vehicle and charger when there is
lightning. A lightning strike may back feed into the
charger causing damage and possible personal
injury or death.
• Make sure the charge connector is removed from
the charge port before starting your vehicle. If the
charge connector is only partially engaged and the
connector latch is unlocked, it is possible to start
the vehicle.
• Do not plug in or unplug the plug with wet hands
and do not stand in water, liquid or snow. This may
cause an electric shock which may result in serious
personal injury or death.
• Do not disassemble or modify the charge port or
the EVSE (Electric Vehicle Supply Equipment). This
may cause a fire.
• If you notice an unusual odor or smoke coming
from the vehicle, stop charging immediately.
• Be careful not to allow your hands, hair, jewelry or
clothing to come into contact with, or get caught in,
the traction motor cooling fan. The cooling fan can
start at any time during charging.
• Make sure the cap is closed on the charge port
when charging is finished. If the charge port cap is
open, water or foreign materials may enter the
charge port and cause short circuit.
• Do not attempt to perform a jump start on the 12-
volt battery at the same time that the Li-ion battery
is being charged. Doing so may damage the vehicle
or charging equipment.
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STARTING CHARGE
1. Make sure the vehicle has power off.
2. Twist-open the charging port.
3. Plug in the cable to the vehicle – a green light on
the vehicle charging socket will turn on.
4. After the charging point communicates and
connects – a red light will start blinking fast.
5. After charging starts - the red light will blink
according to state of charge:
0-30% SOC: ___*
30-70% SOC: ___* *
70%-100% SOC: ___* * *
After charging is finished – the green light will be turned
on and vehicle will disconnect from the charging point.
If charging is not finished after 4-5 hours – battery heater
might be running or 12V battery is low and being charged.
Charge vehicle even after driving in hybrid modes batteries will be dis-balanced, so full charging is very
important.
Charge vehicle only using IEC-62196 Mode 3, Type2 EV
compliant equipment.
NOTE:
- If electrical power is interrupted while charging,
charging restarts automatically when the electrical
power is restored.
- If the charge port is frozen, melt the ice using a hair
dryer. After the ice has melted, charge the Li-ion
battery. Forcing the charge connector to connect may
cause a malfunction.
- When the ambient temperature is 0°C or less, charging
time may be longer than normal and the level to which
the lithium battery can be charged may be less than at
higher temperatures.
CHARGING
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1. Electric motor driving power.
2. Electric motor regeneration power.
3. Regenerated range, 2 km scale (Max 10 km). And
kilometers driven in EV since last charge.
4. Power of hybrid assist depending on driving
mode and SOC.
5. Average energy efficiency.
6. Range and battery capacity.
7. Diesel engine power and average fuel
consumption.
8. Percentage of many kilometers were driven in
EV mode since last charge.
9. Drive/Reverse selector (EV mode only)
10. EV mode button.
11. Power Mode button (Available is SOC > 20%)
12. Save Mode button
13. Charge Mode button (Available is SOC < 30%)
When driving on EV mode – original vehicle dashboard
shows electric drive system information.
1. Speed limiter indication light shows speed is limited to
70-80 km/h.
2. If any error occurs on EV driveline – the master
warning light will turn on.
3. Speed is displayed as usual
METERS AND GAUGES - 1
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Efficiency screen should be used in EV mode. It indicates
average and actual energy consumption for maximum
driving efficiency.
1. Average efficiency of last 10 min drive.
2. Battery state of charge.
3. Current efficiency.
4. Estimated EV range (depends on efficiency).
Charging screen appears automatically for 3 minutes after
cable was plugged.
1. Charger output power.
2. Charging cable type.
3. Time until full charge.
4. Charger output voltage.
5. Charger output current.
6. Battery state of charge.
METERS AND GAUGES - 2
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Vehicle Settings Screen
1. Regeneration switch off. Can be used when
driving on icy roads.
2. Power Mode – Disables diesel engine power
limiter. Should be used for towing > 750kg
3. Dim screen brightness when headlights are on.
4. Green Zone on/off
5. Start stop system switch (starts and stops diesel
engine automatically depending on a green
zone).
6. Switch to Save mode using clutch.
Climate settings screen.
Climate settings screen is used on vehicles equipped with
high voltage electric climate control.
1. Auxiliary power being used at the moment in
kW.
2. Settings for A/C power in kW
3. Settings for Heating power in kW
4. Battery state of charge.
METERS AND GAUGES - 3
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The fleet management system provides vehicle tracking,
operation reports, service warnings and other functions.
The integrated fleet management system allows to simply
draw any geographical zone (green zone) where the
vehicle shall operate in pure electric mode only.
When entering into such a zone, the vehicle warns the
driver and automatically switches off the diesel engine.
Fleet management software and user manual can be
downloaded from: www.elintamotors.com/iPHEV
The software is designed to work with Windows 7;
Windows 8 OS.
The vehicle is equipped with additional electric power
steering pump unit and electric brakes vacuum pump
while running on EV mode.
All safety features ABS, VSC, ASR are available in both EV
and hybrid modes.
To switch off ASR use original ASR off button.
Regeneration will be reduced or cut-off if slip is noticed on
the rear wheels.
No other equipment, such as seat belts, airbags etc., are
effected by the iPHEV system.
NOTE:
- Hill holder system is not available on EV mode,
because the clutch pedal is not in use.
FLEET MANAGEMENT
SAFETY
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While is settings screen – hold Elinta Motors logo for 2 sec.
Pop-up window will appear asking to switch to service
mode.
1st and 2nd sceeens indicate battery, drive, charge and
hybrid system parameters.
3rd diagnostics screen indicated inputs and outputs of the
PHEV drive system
4th screen indicated DTC log.
SERVICE INFORMATION
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HEATING
Vehicle is equipped with independent heater. The control
panel is located on the left side of the steering wheel [1].
Use independent heater while driving on EV mode.
When using the clock controls, remember that when the
symbols are flashing fast you are in adjustment mode. If
no button is pressed for five seconds the displayed time is
saved. If buttons (8) or (3) are pressed for longer than two
seconds, fast back/forward mode is on.
Activation
Manual: by operating the immediate heating button [6].
The display will show the duration and the symbol for the
heating mode [9].
The duration stops being displayed after 10 seconds.
Automatic: at the time of activation of programmed
heating or ventilation.
Disengagement
Manual: by operating the immediate heating button [6].
Automatic: At the end of the programmed duration, the
display will turn off.
CLIMATE CONTROL
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COOLING
Vehicles equipped with climate control unit has installed
electric A/C unit. To save the battery capacity A/C will only
work if interior temperature is higher than pre-set
temperature on [1] turning knob.
A/C will only work if fan speed knob [4] is set to at least II
speed.
A/C can turn on automatically if high temperature is
detected. To turn off A/C - use power button [3] to
disengage the climate control.
After switching to EV mode – climate control will
automatically switch to battery saving mode. To re-enable
the climate control – adjust the fan speed [4].
Vehicle without climate control – use [5[ A/C button to
engage/disengage cooling. Make sure [1] temperature
turning knob is set to low position.
Do not use A/C together with heating.
Using A/C can reduce pure EV range by 20% or reduce fuel
efficiency by 3-5%.
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POWER LIMITATION WHILE DRIVING
Vehicle can limit motor power due to different factors
- Vehicle was not plugged in and battery temperature
dropped below -10 C. Vehicle will automatically switch
to hybdrid mode and heat batteries.
- State of charge is lower than 10%
- If state of charge drops to 0% - vehicle will start the
engine and drive on charge mode.
- Motor, battery or motor controller temperatures are
too high.
- Battery voltage is too low.
- Vehicle stability control was activated due to wheel
slip (temporary power reduction).
POWER LIMITATION WHILE BRAKING
- Regeneration is turned off from 100% to 95% SOC.
- From 95% to 85% regeneration increases gradually.
- Regenration can be cut off if stability control is
activated and wheel slip is detected.
POWER LIMITATION WHILE CHARGING
Charging power can be limited due to different factors
- Selected lower power charging cable than 16A
- Battery temperature is high
- Battery temperature is too low
- Charger temperature is too high
HYBRID SYSTEM LIMITATION
In case of critical system failure – iPHEV drive system can
be disengaged.
To manually disengage the system:
- Enter SAVE mode
- Hold SAVE mode button for 5 sec
- Message “iPHEV system disengaged” should be seen.
POWER LIMITATION
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Vehicle should be serviced every 30.000 km or at least
once per year.
Regularly check power steering fluid and coolant levels.
For service please contact your local service provider:
Warranty of 2 years, or less than 100.000 km is provided
on following components:
• EDS-90 motor controller
• LCM-160-6 induction motor
• ESS-15-3 battery module
• HCU-3.0 Hybrid control unit
• Hybrid LCD unit
• FM Blue GSM tracker
• Charging socket
• Charging cable
• Cooling system components
• Vacuum brake pump
• Electro-Hydraulic steering pump
• Low voltage wiring
Vehicle warranty is valid provided no mechanical damage
and no unautorized modifications is done to any of these
components.
In case of mechanical damage i.e. cooling system failure
can damage other components due to overheating.
MAINTENANCE
WARRANTY
COMPANY CONTACT INFORMATION
HERE
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General status
0
System off
249
EV mode – accelerator fully depressed
250
EV mode
251
HEV mode
252
SAVE mode
253
CHG mode
EDS-150 faults
60
Current sensor failure
61
Over current fault
62
Phase U Fault
63
Phase V Fault
64
Phase W Fault
65
Master Inverter Fault
66
Encoder Error
67
DC Over-voltage
68
DC Under-voltage, pre-charge failure
69
DC Link error
70
DC Link disconnected
75
12V power supply too low (<10,5V)
79
Unexpected emergency shut-down
Temperature
71
MCU board temperature error (>125 C)
72
IGBT temperature error (>85 C)
73
Motor temperature error (>150 C)
74
IGBT temperature sensor failure
130
IGBT Temperature warning (>70 C)
131
Motor power limited (>75 C)
132
IGBT Temperature critical (>75 C)
133
Motor temperature critical (>85 C)
134
IGBT over-heat lock (> 80 C)
135
Motor over-heat lock (> 90 C)
136
Low battery temperature (< -15 C)
137
Low EDS temperature (< -25 C)
HCU STATUS VALUES
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Battery system
150
Low voltage warning
151
Critically low voltage. Power disconnected!
152
Critically high voltage. Power
disconnected!
153
Battery over-current warning >400A
154
Battery over-current. Power diconnected
155
Battery temperture warning
156
Batteries overheat. Power disconnected!
157
Too low temperature (< -25 C)
158
Lost cell commnunication. ESS Fatal Error
159
Leakege current detected
160
No CAN communication with BMS
HCU Faults
50
Engine starter failure
51
Cooling system failure
52
LCD CAN-bus communication error
53
Engine shut-down failed
54
DC-DC failure
55
Main contactor failure
56
Vacuum pump failure
57
EHPS module failure
58
CAN-bus steering angle sensor error
Base vehicle and diesel engine
80
Check glow plugs
81
Water in oil filter
82
Low oil level
83
Excess radiator temperature
84
ESP Failure
85
ASR Failure
86
EBD Failure
87
ABS Failure
88
Check brake pads
89
Low brake fluid
90
Check engine
91
CAN-C/CAN-B communication error
25
Charging status and faults
200
Pre-charge stage
201
Main Charging stage
202
Balancing stage
210
Charging Error
211
Cable not recognized
212
Charging point or cable failure
213
Charger failure
220
Charging finished OK
Fuses:
F1 - Motor controller and reverse gear relay – 10 A
F2 - Vacuum pump – 20 A
F3 – Cooling Fan – 15 A
F4 – Cooling pump – 7.5 A
F5 – Engine Start / Stop – 30 A
F6 – Main Power for HCU – 10 A
Relays:
RL1 – Motor controller enable
RL2 – Vacuum pump relay
RL3 – Reverse gear relay
RL4 – Engine start relay
RL5 – Engine stop relay
FUSE BOX
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