Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on September 18, 2008.
As of Wednesday, September 18th, 2019 this Executive Order has not been overturned or superceeded.

Approved Parts

ModelsModificationRemarks
2004 through 2008 model-year Toyota 1.5 liter Prius hybrid-electric vehiclesThe conversion system includes a lithium ion add-on battery pack, a current sensor, battery temperature sensors, and a controller.This exemption is limited to sales of 500 L5 Battery Range Extender Modules conversion systems.

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-647
  • Executive Order 647 / D647
  • ARB # D-647
  • Executive Order No: D-647
  • C.A.R.B. No. D-647
  • Resolution D-647
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-647 PDF

D-647 Document:



                                       State of California
                                   AIR RESOURCES BOARD

                                   EXECUTIVE ORDER D—647

                                  Relating to Exemptions under
                               Section 27156 of the Vehicle Code

                                        A123Systems, Inc.
                           _ L5 Battery Range Extender Modules
                        Off—Vehicle Charge Capable Conversion System |

 Pursuant to the authority vested in the Air Resources Board by Section 27156 of the Vehicle
 Code; and

 Pursuant to the authority vested in the undersigned by Sections 39515 ahd 39516 of the
 Health and Safety Code and Executive Order G—02—003;                                 |

 T IS ORDERED AND RESOLVED: That installation of the L5 Battery Range Extender
 Modules (BREM) off—vehicle charge capable (OVCC) conversion system, manufactured by
 A123Systems, Inc. of 10 Avenue E, Hopkinton, Massachusetts 01748, has been found not
 to reduce the effectiveness of the applicable vehicle pollution control system, and therefore,
 the L5 BREM OVCC conversion system is exempt from the prohibitions in Section 27156 of
 the Vehicle Code for installation on 2004 through 2008 model—year Toyota Motor
 Corporation 1.5 liter Prius hybrid—electric vehicles.

 This exemption is based on evaluation of the L5 BREM OVCC conversion system under the
 "Procedures for Exemption of Add—On and Modified Parts" (Procedures), last amended
 June 1, 1990. Exemption of the L5 BREM OVCC conversion system under these
 Procedures is limited to sales of five hundred (500) L5 BREM OVCC conversion systems.

 The L5 BREM OVCC conversion system includes a lithium ion add—on battery pack, a
 current sensor, battery temperature sensors, and a controller.

  This Executive Order is based on emission testing A123Systems, Inc. conducted with the
  L5 BREM OVCC conversion system. The Air Resources Board reserves the right to
  conduct additional emission tests in the future. If such test results demonstrate that the L5
  BREM OVCC conversion system adversely affects emissions, this Executive Order shall be
  effectively rescinded as of the date the test results are validated. Further, if such test
  results or other evidence provides the Air Resources Board with reasons to suspect that the
  L5 BREM OVCC conversion system will affect the durability of the emission control system,
  A123Systems, Inc. shall be required to submit durability data to show that the durability of
  the vehicle emission control system is not, in fact, affected and/or that the add—on or
_ modified parts demonstrate adequate durability. _

 This Executive Order is valid provided that installation instructions for the L5 BREM OVCC
 conversion system do not recommend tuning the vehicles to specifications different from
 those of the vehicle manufacturer.

 Changes made to the design or operating conditions of the L5 BREM OVCC conversion
 system, as exempt by the Air Resources Board, which adversely affect the performance of
 the vehicle‘s emission control system, shall invalidate this Executive Order.


                                                   9.

   Marketing of the L5 BREM OVCC conversion system using identification other than that
   shown in this Executive Order or for an application other than that listed in this Executive
   Order shall be prohibited unless prior approval is obtained from the Air Resources Board.

  Exemption of the L5 BREM OVCC Conversion system shall not be construed as exemption
o to sell, offer for sale, or advertise any component of the system as an individual device.

   This Executive Order shall not apply to any L5 BREM OVCC conversion system advertised,
   offered for sale, sold with, or installed on a motor vehicle prior to or concurrent with transfer
   to an ultimate purchaser.

   This Executive Order does not constitute any opinion as to the effect the use of the L5
 _ BREM OVCC conversion system may have on any warranty either expressed or implied by
   the vehicle manufacturer.              ‘

   No claim of any kind, such as "Approved by the Air Resources Board," may be made with
   respect to the action taken herein in any advertising or other oral or written communication.

   In addition to the foregoing, the Air Resources Board reserves the right in the future to
   review this Executive Order and the exemption provided herein to assure that the exempted
   add—on or modified part continues to meet the standards and procedures of California Code
   of Regulations, Title 13, Section 2222, et seq.

   THIS EXECUTIVE ORDER DOES NOT CONSTITUTE A CERTIFICATION,
   ACCREDITATION, APPROVAL, OR ANY OTHER TYPE OF ENDORSEMENT BY THE
   AIR RESOURCES BOARD OF ANY CLAIMS OF THE APPLICANT CONCERNING
   ANTI—POLLUTION BENEFITS OR ANY ALLEGED BENEFITS OF A123SYSTEMS, INC.‘S
   L5 BATTERY RANGE EXTENDER MODULES OFF—VEHICLE CHARGE CAPABLE
   CONVERSION SYSTEM.

   Violation of any of the above conditions shall be grounds for revocation of this Executive
   Order. The Executive Order may be revoked only after a ten—day written notice of intention
   to revoke the Executive Order, in which period the holder of the Executive Order may
   request in writing a hearing to contest the proposed revocation. If a hearing is requested, it
   shall be held within ten days of receipt of the request, and the Executive Order may not be
   revoked until a determination is made after the hearing that grounds for revocation exist.

   Executed at El Monte, California, this      __/ g day of September 2008.



                                          t Annette Hebert, Chief
                                            Mobile Source Operations Division




              A’IZSSYSTEMS, INC. — L5 BATTERY RANGE EXTENDER MODULES
              OFF—VEHICLE CHARGE CAPABLE CONVERSION SYSTEM — D—647


                                                   EVALUATION SUMMARY

Manufacturer Name: A123Systems, Inc.

Name of Device: L5 Battery Range Extender Modules Off—Vehicle Charge Capable Conversion
System                                             |

Background:
      A123Systems, Inc. of 10 Avenue E, Hopkinton, Massachusetts 01748 has applied for
exemption of its L5 Battery Range Extender Modules (BREM) off—vehicle charge capable
(OVCC) conversion system from the prohibitions in Section 27156 of the California Vehicle
Code. The system is designed for 2004 through 2008 model—year Toyota Motor Corporation
1.5 liter Prius hybrid—electric vehicles (HEV). These vehicles are subject to the following
standards:                                                                    |
1.       LEV || SULEV Federal Test Procedure (FTP) exhaust emission standards
2        Supplemental Federal Test Procedure exhaust emission standards —
3.       Zero—fuel evaporative emission standards
4.        On—Board Diagnostic II System regulations

Recommendation:                                                                             |
          Grant exemption to A123Systems, Inc. as requested and issue Executive Order D—647.
This exemption is based on evaluation of the L5 BREM OVCC conversion system under the
"Procedures for Exemption of Add—On and Modified Parts" (Procedures), last amended June 1,
1990. Exemption of the L5 BREM OVCC conversion system under these Procedures is limited
to sales of five hundred (500) L5 BREM OVCC conversion systems.

Device Description:
        The L5 BREM is an OVCC conversion system that provides supplemental electrical
energy to the Prius via an add—on battery pack recharged from a standard 110 volt outlet. It
allows the Prius to derive the needed propulsive energy from electrical energy rather than from
the internal combustion engine (ICE) more of the time than the stock Prius. The LS battery is
connected in parallel to the Prius battery. The battery features are:

           Feature               _        M23Systems LS BREM            Toyota Prius
            Battery                             Lithium ion          Nickel—metal hydride
          Connection                              Paralliel                   ——
        Charge time (h)                        4.5 @ 110V                     ~—
         Weight (kg)                                 85                      45
     Energy capacity (kWh)                          4.7                      1.3
     Charge capacity (Ah)                           25                       6.5
      Nominal voltage (V)                185 @ 50% state of charge          201.6
        Cell voltage (V)                            3.3                      1.2
                                                    616                      168
        Number of cells                      (14 sub—modules,           (28 modules,
                             |             44 cells/sub—module)        6 cells/module}
         Charger (kKW)               |        1 on 110V outlet                ——

        The L5 battery is used in conjunction with a controller that communicates with the Prius
hybrid system controller and battery. The LS controller acts as a gateway for all data required
by the Prius hybrid system controller. The L5 controller reads the demand placed on the Prius
battery by the Prius hybrid system controller and determines how much electrical power to
supply to the electrical drivetrain from the L5 battery in substitution of electrical power from the


                                                                                       (Page 2 of 4)
Prius battery. The L5 battery provides power up to the L5 DC—DC converter limit of 10kW .
Under driving conditions where more than 10 kW is required (e.g. hard acceleration), power is
drawn from both L5 and Prius batteries. The L5 controller provides the appropriate signals to
the Prius hybrid system controller which then uses them per the original Prius algorithms which
are unaltered. A123Systems has presented that the algorithm or logic that determines whether
to use the battery, ICE, or a combination of the two remains Toyota‘s logic. The L5 controller
does place an "EV Mode" request to the Prius hybrid system controller which responds to the
request based on drive conditions, available electrical energy, and other parameters. _
A123Systems has presented that the algorithm or logic by which the Prius hybrid system             |
controller either honors or rejects the "EV Mode" request remainsToyota‘slogic. The same LS
controller calibration/code is used on all the Priuses in this application (production code number
PT491009—0010).
       Most of the electrical power from the L5 battery is used to drive the vehicle. Some
power is transferred to the Prius battery to prevent state of charge (SOC) drift (e.g. to keep the
Prius battery at the normal 60 percent SOC, power is transferred from the L5 battery rather than
from the ICE).                                                              |
       L5 operation is indicated with a light on the dash with the L5 battery status (e.g. SOC)
shown in the user information display. When the L5 battery is fully depleted, the indicator light
dims, and the information display shows the Prius battery status. A123Systems has presented
that with a fully depleted L5 battery, the vehicle returns to the original Toyota design. In the
case where the L5 battery safety or operating parameter limits are exceeded, the L5 battery is
taken out of operation. In this case, A123Systems has presented that the vehicle remains fully
operational and again returns to the original Toyota design, same as when the L5 battery is fully
depleted under normal operation. There is a manual on/off switch for the LS battery on the
dash. Once set to the "on" position, the system is fully automatic.                |
      A123Systems has stated that no modifications to Toyota‘s On—Board Diagnostics I|
System are made. A123Systems warrants the L5 BREM OVCC conversion system for
defective material or workmanship for 3 years from the date of installation. A123Systems has
stated that if Toyota denies its warranty due to a problem caused by the L5 BREM OVCC
conversion system, A123Systems will pay for the otherwise warranted repair.

Discussion/Basis for the Recommendation:                           ;
       This exemption is based on emission testing A123Systems performed with the L5 BREM
OVCC conversion system. Results are presented below:
Exhaust Emissions:
                                   CVS—75 FTP Emissions (grams/mile)           |
                             NMOG‘         cCO         NOx        HCHO
  CD® Test 1 (7/31/2008)     0.00591      0.0567      0.0065           —
  CD® Test 2 (8/6/2008)      0.01130      0.0503      0.0063           ——
        CD Average           0.00861      0.0535      0.0064           —
        CD with DF           0.01201      0.1335      0.0074               —
         CD Final             0.012        0.13        0.01            —
  CS* Test 1 (7/24/2008)     0.01147      0.0943      0.0049
   CS* Test 2 (8/7/2008)     0.01010      0.0740      0.0100           —
       _CS Average           0.0 1079     0.0842      0.0075           —~
        CS with DF           0.01419      0.1642      0.0085
         CS Final             0.014.       0.16        0.01
  150,000—Mile Toyota DFs    0.0034        0.08        0.001           na
  150,000—Mile Standards      0.010        1.0         0.02        0.004
 150,000—Mile Toyota Cert.    0.009        0.10        0.01            na


                                                                                                                    (Page 3 of 4)
Notes:
         Testing was conducted at Emissions Research and Measurement Division of Environment Canada in Ottawa
         Ontario, Canada.
         Test vehicle — test group 8TYXVO1.5HC3 (LEV II SULEV); evaporative family 8TYXROO3OA42 (zero—fuel);
         odometer reading 10,470 miles
         Test fuel — federal gasoline meeting specifications set forth in 40 CFR 86.113—04(a)(1) (Tier 2)
         NMOG/NMHC ratio of 1.04 was used to calculate NMOG.
         HCHO was not sampled. HCHO conversion ratio, deteriorationfactor, and Toyota certification level were not
         available.
         Charge depleting exhaust emission test consisted of a series of UDDS tests following a cold soak. The test
         began with a fully charged L5 battery and ended when charge sustaining operation was achieved for a pair of
         UDDS tests. Each UDDS test was separated by a 10—25 minute hot soak period. Emission canister was purged
         and loaded to 1.5 times its working capacity. Two charge depleting exhaust emission tests were conducted to
         check the repeatability of the measurements.
         Charge sustaining exhaust emission test consisted of a pair of UDDS tests following a cold soak. This test was
         conducted with the L5 battery disengaged. Each UDDS test was separated by a 10—25 minute hot soak period..
         Emission canister was loaded to 2—gram breakthrough.

        At the time of A123Systems‘ testing, test procedures were still being ‘developed for
OVCC HEVs. Existing test procedures for HEVs were modified to better assess the emission
characteristics of an OVCC converted Prius. A123Systems was required to perform duplicate
cold start charge depleting (CD) tests, each CD test consisting of a series of UDDS tests with
the L5 battery fully charged until charge sustaining (CS) operation is achieved for a pair of
UDDS tests. Duplicate CD tests were required to check the repeatability of the measurements.
After adjustment with Toyota‘s deterioration factors, the average CD CO and NOx emissions
were below the certification standards but the average CD NMOG emissions were above the
standard. A123Systems also presented results of two cold start CS tests. Each CS test
consisted of two UDDS tests with the L5 battery disengaged, where the vehicle is expected to
return to the stock Toyota mode. The average CS CO and NOx emissions also met the
standards while the average CS NMOG emissions were above the standard. All CS emissions
were at or above the CD emissions. For further evaluation, A123Systems presented THC data
from additional engineering tests performed on the same vehicle. They are shown below along
with the THC data from the tests presented above for comparison:                  |


                                                                      THC (g/mi)

                           UDDS 1           UDDS 2               UDDS 3             UDDS 4              UDDS 5              UDDS 6

                        Bag 1   Bag 2    Bag 1    Bag 2   Bag 1      Bag 2   Bag 1      Bag 2     Bag 1     Bag 2     Bag 1     Bag 2


            7/22/08"°   0.022    0.000   0.015    0.000     ——        ——       —         _—         —        _—         _        __

    cp      7/31/08‘°   0.014    0.000   0.011    0.000   0.013      0.001   0.016      0.000     0.000     0.000     0.000     0.000

             8/6/08°    0.040    0.003   0.013    0.000   0.015      0.000   0.011      0.000     0.000     0.000     0.000     0.000

            819108‘     0.024    0.000   0.000       —      —         ——       ——            _—     —        __

    cs      71241086    0.024    0.003   0.023    0.007     ——        ——       ——        ——         —        __

            erios® | o.0s1       0.000   0.000    0.000     —         a        _             o      .        l

Notes:
5         Emission canister was purged and loaded to 1.5 times its working capacity.
6        Emission canister was loaded to 2—gram breakthrough.
*        L5 battery was disengaged.

             The THC levels appearted to vary from test to test.


                                                                                                             (Page 4 of 4)

  Evaporative Emissions:

                8/19/2008                 Hot Soak      2—Day Diurnal          (g*:asm*/feDst)
            2—Day Diurnal Test              0.00             na‘        0.22       0.22
            Emissions with DF                ~——                   ——             0.241

                   Final                     ——                    ~—              0.24

         150,000— Mile ARB ADF®              ——                    ——             0.021
          150,000—Mile Standard      —|      ——                    ~—              0.35
         150,000—Mile Toyota Cert.           ——                    ~—              0.14

 Notes:                                                  |
e          Testing was conducted at Emissions Research and Measurement Division of Environment Canada in Ottawa
           Ontario, Canada. Test vehicle— test group 8TYXVO1.5HC3 (LEV JI SULEV); evaporative family 8BTYXROO30A42
           (zero—fuel); odometer reading 10,638 miles
 e         Test vehicle — test group 8TYXVO1.5HC3 (LEV II SULEV); evaporative family 8TYXROO030A¥42 (zero-fuel)
           odometer reading 10,470 miles
           Test fuel — federal gasoline meeting specifications set forth in 40 CFR 86.113——04(a)(1) (Tier 2)
           Environment Canada‘s system only reports the highest emissions and does not record the lower value.
CO . [




           Toyota‘s deterioration factor was not available. ARB assigned deterioration factor of 0.021 for LEV lIl—evap
           vehicles (not zero—fuel evap) was applied.

         To assess the impact on evaporative emissions, A123Systems performed a 2—day
 diurnal evaporative emission test. The L5 battery was fully charged for the test. Data showed
 that the evaporative emission level remained below the certification standard even with the
 reduced canister purge afforded from a fully charged L5 battery.
                Environment Canada reported no diagnostic trouble codes or malfunction indicator lights
 throughout testing. Based on the above and the limited installation allowed under this Executive
 Order, the L5 BREM OVCC conversion system is exempted. This evaluation does not address
 any claims of fuel economy benefits, electric driving range, or charge time.                |



Document Created: 2008-09-19 16:04:47
Document Modified: 2008-09-19 16:04:47

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