EMP’s Mini-HybridTM Thermal System for Transit Bus Market

Go Green & Save Money with EMP’s MiniHybrid system

Marcus Jackson West Coast Regional Sales/Service Manager

Established 1981 Current Employment ~400 Precision Machining Facility, Escanaba, MI Robotic Assembly Facility, Greenfield, IN Engineering, Validation, Assembly Facility, Escanaba, MI (Mini-Hybrid Production) TS and Six Sigma certified

Current OEM Customers:

Caterpillar, International, Sauer Danfoss, John Deere, Cummins, DDC/Freightliner, Volvo/Mack, Paccar, Eaton, Newflyer, Gillig, NABI, Orion, El Dorado

Major Markets: Defense, On Highway, Off Road, Hybrid Vehicles, Transit

Key Awards: 2001 Michigan Manufacturer of the Year, 2005 R&D Excellence in Business Award The EMP Mini-Hybrid received the prestigious 2008 "Clean Air Excellence" Award from United States Environmental Protection Agency.

Company Overview

Mini-HybridTM

The Mini-HybridTM is an electric cooling system kit that replaces the standard hydraulic cooling system on transit buses.

Converting to an electric cooling system: • Increases fuel economy • Lowers emissions • Lowers maintenance costs • Increases horsepower • Reduces the risk of hydraulic fires

Over 3,000 Units in Field across North America

• Over 3,000 MINI-HYBRIDTM Electric Cooling Systems in Service. • Serving 70+ Municipal Transits in North America every day. • MH kits on 18 of top 20 transit properties. • Shipping 60+ MINI-HYBRIDTM Thermal Systems week.

Base Kit of the Mini-Hybrid

Fil-11 Electric Fans

Optimized Radiator and CAC

Components included in Mini-Hybrid Base Kit: • (8, 9, or 10) EMP Fil-11 24 Volt Pusher Fans • (1) EMP TMC Master Controller • (1) Aluminum Radiator • (1) Aluminum Charge Air Cooler • (1) Powder coated Steel Frame & Fan Shroud • Jacket Water & Charge Air Temperature Sensors • Wiring Harness • Installation mountings and hardware • P450 Air cooled 450 amp alternator • Power Steering Pump-optional • All metal piping to engine-optional • Downloadable Service Tool • Made in America

TMC Fan Controllers

P-450 Alternator

• Brazed aluminum bar/plate construction on both radiator and CAC is much stronger than conventional tube fin copper/brass heat exchangers

• Cross-flow configuration • Welded tanks eliminate

tank to header leaks • Pressure cycle test

– 200 PSI for 15,000 cycles

Heat Exchangers

Bar & Plate Design

Features the competition doesn’t offer

Integrated Controlled Fans

• Fully controllable or single speed • Locked Rotor Protection

• Sealed & Fully Submersible

• 12 or 24 Volt Models

• Brushless, Sensorless Motor

• Programmable Reversal

• Temperature Switch Input

• Closed Loop Temperature Control

• Pusher or Puller Configurations

• Integrated Controller

• Motor and Controller Diagnostics

• Finger Guard Option Available

• E-Mark Certified

Features:

Features the competition doesn’t offer

Power 450amp Air Cooled Alternator

• EMP’s air cooled, brushless Power 450 comes standard with the min-Hybrid cooling system

• Designed to last: filter-less air cleaning system, oversized bearing design, highest efficient alternator on the market

• Drop in replacement • Keeps your batteries fully

charged at idle and extends life

Brushless Alternator Comparison

150

200

250

300

350

400

450

500

550

1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500

Alternator, RPM

Cur

rent

, Am

ps

Power 450

Competitor A

Competitor B

Competitor C

• Most transit buses operated at idle and low speeds

– Power 450 provides Best in Class amperage output in these speed ranges

EMP Components: Testing & Validation

– HALT/FMVT Highly Accelerated Life Testing

Failure Mode Verification Testing – Thermal Fatigue – Thermal Shock – High Pressure Wash – Fluids Compatibility – Salt Spray – Dust – Submersion – Humidity – Vibration – Operational Shock – Transit Drop – Handling Drop – Cycling – EMI/EMF – Durability

In transit applications fans operate at max speed less than

2% of the time

Fans are tested at Max-Speed/ Max-Hi Temp

Competitors have not been

able to pass vibration testing

How it works 4/6 Fan Control

Speed of Top 2 Fans Controlled by CAC or Intake Manifold Temp

Speed of Bottom 4 Fans Controlled by Jacket Water Temp Baffle Locations

2

1 3

4

5

6

7

8

CAC

Radiator

Speed of Shared 2 Fans Controlled by Highest Speed Command (CAC or JW Temp)

• Fans Consume Energy Only if Needed • Variable Speed Fans Run At Low Speed

Coolant Fan Speed Control - Cummins ISB/C/L/X -

Coolant Temperature

Max

Coo

lant

Tem

p

Eng

Dia

gnos

tic T

emp

107 113 91 102 82 93

Goal: Keep engine as warm as possible Constraints:

1. Fans on after thermostat opening 2. Fans full on below engine max 3. Avoid diagnostic fault codes

5000

2500 Curbside

5500

8 fans 6 fans

EM

P C

ritic

al T

emp 99

AE

B M

ax F

an T

emp

EM

P Fa

n O

n Te

mp

2875

750

1813

3938

180 196 199 210 225 235 216 °C °F

CAC Fan Speed Control - Cummins ISB/C/L/X -

CAC Temperature (DegC)

45 69

5000

2500 Curbside

5500

8 fans 4 fans

EM

P C

ritic

al T

emp

65

AE

B M

ax F

an T

emp

EM

P Fa

n O

n Te

mp

2875

750

1813

3938

°C °F 113 156 149

Cummins ISL 280G, , El Paso, TX Summer Fan Operation

0.0%

23.7

% 27.0

%

23.0

%

15.7

%

6.2%

4.4%

0.0%

140

0 3 14

36

80

204

160

0%

5%

10%

15%

20%

25%

30%

Revers

e Off75

018

1228

7539

3850

0055

00

Fan Operating Speed

Perc

ent o

f Ope

ratio

n

0

50

100

150

200

250

Curre

nt C

onsu

mpt

ion

@ 2

8VDC

(A

mps

)

Fan Operation Summer Cooling System Current

Fans Rarely Operate At Maximum Capability

Fan Performance - Program History Data -

Fan Operation Percent of Time at Fan Speeds

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 1000 2000 3000 4000 5000

RPM

0

20

40

60

80

100

120

140

160

180

Mesa 8-months WMATA - 9 months MARTA - 12 months TriMet - 14 months Amps

System Architecture

Temps

LED & Reverse

Transmission Engine Vehicle J1939

Service Adaptor

J1939

Temps

PWMs EMP-Link™ 2

Transmission Engine Vehicle J1939

Service Adaptor

J1939

EMP-Link™1

Telematics Telematics

LED & Reverse

Original Mini-Hybrid Generation II Mini-Hybrid

Features & Options

Included Features • Curbside Noise Abatement

– 2500 RPM Limit When Vehicle Stopped

– < OSHA 6 hour exposure level

– Will Exit If Necessary to Protect Engine

• Fan Reversal – Pushbutton or Automatic

• Fail Safe (4000 RPM) • Fault Tolerance - Fan

Redundancy • LED Blinks Fault Codes • Clever Devices (Telematics) • ZF Transmission Fan Request • Electrical Load Reduction (AC

Shutdown)

Available Options • Temperature Regulation Set points • Temperature Regulation Source

– EMP Sensors - or - Engine Sensors via. J1939

• Minimum Fan Speed – Engine Compartment Air

Circulation • Fan Reverse Duration • Fire Suppression via. Wakeup Signal • J1939 Addresses • J1939 Diagnostic (DM1) Message

Features the competition doesn’t offer

EMPower Connect™

• Downloadable service tool • Main Features

– Full Diagnostic Readout – Virtual Dashboard – View Calibration – Calibration File Upload

• Other Features – Reflash – Data Plot – Data Logging – Histograms – Download of Controller Data

• Customer Viewable File • Engineering File

• Multi-Level Security • No cost and no license fees • Competition does not offer service tool

Kit Layout & Component Locations

Fault Code Lookup

Fan Speed Readout

Coolant Temp

CAC Temp

Fault Code List

Fuel Savings

Average Fuel Economy ImprovementWith EMP Mini-Hybrid System

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

Winter Summer

7

7%

3%

Fuel Savings

Mini-Hybrid provides more fuel savings throughout the engine rpm range. Typical fuel economy ranges from 3% to 10% based on duty cycle, climate, and engine type.

Model Annual Mileage

Fuel Economy

10% Fuel Savings

Gallons $

New Flyer 10 million 3.27 mpg 305,810 $611,621

Neoplan 2.5 million 3.07 mpg 81,433 $162,866

Total

12.5

million

N/A

387,244

$744,487

Preliminary MTA evaluation of EMP miniHybrid system

demonstrates fuel economy improvement of 7-10%

Fuel Economy Results

MBTA (Boston)Average 10% Improvement

0

0.5

1

1.5

2

2.5

3

3.5

4

Dec-07 Jan-08 Feb-08 Mar-08 Apr-08 May-08

Jun-08 Jul-08 Aug-08 Sep-08

MP

G

EMP Fleet

WMATA (Washington DC)Average 6% Improvement

0

0.5

1

1.5

2

2.5

3

Aug-07

Sep-07

Oct-07

Nov-07

Dec-07

Jan-08

Feb-08

Mar-08

Apr-08

May-08

Jun-08

Jul-08

Aug-08

Sep-08

MP

G

EMP Fleet

g

0

0.5

1

1.5

2

2.5

3

3.5

Oct-07

Nov-07

Dec-07

Jan-08

Feb-08

Mar-08

Apr-08

May-08

Jun-08

Jul-08 Aug-08

Sep-08

MPG

EMP Fleet

Boston 10% D.C. WAMATA 6%

Seattle 4% Oahu 10% Tri-Met 4%

Omni-Trans 7%

Power to Wheels - MARTA Study -

Net Engine Power Relative to Adverised Power CurveShop Air supplied to Bus, No Steering Input, AC Off, Interior Lights Off

0

50

100

150

200

250

300

600 800 1000 1200 1400 1600 1800 2000 2200

Engine Speed (rpm)

Flyw

heel

Hor

sepo

wer

Advertised PowerBase Fan OffBase Fan EngagedEMP 1800EMP 5000

Torque Improvement

Mini-Hybrid reduces thermal events by eliminating the hydraulic fan system and reduces maintenance costs

Safety, Maintenance, Diagnostics

MTA spends an average of $1 million annually on parts and labor to repair hydraulic, radiator, and alternator related failures – $2,740 for each New Flyer – $4,040 for each Neoplan – Total Savings: $1 million

Annual Savings

Before EMP After EMP

Any Questions

For more information please contact: Marcus Jackson

EMP (928) 710-4089

Marcus.Jackson@emp-corp.com