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ProlongPro® Battery System User Manual

Table of Contents

Safety Warnings and Usage Precautions
Battery Reconditioning Process Overview
  Preventative Maintenance Reconditioning Process Detail
  ‘Failed’ Battery Repair & Reconditioning Process Detail

ProlongPro Charger
  System Setup
    Use of system requires at least one Prolong Car Harness
  Sufficient cooling of hybrid battery
    Sufficient AC power (110V 15A or better Dedicated Circuit recommended)
    Sufficient System ventilation
  User Interface (Navigation)
    A/C power cord
    Power Switch
    Voltage Meter
    Current Meter
    LCD Display
    System Idle LED
    Charging LED
    Next Button
    Enter Button
    Back/Stop Button
  User Interface (LCD Display)
    Power On Home Screen
    Select Make
    Select Model
    Select Charge Mode
    Select Cell Balancing Time
    BATTERY COOLING WARNING
    Confirmation Screen
    Aborting Charge
  Warnings & Errors (Charger)
    Warning: High current (bulk charge) capacity limit reached (C1)
    Warning: Taper current (absorption charge) capacity limit reached (C2)
    Warning: Low current (balance charge) capacity limit reached (C3)
    Error: Polarity Reversed or No Battery Connected (E1)
    Error: Inadequate Voltage Increase Detected (E2)
    Error: Battery Voltage Decrease Detected (E3)
    Error: Battery Voltage Decrease Detected (E4)
    Error: Unexpected Current Increase - 3A (E5)
    Error: Unexpected Current Increase - 0.5A (E6)
    Error: Charger Over Temperature (E7)

ProlongPro Discharger
  System Setup
    Use of system requires at least one Prolong Car Harness
  Sufficient cooling of hybrid battery
    Sufficient AC power (110V 5A or better)
    Sufficient ventilation
  User Interface (Navigation)
    A/C power cord
    Module Testing Harness
    Power Switch
    Voltage Meter
    Current Meter
    LCD Display
    System Idle LED
    Discharging LED
    Next Button
    Enter Button
    Back/Stop Button
  User Interface (LCD Display)
    Power On Home Screen
    Select Mode
      Pack Discharging
      Select Make
      Select Model
      Select Discharge Termination Voltage
      Confirmation Screen
      Aborting Discharge
      System Cooldown
    Module Testing
      Module Test Selection
      Internal Resistance (IR)/Load Test
      Capacity Test
    Errors (Discharger)
      Error: Module Test Overvolt
      Error: Module Test Undervolt
      Error: Unexpected Current Increase (E2)
      Error: Battery Not Detected (E3)
      Error: Pack Over Voltage (E4)
      Error: Discharger Over Temperature (L1) (R2)

Technical Specifications
    ProlongPro Charger
    ProlongPro Discharger

 


 

Safety Precautions

THIS EQUIPMENT IS FOR QUALIFIED PROFESSIONALS ONLY.  DO NOT USE THIS PRODUCT WITHOUT PROPER KNOWLEDGE, TRAINING, AND SAFETY SKILLS.  IMPROPER USE CAN RESULT IN DAMAGE TO THE EQUIPMENT, DAMAGE TO THE BATTERY, OR INJURY TO YOUR PERSON. HYBRID AUTOMOTIVE LLC WILL NOT BE HELD LIABLE FOR DAMAGES RESULTING FROM IMPROPER USAGE OR FAILURE TO FOLLOW OPERATING INSTRUCTIONS. 

High Voltage can kill you.  High Voltage DC is especially dangerous.  Do not attempt to work on hybrid vehicle batteries unless you are properly trained and qualified.

Do not use if you are unsure of how to safely disassemble, repair, and reassemble high voltage battery pack assemblies.

Do not use without proper battery cooling systems.  Improper, insufficient, or excessive battery cooling voids all warranties.  Hybrid Automotive LLC will not be held liable for damages resulting from improper usage or failure to properly cool the hybrid battery and/or ProlongPro systems.

Wear proper safety equipment, including high voltage gloves and eye protection at all times.

Do not attempt to operate the system on less than the minimum AC power required for the ProlongPro Charger.

Use at your own risk.  Hybrid Automotive LLC will not be held liable for improper use resulting from inadequate user training, installation, connection, or insufficient safety precautions. Return to top

Battery Reconditioning Process Overview

NiMh Hybrid electric vehicle battery reconditioning consists of two primary elements: (1) charging/cell balancing the battery pack and (2) deep discharging the battery pack to progressively lower voltage levels.  Battery reconditioning is combining the charging/cell balancing process and deep discharging process multiple times to recondition the battery.  This combined process will break down voltage depression (memory effect) within the battery cells and equalize the cell voltage levels with each other.  The ending result is a battery with more usable capacity (for a period of time) that the vehicle to take advantage ofReturn to top

Preventative Maintenance Reconditioning Process Detail

Note: While not required, we recommend disconnecting the 12V AUX battery to ensure it is not accidentally discharged by interior lights while performing the reconditioning process.

1) Install the Prolong Car Harness onto the battery pack, being sure to properly connect it to the hybrid battery cooling fan.  Refer here for car harness installation instructions.

2) Charge the battery using the 'Charge & balance' setting.  Select a Cell Balancing Time of at least '1 hour'.

3) Discharge the battery to at least 0.8V per cell average.  For example, on a Prius battery pack that has 168 cells, the Discharge Termination Voltage selected would be 168*0.8=134 Volts.  (Refer to this table for pack level voltage termination points.)

4) Charge the battery using the 'Charge & balance' setting.  Select a Cell Balancing Time of at least '1 hour'.

5) Discharge the battery to at least 0.5V per cell average.  For example, on a Prius battery pack that has 168 cells, the Discharge Termination Voltage selected would be 168*0.5=84 Volts.

6) Charge the battery using the 'Charge & balance' setting.  Select a Cell Balancing Time of at least '1 hour'.

7) Discharge the battery to at least 0.3V per cell average.  For example, on a Prius battery pack that has 168 cells, the Discharge Termination Voltage selected would be 168*0.3=50 Volts.

8) Charge the battery using the 'Charge & balance' setting.  Select a Cell Balancing Time of at least '4 hours'.

9) Disconnect the charger and allow the battery to rest for at least one hour before attempting to start the vehicle.

The above process constitutes one battery reconditioning treatment. Return to top

‘Failed’ Battery Repair & Reconditioning Process Detail

1) Remove the battery pack from the vehicle.  The car harness installation instructions located here can be used as a guide for hybrid battery removal.

2) Remove the battery pack buss bars to isolate each module/stick for testing.

3) Using the ProlongPro Battery Discharger module testing process, identify failed modules and remove them from the battery pack.

4) Replace failed modules with good tested quality replacement modules.  We offer quality tested used modules with a 12 month warranty.  Contact us for more information.

5) Reassemble the battery pack and install it into the vehicle along with a Prolong Car Harness, being sure to properly connect it to the hybrid battery cooling fan.  Refer here for car harness installation instructions.

Note: While not required, we recommend disconnecting the 12V AUX battery to ensure it is not accidentally discharged by interior lights while performing the reconditioning process.

6) Charge the battery using the 'Charge & balance' setting.  Select a Cell Balancing Time of at least '1 hour'.

7) Discharge the battery to at least 0.8V per cell average.  For example, on a Prius battery pack that has 168 cells, the Discharge Termination Voltage selected would be 168*0.8=134 Volts.  (Refer to this table for pack level voltage termination points.)

8) Charge the battery using the 'Charge & balance' setting.  Select a Cell Balancing Time of at least '1 hour'.

9) Discharge the battery to at least 0.5V per cell average.  For example, on a Prius battery pack that has 168 cells, the Discharge Termination Voltage selected would be 168*0.5=84 Volts.

10) Charge the battery using the 'Charge & balance' setting.  Select a Cell Balancing Time of at least '1 hour'.

11) Discharge the battery to at least 0.3V per cell average.  For example, on a Prius battery pack that has 168 cells, the Discharge Termination Voltage selected would be 168*0.3=50 Volts.

12) Charge the battery using the 'Charge & balance' setting.  Select a Cell Balancing Time of at least '4 hours'.

13) Disconnect the charger and allow the battery to rest for at least one hour before attempting to start the vehicle.

Return to top

ProlongPro Charger

ProlongPro Battery Charger 
- Will charge (vehicle empty [40% SOC] to vehicle full [80% SOC]) a NiMh hybrid batteries pack in 1-3 hours 
- Works with all common NiMh battery sizes up to 250 cells 
- User selectable charge/balance mode vs. charge only (PHEV) modes.
- User programmable cell balancing time 
- Compatible with all Prolong Car Harnesses 
- Audible alert when finished (can be disabled by user)
- Reverse polarity protection to prevent system damage from incorrect battery connection 
- Thermal protection to prevent against excess heat damage

Return to top

System Setup

System must be placed on a solid flat surface with proper ventilation.  Before powering unit on, connect to Prolong Car Harness and plug the system into a sufficient AC power source. Return to top

Use of system requires at least one Prolong Car Harness

The ProlongPro Battery Charger is designed to connect to the battery pack being charged via a Prolong Car Harness.  At least one Prolong Car Harness for the desired battery type/size to be charged is required to use this product. Return to top

Sufficient cooling of hybrid battery

The hybrid battery will generate heat during the charging and cell balancing process.  Maintaining active ventilation of the battery using the factory designed airflow duct work passages is critical for proper battery cooling.  Airflow MUST pass between the modules along the cell walls for proper cooling.  Blowing a fan across the top of the battery is NOT sufficient.  Insufficient or excessive airflow will change battery temperatures and result in inaccurate reading by the ProlongPro systems.  These inaccurate readings may result in system and/or battery damage.  DO NOT use anything other than the vehicle's original hybrid battery fan and duct work to cool the battery, or damage may result.

Using the Prolong Car Harness and hybrid battery cooling fan with the necessary ducting is critical to maintain safe battery temperatures.  Do not use without proper battery cooling.  Improper, insufficient, or excessive battery cooling voids all warranties.  Hybrid Automotive LLC will not be held liable for damages resulting from improper usage or failure to properly cool the hybrid battery and/or ProlongPro systems. Return to top

Sufficient AC power (110V 15A or better Dedicated Circuit recommended)

The ProlongPro Charger draws a peak current of 14A at 110V.  Due to this we recommend a dedicated 110V 15A circuit be used.  If using extension cords, they must be at least 12 gauge wire thickness. Return to top

Sufficient System ventilation

The ProlongPro Charger system will generate heat while in use. A minimum of 12" clearance on all sides is required for proper ventilation. Do not block the system cooling fan intakes or back panel exhaust grill. Return to top

User Interface (Navigation)

The system has several components that require proper user knowledge for safe operation of the system.  These include the A/C power cord, power switch, voltage meter, current meter, LCD display, system idle LED, charging LED, next button, enter button, and back/stop button. Read below for a description of and detailed instructions for each item. Return to top

A/C power cord

The A/C power cord is used to supply the system with the necessary A/C power required for proper operation.  It is a 14/3 Type B plug & cord.  If replaced, a minimum of 14AWG three pole (line, neutral, ground) appliance power cord should be used. Return to top

Power Switch

The power switch is used to turn the system on and off. Return to top

Voltage Meter

The voltage meter displays battery pack voltage.  This is displayed in volts DC (direct current).  The meter has a range of 0-500VDC.  If voltage is seen on the display, the battery is connected to the system.  If voltage is displayed as a negative number, the battery connection polarity is reversed and must be corrected before charging. Return to top

Current Meter

The current meter displays current flowing into the battery pack.  This is displayed in amps DC (direct current).  The meter has a range of 0-5A.  While idle, small trace currents under 0.05A are normal. Return to top

LCD Display

The 16 character 4 row LCD display is the primary user interface.  It will display system state, prompt for user input, and display status messages critical to system operation. Return to top

System Idle LED

The system idle LED illuminates to tell the user the system is powered on and not presently charging a battery pack.  This could be due to the system requiring additional user input or a charge cycle is complete. Return to top

Charging LED

The system charging LED illuminates to tell the user the system is currently charging a battery pack. Return to top

Next Button

The next button is used to navigate available options on the LCD display.  Pressing Next will cause the cursor to 'scroll down' to the next available option being presented to the user. Return to top

Enter Button

The enter button is used to navigate available options on the LCD display.  Pressing Enter will select the option with the cursor currently next to it. Return to top

Back/Stop Button

The back/stop button is used to navigate available options on the LCD display, abort system operations, and disable/enable the system buzzer.  Pressing the back/stop button while navigating menus will 'scroll up' the cursor to the previous available option being presented to the user.

Pressing and holding the back/stop button for one second while the system is charging will abort the charge process and return the system to idle

BUZZER DISABLE/ENABLE: Pressing and holding the back/stop button for three seconds while the system is on the Power On Home Screen will disable the system buzzer across all functions.  Pressing and holding the back/stop button for another three seconds while the system is on the Power On Home Screen will re-enable the system buzzer across all functions.  Note this will only work on the Power On Home ScreenReturn to top

User Interface (LCD Display)

There are many different screens presented to the user on the LCD display depending on how the system is being used.  Refer below for details on selected screens/prompts. Return to top

Power On Home Screen

The Power On Home Screen is the first screen visible when the system powers on.  It displays the software version being used by the system.  This screen confirms that the system has successfully powered on and is ready for use.  

Pressing and holding the back/stop button for three seconds while the system is on the Power On Home Screen will disable the system buzzer across all functions.  Pressing and holding the back/stop button for another three seconds while the system is on the Power On Home Screen will re-enable the system buzzer across all functions.  Note this will only work on the Power On Home ScreenReturn to top

Select Make

The Select Make screen prompts the user to select the vehicle make (manufacturer) battery type to be charged.  For example, if charging a 2007 Prius battery pack, the vehicle make is Toyota.  Battery Size is an available option for custom battery size/out of vehicle battery charging. Return to top

Select Model

The Select Model screen prompts the user to select the vehicle model battery type to be charged.  For example, if charging a 2007 Prius battery pack, the vehicle model is 04-15 Prius.  Cell Counts are an available option for custom battery size/out of vehicle battery chargingReturn to top

Select Charge Mode

The Select Model screen prompts the user to select the charging mode to be used by the system.  Depending on Software version, there are three different charging profiles available:

The below three options are available:
1) Charge & Balance - Charge the battery until the current drops to 0.5A, then continue charging/balancing the cells for the amount of time to be selected in the next menu.
2) Charge Only - Charge the battery until the current drops to 0.5A, then stop.  This will charge the battery to approx. 80% state of charge.
3) Extended Diagnostic Support - Charge the battery until the current drops to 1.0A, then stop.  If voltage decreases by 5V or more, restart charging.  User must press the Back/Stop button to exit this mode.

Return to top

Select Cell Balancing Time

The Select Cell Balancing Time screen prompts the user to select the amount of time for the system to top charge/balance cell voltages once the current drops into the cell rebalancing zone (i.e. below 500mA).  User options vary from 1 hour to 24 hours. Return to top

BATTERY COOLING WARNING

This screen will prompt the user to confirm that the battery is being cooled by the original equipment manufacturer (OEM) installed hybrid battery cooling fan and duct work.  This defaults to "No".  If the user selects "No" the system will provide guidance for installing and using the OEM battery fan and ductwork. 

The user must explicitly acknowledge that they are using the OEM battery fan and duct work in order to use the system.  This is done by changing the cursor to "Yes" and pressing enter.  Do not do this unless the battery is being cooled by the OEM hybrid battery cooling fan and duct work.

Do not use without proper battery cooling.  Improper, insufficient, or excessive battery cooling voids all warranties.  Hybrid Automotive LLC will not be held liable for damages resulting from improper usage or failure to properly cool the hybrid battery and/or ProlongPro systems. Return to top

Confirmation Screen

This screen displays all user inputs for review.  This is the final opportunity for the user to review their inputs and verify they are correct. Return to top

Aborting Charge

Press and hold the back/stop button for one second while the system is charging to abort the charge process and return the system to idle. Return to top

Errors (Charger)

The ProlongPro Charger System has several safety mechanisms to protect itself and a connected hybrid battery against damage.  To aid in diagnostics, the charger system will save extensive details on the three most recent errors encountered.  The can be viewed by selecting the "Prior Error Recovery" option on the "Select Make" menu.  Below is a summary of each warning/error with details on what causes the condition to occur. Return to top

Warning: High current (bulk charge) capacity limit reached (C1)

This warning will be displayed when the charger delivers the maximum Amp-hours (Ah) of energy into the battery during the peak current (bulk) charging phase. The purpose of this safety is to prevent over charging the battery.

If this warning is displayed, then the battery is fully charged and should not be charged any further. No specific action is required when encountering this message. Instead, the user should proceed to the next step in the battery reconditioning process. Return to top

Warning: Taper current (absorption charge) capacity limit reached (C2)

This warning will be displayed when the charger delivers the maximum Amp-hours (Ah) of energy into the battery during the taper current (absorbtion) charging phase. The purpose of this safety is to prevent over charging the battery.

If this warning is displayed, then the battery is fully charged and should not be charged any further. No specific action is required when encountering this message. Instead, the user should proceed to the next step in the battery reconditioning process. Return to top

Warning: Low current (balance charge) capacity limit reached (C3)

This warning will be displayed when the charger delivers the maximum Amp-hours (Ah) of energy into the battery during the balance charging phase. The purpose of this safety is to prevent over charging the battery.

If this warning is displayed, then the battery is fully charged and should not be charged any further. No specific action is required when encountering this message. Instead, the user should proceed to the next step in the battery reconditioning process. Return to top

Error: Polarity Reversed or No Battery Connected (E1)

This error will be displayed when no battery is connected, or if the battery connection polarity is reversed when starting a charge cycle.

If this error is displayed and the voltage display reads zero volts, then recheck the Prolong Car Harness connections, car harness fuse, or ProlongPro Charger internal fuse. 

If this error is displayed and the voltage display reads negative volts, the battery connection polarity is reversed.  Recheck the Prolong Car Harness connections against the installation instructions located hereReturn to top

Error: Inadequate Voltage Increase Detected (E2)

While charging at peak current battery voltage should be rising. While the charge current is above ~3.2A, if battery voltage stops rising for more than four minutes the system will shut down and alert the user to error E2. This fault is to protect against possible battery over temperature event.  

If encountered, check hybrid battery temperature.  If battery temperature is cool, restart the charge while closely monitoring battery voltage and temperature. Return to top

Error: Battery Voltage Decrease Detected (E3)

While current is between ~3.2A and ~500mA, voltage should be stable or rising slowly.  If battery voltage decreases by more than 500mV while current is between 3.2A and 500mA, the system will shut down and alert the user to error E3. Once the voltage reaches the taper threshold, the voltage will stabilize and hold nearly steady while the current decreases.  While voltage will not climb in this phase of charging, a decrease in voltage could be a potential sign of battery over temperature event.

If encountered, check hybrid battery temperature.  If battery temperature is cool, restart the charge while closely monitoring battery voltage and temperature. Return to top

Error: Battery Voltage Decrease Detected (E4)

While current is below 500mA, the battery is top charging/cell balancing and slow oscillation of pack voltage is normal (~1-3V range).  However, if the battery is not being sufficiently cooled, it may become warm and voltage may decrease beyond acceptable limits.  If battery voltage decreases by more than 5V during top balancing, the system will shut down and alert the user to error E4.  

If encountered, check hybrid battery temperature.  If battery temperature is cool, restart the charge while closely monitoring battery voltage and temperature. Return to top

Error: Unexpected Current Increase - 3A (E5)

The ProlongPro Charger constantly monitors the charge current being delivered to the battery.  In normal operating conditions, once the current drops below 3.0A, it should not rise back above this level.  If the current being delivered to the battery drops below 2.9A for at least 10 seconds, then rises back above 3.0A for at least ten seconds, then the system will shut down and alert the user to error E5.

If encountered, check battery temperature.  Verify battery fan is running, free of obstructions, and air can be felt exiting the battery pack ducting.  Cool the battery by leaving the charger powered on in an idle state for 10-15 minutes.  Verify ambient temperature is not above system rated maximum ambient temperature of 100 degrees Fahrenheit (38 degrees Celsius). Return to top

Error: Unexpected Current Increase - 0.5A (E6)

The ProlongPro Charger constantly monitors the charge current being delivered to the battery.  In normal operating conditions, once the current drops below 0.5A, it should not rise back above this level.  If the current being delivered to the battery drops below 0.5A for at least 10 seconds, then rises back above 0.6A for at least ten seconds, then the system will shut down and alert the user to error E6.

If encountered, check battery temperature.  Verify battery fan is running, free of obstructions, and air can be felt exiting the battery pack ducting.  Cool the battery by leaving the charger powered on in an idle state for 10-15 minutes.  Verify ambient temperature is not above system rated maximum ambient temperature of 100 degrees Fahrenheit (38 degrees Celsius). Return to top

Error: Charger Over Temperature (E7)

The ProlongPro Charger has internal temperature monitoring.  If the Charger internal temperature rises above this safety threshold, the system will abort the process, revert to idle, and alert the user to error E7.

If encountered, check charger temperature.  Verify both charger cooling fans are running and free of obstruction.  Cool the charger system by leaving it powered on in an idle state for 10-15 minutes.  Verify ambient temperature is not above system rated maximum ambient temperature of 100 degrees Fahrenheit (38 degrees Celsius). Return to top

ProlongPro Discharger

ProlongPro Battery Discharger with integrated module tester 
- Will discharge  (vehicle full [80% SOC] to vehicle empty [40% SOC]) a NiMh hybrid batteries in 2-4 hours 
- Works with all common NiMh battery sizes up to 250 cells 
- Includes integrated six/eight cell module testing capabilities including: 
          Internal Resisitance/Load Testing 
          Capacity Testing 
- Pack discharging includes multiple user selectable discharge termination voltage points 
- Compatible with all Prolong Car Harnesses 
- Audible alert when finished (can be disabled by user)
- Reverse polarity protection to prevent system damage from incorrect battery connection 
- Thermal protection to prevent against excess heat damage

Return to top

System Setup

System must be placed on a solid flat surface with proper ventilation.  If using for pack level discharging, connect to Prolong Car Harness and plug the system into a sufficient AC power source before powering it on. Return to top

Use of system requires at least one Prolong Car Harness

The ProlongPro Battery Discharger is designed to connect to the complete battery pack being discharged via a Prolong Car Harness.  At least one Prolong Car Harness for the desired battery size to be discharged is required to use this product.

The ProlongPro Battery Discharger has an integrated module testing harness.  When performing module testing, the integrated module testing harness will be used and a Prolong Car Harness does not need to be connected to the system. Return to top

Sufficient cooling of hybrid battery

The hybrid battery will generate heat during the discharging process.  Maintaining active ventilation of the battery using the factory designed airflow duct work passages is critical for proper battery cooling.  Airflow MUST pass between the modules along the cell walls for proper cooling.  Blowing a fan across the top of the battery is NOT sufficient.  Insufficient or excessive airflow will change battery temperatures and result in inaccurate reading by the ProlongPro systems.  These inaccurate readings may result in system and/or battery damage.  DO NOT use anything other than the vehicle's original hybrid battery fan and duct work to cool the battery, or damage may result.

Using the Prolong Car Harness and hybrid battery cooling fan with the necessary ducting is critical to maintain safe battery temperatures.  Do not use without proper battery cooling.  Improper, insufficient, or excessive battery cooling voids all warranties.  Hybrid Automotive LLC will not be held liable for damages resulting from improper usage or failure to properly cool the hybrid battery and/or ProlongPro systems.

Return to top 

Sufficient AC power (110V 5A or better)

The ProlongPro Discharger draws a peak current of 2A at 110V.  Any standard 110V Type B wall socket should be fine.  If using extension cords, they must be at least 14 gauge wire thickness. Return to top

Sufficient ventilation

The ProlongPro Discharger system will generate up to 1,100 watts of heat while in use. This is a LOT of heat.  A minimum of 12" clearance on all sides is required for proper ventilation. Do not block the system intakes or back panel exhausts. Failure to properly ventilate the system will lead to hardware damage. Return to top

User Interface (Navigation)

The system has several components that require proper user knowledge for safe operation of the system.  These include the A/C power cord, module testing harness, power switch, voltage meter, current meter, LCD display, system idle LED, discharging LED, next button, enter button, and back/stop button. Read below for a description of and detailed instructions for each item. Return to top

A/C power cord

The A/C power cord is used to supply the system with the necessary A/C power required for proper operation.  It is a 14/3 Type B plug & cord.  If replaced, a minimum of 14AWG three pole (line, neutral, ground) appliance power cord should be used. Return to top

Module Testing Harness

The module test harness is a use to connect to hybrid battery pack modules (six cell or eight cell module assemblies) for testing.  It should be stored in the provided storage compartment on the back of the system when not in use. The harness is an 8AWG pair of wires cut to a precise length with crimped and soldered ring terminals for battery module connection.

DO NOT MODIFY THIS HARNESS.  The system is carefully calibrated to use this harness as it is built during the manufacturing process.  Very high currents pass through this harness.  Changing the wire length or connector type (for example replacing the ring terminals with clip leads) will change resistances in the harness and render the systems readings and outputs incorrect.   Return to top

Power Switch

The power switch is used to turn the system on and off. Return to top

Voltage Meter

The voltage meter displays battery pack voltage.  This is displayed in volts DC (direct current).  The meter has a range of 0-500VDC.  If voltage is seen on the display, the battery pack is connected to the system.  If voltage is displayed as a negative number, the battery connection polarity is reversed and must be corrected before discharging. 

Note, when performing module testing, the voltage meter will not be used.  Test status and results will be displayed on the LCD Display. Return to top

Current Meter

The current meter displays current flowing out of the battery pack.  This is displayed in amps DC (direct current).  The meter has a range of 0-5A.

Note, when performing module testing, the current meter will not be used.  Test status and results will be displayed on the LCD Display. Return to top

LCD Display

The 16 character 4 row LCD display is the primary user interface.  It will display system state, prompt for user input, and display status messages critical to system operation. Return to top

System Idle LED

The system idle LED illuminates to tell the user the system is powered on and not presently discharging a battery pack or performing module testing.  This could be due to the system requiring additional user input or a discharge/module test cycle is complete. Return to top

Discharging LED

The system discharging LED illuminates to tell the user the system is currently discharging a battery pack or performing module testingReturn to top

Next Button

The next button is used to navigate available options on the LCD display.  Pressing Next will cause the cursor to 'scroll down' to the next available option being presented to the user. Return to top

Enter Button

The enter button is used to navigate available options on the LCD display.  Pressing Enter will select the option with the cursor currently next to itReturn to top

Back/Stop Button

The back/stop button is used to navigate available options on the LCD display, abort system operations, and disable/enable the system buzzer.  Pressing the back/stop button while navigating menus will 'scroll up' the cursor to the previous available option being presented to the user.

Pressing and holding the back/stop button for one second while the system is discharging a battery pack or performing module testing will abort the process and return the system to idle

Pressing and holding the back/stop button for three seconds while the system is on the Power On Home Screen will disable the system buzzer across all functions.  Pressing and holding the back/stop button for another three seconds while the system is on the Power On Home Screen will re-enable the system buzzer across all functions.  Note this will only work on the Power On Home ScreenReturn to top

User Interface (LCD Display)

There are many different screens presented to the user on the LCD display depending on how the system is being used.  Refer below for details on selected screens/prompts. Return to top

Power On Home Screen

The Power On Home Screen is the first screen visible when the system powers on.  It displays the software version being used by the system.  This screen confirms that the system has successfully powered on and is ready for use.  

Pressing and holding the back/stop button for three seconds while the system is on the Power On Home Screen will disable the system buzzer across all functions.  Pressing and holding the back/stop button for another three seconds while the system is on the Power On Home Screen will re-enable the system buzzer across all functions.  Note this will only work on the Power On Home ScreenReturn to top

Select Mode

The Select Make screen prompts the user to select which task they want the system to perform.  The two options are full battery pack discharging "Pack Discharging" and individual/single module "Module Testing". Return to top

Pack Discharging

When full battery pack discharging "Pack Discharging" is selected on the "Select Mode" screen, the following displays/prompts will become sequentially presented to the user. Return to top

Select Make

The Select Make screen prompts the user to select the vehicle make battery type to be discharged.  For example, if charging a 2007 Prius battery pack, the vehicle make is Toyota.  Battery Size is an available option for custom battery size/out of vehicle battery discharging. Return to top

Select Model

The Select Model screen prompts the user to select the vehicle model battery type to be discharged.  For example, if charging a 2007 Prius battery pack, the vehicle model is 04-15 Prius.  Cell Counts are an available option for custom battery size/out of vehicle battery dischargingReturn to top

Select Discharge Termination Voltage

The Select Discharge Termination screen prompts the user to select how deep the battery pack will be discharged. This menu is dynamic and will change depending on the battery size (number of cells) selected.  All discharge termination values are the same when adjusted for the number of cells in the battery pack.  Said another way; while the discharge termination values vary due to the differing cells counts contained in each battery pack configuration, they are the same when considered on an individual cell level. 

In order for the voltage depression memory effect to experience any reversal, the cell must be drained to AT LEAST 0.8 volts.  Discharging a cell to a termination value above 0.8 volts will not result in any voltage depression reversal. 

The four discharge termination values are 0.8 volts per cell average, 0.5 volts per cell average, 0.3 volts per cell average, and 0.1 volts per cell average.  Multiplying these cell level average values with the number of cells within a battery pack will result in the values shown on the system LCD screen.

For example, a 2007 Prius battery pack has 168 cells.  The four available discharge termination voltages displayed by the system for a 04-15 Prius are 134 volts, 84 volts, 50 volts, and 17 volts.  Expressed mathematically, 168 cells x 0.8 volts per cell = 134 volts; 168 cells x 0.5 volts per cell = 84 volts; 168 cells x 0.3 volts per cell = 50 volts; and 168 cells x 0.1 volts per cell = 17 volts

For a table showing all battery pack sizes and corresponding discharge termination values, click hereReturn to top

Confirmation Screen

This screen displays all user inputs for review.  This is the final opportunity for the user to review their inputs and verify they are correct. Return to top

Aborting Discharge

Pressing and holding the back/stop button for one second while the system is pack discharging or module testing will abort the discharge process and begin the system cool down processReturn to top

System Cooldown

After a discharge cycle is complete, or when the user aborts a discharge, the system will run through a seven minute cool down process.  This allows the system to properly cool internally and prevent system damage.

Pressing and holding the back/stop button for one second during the cool down process will abort the cool down and return the system to idle. Return to top

Module Testing

When individual/single module "Module Testing" is selected on the "Select Mode" screen, the following displays/prompts will become sequentially presented to the userReturn to top

Module Test Selection

The Select Module Test screen prompts the user to select the type of module test to be performed.  Their are two options, Internal Resistance (IR)/Load Testing and Capacity Testing. Return to top

Internal Resistance (IR)/Load Test

Internal Resistance (IR)/Load Testing evaluates how efficiently energy can be extracted from cells within a module.  The lower the internal resistance or lower the voltage drop, the better the condition of the cells within a moduleThe higher the internal resistance or greater the voltage drop, the worse the condition of the cells within a module. 

Matching modules that contain cells with similar internal resistance will result in a better performing battery pack assembly.  For more information about battery cell Internal Resistance, we recommend this link: https://en.wikipedia.org/wiki/Internal_resistance

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Capacity Test

Capacity Testing evaluates how much energy can be delivered by the cells within a module at a given voltage/current.  The higher the Ah of capacity, the better the condition of the cells within a moduleThe lower the Ah of capacity, the worse the condition of the cells within a module. 

Matching modules that contain cells with similar capacity will result in a better performing battery pack assembly. For more information about battery cell Capacity, we recommend this link: https://en.wikipedia.org/wiki/Battery_(electricity)#Capacity_and_discharge

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Errors (Discharger)

The ProlongPro Discharger System has several safety mechanisms to protect itself and a connected hybrid battery or module against damage.  Below is a summary of each fault with details on what causes the fault condition to occur. Return to top

Error: Module Test Overvolt

This error will be displayed during module testing when the module voltage detected by the system is greater than the allowable maximum.  The system maximum is approximately 12 Volts.

If this error is displayed, ensure the system is connected to only one module.  Check the module test harness connections.  If connections are correct, measure voltage of the module to ensure it is less than 12 volts. Return to top

Error: Module Test Undervolt

This error will be displayed during module testing when the module voltage detected by the system is less than than the allowable minimum.  The system minimum is approximately 6 Volts.  This may also be seen if no module is connected.

If this error is displayed, ensure the system is connected to a module.  Check the module test harness connections.  If connections are correct, measure voltage of the module to ensure it is more than 6 volts. Return to top

Error: Unexpected Current Increase (E2)

This error will be displayed when the amount of current (Amps) being extracted from the battery rises unexpectedly.  During a discharge cycle, the current being extracted from the battery should be decreasing over time.  If the current rises for an extended period of time (averaging is used to eliminate noise) then the safety relay will open terminating the discharge and this error will be displayed.

This could be a hardware issue.  If this error is displayed, restart the discharge cycle and carefully monitor the current (Amps) being extracted from the system. If the current is greater than 3.5A and/or the error reoccurs, terminate the discharge and contact us.  If the discharge current repeatedly rises during the discharge process and/or the error reoccurs, terminate the discharge and contact us.  Return to top

Error: Battery Not Detected (E3)

This error will be displayed when the discharger is not electrically connected to the battery.  This is typically seen when the battery disconnect switch is not fully installed or a fuse has opened. 

Make sure the orange safety switch is installed and locked into the closed position.  There are two safety fuses in the circuit.  One is in the car harness that connects from the discharger to the battery.  The second is inside the discharger itself.  Measure battery voltage where the harness connects to the battery pack with a multi-meter.  If battery voltage is seen the next step is to test at the other end of the harness where it connects to the discharger.  Measure pins 1 and 4.  If no battery voltage is seen, the fuse in the car harness needs replacing.  If battery voltage is seen the fuse in the car harness is good and the fuse inside the discharger needs to be tested.  It is harder to get to.  Remove the discharger lid and use a small mirror to locate the fuse on the back of the circuit board.  Remove and test that fuse.  If that fuse is good contact us for further assistance.  Return to top

Error: Pack Over Voltage (E4)

This error will be displayed when the actual battery voltage is greater than the allowable maximum for the battery size selected.  To protect itself against damage, the system will not perform pack discharging when voltages above safe levels for each battery type are present. 

If this error is displayed, recheck the battery pack size selected via the LCD screen matches the actual battery size connected to the system Return to top

Error: Discharger Over Temperature (L1 or R2)

The ProlongPro Discharger has internal temperature monitoring.  If the discharger internal temperature rises above this safety threshold, the system will abort the process, revert to idle, and alert the user.

If encountered, check discharger temperature.  If the error code is L1, the left side of the resistor assembly is causing the fault.  If the error code is R2, the right side of the resistor assembly is causing the fault.  Verify all five discharger cooling fans are running and free of obstruction.  Cool the charger system by leaving it powered on in an idle state for 10-15 minutes.  Verify ambient temperature is not above system rated maximum ambient temperature of 100 degrees Fahrenheit (38 degrees Celsius). Return to top

Technical Specifications

See below for technical specifications. Return to top

ProlongPro Charger

Input is factory preset to either 110V Version or 220V Version:

110V Version:
100 - 120VAC
50/60Hz
0 - 14A
220V Version:
200 - 240VAC
50/60Hz
0 - 7A

Output:
1: 0 - 370VDC
    0 - 3.3A
2: 12VDC
    0 - 5A

Maximum ambient temperature: 100 degrees Fahrenheit (38 degrees Celsius)

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ProlongPro Discharger

Input:
88 - 264VAC
47 - 63 Hz
0 - 2A

Output:
1: 0 - 1,100 Watts 
2: 12VDC
    0 - 5A

Maximum ambient temperature: 100 degrees Fahrenheit (38 degrees Celsius)

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