ProlongPro Thunderbolt - Owners Guide

For Help with your ProlongPro Thunderbolt system, call us at 800-589-0730, email us at support@hybridautomotive.com, or review the complete setup and user manual below:

Table of contents:

What’s included in the box

ProlongPro Thunderbolt Complete Package Video:

The ProlongPro Thunderbolt Battery Repair System Complete Package includes:

  • ProlongPro Thunderbolt system
  • One-year license to the ProlongPro software app
  • ProlongPro Battery Charger
  • ProlongPro Battery Discharger
  • ProlongPro Battery Cooling Table (Compatible with Toyota batteries up to 34 modules)
  • 10” Android tablet
  • Module serial number QR scanner
  • Module voltage monitoring harness A
  • Module voltage monitoring harness B
  • High voltage interconnect harness
  • Battery temperature sensor harness
  • Honda battery connection hardware adapter kit
  • Quick start sheet
  • Online setup instructions & user guide
  • Two year warranty

The ProlongPro Thunderbolt Battery Repair System is compatible with both 110V and 220V AC mains out of the box. Return to top

ProlongPro Thunderbolt Upgrade Package Video:

The ProlongPro Thunderbolt Battery Repair System Upgrade Package includes:

  • ProlongPro Thunderbolt system
  • One-year license to the ProlongPro software app
  • ProlongPro Charger upgrade board
  • ProlongPro Discharger upgrade board
  • ProlongPro Battery Cooling Table (Compatible with Toyota batteries up to 34 modules)
  • 10” Android tablet
  • Module serial number QR scanner
  • Module voltage monitoring harness A
  • Module voltage monitoring harness B
  • High voltage interconnect harness
  • Battery temperature sensor harness
  • Honda battery connection hardware adapter kit
  • Quick start sheet
  • Online setup instructions & user guide
  • Two year warranty

The ProlongPro Thunderbolt Battery Repair System is compatible with both 110V and 220V AC mains out of the box. Return to top

Initial hardware setup, App configuration, Bluetooth and Wifi configuration:

Please refer to this video for initial setup and system configuration instructions:

ProlongPro Android App: The ProlongPro Android App is required to use the Thunderbolt system.  It can be downloaded from the Google Play store by clicking on this link.  You must accept the app permissions "Allow Device Location" and .  The app requires ongoing communication from the Thunderbolt system.  To enable this, the 'Stay Awake' option must be enabled in the developer options menu.  Refer to the 'Initial hardware setup, App configuration, Bluetooth and Wifi configuration video' for instructions on how to configure the tablet and ProlongPro App correctly. Return to top

Wireless connections diagram and definitions:

wireless-connection-diagram-marked.png

  1. Tablet/ProlongPro App Wifi Internet connection: This Wifi (wireless Internet) connection is used by the tablet to download the ProlongPro App from the Google Play store. Refer to tablet operating instructions for the setup and configuration of this connection. A working Internet connection is required at all times when using the ProlongPro App.
  2. Tablet/ProlongPro App to Thunderbolt Device Bluetooth connection: During normal use, this Bluetooth connection is used by the Tablet/ProlongPro App to send and receive commands and data from the Thunderbolt hardware device. During setup and configuration, this Bluetooth connection is also used to connect to the Charger and Discharger to configure their Wifi connections.
  3. Thunderbolt Device to Charger/Discharger Bluetooth connection: This Bluetooth connection enables communication between the Thunderbolt hardware and the Charger or Discharger, depending on the operation being performed. On the Charger and Discharger blue LCD screen, you can view the status (connected/disconnected) of this Bluetooth connection at any time.
  4. Thunderbolt Device Wifi Internet connection: This Wifi (wireless Internet) connection is used to automatically download & install new Thunderbolt firmware versions as they become available. This Wifi connection is configured using the settings screen of the ProlongPro App. (A software license is not required to configure this connection.)
  5. Charger Wifi Internet connection: This Wifi (wireless Internet) connection is used to automatically download & install new charger firmware versions as they become available. This Wifi connection is configured using the settings screen of the ProlongPro App. (A software license is not required to configure this connection.)
  6. Discharger Wifi Internet connection: This Wifi (wireless Internet) connection is used to automatically download & install new discharger firmware versions as they become available. This Wifi connection is configured using the settings screen of the ProlongPro App. (A software license is not required to configure this connection.) Return to top

Wifi network requirements: The wireless network used by the ProlongPro Thunderbolt, Charger, and Discharger, must meet the following requirements:

  • Must be the same Wifi network as Android tablet with ProlongPro App
  • Network cannot be behind a hard firewall or Enterprise network
  • Network must be a 2.4GHz capable router, Channels 1-11
  • Network must allow WPA/WPA2 encryption, have SSID broadcast enabled
  • Note: For security reasons, we do not recommend using WEP Wifi settings. Return to top

Upgrading an existing ProlongPro Charger: This video demonstrates the process of how to upgrade a ProlongPro Charger with software versions 1.x or 2.x to be compatible with the ProlongPro Thunderbolt system. The update process does require a moderate computer hardware replacement skills. If you would rather not perform this upgrade yourself, we do offer a low-cost trade-in program. Please contact us for additional details. Return to top

Upgrading an existing ProlongPro Discharger: This video demonstrates the process of how to upgrade a ProlongPro Discharger with software versions 1.x or 2.x to be compatible with the ProlongPro Thunderbolt system. The update process does require a moderate computer hardware replacement skills. If you would rather not perform this upgrade yourself, we do offer a low-cost trade-in program. Please contact us for additional details. Return to top

Minimum compatible version checking: As features and functionality are added to the Thunderbolt system, new versions of the ProlongPro Software and TB, Charger, & Discharger firmware will be released. These new versions may have interdependencies across hardware devices in order to function properly. To ensure all systems are on a minimum compatible software version, the ProlongPro Software performs a version test and alerts the user if any devices have a non-compatible software version. In this situation, please ensure the device requiring an update is connected to the Internet. Allow the device approximately 8-12 minutes to download and install the new firmware version. If after 15 minutes the device has not updated please contact us for support.

If the device has already installed the new version, but that version is not being recognized by the ProlongPro app version check process, force the ProlongPro Software to connect with each device and obtain up to date firmware version information by pressing the “Get Software Version” button in the settings screen. Return to top

Reconditioning types – Dynamic vs Static: The ProlongPro Thunderbolt system includes automated cycling (charging and discharging) of the hybrid battery pack. In addition, the Thunderbolt system can monitor every module within a battery pack as it is being charged and discharged. This allows the Thunderbolt system to adjust the charging and discharging process based on direct feedback from modules in the battery being serviced. The different modes are defined for the user and able to be selected on the “Recondition” screen of the ProlongPro App. Return to top

Charger & Discharger – Standalone vs Thunderbolt mode: The ProlongPro Charger and ProlongPro Discharger can be used both with the Thunderbolt system as well as standalone systems. Standalone means they are able to be used by themselves without being connected to the Thunderbolt system. To change the ProlongPro Charger and ProlongPro Discharger mode from Standalone mode to Thunderbolt mode, press and hold the Enter button for five seconds. To change the ProlongPro Charger and ProlongPro Discharger mode from Thunderbolt mode to Standalone mode, press and hold the Enter button for five seconds. Return to top

Software License: The ProlongPro software application requires a valid software license in order to use the Android application for battery servicing and repair. The battery servicing and repair capabilities of the ProlongPro software application will not work without a valid software license. Using the ProlongPro App for Wifi setup of other ProlongPro devices (such as the charger and discharger) do not require a software license.

A one-year software license is included with the purchase of a Thunderbolt system. The software license key is a single use, server validated key that cannot be installed on more than one instance of the ProlongPro App. If the ProlongPro App is uninstalled and reinstalled onto the same tablet, the software license key may not work for the re-installation. If you have a valid software license but are having validation trouble in the ProlongPro App, please contact customer support for assistance.

When purchased, the software license key is delivered via email typically within one business day. For faster service, please contact customer support. The one-year license period begins the on the date that it is entered and activated within the ProlongPro App, not the date that it is emailed after purchase. One-year renewals can be purchased via the Hybrid Automotive Professional store for a nominal fee. The license renewal cost supports ongoing improvements, increased features & functionality, and bug fix support. Return to top

Thunderbolt system usage overview

Please refer to this video for a high-level overview of the ProlongPro Thunderbolt system. This video is not an exhaustive ‘how-to’ for hybrid battery repair. The purpose of this video is only to give a overview of how to use the ProlongPro Thunderbolt system:

ProlongPro App screen by screen instruction videos

Home Screen:

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The home screen is the first page viewed after opening the app and accepting the End User License Agreement (EULA). All battery servicing begins on this screen. This is also where to access help for the ProlongPro App. Return to top

IR Testing Screen:

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The IR Testing screen is used primarily to perform module internal resistance (IR) testing, record module resting voltage, and enter module serial numbers and internal reference numbers. Return to top

Recondition Screen:

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The Recondition screen is used primarily for initiating module capacity testing and battery pack reconditioning. From this screen the user can input into the software whether the individual module voltage monitoring wires are installed onto the battery pack being service, choose whether they want to perform a module capacity test, dynamic reconditioning, or static reconditioning of the battery pack. They are then able to select how many times the battery is cycled and how long they want to top balance the battery cells. While the battery process is underway, system updates, Ah charged/discharged, and battery temperature is displayed. This is also where any error messages will be displayed.

Module Voltage Monitoring: If module voltage monitoring is disabled (off), only Static reconditioning type will be available. This means the Thunderbolt system is receiving no module level voltage information from the battery pack. Static reconditioning means the ProlongPro Thunderbolt system will use pre-programmed discharge curves that adjust based on the full battery pack voltage only. This is useful for servicing batteries that are installed in a vehicle without removing them. If module voltage monitoring is enabled (on), then both static and Dynamic reconditioning types are available to use.

Reconditioning Type: The select recondition type menu has four options:

  • Module Capacity Test: The capacity test process will pre-charge the battery for 20 minutes (approximately 1.0Ah), or until any one non-ignored module reaches a 1.42V per cell average (8.5V on a six-cell module). Then the system will immediately begin discharging the battery to perform the capacity test. During the capacity test, the system will record the following values: (A) CAP: Capacity (Ah) extracted when module reaches 1.0V per cell average (6.0V on a six-cell module), or total extracted if capacity test terminates prior to module reaching 1.0V per cell average, (B) CAPOD: Additional capacity (Ah), if any, extracted below 1.0V per cell average, and (C) Vend: Module voltage at end of capacity test. The capacity test is terminated when one of two conditions occur: (1) any six non-ignored modules drop below 0.7V per cell average, or (2) all modules in the battery drop below 1.0V per cell average.
  • Dynamic: CC-CV-CC: The Dynamic Constant Current-Constant Voltage-Constant Current reconditioning type will charge at maximum output - constant current (CC) - until any one (non-ignored) module reaches 1.42V per cell average (8.5V* on a six-cell module). Then step current down & continue reducing charge current down to 0.35A, and finally continue charging at minimum current for the user selected “cell balancing time" period. Then the system will discharge at maximum load - constant current (CC) - until any one (non-ignored) module reaches 1.0V per cell average (6.0V* on a six-cell module), then maintain constant voltage (CV) of that module while tapering pack discharge current down to 0.4A. Discharge will continue at 0.4A constant current until the termination criteria is met. The first dynamic discharge cycle terminates when any one module discharges to 0.8V per cell average. Subsequent dynamic discharge cycles terminate when any one module discharges to 0.4V per cell average.
  • Dynamic: Step Down: The “Dynamic: Step Down” reconditioning type will charge at maximum output - constant current (CC) - until any one (non-ignored) module reaches 1.42V per cell average (8.5V* on a six-cell module). Then step current down & continue reducing charge current down to 0.35A, and finally continue charging at minimum current for the user selected “cell balancing time" period. Then the system will discharge at maximum current until any one (non-ignored) module reaches 1.0V per cell average (6.0V* on a six-cell module), then immediately reduce current to 1A and continue discharging until any one (non-ignored) module again reaches 1.0V per cell average, then immediately reduce current to 0.4A and continue discharging until any one (non-ignored) module again reaches 1.0V per cell average. Then the discharge process will terminate.
  • Static: Static cycling does not monitor module voltages during charging and discharging cycles. Instead, the charger and discharger cycle the battery using pre-programmed amperage curves. These curves are the same as what is used by the charger and discharger in ‘stand-alone’ mode. The first discharge cycle will terminate when the pack reaches a 0.8V per cell average. The second discharge cycle will terminate when the pack reaches a 0.6V per cell average. Subsequent discharge cycle will terminate when the pack reaches a 0.5V per cell average.

*This value is adjustable in the settings screen.

Reconditioning Sequence: The select recondition sequence menu allows the user to decide how many charge discharge cycles they would like to perform on the battery. The ProlongPro App and Thunderbolt system use a ‘step down’ approach, discharging the battery to a slightly lower termination voltage with each cycle.

Cell Balancing Time: The select balancing time allows the user to set how long the system will top balance the battery cells. Top balancing is charging below 0.5A current level. This allows the cells in the battery pack to equalize voltages with each other.  Return to top

Capacity Screen:

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The capacity screen is used to view module and pack level data captured during the capacity test and reconditioning processes. It has three main sections accessible by pressing the desired button on the top right side of the screen. These sections are Real Time Module Voltage, Discharge Line Graphs, and Data Table.

  • Real Time Module Voltage: The real time module voltage screen is used to view module voltages during the capacity test and reconditioning processes. The bar graph colors will change from green to yellow and red based on hard coded voltage ranges. Real time module ignoring: This view is where individual modules can be marked as ‘ignore’. This real time ignore capability is done by tapping on the eye icon at the far-left side of each modules graph line. Once a module is marked as ignored, it will no longer be included in the system calculations for capacity testing, dynamic reconditioning, or termination or processes. This is useful as is allows defective modules to be marked out or ignored by the software without having to disrupt the process. This allows the remaining modules to continue being serviced and all defective modules to be replaced as a single step in the process (after the desired processes are complete).
  • Discharge Line Graphs: The discharge line graphs screen has two subsections, Module Discharge Line Graphs and Pack Discharge Line Graphs.
    • The Module Discharge Line Graphs allows the user to view discharge line graphs (discharge curves) for each individual module in the battery pack. This data is captured during the module capacity test and each discharge cycle during the reconditioning process. To customize the graph displayed, the module discharge graphs can be controlled in several ways. Individual module discharge graphs and each discharge cycle can be individually turned on and off by selecting or deselecting their respective check boxes. This allows users to compare multiple modules to each other during a single discharge, as well as compare a single module’s discharge curve across multiple cycles. The user can zoom in and out using two fingers or by using the plus and minus icons on the top right corner of the graph. Any line on the graph can be tapped on to retrieve the module number. At any time, the view reset icon (round arrow) at the top right corner of the graph will reset the screen to the default zoom level.
    • The Pack Discharge Line Graphs allows the user to view overall pack discharge line graphs for each discharge cycle during the reconditioning process. Each pack discharge graph can be individually turned on and off by selecting or deselecting their respective check boxes. This allows users to compare pack discharge curve across multiple cycles. The user can zoom in and out using two fingers or by using the plus and minus icons on the top right corner of the graph. Any line on the graph can be tapped on to retrieve the pack discharge number. At any time, the view reset icon (round arrow) at the top right corner of the graph will reset the screen to the default zoom level.
  • Data Table: The module discharge data table screen has pack level and module level capacity data. This is useful for analyzing numerically the capacity and performance of each module in a battery pack. To view full battery pack information, tap on the “Full Battery Pack” dropdown at the top left of the screen. This information is the same information that is displayed as the ‘Discharge Results Report’ by the discharger when used in stand-alone mode:
    • Useable Capacity Extracted (Ah): This is the capacity extracted from the battery in the voltage range that is typically utilized by the vehicle while in operation (from approximately 80% to 40% of the overall capacity range) displayed in Amp Hours.
    • Useable Capacity Extracted (Wh): This is the capacity extracted from the battery in the voltage range that is typically utilized by the vehicle while in operation (from approximately 80% to 40% of the overall capacity range) adjusted for voltage and displayed in Watt Hours.
    • Comparable result?: This indicated if the Usable Capacity extracted covered a wide enough range for the result displayed to be comparable across discharge cycles. If the discharge started at too low of a voltage or ended at to high of a voltage the usable capacity captured would be incomplete and thus the result would not be comparable.
    • Total Capacity Extracted (Ah): This is the total capacity extracted from the battery regardless of starting and ending voltage, displayed in Amp Hours.
    • Total Capacity Extracted (Wh): This is the total capacity extracted from the battery regardless of starting and ending voltage, adjusted for voltage and displayed in Watt Hours.
    • Discharge Starting Voltage: This is the voltage of the battery when the discharge process started.
    • Discharge Ending Voltage: This is the voltage of the battery when the discharge process ended.
    • Delete Discharge Data: This checkbox allows the user to delete ALL DATA related to a particular discharge cycle. This includes pack level data, module data tables, and all graphs
    • Note: A maximum of eight discharge data sets can be stored for a single battery service. If more than eight cycles are attempted, the first cycle will be discarded and replaced by the newest discharge data set.
  • Module level data table: The module level data table displays individual module level data captured during the capacity test and discharge processes. This is displayed in the table along with the module serial #, resting voltage, and internal resistance testing results. Note the Capacity test and Discharge header titles can be tapped on the read explanations for each value.
    • Capacity Test - CAP: Capacity (Ah) extracted when module reaches 1.0V per cell average, or total extracted if capacity test terminates prior to reaching 1.0V per cell average.
    • Capacity Test - CAPOD: Additional capacity (Ah) extracted below the 1.0V per cell average.
    • Capacity Test - Vend: Module voltage at end of capacity test.
    • Discharge - CAP: Capacity (Ah) extracted at 1.0V per cell average, or total extracted if discharge terminates prior to module reaching 1.0V per cell average.
    • Discharge - DD1: Additional capacity (Ah) extracted between 1.0V per cell average and the greater of discharge termination or 0.8V per cell average.
    • Discharge - DD2: Additional capacity (Ah) extracted between 0.8V per cell average and the greater of discharge termination or 0.5V per cell average.
    • Discharge - Vend: Module voltage at end of discharge.
    • Discharge - RP: Cell polarity reversal count during discharge.
  • Export CSV: The Export CSV button on the top right side of the screen will export the module data table to a CSV file, open the default mail application, and compose an email with the CSV file attached. This allows the compiling and manipulation of the data in your favorite spreadsheet application. Return to top

Report Screen:

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The report screen is used to generate the battery service results report. This report can be provided to each customer to quantifiably show them the work performed on their hybrid battery. Similar to an alignment results report, this is a powerful way to show the vehicle owner not only that work was done, but how much their exact battery was improved by the service process.

The report has pre-formatted space for your company logo, company name, address, phone, website, and email. In the app, the left side of the report screen is used to pre-populate these fields. Once these fields are completed, the information will be retained by the app unless it is edited again by the user.

On the right side of the report screen allows you to choose which battery data is included on the customer report. Available options are:

  • Bar graph of module internal resistance: This will display, in bar graph form, module internal resistance in milliohms. This test is performed on the IR Testing Screen.
  • Line graph of pack discharge (all cycles): This graph shows the overall usable capacity improvement delivered by the pack cycling process. Typically, the module IR test is performed as a diagnostic step - before replacing modules with failed cells. This is useful for showing which modules had excessing internal resistance and had to be removed from the battery pack assembly. This graph can be viewed within the ProlongPro App on the Capacity screen -> Discharge Line Graphs -> Pack Discharge Line Graphs view.
  • Line graph of module capacity test: This graph shows the discharge curve for each individual module during the module capacity test. Typically, the capacity test is performed as a diagnostic step - before replacing modules with failed cells. This is useful for showing the variation in discharge curves and which modules had poor capacity requiring removal from the battery pack assembly. This graph can be viewed within the ProlongPro App on the Capacity screen -> Discharge Line Graphs -> Module Discharge Line Graphs view and selecting the “Capacity test” and “All” check boxes.
  • Line graph of module discharge (last cycle): This graph shows the discharge curve for each individual module during the final discharge of the reconditioning process. This is useful for showing the improvement in the discharge curves after the reconditioning process is complete. This demonstrates the improvement delivered to the battery at the individual module level. This graph can be viewed within the ProlongPro App on the Capacity screen -> Discharge Line Graphs -> Module Discharge Line Graphs view and selecting the highest numbered discharge cycle and “All” check boxes.

To create the report, press the “Generate Battery Report PDF” button. The ProlongPro app will generate the report, open the default mail application, and generate an email with the report attached. You can use this to email it directly to the customer, or email it to yourself to print and present to the customer when they are picking up their vehicle.  Return to top

Settings Screen:

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The Settings screen is used to configure the ProlongPro App. It is separated into five sections:

  1. ProlongPro Android App. This is where app specific values are viewed and configured. These include the app version, software license key, license expiration date, app Bluetooth connection control, and error history view.
  2. ProlongPro Charger & Discharger: This is where the charger and discharger Wifi configuration and firmware versions are viewed and configured.
  3. ProlongPro Thunderbolt: This is where the Thunderbolt system Bluetooth, Wifi configuration, and firmware versions are viewed and configured.
  4. Reconditioning settings: This is where several app variables can be adjusted. These include:
    1. Rest time between charge & discharge cycles - How long the system will rest the battery cells between charge and discharge cycles.
    2. Dynamic reconditioning maximum module voltage - This setting controls at what module voltage a dynamic charge will stop delivering maximum current to the battery and begin the tapering process. This is displayed as a six-cell module value. The system automatically adjusts this value to eight-cell modules when applicable.
    3. Dynamic reconditioning minimum module voltage - This setting controls at what module voltage a dynamic discharge will stop drawing maximum current from the battery and begin the tapering process. This is displayed as a six-cell module value. The system automatically adjusts this value to eight-cell modules when applicable.
    4. Battery temperature format - Allows the user to adjust the battery temperature format between Celsius and Fahrenheit.
  5. Device ID values: This shows the unique processor Device ID values for each part of the Thunderbolt system. This information may be requested by Hybrid Automotive support when troubleshooting certain issues. Module Voltage Test: This is used to test and display module voltages. This view will only function when the system is idle. This can be useful when troubleshooting certain issues.  Return to top

FAQ:

  • Q: Do we have direct access to the raw data as an Excel file or similar?

A: All battery service files can be exported in a CSV format, allowing direct manipulation in your favorite spreadsheet application.

  • Q: Is the data stored locally or in the cloud? (i.e. auto backups?)

A: For mobile app software version 1.x, data is stored on the tablet. We do plan to enable cloud backups in the future. In the meantime, we recommend using dropbox or similar to back up the data files.

  • Q: Can you export the module serial numbers so I print human friendly labels to stick on the modules?

A: Yes, the module serial numbers are included in the csv export file.

  • Q: Is there a remote screen app compatible with your controller? (so a user can look at the system remotely and see how it’s doing in real time another location without having to walk back into the shop)

A: Any third-party Android tablet remote screen app can be used. We have not tested any specific app for this yet. If you have one that works well, please let us know so we can add it here!

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