Prolong Battery Systems featured in Parts & People Magazine

There is a "Discharging" LED, no Discharge complete one (at least on the unit I have which is what Jeff has just brought to market).

Was the fault LED illuminated? Or were there no LEDs on when you went back to the Discharger?

When the battery pack is at a higher voltage, the discharge rate was at around 1.5, but then would decrease as the pack voltage was less.

 

No. The Discharging light was flashing and the alarm was bleeping. According to the "new" manual, that means it's done discharging. As I pointed out, there are contradictory instruction manuals on the site.

 

Those instruction manuals are for two different devices. The older, "Intelligent" one does not mention the 4-6 hour charge after reaching maximum charge. It appears to have a knob that selects discharge voltage. Obviously some other detail differences like when to press the reset button.

On the new discharger, you just plug it in and press the button for the discharge voltage. When it's done, lights are blinking and the voltage recovers to higher than the discharge voltage selected.

 

Perhaps, but you'd not realize that when clicking the link(s). That's why I was confused...I had the wrong instruction page.

 

@jeff652 what happens if you leave the prolong charger charging a battery pack over night? Can any serious damages occur to the pack or to my car?

 

Good morning sorry I asking here but phone it’s not a option when nobody answer it, so I have a RMA for my discharge under warranty send it to you, you received the 24 of February 2021 today is 25 March 2021 and I haven’t hear nothing from you and when I call I never get someone to talk, good luck am not waiting for this to fix my battery because it’s already over a month and still going, so when I will get my discharge back? I try emailing also but didn’t get a reply.

 

Can anyone tell me if this company still on business, they took my discharger over a month ago for warranty and I haven’t hear from them after, no good business practice over a month delivery to them, how can I get my money or discharger back when it’s not way to contact them!

 

Go to THIS page on their website. There you will find: phone number, two (2) email addresses, and a message field you can enter and send to them.

 

Thank you but the message option when I hit send it doesn’t work and say to try later and I did try later different days and still no sending, email support and not reply call and nobody answer, what it big mistake I did.

 

Finally received a reply, I guess they feeling my heat but lies they say it’s not a month so here my proof and their reply....

No, it has not been over a month, we received the unit on 3/4/2021, and I did mention that the turnaround time is 2-3 weeks after we get the unit. Today will be the end of the third week. The unit was repaired and it was returned to the warehouse yesterday afternoon, the unit will be processed and sent back to you today.

Best regards,
George R

Fedex tracking number: 783867082578 so why George said 3/4/2021, delivery by fedex doesn’t count as received by this company, what type of joke is this.

 

who is this h.hernandez character?

 

This is the character that signed for fedex delivery, I shipped fedex.

 

he probably has your discharger working on his battery

 

Thanks George

I haven’t charged or discharged since this happened so I don’t know if they’re working or not.

I completely disconnected it when I suspected the green box of electrical burning smell which I confirmed when I opened it up by stronger odor inside.

This does in fact cause harm to my hybrid battery system since it interfered with the hybrid cooling fan’s ability to keep my hybrid battery bank at normal operating temperature and was overheating while I was 130 miles away from home.

I know that Dr. Prius has relationship with HA and that app is what I was able to use to verify that my battery bank was over temperature.

I have only performed one full reconditioning cycle due to the first negative problems I experienced with the Prolong charger and fuse.

For a system that costs $850 including tax and shipping, I never would’ve expected so much of my time wasted on trying to troubleshoot with the help of the internet and my multimeter to ‘make’ a brand new system properly work as designed.

The harness is almost $200 or 1/4 of the cost of the system and the process cannot be performed without it! I’ve only been able to ‘successfully’ (I think it was successful but I honestly don’t know) use it 6 times minus the times I used it briefly in my first attempt at an unsuccessful reconditioning due to fuses.

I never emailed HA with what I did discover upon my troubleshooting and disassembly of my car again so I could gain access to the harness fuse which was suspected to be blown by HA.

Well it wasn’t the harness fuse nor the charger fuse. The charger fuse did not have the specified 1.15amp fuse per HA’s email at that time. It had the same 3.15amp fuse as the harness.

I replaced the fuse that came installed in charger as it was shipped to me brand new with the correct specified fuse of 1.15amp.

I also learned from the amazing Priuschat folks that it is helpful to disconnect both hybrid battery switch and 12V battery prior to connecting Prolong harness to charger and discharger to help prevent the mini arc flash occurring inside the charger that I experienced every time I connected it to my harness prior.

I don’t know what was actually causing my initial problems with the system but an overrated fuse may have attributed.

I’ve honestly had nothing but trouble with this system and now I’m unable to obtain a replacement harness which may be defective from when I received this ‘Deluxe’ System.

I hope HA reconsiders sending me a new harness at their expense since mine is practically new but certainly defective in at least one of the cooling fan controller circuits override green boxes and was not something I caused as I’ve actually driven very few miles since I first installed it.

I was still an advocate for HA and the Prolong System and even recommending it in forums despite the prior troubles I encountered.

If I choose to send the harness back for warranty repair, how can I verify that it is functioning safely and properly?

Without jeopardizing components of my vehicle?

And I assume it’s at my expense to ship it back? How long will the repair process take approximately?

I’ve seen some bad experiences other customers have encountered while waiting for warranty repairs. And they don’t even have to disassemble their entire car interior for the harness!

I realize it’s not your policy George and this is not directed at you

I’m sorry I’m just frustrated with this whole situation!

Sincerely,
Bear&meg

iPhone

On Sep 28, 2021, at 1:13 PM, Hybrid Automotive Support <[email protected]> wrote:

Hi Bear&meg,

The thing is that the warranty does not include sending replacement parts when something like this happens, we have the unit be sent back and repair for the customer. Based on what you said you already check that the high-voltage wires are working fine because you were able to charge and discharge the battery, the only ones you are having issues with are the green boxes, so I see it pointless sending a new harness, about the green box you can connect them to each other, and make sure they are being properly held by the zip tie so that they don't move around. No there are no fusses in the green boxes, there is actually nothing that compromises your battery or charger from the green box connectors or the wires that go to the gree boxes.

Regards,
George R.
Ticket: https://support.hybridautomotive.com/helpdesk/tickets/25270

On Tue, 28 Sep at 12:42 PM , (Removed for privacy) wrote:
Thanks so much for the information and help George!

I can’t do the method of connecting each reconditioning because I don’t wanna take my car apart every time

But I would appreciate a new harness since I’m not sure if any other wires were damaged. Also I don’t feel confident in my abilities to attach new green boxes lol

If I leave the green boxes disconnected do I leave the wire harness connectors disconnected from itself on the green box? Or leave them connected to each other on green box?

Is there a fuse on the circuit board inside green box? How would or can I prevent this from happening or causing damage since it didn’t blow harness fuse?

Thanks again,
Bear&meg

iPhone
On Sep 27, 2021, at 1:57 PM, Hybrid Automotive Support <[email protected]> wrote:

Hi Bear&meg,

It does sound like the issue is the fan box, if you don't trust the green fan box a replacement harness I don't think it will be the answer. You could just bypass it and connect it as it was originally and whenever you need to recondition the battery connect it again, I have seen cases where the green control box is able to power the cooling fan while doing the recon process, but after that is done the car and they try to drive the car the fan won't turn on while connected to the 12v original harness.

Another thing I could do is just send you the green control boxes, I think that might be the safest way to determine that you won't have that issue again.
Regards,
George R.
Ticket: https://support.hybridautomotive.com/helpdesk/tickets/25270

On Mon, 27 Sep at 12:06 PM , (Removed for privacy) wrote:


My order number is 3xxxxx from May 2021.

I was able to finally perform a full 3-cycle reconditioning in July 2021 and gained improved mpg!

However, I just recently experienced a worrisome situation that caused me to disassemble my vehicle and remove the car harness.

I suspect, without performing any testing because I don’t really know how to lol, the cooling fan circuit controller (green box) to be the source of my issue because while driving on my way home from a 260 mile round trip after my car sat for 8 hours upon arrival.

I started my vehicle to proceed home and sat in it while it was in Ready state for approximately 10 minutes while I took a phone call.

Then after reversing out of parking spot, and not even 100ft away I detected a strong electrical burning smell from behind driver’s seat in rear of my vehicle.

I immediately pulled over and actually suspected a couple power tools I had with me and had hastily packed away with their lithium ion batteries still connected. So I removed those from their tools and stored away separately safely and securely and then resumed my 130 mile trip home.

About 2 miles later I again smelled the strong odor of electrical burning and this time I was super nervous about my hybrid battery as I sniffed around for the source. I didn’t have all of my tools with me nor did I want to deal with out of town towing, lodging, and repairs.

I again immediately pull my car off the city road onto shoulder and turn it off. I sniff around and detect the strongest source of smell to be from my hybrid battery compartment especially directly behind driver’s seat.

It was a high temp ambient environment I was in at approximately 90F so I decide to crank my AC to maximum and also use the rear blower to help circulate the cool air.

This was how I was able to make it home albeit a 2.5-3hour drive ultimately took 6 hours due to my stopping and turning my car off to let it rest while I researched online.

During this trip home, I remembered I had recently downloaded Dr. Prius/Hybrid Assistant App on my iPhone and had fortunately put the veepeak OBD-II scanner in my glove box.

So upon connecting the scanner and using Dr. Prius app, my fears were confirmed that the battery bank behind driver’s seat was several degrees hotter than the other 2-even the passenger one which is always a few degrees hotter due to its location over manifold air intake.

The above all occurred last Wednesday and I was able to disassemble my car interior yet again lol to see what was going on under there.

I did not observe any visible electrical burning but the strongest source of the electrical burning smell was from the harness assembly cooling fan green box circuitry.

I removed the 4 screws and opened the case and this was the source of the smell, but again I didn’t see anything burned only smelled it.

I also tested the harness fuse for continuity and it tested to be in working function.

Before I disconnected and opened the green box, I did turn my car on to verify that each of the cooling fans was activated and on which they were.

But my car then began sounding horribly loud and idling roughly and gave me the “triangle of death” warning symbol along with the “Check Hybrid and AWD Systems” messages. The cooling fans sounded as if they were all at maximum speed and going to spin right out of their housing units and there was a significant force of air blowing from my engine compartment towards me at front of vehicle.

I then used Dr. Prius app and it indicated a P3105 battery code. Upon internet search of this general code, the cooling fans and HV ECU fall under this category. So I’m freaking out inside at this point!

I turned my vehicle off and disconnected my hybrid and 12v batteries again and decided to remove the Prolong Car Harness entirely.

I reinstalled all components necessary for hybrid battery function and safety and used Dr. Prius app and veepeak while I drove about 50 miles at mostly 30 mph with several miles at 55 mph. And the codes disappeared and my previously perfectly functioning car was and is seemingly back to normal.

I’m not sure where to go from here nor what to do. I want to be able to use my rather expensive Prolong Deluxe Reconditioning System without having to worry about it destroying my vehicle opposed to saving it!

I was promoting it via Toyota Nation and Priuschat but now I’m not so certain because I’ve honestly had nothing but troubles with this system and don’t fully trust that it will help my hybrid battery system at this point, despite the increased mpg benefit that I experienced before having to disconnect my batteries again so everything was reset and I don’t know that I’m still having mpg improvements as I haven’t kept a physical record.

I cannot keep spending hours and days disassembling my vehicle interior to access what I deem to be a faulty harness at the very least. And currently I feel that I cannot fully rely on technical support nor warranty protections from Hybrid Automotive.

I hope that HA can please help with my issue and put my fears at ease and give me confidence to be able to use my Prolong Deluxe Reconditioning System again.

There does not seem to be too many HV SUV owners using this system or they aren’t posting online about it so the most help I’ve found is on Priuschat but it would be nice to have more information in general from HA about HV SUV’s and troubleshooting.

Is there a harness available that does NOT include the cooling fan control green boxes? Or can I use a new replacement harness without installing the green boxes or splice them out?

I live a mild climate area and can leave my doors and hatch open when I perform reconditioning and can utilize a separate fan if necessary. I don’t trust the cooling fan control circuit green boxes to allow my cooling fans to properly function for the majority of the time when I’m not using prolong system because of what I’ve most recently experienced.

Any help and advice and hopefully a replacement harness at the very least would all be greatly appreciated

Thank you for your help and time!

Sincerely,
Bear&meg

2006 Toyota Highlander Hybrid AWD Base model 3.3L V6


iPhone

***emails are chronological from bottom to top. I removed my personal email, name, and order number for privacy***

This is the second encounter I’ve had via email with George and once during phone call while I was installing my harness. However, the resolution I need never does transpire. I am unsure of what else to do at this point and really do not feel confident in the Prolong Deluxe Reconditioning System going forward as most of the information I’ve received via “technical” support is lacking adequate service troubleshooting or advice. I hope that HA can convince me otherwise that the Prolong Deluxe Reconditioning System is safe for my vehicle and a quality product that HA stands behind and supports their customers as much as they’ve supported HA. Thank you in advance @jeff652

P.S. it would be satisfactory if there were some troubleshooting guides for identifying a faulty component or brief instruction on how to test a harness, charger, discharger etc etc to make sure things are working properly. I’m not just out to get a free harness as I don’t even fully feel comfortable keeping a brand new one installed. But the offer would speak volumes to HA’s customer service and appreciation

 

wow!

 

Yeah sorry it’s lengthy and my back and forth emails between George and I.
I’m feeling ‘stuck’ by obviously wanting to use my Prolong and only ever dealing with George for my problems.

So I thought I’d try another route lol idk what to do at this point and my car interior is still completely apart up to the front seats.
I’m not sure if I received a ‘lemon’ or this system is not adequately equipped for HV SUV
I’ve read only good things about Jeff on Priuschat and have watched some of his Thunderbolt YouTube videos which reinforce his expertise in this area and hopefully he can help me with my Deluxe Reconditioning System I purchased in May 2021 but only installed and used first albeit briefly in June and full reconditioning in July.

 

You could send Jeff a private message....That might help.
Or you could request a refund, and maybe contact your credit card about it????

Mine did the charge discharge cycles just fine. But I had a hybrid error and it wouldn't start.
At least I don't think it would start? I don't remember.
But I eventually by passed the harness and connected the fan back to stock and everything ran fine.
I emailed them and they said they said it was the harness and sent one to me. It took about a week?
And it was about a week before I could install it. I won't know if the problem is resolved until the next time
I need to run it through the cycle again.
I had installed the harness a week before I was able to use it and it woroked fine.
So maybe something happened during the charge/discharge cycles.
This time I left enough room to easily reconnect the fan if I have the same problem next time.

I certainly hope they will stand behind there product and get you a working system...

Sadly, they have no competition so you can't go anywhere else.

 

Thanks @ASRDogman I went to his profile and was going to do that but I didn’t see an option for pm?? I probably missed something!

I’m sorry I should’ve not been so impulsive and couldn’t think of how else to contact him when I didn’t see pm option.

Yeah I searched for alternative options after my experience upon my initial reconditioning attempt and didn’t find much else especially for HV SUV’s. And it’s a major hassle because my 3 hybrid batteries are located under the second row seats but to access them EVERYTHING must be removed from the rear hatch to behind the front seats and it’s a lot of parts and bolts and heavy seats! But I’m much faster now lol since I’ve done several times for harness installation and another project

I’m currently considering finding a hybrid mechanic with the Thunderbolt system to perform a comprehensive inspection of my hybrid battery and vehicle and then I’ll at least have a baseline of ‘data’ to work with and this would help me feel more comfortable and confident using my Prolong System in the future. Or I was just gonna take the loss as an expensive mistake even though I know the benefit is there but I’m just not sure for my size hybrid battery or if it’s something else??

I’m also gonna use the system to learn more about electrical components and testing with my multimeter so I guess it’s not a complete loss lol

Thanks again for advice

 

Have you tried phoning?
Emails are a pain....