Prolong Discharger problem

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by bdubs85, Jan 11, 2021.

  1. MEOVN63

    MEOVN63 New Member

    Joined:
    Jul 28, 2022
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    Location:
    Los Angeles
    Vehicle:
    Other Hybrid
    Model:
    N/A
    I bought the Prolong Deluxe kit for my 2010 Toyota Camry Hybrid. The charger unit is working fine. However, the I was not able to get the Discharger unit working at all. Each time I turn on the Discharger unit, the Fault light started flash RED and the unit does not do anything. Press and hold reset button does not do anything.
    Talking to George at Hybrid Automotive, he provided RMA # and I sent the unit back for repair. Two weeks later, I received the unit and plugged it in - It still not working as it showed the same original problem (flashing red Fault light). This is very frustrating experience (as I really do miss Amazon)! Called and talked to George, he told me to record a video to show the issue so he can send that to the factory so they can make a decision! What kind of customer service is this when the company sold unit to customer at high price (it is definitely not cheap for the Deluxe kit)? Very disappointed. I am wondering if others have the same problem and how to resolve with the company. Thank you very much for your info
     
    VFerdman likes this.
  2. VFerdman

    VFerdman Senior Member

    Joined:
    Jul 5, 2017
    1,179
    1,194
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    Location:
    Western Massachusetts
    Vehicle:
    2007 Prius
    Model:
    Three
    I would like to add to this thread from my experience. I purchased the deluxe kit, which includes a charger, dis-charger (electronic, not light bulb) and harness for Gen 2 Prius. I have owned it since 2017 and have used it once a year on my 2007 Gen 2 Prius with original battery. Everything worked well until a fuse blew in the charger and I had to go inside and replace the fuse with a 2A on recommendation of the Prolong tech support. All good. Fast forward to my latest session last week. All was going well, but during the first discharge cycle, the process stopped dead after getting the battery to about 180V and just kept reading 0.001A current and unit staying stone-cold. One minute it was working fine and staying nice and warm (that is how it discharges the battery, it warms up some power resistors inside). Being an electronic tech (among other things), I took the unit to my electronic bench and opened it up. I must say, it is put together very well inside except for one thing. The bank of power resistors, which is enclosed into a metal case, consists of eight 12 ohm resistors connected in series with bus wires. Well, those bus wire connections were done very poorly in my unit and one of the solder joints just let go because of the heat. To make a long story short, I replaced all the bus wires with my own, which I made longer so as to be able to wrap the ends around the resistor eyelets before soldering. I used regular electronic solder that melts around 700 degrees F or so. I don't think it should ever reach that (or we have bigger problems). After putting the unit back together, everything worked great and I completed my conditioning just fine. It was just very obvious that the resistor pack was not assembled well. The bus wires barely made contact with the resistors, were not wrapped and only attached by solder blobs that were not even all that strong. Basically relying on solder for mechanical connection. That is never ever a good idea and solder is not designed to provide mechanical hold. As someone who knows how to put these kinds of things together, I can say that the resistor pack in my unit was not put together properly and the failure was predictable. The solution is stupidly simple. Eight pieces of wire to replace the other eight pieces of wire. I could have just re-soldered the failed joint, but that would not address the root cause of the problem. So I took the better part of an hour and re-did the whole resistor pack. If anyone has a non-working dis-charger and Prolong is not addressing the issue, I may be able to help. Please contact me and we may be able to solve your problem. These are very expensive pieces of equipment and are generally well-made. I think the resistor pack was probably purchased as a unit from somewhere and that somewhere did not do a good job of putting it together. The parts themselves are good and everything inside looks good and construction of the box is super-sturdy. Just weak solder joints on the very part that takes the brunt of the physical work (heat).