Reconditioning Experience with Hybrid Automotive's Prolong System

this makes sense, thanks

 

is there any way to flatten out a module? one of the 2 I ordered from Hybrid Automotive was slightly bent and so I couldn't install both (the other had a less severe bend). luckily only one of the 2 in the block needed replacing.

 

I suspect @jeff652 would replace it. Perhaps inadequate packaging before shipping?

 

the box was a little beat up and not much bigger than the diagonal on these so I suspect it got dropped on the corner. waiting to hear back from customer support

 

Snap a few pics of it and call us on Monday, we'll send a replacement to you.

 

Bent modules are usually the ones that sit on the outside of the pack, #1 and #28. Unless it's extremely bent you should be able to use it.

 

That may be true but the business owner already offered a replacement in the post above yours.

 

I saw similar when I completely disassembled my pack to shuffle all the modules during a repair. Once I tightened the big bolts, it sandwiched them back to parallel and all the small mounting screws lined up. FWIW

 

believe me I tried it on the end and there was no way I was getting that thing to fit, and doubt it would have been an easy job even with another set of hands.

 

You people should be removing the exterior case from the modules.

1. Remove the bus bars
2. Remove the 8mm bolts from under the case
3. Remove the 2 10mm nuts on the case corners
4. The bottom of the case should come off.

Now you're free to work on the modules without having to disfigure the modules, the case or your hands

 

not sure that would have helped as there's no real a way to push the modules together while trying to get the end piece on. even without the bent module I had to put the end in, then force the last module in the remaining space.

 

There's not suppose to be any pushing, it suppose to be effortless. The modules are held together by their clamps. 4 12mm bolts on top (you only need to loosen 2 on 1 side), 4 12mm bolts on the bottom (you also need to loosen 2 of these on 1 side). Once those bolts are tightened, they should fit perfectly into the base of the case.

You are NOT suppose to unbolt the clamping bolts until you remove the 28 modules from the base of the case. If you're following youtube videos, then there might be a problem because 99% of them are doing it wrong

 

I'm pretty sure his issue was caused by the fact that he was working with a hot pack, fresh out of the car or off the charger. The modules build internal pressure while in use and swell, the caged keeps them tightly together and this is the cause for the bent outside modules. It takes 6 to 12 hours for them to cool off before they can be disassembled/assembled without much hassle.

 

Oh yes, never work on a hot pack, need to let it rest overnight

 

neither was the case. car had been sitting cold for 3+ days

 

Here we go.
I've got a 2005 Prius with 212,000 miles. We bought it 6,000 ago with a dead battery. I replaced block 8 and got it running....for 5 months, then the next mole appeared, so I whacked block 5.
I've now got it on the first charge of a recondition.
Currently about 60F outside.
Starting voltage 236v.

I haven't found a definitive instruction as to when to stop the charge. Is there a certain voltage?

 

Charge for about 24 hours and then start the discharge. Since you've done it 5 months ago, you're probably only needing 1 or 2 discharges and you'll be good to go

 

240V is a great target, and if you check previous threads, you'll see that some of my "long soaks" have ended up at 240V (after about 40 hours) - so 240V has become my target, and I'll be doing a ½ yearly full-recondition at the end of this month, so watch this space!

 

Hmmmmm I've gone from 236v start voltage, and I just checked, after 4 hr 40 mins I'm at 239v. Does that sound reasonable or is that a bit quick, hinting at a poor battery?

 

Mine is plugged in as we speak. Time for the every 1/2 year full recondiiton. After the long 40 hour soaks in December things have been much more stable and the charge-only cycle in March held up better. I think I'm going to back off a little though because the temperature is already pretty warm here. This time I'm going to try to get away with only two discharge sessions (skipping the lowest voltage one) and I won't go anywhere near 40 hours on a charge. I'll go long in December again.

If it works, great. If it doesn't I can always give it a boost a little ahead of schedule.