• 130 N. West Street Crown Point, Indiana 46307
  • Toll Free:   866 894-7337

Hybrid vehicle battery reconditioning | repair equipment

Home :: Hybrid Vehicles :: Hybrid vehicle battery reconditioning | repair equipment

Hybrid vehicle battery reconditioning, repair and maintenance equipment for individual | fleet servicing

What is an HEV battery module?

Modules are nickel metal hydride (NiMH) battery cells connected in series. A NiMH battery cell has a nominal voltage of 1.2 V. A Ford Escape has 5 cylindrical NiMH cells per module. A Toyota Prius has 6 prismatic NiMH cells per module. HEV traction battery pack consists of modules configured in series. A Ford Escape has two 25-module traction packs. A Prius has a single 28-module pack.

  cells/module module V type modules/pack pack V
Ford Escape 5 6 cylinder 25 150 V
Prius 6 7.2 prismatic 28 202 V
Honda 6 7.2 cylinder 26 187 V

What does “out of balance” mean?

Hybrid electric vehicle (HEV) battery modules undergo shallow depth of discharge. Unused electrode material becomes physically separated and unavailable. This reversible failure mode causes module-to-module variation of amp-hour (Ah) capacity. These variations constitute an “out of balance” battery pack. Reversible loss of capacity is often referred to as the “memory effect”.

What is battery reconditioning, conditioning or repair?
Reconditioning: (1) extract vehicle battery pack, (2) remove high voltage cable, (3) parallel connect modules to EVc conditioning equipment, (4)  rapidly identify and switch-out high resistance modules (e.g., > 10 mΩ for a 6 cell module) and (5) subject modules to a series of deep, split-current, cycling and pulses (i.e., the protocol). Reconditioning is done in parallel because individual module voltages cannot be controlled when connected in series. Modules are initially charged at high currents and low voltages. The charge currents taper down as the end of charge voltage is approached. EVc battery conditioning equipment automates the entire charge/discharge protocol. 

What tool is used for battery conditioning / repair?
The EVc-10 and EVc-30  are fully automated battery cyclers that recondition or repair modules that have undergone reversible failure modes such as “memory effects” due to repetitive shallow depths of discharge. Battery reconditioning is also known as battery refurbishing, conditioning or repair. We highly recommend that EVc users procure a QR code reader to track module history.  We suggest the Code Reader 900FD.  


EVc hybrid electric vehicle battery repair unit.

EVc-30 hybrid vehicle battery reconditioning unit connected in parallel to a 28-module Prius pack.















How long does it take to recondition a hybrid battery pack?
Assuming a 5-day work week (24 hrs/day), an EVc-30 can recondition 212 modules per week, with a direct  labor requirement of 6 hrs./week.

What battery conditioning data does the EVc provide?
The EVc gives internal resistance, amp-hour and watt-hour capacity for every module. This enables the ranking of modules for pack rebuilding. Output files are exemplified below:

Toyota Highlander (click on figures to expand)

EVc-30 provides complete data for every module reconditioned.

EVc-30 data: Toyota Highlander pack before reconditioning.

Note the uniformly low internal resistance of the EVc-30 reconditioned pack.

EVc-30 data: Toyota Highlander pack after reconditioning.


Ford Escape (click on figures to expand)

Before reconditioning there is wide variability in the amp hour capacity in internal resistance.

EVc-30 data: Ford Escape pack before reconditioning


Pack reconditioning removes variability in Ah capacity and internal resistance.

EVc-30 data: Ford Escape pack after reconditioning



Toyota Prius (click on figure to expand)

There is wide variance in Ah capacity and internal resistance prior to reconditioning.

EVc-30 data: Toyota Prius pack before reconditioning

Reconditioning removes Ah and internal resistance variability.

EVc-30 data: Toyota Prius pack after reconditioning


Battery-sorting software module

Critical battery parameters are calculated

Real time display of comparative battery parameters and charge/discharge curves















How do I learn more about battery repair prior to purchasing an EVc?
The hands-on hybrid electric vehicle battery reconditioning short course has participants interfacing a Prius pack to the EVc-30 reconditioning unit and going through the entire reconditioning process.  On the second day, results of the overnight process are thoroughly discussed.   

Testimonials from existing EVc users

Click here for specifications and prices.



Max Load Voltage  10 V/channel (Customized up to 20V)
Max Load Current 5A per channel
Number of channels  10, 30 or 40 channel systems
Applied Current Accuracy 0.5% of the Applied Current
Applied Current Resolution .3 mA
Potential Measurement
Measured DC Potential Ranges 10 V/channel (Customized up to 20V)
Resolution  .6mV
Accuracy 0.08 or 0.03% of FSR
Current Interrupt Resistance 
Data Acquisition Speed 12.5 kS/s
Serial Resistance Precision 0.5 %
Measurement logging time 1 second


What if I need additional training after an EVc purchase?


New owners of EVc reconditioning equipment receive a complementary 5-hour EZtime ticket. This complementary on-line (TeamViewer) training provides sufficient time for remote reconditioning of your first 2 packs simultaneous with the suggested training agenda.  

  • On-line training provided after customer receives purchased EVc unit. Training includes:
    • Unpacking and set-up of EVc unit.
    • Connections to prismatic or cylindrical modules
    • Use of EVc to identify high resistance modules
    • Module reconditioning
    • Database module sort and pack build-up.
  • Additional 5-hour EZtime tickets can be purchased for $175.


Call 219-644-3231 for more details