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HEV battery reconditioning equipment and training

Home :: Hybrid Vehicles :: HEV battery reconditioning equipment and training

Hybrid electric vehicle (HEV) battery reconditioning/refurbishing equipment.

What is an HEV battery module?
Modules are nickel metal hydride (NiMH) battery cells connected in series. An NiMH 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. A traction battery pack comprises modules that are configured in series. A Ford Escape has two 25-module traction battery packs.  A Prius has a single 28-module pack. Modules must be reconditioned in parallel, not in series. One cannot control individual module voltages when they are connected in series (as in the vehicle).

  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. Ah capacity variations are characteristic of “out of balance” battery pack modules.

What is reconditioning (or conditioning)?
Reconditioning is (1) removal of the traction battery pack from the vehicle, (2) removal of the series connection high voltage cable, (3) connecting all the modules in parallel to an EVc reconditioning unit, (4) rapidly identifying and removing high resistance batteries and finally (5) subjecting the remaining pack modules to a series of deep, split-current, cycling. 

What tool is used for reconditioning?
The EVc-10, EVc-30 and EVc-40 are fully automated battery cyclers that are used to recondition or repair modules that have undergone reversible failure modes such as the acquisition of memory effects due to repetitive shallow depths of discharge. Reconditioning is also known as battery refurbishing, or conditioning.


Hybrid electric vehicle battery refurbishing equipment.

EVc-30 hybrid electric vehicle battery reconditioning tool.















How long does it take to recondition an HEV pack?
An EVc-40 can recondition 120 modules in 2 days with a labor requirement of 5 person-hours.

What data output 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 prior to an EVc purchase?
Hands-on hybrid electric vehicle battery reconditioning short course enables hands-on participation in a reconditioning demonstration. After the purchase of an EVc unit, NuVant provides a deep training that will be all you  need to start you business.


For EVc specifications and prices click here.



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


How do I get complete training after an EVc purchase?

EVc training in Crown Point, Indiana or on-line with TeamViewer: $1000/person

  • 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.
  • In-house training is one-on-one with NuVant experts.

Start with a low-cost EVc-05 or EVc-10. Trade up to the EVc-30 or -40 as you gain experience and confidence.

Call 219-644-3231 for more details