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EVc hybrid battery repair tools

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Hybrid vehicle battery reconditioning & cell balancing

You can purchase a new or refurbished hybrid vehicle battery from Thornaut. When you install our new or refurbished batteries, you will get a core return. The core modules can be reconditioned and placed in valuable inventory. The EVc units will refurbish cores with no prior experience required. Anyone can recondition, balance and replace a battery using the EVc battery repair system of equipment and software.

Battery reconditioning and cell balancing is a well understood process initially developed for NiCad batteries. NuVant has simplified the process to bring electrochemistry to the streets.  The EVc unit is a push-one-button-after-wire-up system for mom and pop shots to large vehicle operators. The EVc-120 will refurbish a 240 module hybrid bus core with less than 12 hours of labor and a bit over 1 day of unit processing time.

EVc-30 reconditioning a Prius module assembly

We ship world-wide! Over 100 EVc battery reconditioners operate in 14 countries / 6 continents!

Niagara Frontier Transit Authority has initiated use of reconditioned modules (240 modules/pack) on their public transport buses. 

The turnkey system includes:

  • software configured laptop computer (USB connection to the EVc unit)
  • battery pack cooling box
  • free software upgrades

The EVc battery reconditioner comes in 3 models:

Provide your full information and NuVant will respond within 24 hours.

EVc info sheet


Video: How to use the EVc Battery Reconditioner


Equipment for hybrid vehicle battery reconditioning, repair and balancing 

What is a hybrid battery module?

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

 cells/modulemodule Vtypemodules/packpack V
Ford Escape56cylinder25150 V
Prius67.2prismatic28202 V
Honda67.2cylinder26187 V

What does “out of balance” mean?

The driving cycle of a hybrid vehicle subjects the battery pack to repeated shallow depths of discharge of less than 10% of the battery capacity. The unused capacity undergoes a correctable degradation process that reduces battery capacity. This failure process (i.e., module-to-module variation of amp-hour (Ah) capacity) is referred to as an “out of balance” pack. The modules have a memory of the small capacity demanded, thus resulting in the term “memory effect”.

What is battery cell balancing?

Reconditioning recovers lost capacity. When reconditioned modules are sorted and positioned for optimum performance, the battery pack is balanced. The steps are:
1 Extract the hybrid battery pack from the vehicle
2 Remove the high voltage cable
3 Connect modules in parallel to the EVc-30 (see photo below)
4  Press the start button.

The output report:
identifies high resistance modules (e.g., > 10 mΩ for a 6-cell module).
b enables sorting and selecting of modules for pack assembly based on amp-hour or watt-hour capacity.
pairs up modules into blocks based on module rest voltage.
archives all data for your warranty  management program.

EVc units are priced for a payback period of less than 2 months when fully deployed. The EVc tools are simple to use.

What tools are required for hybrid battery reconditioning and repair?

The required tools are (1) a menu driven charge discharge cycler (the EVc tool),  (2) software for analysis of amp-hour capacity and midpoint voltage data on every module maintained in inventory, (3) a QR code reader and (4) a 50 inch-pound torque limited nut driver.

Hybrid battery repair tool:  EVc-30
Includes EVc unit, training and EVc software (EVcharge). EVcharge imports module state-of-health data from the EVc-30.

How long does it take to recondition a hybrid battery pack?

High quality cell balancing requires a minimum of 20 hours on the EVc tool. NiMH modules have system parameters specific to the form factor (e.g., prismatic versus cylindrical) and number of cells in series (e.g., Ford Escape: 5; Prius prismatic: 6; etc.). These parameters govern the choice of recipe parameters. Balancing recipes and their automated implementation are covered in the NuVant battery reconditioning course.  The business model is: 1. Establish an inventory of reconditioned modules archived with watt-hour capacity and nominal module voltage data. 2. Replace customer hybrid batteries. 3. Recovery the battery core from the customer.

What kind of data does the EVc output file provide?

NuVant EVc units are the only systems on the market that provide:
(1) internal resistance
(2) amp-hour capacity
(3) watt-hour capacity
(4) nominal module voltages

The chart below is a real time display of module parameters during the cell balancing process.

Screenshot of EVc module data

Example EVc output files for popular traction battery packs are shown below.

Toyota Highlander (click on figures to expand)

EVc data from Toyota Highlander Pack (before reconditioning)
Toyota Highlander EVc data (after reconditioning)

Ford Escape (click on figures to expand)

Ford Escape EVc data (before reconditioning)
Ford Escape EVc data (after reconditioning)

Toyota Prius (click on figure to expand)

Toyota Prius EVc data (before reconditioning)
Toyota Prius EVc data (after reconditioning)

How can I rapidly start up my battery replacement and installation business? 

The hands-on hybrid electric vehicle battery reconditioning short course allows participants to connect Prius pack modules to an EVc reconditioning unit for cell balancing. During the reconditioning process, the terminology required for understanding cell balancing will be thoroughly explained.  On the second day, results of the overnight process are thoroughly discussed along with data processing.

EVc Specifications

Load
Max Load Voltage 10 V/channel (Customized up to 20V)
Max Load Current5A per channel
Number of channels 10, 30 or 40 channel systems
Applied Current Accuracy0.5% of the Applied Current
Applied Current Resolution.3 mA
Potential Measurement
Measured DC Potential Ranges10 V/channel (Customized up to 20V)
Resolution .6mV
Accuracy0.08 or 0.03% of FSR
Current Interrupt Resistance 
Data Acquisition Speed12.5 kS/s
Serial Resistance Precision0.5 %
Measurement logging time1 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
    • BRIMS package for business management.
  • Additional 5-hour EZtime tickets can be purchased for $450.

Call 219-644-3231 for more details!

For zero down payment alternate to the NuVant financing plan, consider Crest Capital Financing for US buyers.

For USA Financing: Crest Capital Financing 

Crest Capital finances NuVant products