Bringing EV Batteries Back to Life
Businesses, repair shops and battery shops across the world have utilized the NuVant EVc-30 to recondition hybrid vehicle batteries for nearly a decade. The EVc-30 creates the ability to generate a high ROI to service providers by reconditioning old and damaged batteries. It is simple to use and can recondition a hybrid battery pack with less than 90 minutes of labor. Reconditioned batteries also offer a solution to customers with an immediately available, high-quality, and cost-effective alternative to a new battery. And each time we bring an old battery back to life, we reduce the cost and environmental impact of mining and manufacturing new batteries.
As a leader in the hybrid battery aftermarket, A3 Global and NuVant Sytems invested in the development of the next-generation electric vehicle battery tester for EV lithium-ion batteries. The marketplace did not have the technology nor equipment to adequately process lithium-ion electric vehicle batteries, until now. Introducing the NuVant LVc-40.
Sneak Peek of the LVc-40 (Lithium)
The NuVant LVc-40 services the most common types of electric vehicle batteries. It allows a technician to identify faulty modules and cells within electric vehicles when their warranties have lapsed and the battery begins to lose its capacity.
Like the EVc-30 (NiMH), the LVc-40 (Lithium) has 30 channels and offers 3 to 10 V operational voltage range, allowing a battery pack to be processed with only 90 minutes of labor.
- Charge/discharge Li-ion modules and cells
- Identify weak cells (voltage, Ah capacity, internal res)
- Replace weak cells with balanced cells
Currently, the LVc-40 has been beta prototyped and is undergoing field testing. It will be available for pre-order purchase in late 2022 with shipments in late 2023.
Comparing the EVc-30 and LVc-40 models
Where the LVc-30 differs from the EVc-30 is in its ability to service Li-on electric vehicle batteries. Both tools allow for 30 modules/cells to be processed a day and come with everything required to get started.
A comparison of battery types that can be serviced:
LVc-40 (Lithium) Battery Types
- Tesla
- ETruck
- Nissan Leaf (Gen 1 2)
- Other EV batteries (LFP, NMC, etc.)
- to come in 2023
EVc-30 (NiMH) Battery Types
- Toyota Camry Hybrid
- Toyota Prius (and Prius C)
- Toyota Avalon Hybrid
- Toyota Highlander Hybrid
- GM Tahoe Hybrid
- GM Escalade Hybrid
- GM Yukon Hybrid
- Honda Civic Hybrid
- Honda Accord Hybrid
- Other HEV batteries (NiMH)
Take advantage of the hybrid and electric vehicle markets
If you want to take advantage of the market right now, battery reconditioning for hybrid vehicles is the place to be. The hybrid market is mature, and vehicles are increasingly entering the aftermarket service range. The hybrid vehicle market continues to grow year after year, and that is a trend that will continue as individuals and fleets replace their gas vehicles with more fuel-efficient alternatives. The technology is also mature enough for the aftermarket services such as battery reconditioning to provide ample revenue for businesses.
If you want to take advantage of future aftermarkets and be a first mover in the industry, consider the electric vehicle battery market.
Currently, the EV battery refurbishing market is much smaller than the hybrid market simply because hybrid vehicles have been around longer and many are beyond their battery’s warranty. But, now that the EV market is over 10 years old and growing quickly, the market for servicing EVs is here.
Whether you want to take advantage of the biggest market, become a leader in the growing EV market or both, it can be quite a profitable venture. All you need is the equipment and the knowledge to do so.
Nuvant provides both — offering state-of-the-art reconditioning and repair equipment for HEVs and EVs, and offering all start-up resources needed to open a business — such as training and cores.
Partner with us to bring electrochemistry to the streets! Explore hybrid and electric products here.
This Article Contains
Battery reconditioning is the process of returning dead battery cells to full health and charging capacity.
But why is reconditioning even needed in the first place?The lead acid battery generates electrical energy through a chemical reaction between its electrolyte fluid (consisting of sulfuric acid and water) and lead plates.
Each time a battery discharges, lead sulfate crystals form on the battery plates. When the lead acid battery is recharged, the lead sulfate disperses.
However, not all of it goes away.
With time, the lead sulfate crystals build up, affecting the charging and discharging capacity of the battery. This condition is called sulfation.
Sulfation causes the battery to undergo longer charging times, have less charge capacity, and become less efficient until it eventually can’t hold a charge.
Here’s where battery reconditioning steps in.
The battery reconditioning process helps clean off the excess lead sulfate crystals in each battery cell and replenish its electrolyte solution, allowing the battery to function almost like new.
So, how is battery reconditioning done?
Lead Acid Battery Reconditioning (Step-By-Step Guide)
Battery reconditioning can be done on both a flooded lead acid or sealed battery.
It involves these seven steps:
Before you begin, there are a couple of things you need to get ready ahead of time.
Required Items
Here’s what you’ll need to have on hand.
- Protective gear (safety goggles, apron, chemical-resistant gloves, etc.)
- Toothbrush, steel wool, or battery terminal cleaner
- Flathead screwdriver
- Funnel
- Bucket
- Battery charger
- Voltmeter or multimeter
Safety Measures
To start, suit up with your protective gear. Battery electrolyte contains sulfuric acid, and you don’t want any on your skin or clothing. Make sure you work in a well-ventilated area in case of splashes, spills, or released fumes.
Check your car battery for any kind of damage — cracks, bloating, leaking. Don’t bother reconditioning a physically compromised battery. Get a new battery.
Check The Battery Voltage
Checking the battery voltage will tell you if the battery is viable for reconditioning.
The standard 12V car battery has six cells. Each battery cell generates a cell voltage of 2.1V, so a healthy battery reading will be around 12.6V.
Touch the voltmeter or multimeter (that’s set to read voltage) to the battery terminals — the red cable to the battery’s positive terminal and the black cable to the negative terminal.
The battery may be reconditioned for a voltage reading between 10V-12.6V. If it’s less than 10V, you have a completely dead battery and should replace it.
If all is fine, you’re ready to proceed with the reconditioning process:
Mix The Cleaning Solution
Mix the baking soda with distilled water to create a watery paste. The ratio should be 2:1 or 1:1 of baking soda to distilled water. Don’t use any other type of water (like tap water) as these may contain unsuitable trace minerals.
This solution will act as the battery cleaner and also to neutralize any acid spills.
Clean The Battery Of Corrosion
Detach the battery cables — negative (-) battery terminal first, then the positive terminal.
Apply the cleaning solution to any corroded battery terminal, then use the toothbrush or steel wool to scrub. Corrosion impedes the transfer of electrical energy, so it’s important to remove it from the terminals and cable connectors.
Alternatively, a dedicated battery terminal cleaner would also work here.
Empty The Battery Cells
Remove each battery cap and place them in a temporary container, so you don’t lose them. If it’s a sealed battery, use the flathead screwdriver to pry off the battery cover and battery cell caps underneath.
Carefully empty the battery acid from each cell into the bucket.
Add around 500gm of baking soda to the bucket to neutralize the battery acid, so it’s safe for disposal at a recycling center.
If there are any spills, pour the baking soda cleaning solution to neutralize this too.
Clean The Battery Cells
With a funnel, fill each battery cell with the cleaning solution. Replace the battery caps and shake the battery between 30 seconds to 1 minute.
Open the battery caps again and empty the cleaning solution into the bucket.
Replace The Battery Electrolyte
Dissolve 120gm of Epsom salt in 1 liter of distilled water (this creates an electrolyte of 1 molar concentration). You can warm up the water to help dissolve the Epsom salt. Mix it well until there aren’t any solids left.
Fill each battery cell and close the battery caps. Shake to distribute the salt evenly.
Recharge The Battery
Set the battery in a safe and secure area.
Remove the battery caps again as an additional precaution — the electrolyte solution will heat up and may overflow during charging.
Connect the battery charger to the battery terminal — the red wire to the positive terminal and black wire to the negative terminal.
Keep the charger as far away from the battery as possible, then set it to charge a very low current of 12V / 2 Amps. Charging at a low current allows the Epsom salt to break down the lead sulfate crystals on the battery plates.
Let the battery charger run for 24-36 hours.
Test Battery Voltage And Loading
Disconnect the battery charger and check the battery voltage with the voltmeter. The readings should be around 12.42V. If lower, reconnect the battery charger and charge up for another 12 hours.
If all is well, perform a rudimentary load test:
- Reinstall the battery, turn the ignition key to “ON,” and switch on the high beams
- Check the battery voltage again
Battery Reconditioning FAQs
Here are the answers to some common questions on battery reconditioning:
What’s The Difference Between Reconditioning And Recharging?
Battery recharging is simply charging up the battery for a period of time.
Battery reconditioning, however, means restoring a battery to full functioning capacity. It’s not the same as battery conditioning when you charge a new device battery before using it.
While battery reconditioning can be done with materials found at home, there are also services that use a dedicated battery regenerator (or battery reconditioner). The battery regenerator uses high-powered pulses to break down sulfation on battery plates.
Why Would I Want To Recondition My Car Battery?
There are several advantages to reconditioning batteries.
Car battery reconditioning can:
- Extend your battery life: Lead acid batteries typically last 3-5 years. Reconditioning an old rechargeable battery can extend its life by a year or two.
- Save costs: You can save some money by not having to purchase a new battery.
- Help the environment: Fewer batteries will be disposed of, lessening the exposure of pollutants to the environment.
When Shouldn’t I Recondition A Battery?
There are a couple of situations where you shouldn’t recondition a battery.
- When the batteries have been reconditioned three times or more: Battery performance degrades with every reconditioning (and age), so it reaches a point when it can’t be refurbished anymore.
- When the battery is damaged: A physically damaged battery shouldn’t be reconditioned.
- When reconditioning materials aren’t available: If you don’t have the right materials, don’t attempt reconditioning.
How Long Do Reconditioned Batteries Last?
A reconditioned battery can typically last around one year, so you can theoretically extend its life by at least three years if you repeat the process a few times.
When Should I Recondition A Car Battery?
Battery reconditioning is typically performed when it has lost around 30-40% of its original capacity. However, if it’s lost part of its plates from sulfation or is severely corroded, it might not be recoverable.
Note that desulfation using a battery regenerator (battery reconditioner) can be done at any time. It can help improve batteries that are even as young as 1-2 years old.
Can Other Types Of Batteries Be Reconditioned?
Yes. Lead acid batteries aren’t the only ones that can be reconditioned.
For example, a laptop battery is well-suited for reconditioning. This is typically a lithium ion battery, NiMH, or NiCad battery.
Hybrid battery reconditioning is also an option for the relatively expensive hybrid vehicle battery. Just know that each battery type has its own reconditioning methodology due to differences in chemistry.
What Is The EZ Battery Reconditioning Program?
EZ Battery Reconditioning is an online program for battery fixing, recharging, and reusing.
The EZ Battery Reconditioning guide covers different types of batteries, including the:
- Lead acid battery
- Lithium ion battery
- Alkaline battery
- AGM and SLA batteries
- NiCad battery
- Forklift battery
- Laptop battery
How to recondition hybrid batteries
Reconditioning a hybrid battery consists of charging, discharging and balancing the battery pack. This process breaks down the voltage depressions within a battery’s cells restoring the usable capacity and balancing the voltage levels between each cell. At the end of the reconditioning process, the battery will have a better capacity output for the vehicle to utilize.
Reconditioning can be a relatively easy process for those who have the proper knowledge and the right equipment. Here is a simplified version of the steps it takes to recondition hybrid batteries:
- Inspect the battery
- Remove and replace any broken modules
- Charge and discharge modules in parallel
- Use a hybrid battery reconditioning tool for this step
With the right tools, equipment and expertise, reconditioning can become a valuable resource for repairing hybrid vehicles. Here’s a video that demonstrates how to recondition and repair a hybrid electric vehicle battery with reconditioning equipment. https://youtu.be/IImnqNn6NXA
Examples of EVc output before and after conditioning
There are some who are skeptical of how well reconditioning works. To get a true understanding of what reconditioning does and how well it works, you have to see it in action. Below you will see real examples of EVc output files for popular traction battery packs.
Ford Escape Battery Reconditioning Data
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.
When it comes to reconditioning hybrid batteries, there is some equipment and tools that are required.
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.
Our top selling Hybrid Battery Repair Tool is the EVc-30. When purchasing, it includes the EVc unit, training and EVc software (EVcharge). EVcharge imports module state-of-health data from the EVc-30.
Examples of EVc output before and after conditioning
There are some who are skeptical of how well reconditioning works. To get a true understanding of what reconditioning does and how well it works, you have to see it in action. Below you will see real examples of EVc output files for popular traction battery packs.
Ford Escape Battery Reconditioning Data
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.
When it comes to reconditioning hybrid batteries, there is some equipment and tools that are required.
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.
Our top selling Hybrid Battery Repair Tool is the EVc-30. When purchasing, it includes the EVc unit, training and EVc software (EVcharge). EVcharge imports module state-of-health data from the EVc-30.
Hybrid battery reconditioning Information for Shop owners and Businesses
As the vehicle market rapidly changes, many garages and auto shops wonder if adding a hybrid battery reconditioning service is worth the time, effort and investment.
Electric and hybrid vehicle sales in the United States nearly doubled from 2020 to 2021. As more and more consumers are turning to electric and hybrid vehicles, they will seek reconditioning as a cost-effective solution to repairing their batteries.
For a business owner to decide whether a service is right for them, they need to consider more than if there is a market for the product. As you’ve discovered earlier in this guide, there is equipment required and knowledge to implement this type of service. We find that owners ask themselves three main questions when thinking about adding a reconditioning service to their offerings:
- Is there a market for it
- Are our people capable of learning the necessary skills
- Is the investment worth it?
At NuVant, when we sell reconditioning equipment we offer training on how to use the tools. We also provide free educational webinars every month as refresher courses or to help mechanics hone their skills. We believe that the use of the HEV tools shouldn’t be the thing that stops businesses from reconditioning batteries.
This leaves the main question of is it worth it, up to the individual shop owners. Here is a blog article that breaks down the ROI of hybrid battery reconditioning to help you understand the numbers. However at the end of the day, it’s up to you to decide if it’s worth your investment.
While reconditioning equipment is out of reach for most consumers, it’s a great investment for shop and fleet owners. This creates a win-win situation for both shops and consumers. Consumers have a chance to save by reconditioning rather than fully replacing their batteries, fleet owners can benefit in a similar fashion, and shop owners have an opportunity to generate a positive return on their investment easily within the first year of implementing this service.
The first step for your shop is to purchase the required equipment. Click here to request a quote. If you would like to speak with someone about what’s required to make this work for your shop, then contact us and we can help you understand the process.