HEV & EV Power Tester

The EVd-40 Power Tester is a pre- and post-reconditioning tool for quality control of aftermarket HEV & EV battery production. The equipment integrates a “smart” charger (Sorensen XG 1700 or Kepco KLN 1500W) with NuVant Systems high power discharge electronics. The "power test" discharges battery packs at high power (10,000 watts), while tracking module voltages. The software monitors up to 40 module voltages at a time, identifying any weak modules. The "smart" charger performs charging constant current (CC), constant voltage (CV) and complex mixed mode constant current – constant voltage (CCCV) charging protocols at voltages up to 600 V. This enables recharge of any type of rechargeable battery. 

Testing Equipment

Max Discharge Power
10,000 watts
Number of voltage sensors
up to 40
Max Charge Power
1690 watts
Max Charge Voltage
600 V
Max Charge Current
2.8 A
CC-CV Indicator
CV: TTL High (4-5 V) CC: TTL Low (0-0.6 V)
Data Acquisition
Cortex-M4F (120Mhz)
Min Sampling Interval
200 ms (40 modules)
DAC Resolution

The EVd-40 can discharge batteries at high power (10,000 watts). A Prius battery subjected to this discharge power will exceed initial currents of 40 amps. The EVd-40 is equipped with 40 sensors for measurement of individual module voltages during Power Test discharges. The Power Test tool uses a high voltage harness for monitoring up to 40 Toyota prismatic modules during the high power discharge. Custom harnesses for individual module monitoring of other batteries can be prepared upon request. Individual module voltage monitoring during high power discharge identifies weak modules that are not identified during lower power battery reconditioning processes.

The system includes:

  • software configured laptop computer (USB connection to EVd unit)
  • software upgrades

Note: Because the number of modules (and order of modules) vary per vehicle battery pack, the EVd battery harnesses are not interchangeable. EVd buyers must purchase battery harnesses for their specific battery pack.

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