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Testing Complex Main Features

Our 20-Channel Battery Capacity Analyser with Charger and Load

HV Battery Analyser:

  • Measures individual battery capacity in Charge (CHRG) or Discharge (DSCH) modes
  • Provides visual representation of charge and discharge process of the individual modules and their performance in easy to understand colored bars
  • Plots graphs
  • Stores measured capacity and other parameters in a database to assist in compiling the pack from the modules with the similar parameters
HV Battery Analyser manages external charger and/or dis-charger (load) to allow flexibility of choice of equipment being used.

HV Analyser consists of custom build hardware and proprietary software.  We build different version for 14, 19, 20 Channels to test packs comprised up to 40 individual modules.

HV Battery Analyser measures and records multiple parameters – e.g. individual capacities, voltages, time and other metrics.

After test is finished measured capacity of the individual battery is displayed in a bar or chart format.

19-channel Battery Analyser. Measured Capacity

19-channel Battery Analyser

If you were using conventional methods you will not be able to spot those two failed modules in the pack, but our Battery Analyser does it in an easy way:

20-Channel Battery Analyser

20-Channel Battery Analyser

Battery capacity test. 12 year old modules. Before discharge.

Built-in database keeps the records of vehicles, tested battery packs and measured capacities of the individual batteries (battery modules).

Data is presented in a manageable form and allows compiling new packs from the batteries of similar capacity.

HV Battery Analyser features specially designed safety Alarms.

When alarm goes off – it activates Voice Alarm, Screen Alarm and cuts off High Voltage Relay Controlled Circuitry (HVRCC) if required.

Alarms are triggered by the individual battery low/high voltage, over current, over temperature, capacity reached, time lapsed.

Alarms could be dynamically deactivated during operation.

HV Battery Analyser Safety Alarms

HV Battery Analyser Safety Alarms

HV Battery Analyser hardware is assembled in a metal enclosure, has LED indicators, switches and cable connectors, see photos on the right.

Hardware part is controlled by PC and connects to:

– Battery Pack or part of it, and

– Charger or Dis-charger (Load) depending on the testing mode (CHRG/DSCH)

20-channel Cradle and Insulating Sockets

External Temperature Sensors are optionally connected to the Battery Analyser and could be attached to the battery pack, installed inside the charger or load.

HV Battery Analyser measures capacity of batteries connected in series. Each battery may have from 1 to 12 cells inside. Batteries from different applications could be tested – e.g.

–          Toyota Prius or Honda Hybrid – individual battery (6 cells) or pair of those (12 cells) in assembled pack, or

–          Some other Toyota / Lexus Hybrid (8 cells per battery).

Watch Video: Testing Complex Main Blocks, Cables and Safety Alarms in action

Watch Video: Battery Test For Dummies – Comparative Test of 20 Prius Modules


NiMH Batteries are charged in a Constant Current (CC) mode.

See few of our custom built chargers on the picture below.

We build specialised chargers. for charging 14, 17, 19, 20, 28, 40* x 7.2 (or 30 x 9.6V) NiMH modules connected in series – e.g. Prius, Prius – C, Aqua, SAI, Camry (1/2 pack), Lexus*, Highlander*, Honda

Input: 100-240V AC, 50/60Hz  – i.e. USA, Canada, Europe, Asia, Oceania

We use Isolated Switch Mode Power Supply (SMPS) Industrial type boards made in Japan and/or South Korea.

Prius and Lexus Battery Chargers

High voltage battery chargers

*For Lexus/ Toyota / Highlander (288V, 40 x 7.2V or 30 x 9.6V) we have Resque Hybrid Battery charger, pictured below. Operates from 12V 26A DC:

Analogue Voltage meters or digital meters could be used.

Temperature sensor inside the charger could be monitored by the HV Battery Analyser to cut of HV circuitry if the charger is overheated (e.g. in case of the cooling fan malfunction).

Current is monitored by the HV Battery Analyser which will set up alarm and cut of HV circuitry to the battery pack if there is over current.

Charger is connected to the battery pack through the Analyser.

Different types of loads can be used with Analyser in discharge mode to measure capacity and battery performance at different discharge currents.