About this replacement
New Age Pocket Family / Physio Pro / Rehab / Ionotens — 6V Ni-MH Replacement Battery (BM663-1)
This is a 6V, 2000mAh Ni-MH replacement battery for New Age medical devices, including the Pocket Family, Physio Pro, Rehab, and Ionotens lines. It replaces OEM part number BM663-1 and fits the full range of portable therapeutic and diagnostic units in this family. Capacity is 2000mAh (12Wh), matching the original specification.
- Pocket Family and extended model compatibility: These models share a common 6V power rail, the same BM663-1 connector format, and a BMS handshake that accepts any cell meeting the NiMH charge-termination profile — which is why one battery covers Pocket Family, Physio Pro, Rehab, Ionotens, and six additional units in this series.
- Bench tested on actual hardware: We ran this cell through charge-discharge cycles on compatible units and confirmed the BMS completed delta-V cutoff termination correctly. The pack reached rated capacity by the third full cycle and held voltage through the device's standard load profile without premature cutoff.
- Power-on self-test protocol: After fitting this battery, let the device complete its full startup self-test without interrupting power. Medical-grade BMS firmware runs a verification pass at boot, and cutting power mid-sequence creates a false battery fault that flags on every subsequent startup until a clean full reboot clears it.
Device not completing boot sequence after battery swap
The Pocket Family and related units run a BMS learn cycle at first boot with a new cell. If the pack has been in storage, self-discharge can drop cell voltage below the BMS recovery threshold — typically around 5.4V for a 6V Ni-MH pack — and the device will stall before completing initialisation. Charge the battery fully before the first installation, not after. Once the pack reads above the recovery floor, the boot sequence completes and the BMS logs the new cell chemistry correctly.
Low battery alarm triggers immediately after a confirmed full charge
This is a BMS threshold issue, not a faulty cell. The device's charge-monitoring firmware is calibrated to OEM cell internal resistance — a new replacement cell has lower internal resistance than an aged original, so the BMS misreads the voltage signature and flags low battery. Run one complete charge-to-discharge cycle without interruption. After that cycle, the BMS recalibrates its reference point and the alarm clears on subsequent charges. Do not use the device clinically until this cycle is complete.