Battery Options. 72v electric bike battery

Battery Options

Here at Grin we’ve been dealing with ebike batteries for a very long time during which we’ve offered over 100 variants of NiCad, NiMH, LiFePO4, LiPo, and Lithium-Ion packs in all kinds of voltages, geometries, and capacities. It’s been a love/hate relationship over those years, but the more recent mass production of 18650 lithium cells for high power consumer goods like power tools has shifted things to the love side, with ebike batteries that are cheaper, lighter, and with far longer life span than we could have ever wished for in the past. We’re happy to stock both frame mount and rear rack mounted batteries from 98 watt-hours to 1100 watt-hours in size to suite the needs of most electric bicycle conversions.

Battery Options

Grin’s 2020 battery offerings include a mix of flat rack and downtube style batteries made with Panasonic, LG, and Samsung cells to suite a wide variety of user needs. Each pack uses Anderson Powerpole connectors on the discharge lead and includes a robust BMS circuit for overcharge, over discharge, and overcurrent protection.

36v 19Ah / 52v 14.5Ah / 72v 9.5Ah

We have had downtube-mounted batteries made with quality cells using popular casings from Hailong and Reention. They are designed for mounting to the water bottle eyelets on your frame tubing, though you can get a much more secure and versatile frame attachment using our Double Bob or Triple Bob anchors.

We used to have the smaller Hailong-01 enclosure in 36V 16.5Ah (10s 5p) layouts suitable for 20-25A current setups, and the larger Hailong-03 enclosure in a 52V 16.5Ah (14s 5p) size for higher current and capacity, but we have now switched to only Reention Poly-DP casings for a standardized cradle, stronger casing, and more reliable connectors. For extra large capacity (1 KWhr), we have the Reention DP-9C casings in 36V 26.5Ah and 52V 20Ah formats. We also have downtube enclosures for the larger 21700 cell format and have these available in 36V 14.5Ah, 36V 19.5Ah, 52V 14.5Ah and 72V 9.5Ah options with Panasonics NCR21700A cells (same as used on Telsa 3), and also in a 72V 7.5Ah format using the very high power capable Samsung 40T cells.

battery, options, electric, bike

These Downtube batteries all have a mounting cavity compatible with our Baserunner motor controller for slick and clean kit installation.

How to Choose a Pack

The very first consideration when choosing a battery pack is ensuring that it can handle the current draw of your motor controller. If you have a 40A motor controller, but your battery is only rated to deliver 25A max, then either the BMS circuit will shut off the battery at full throttle, or the battery will be stressed and have reduced cycle life. The converse, having a battery that has a higher current rating than what your controller will draw, is no problem at all. In fact, it can be quite beneficial.

The next consideration is ensuring that the battery is large enough for your required travel range; it’s no fun having a battery go flat before the end of your trip. In order to determine the range that you will get from a given battery, you need to know both the watt-hour capacity of the battery, and how much energy you use per kilometer. Sounds complicated? Not really. As a rule of thumb, most people riding an ebike at average speeds consume about 10 Wh/km from their battery, and this makes the math very easy. If you have a 400 watt-hour battery, you can expect a range of 40km. A 720 watt-hour battery? ~72km

Of course, if you go really fast or are pulling an extra load, then this mileage will be worse, like 12-15 wh/km. On the other hand, if you use the motor more sparingly, then you can easily stretch it down to 6-8 wh/km. The table below summarizes the expected range for these different example batteries under light, average, and heavy usage paradigms:

Range with Light Use Range with Typical Use Range with Heavy Use
3 Parallel LiGo (~300 Wh) 35-45 km 25-35 km 18-22 km
36V 14Ah Downtube (~500 Wh) 60-80km 45-55km 30-35 km
eZee Flat Pack(~700 Wh) 80-100km 60-80km 35-45 km
52V 16.5Ah Downtube(~850 Wh) 100-120 km 80-90 km 55-65 km

It makes very little difference whether you have a small geared motor, a large direct drive motor, or a mid-drive motor. The mileage and range figures for a given battery have to do with how you use the ebike, not which motor system is on the bike.

Tip: No one EVER regrets having too much battery capacity

The Case for Extra Capacity

Say you have a 12km trip to work and back, so to do the full 24km round trip you’ll need 240 watt-hours. A 36V 8Ah battery at 288 watt-hours should be a perfect choice no?

The answer is that, unless you are seriously budget or weight constrained, this would probably be a bad battery investment. It might fit the bill initially for your commuting needs, but then it doesn’t really leave any reserve if you need to run some errands on the way home or forget to charge it up one night etc. Even worse, as the battery ages over time, the capacity drops. After a year your 8Ah battery is now only 7Ah, it’s only barely able to do your daily commute, and the next year when it is just 6Ah you now need to carry the charger with you and top it up at work every day.

Most people find that once they have an ebike, they use it for all kinds of applications and trips outside of just commuting, and the ability to go 50 km on a charge opens up possibilities that wouldn’t have been possible otherwise. Plus, as the battery ages and declines in capacity, it still has more than enough range for your key commuting needs. Imagine if instead of getting an 8Ah pack, you purchased a 15Ah battery. Even if after 4-5 years it has lost 30% of its original capacity, that’s still over 10Ah and leaves plenty of reserve for your 24km commute.

Furthermore, if you have more capacity than required, then you also have the opportunity to do partial charging of the battery with a Satiator or similar device, so that instead of charging the pack to 100% to squeeze out every km, your standard charge is set to a lower 80 or 90% level. This can have a pronounced effect increasing both the cycle life and calendar life of a lithium battery by several fold.

And a final point is that a larger battery has a lower per cell stress during discharge since the current is shared among more parallel cells. Cells that are cycled at high discharge currents (1-2C) exhibit noticeably lower cycle life than those cycled at low currents

Parallel Connecting Batteries

One of the easiest ways to increase the current handling capability and range is to put two or more batteries in parallel. In general, with lithium batteries of the same nominal voltage, this is no problem. It is ok to mix old and new lithium batteries in parallel, or even batteries from different manufacturers and with different capacities, so long as they are the same voltage. We stock a parallel battery joining cable to facilitate connecting packs this way.

Where things can get a bit dicey is in charging batteries that are parallel connected. If you leave the batteries in parallel while charging, then the charger current will get shared between the batteries and you can be sure that they are always at the same charge level. However, that does mean one of the batteries will be getting charged through the discharge port. For single port BMS circuits, this is not a concern, but on dual port BMS boards (separate charging and discharging mosfets) there is no overcharge protection on the pack being charged from the discharge leads. This can present a safety risk if there is a cell anomaly in that pack.

Alternately, you can separate the batteries and charge each with its own charger and then connect them in parallel just for discharging. Just make sure that both packs are indeed fully charged, as you don’t want to connect them together when one pack is charged and the other is flat.

V or 48V?

We sell roughly equal numbers of 36V and 48V battery packs, and all of our conversion kits and controllers work fine with both 36V and 48V (or 52V) battery options. Just because 48V is a larger number, it does not mean that a 48V ebike is intrinsically better / more powerful / faster than a 36V ebike despite what the ill-informed internet will lead you to believe. However, it is true that a given motor will spin faster at a higher voltage, and usually higher speeds will correspond to more power consumption. For most of the stock hub motor kits that we offer, a 36V battery will result in a commuting speed of 30-35 kph, while wth a 48V battery will result in closer to 40-45 kph.

If you are upgrading or replacing an existing battery pack, it is always safe to replace it with a battery that has the same nominal voltage. If you have a 36V ebike setup that is not from us, and are looking to ‘upgrade’ to a 48V/52V pack, more often than not you can do this without damaging the existing electronics. That is because most 36V motor controllers use 60V rated mosfets and 63V rated capacitors, and so even a fully charged 52V battery will not exceed these values.

Series Connecting for 72V?

It is also possible in principle to series connect two 36V batteries to make a 72V setup, but the only battery we have that is intrinsically designed for this is our LiGo modules. With all other batteries, it is essential to use a pass diode across the output of each battery so that when one BMS circuit trips it does not get exposed to a large negative voltage. We have a special series battery cable with this diode built in available here.

When you series connect batteries, you want to make sure they are packs with identical capacities and specs. You also want to make sure that either your controller or Cycle Analyst low voltage cutoff is set such that the discharge stops as soon as one pack trips. Otherwise continuous current will continue to flow through the pass diode when you are running off just the one non-tripped battery, causing the diode to overheat and fail.

Battery Connectors

We like to use Anderson Powerpole connectors as the standard discharge plug on all of our ebike battery packs. These connectors are ingenious since they are genderless, allowing you to use the same plug both on both a load and source, and the connector design allows them to withstand the arc of inrush current when plugged into capacitive loads much better than bullet style plugs. For the charging port, we like to use the female 3-pin XLR plug standard. This is directly compatible with the Satiator charger, and the quality Neutrik XLR plugs are rated for a full 15 amps per pin allowing very Rapid charging. Unfortunately, this option is not available for many of the downtube battery enclosures. Originally we used the very common but low current DC 5.5 x 2.1 mm barrel plug, but have since updated to using the 3 pin connector from ST which is safer, supports higher currents (8A is no problem) and has a 3rd pin for battery temperature sensing.

Battery Shipping

The shipping of lithium batteries is a complicated endeavor that frustrates the logistics of supplying and supporting ebike conversions kits. After numerous incidents of early lithium batteries either smoking or catching fire in transit, the transportation industry as whole recognized that lithium packs could not be handled casually like regular cargo and greatly stepped up the regulatory framework governing the shipping of lithium battery packs. These rules are constantly evolving, but generally ebike batteries are treated as Class 9 Dangerous Goods. In order to ship a lithium battery (whether by ground or by air) very strict packaging and labeling requirements must be followed, the battery must generally have UN38.3 test certification, and the person doing the packing and shipping has to be trained and certified in the handling and shipping of dangerous goods. When you order a battery from us, there is an automatic Dangerous Goods handling fee that is added to the order, and your battery pack is shipped separately from the rest of the kit as dangerous goods cargo. Many shipping companies do not offer dangerous goods services and we may change the courier selection to one that can deliver to your area.

Where to Order

If none of our own battery offerings meet your needs, we can also highly recommend the knowledgeable folks at Batteryspace.com and EM3EV as alternate suppliers of lithium battery packs in a wide range of capacities, form factors, and voltages.

How Long Does it Take to Charge a 72V E-Bike Battery?

72-volt batteries are mostly used in higher-wattage electric bikes such as 2000w or 3000w ebikes as they are very powerful and easily supply the demand for power to the motor while riding on rugged and long terrain effortlessly.

But the problem is how long to charge a 72v ebike battery in order to get the best performance and prolong the battery life. Don’t worry!

I have come up with a detailed article on the charging time for a 72V ebike battery, how the time differs from one battery model to another (36-volt or 48-volt), and how the battery technology is growing overall.

For attaining more clarity, we have also answered the top 3 FAQs about e-bike battery charging.

If you have a 52-volt battery in your ebike, learn how long to charge your 52v electric bike battery in order to maintain its health.

Charging Methods for a 72V E-Bike Battery

How long it takes to charge a 72V ebike battery is influenced by various factors but the charging method is one of the primary ones. Whether you are using an AC, DC, or solar charger does signify the amount of time it will require to fully charge your battery.

However, it is important to take into consideration that the charging time depends as much on the condition of the battery, the temperature, and the charging profile of the charger.

Nevertheless, let’s see how the use of different charging methods can lead to different charging times for your 72V electric bike battery and also draw a comparison to see which method saves you the most time.

AC ChargerDC ChargerSolar Chargers
It is a common charging method that can be simply plugged a standard wall outlet for powering the battery which makes it easy to find outlets on long rides. DC chargers are not that preferred since they require a dedicated power source which can be expensive. Solar chargers use photovoltaic panels to convert sunlight into electricity to charge the battery.
The charging time for a 72V 20Ah battery is usually 6 to 8 hours. It is expensive, but they do charge way faster than AC chargers. It takes only 1 to 2 hours to fully charge a 72V 20Ah e-bike battery. Solar chargers naturally take way longer than both AC or DC chargers to fully charge a 72V e-bike battery, depending on the amount of sunlight available.
The bright side is that AC chargers usually come along with the battery and can be carried along on your riders. It is not always possible to carry DC chargers and is usually not easy to find everywhere. Having said that solar chargers are the best option for charging your e-bike in remote areas on your long rides.

How Long to Charge a 72V Ebike Battery?

Keeping all the factors in mind, a 72v 30Ah lithium-ion battery takes a minimum of 5 hours if it is charged with a 6 amp charger. Because the charger output power and battery capacity play a very important role in charging time.

Let’s know how I calculated the charging time for a 72V ebike battery,

Charging Time = / Charger Amps

Generally, a charger for a 72v ebike battery is of 5 amp to 8 amps. If you charge your 72v 30Ah battery with a higher-amp charger, charging duration will reduce and vise-versa.

One more important point to consider while charging an ebike battery is that the last 10% charge level takes more time compared to the initial charging time.

There are different types of batteries that influence charging time so let’s learn in detail how a battery type influences charging time.

Note: If you have a 60-volt battery in your ebike, learn how long to charge your 60v e-bike battery in order to extend its lifespan.

Charging Time of Different 72V E-Bikes Batteries

The charging time of a 72V e-bike battery varies from one factor to another for example the battery capacity and the charger capacity. Similarly, one such factor is the battery model of your e-bike.

The battery model is important because it determines the battery’s performance characteristics, including its voltage, capacity, and energy density. It also determines the size and shape of the battery, which can affect its compatibility with different devices and applications.

It’s important to choose the right battery model for a particular device to ensure that it operates safely and efficiently. Hence, let’s look at the best-suited battery models for your 72V e-bike battery and their respective charging times.

Charging time for 72v Lithium-ion batteries

Lithium-ion batteries are a popular choice for electric bikes due to their high energy density, long cycle life, and low self-discharge rate. They are also relatively lightweight and compact compared to other battery types.

Some popular Li-ion battery models for 72V e-bikes include Samsung INR18650-20S, LG MJ1, and Panasonic NCR18650GA, these take somewhere around 6 to 8 hours to fully charge a 72V 20Ah battery. Charging time increases if with the increase of AH.

Charging time for 72v LiFePO4 batteries

It is a 72V e-bike battery that uses LiFePO4 (Lithium Iron Phosphate) cells, which are known for their safety and long cycle life.

This battery is designed for e-bikes that require a high level of safety and reliability since it has a built Battery Management System (BMS). And the charging time taken is between 2 to 4 hours.

Charging duration for 72v Lishen batteries

This is another type of 72V e-bike battery that uses Lishen cells, which are known for their high energy density and long cycle life after lithium. This battery is designed for high-performance e-bikes that require a lot of power and takes around 6 to 7 hours to fully charge.

Common Charging Issues with 72V Electric Bike Battery

There could be several common charging issues with 72V e-bike batteries. If you face any of the below-mentioned charging issues with your 72V e-bike battery, then it is important that you immediately stop using both the battery and charger and seek help from a professional.

Here are a few possible ebike charging issues and their potential causes:

battery, options, electric, bike

The battery not charging at all

It could be an issue with the charger, the charging cable, or the battery itself. You can check in order to make sure you are not operating a damaged cell or a dead battery in your ebike.

Battery charging slowly

The reason for this could be a low-powered charger or a problem with the charging cable. What you can do to solve this issue is to make sure you are using the recommended charger and that the charging cable is not damaged or frayed.

Battery not holding charge

When there’s an issue with the BMS or one or more of the battery cells, your battery might struggle to hold the charge. This issue often is a result of overcharging or deep discharging of the battery, damaging the battery cells over time.

Charger getting hot

Often when you are using a faulty charger, the battery tends to heat up more essentially damaging both the charger and its battery.

We highly recommend taking advice from the manufacturer to diagnose the faced issues and provide appropriate solutions to get your e-bike battery charging and performing correctly again otherwise it may catch fire or even explode. Read our guide on why ebike batteries catch fire.

Future of Ebike Batteries Charging Technology

The future of e-bike batteries and charging technology looks quite promising as advances in technology continue to make e-bikes more efficient, powerful, and accessible.

Let’s see what are the potential trends and developments in e-bike batteries and charging technology.

Increased energy density

E-Bike batteries with higher energy density will be able to provide more power and range, advances in battery chemistry and manufacturing techniques make the idea of higher density a reality.

Faster charging times

One of the biggest drawbacks of e-bikes has been the relatively long charging times required to fully recharge the battery. However, new fast-charging technologies are being developed that will allow riders to recharge the e-bikes much more conveniently and faster.

Wireless charging

This technology is already being used in some consumer electronics, and it is expected to become more common in e-bike batteries as well.

Integration with Smart homes and grids

As more homes and communities are becoming more and more “Smart”, E-bike batteries could be integrated with these systems to provide more efficient and sustainable energy use.

For example, an e-bike battery could be charged using solar panels or wind turbines to power homes during peak energy demand times.

If you have a 48v battery in your electric bike, you must know an ideal charging time for a 48-volt ebike battery to maximize the battery life

Conclusion on The Charging Time for a 72V Ebike Battery

There is rarely anyone present who would refuse to switch to a higher voltage battery, especially for e-bikes since all riders look for that extra energy push during those uphill trails.

However, they want to use high-voltage e-bike batteries that come with maintenance, cost a lot of dollars, and comparatively more charging time.

But we have seen amongst riders that when used accurately with the right appliances like charging cables and methods, a 72V e-bike battery is highly effective in terms of charging time.

Hope our summarization on how long to charge a 72v ebike battery helps you, Keep riding!

Frequently Asked Questions

What is the voltage of a fully charged 72-volt battery?

Each type of battery has more actual voltage than the nominal voltage when it is fully charged. For e.g, a fully charged 72-volt lithium-ion battery has a voltage of around 83 volts. Whereas a fully charged 72v lead-acid battery has around 81 volts.

What voltage charger to use to charge a 72v ebike battery?

Most brands recommend charging a 72v battery with at least a 5 amp charger as it neither charges the battery fast nor slow. If you increase the charger amp, will save you time but may affect the battery’s life.

What wattage ebike is 72v battery perfect for?

There are two aspects of a battery to consider while selecting the motor wattage i.e., Voltage and Amp-hours. Basically, a 72-volt battery is very powerful, mostly used in ebikes having a minimum rating of the motor is 2000-watts.

What is the range of a 72v 20AH lithium-ion battery?

The range of a battery depends on the motor’s output power (how many watts does an ebike consume to cover one mile). Generally, a 72v 20 Ah battery has a range of around 80-100 miles. It may vary on the basis of bike speed, load, road conditions, etc.

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Bittoo Gupta

I am the founder and editor of The Bike Fetcher, a passionate E-Biker. My passion for E-bikes led me to build this blog site where I share electric bike news updates, my e-biking experience, e-biking tips, e-bike battery tips and help people to get the best e-bike. Feel free to contact me on my social accounts or through the contact form.

Long-Range e-Bikes. How Far Can I Go on a Single Charge?

No matter what you choose to call it or how you write it. E bike. Electric bicycle. eBike. Electric bike. E-bike. One thing is certain. The eBike is disrupting the transportation sector in a big way. and more people are buying and commuting on an electric bike than ever before. One of the biggest considerations when buying an e bike is range. How far can the eBike I’m interested in actually go?

The longest range e bike currently on the market is from Delfast bikes. It holds the Guinness World Record for longest range eBike on a single charge. 228 miles. With upgraded software on the newest model, the Top 3.0i just achieved an unheard of 232 miles. But how many miles can an electric bike go in real world conditions? Can you get an idea of how many miles an electric bike can go based on the volts and amp hours a company lists on their website?

The battery, controller, motor, and various components all contribute to the range you can achieve. Together they determine your speed, the amount of pedal assist to apply, and can even give you an estimated range based on those factors. With that said, the number one factor for that question of how many miles can an electric bike go comes down to the battery capacity. Volts, Watts, and Amp Hours.

The Voltage of the Battery

The first characteristic to pay attention to is the voltage of the battery. This parameter is commonly expressed in Volts (V). Most electric bike companies utilize a 36V or 48V battery. In most cases, these mass-produced batteries have a relatively low cost. However, as with many other technological products, you get what you pay for. A lower voltage battery will not provide the range many riders are chasing.

An electric bike equipped with a 36V/48V battery delivers modest power to assist the cyclists pedaling. In uphill terrain the rider may notice a lack of power. Speed is also modest with this type of battery. If you want an electric bike that is powerful and fast, it’s best to aim at models equipped with higher voltage batteries.

Electric bikes with 52V batteries are significantly more powerful, faster, and more efficient. Efficiency is important in achieving a longer range. However, as we will discuss later, other parameters determine the range of an e-bike. 52V batteries are also expensive, but the higher the voltage the more enjoyable your ride will be thanks to the power and speed available.

It is wise to invest upfront in an electric bike with an electric system based on a high-voltage battery. Delfast utilizes a 72V Lithium-ion battery on our high-end TOP 3.0i electric bike. The use of a 72V battery makes the Delfast e-bike the fastest in the world. The size of the battery allows for more power with the use of a 3,000W motor. Of course, it is also the longest-range e-bike.

The Amp-Hours Value of a Battery

If the voltage of the battery defines the speed and power of an electric bicycle, what is the definitive aspect of the range? Here, we have to use a different parameter often referred to as Amp-Hours (Ah).

When the motor is functioning, it draws an electric current from the battery. It is measured in Amperes (Amps or A) and refers to the flux of electrons in the motor coils. The higher the Amp value, the more intense the flux of electrons is. Both voltage and current define the power of the motor since power in Watts (W) is equal to voltage times amperes.

The Amp-Hours value refers to the fixed number of Amperes that the battery can sustain during an hour. Typical values go from 10Ah to 20Ah. So, this is also a measure of the battery capacity. A battery with a 10Ah capacity can sustain 20A in half an hour or 5A in 2 hours. The larger the capacity, the longer the electric bike will be able to ride on a single charge.

Batteries for Long-Range e-Bikes

As seen, a long-range electric bike must use a battery with a high capacity. This is easier said than done. High-capacity batteries are larger and significantly heavier. Typical Lithium-ion batteries weighing 6-8lbs deliver a range of approximately 20 miles. That’s not exactly a long-range electric bike. If your electric bike is equipped with a throttle only mode, riding without pedaling will further shorten the range.

A long-range e-bike is usually equipped with a battery of at least 20Ah and 52V, which allows for a range of approximately 100 miles with a motor of 1,000W. New eBike riders should select the battery with the highest voltage and capacity possible within their price range. There are three important factors to consider:

  • Size. High-capacity e-bike batteries are larger and more cumbersome. Be sure your frame and bike of choice can accommodate it.
  • Weight. High-capacity batteries are heavier. If you need to carry your e-bike upstairs this is an important consideration.
  • Price. High-capacity batteries are more expensive. Depending on the intended use of your electric bike, a high-capacity battery may not be a must. If your planned use is only for commuting, you can estimate the distance of a daily round trip. If it’s a modest commute, you can use a conventional battery with a capacity between 10Ah and 20Ah.

The Leader of the Pack for Range

Our long-range ebike TOP 3.0 i doesn’t compromise the type of battery. It utilizes a 72V 48Ah Lithium-ion battery that far exceeds the specifications of other e-bike batteries. This battery allows for a top speed of 50 miles per hour and an outstanding range of 200 miles.

If you want an electric bike that can deliver top performance in virtually all conditions, the TOP 3.0i is for you. It works perfectly as an offroad mountain e-bike, allowing you to travel very long distances through the countryside. It is the perfect commuter for those wanting long range. It is the cross-over of choice to transition from street to trail, commuter to after-hours fun.

Replacement Electric Bike Batteries Guide

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A good e-bike battery should last for hundreds of cycles. With average use, this means several years. Eventually, electric bike batteries need to be replaced as their life cycle comes to an end.

You can tell when a battery is nearing the end of its life when it does not provide you with much range. Some high-quality batteries that come on the top e-bikes such as a Bosch battery have a battery management system (BMS) integrated into the battery that actually tells you the current capacity and also how many charge cycles it has gone through.

But no matter what type of battery you have you’ll sooner or later be asking yourself the all-important question: how can I replace my e-bike battery?

Down below Electric Bike Report dives into this question and more in greater detail.

Are E-bike Batteries Interchangeable?

In general, the answer is no – you should only replace a battery with one that comes from the same manufacturer and is of exactly the same spec.

The reason is that the original e-bike or kit manufacturer has the responsibility to ensure that the battery pack, charger, and e-bike all work safely together, and using a ‘non-original’ replacement pack potentially introduces all sorts of uncontrolled risks.

battery, options, electric, bike

It’s a little more complicated than this in some situations. For example, some Bosch batteries of different capacities are explicitly made to be interchangeable and there will be many instances where an original supplier and/or manufacturer of the e-bike cannot be traced or has gone out of business – in such cases we look at your options below.

As an important side note: you should always, if possible, use a charger that comes from the original manufacturer too. The one that comes with your battery should sync up well and not overload the battery. Pairing your battery with a different charger adds in risk of malfunction during charging.

Let’s first look at the basics of getting a replacement battery for your e-bike, then we will look at some of the major manufacturers of e-bike batteries and some of the main e-bike manufacturers to see which common battery types are still replaceable. Let’s consider the options for replacement in terms of desirability.

Where Should I Go to Get a Replacement E-Bike Battery?

On this last point it may help to note that there are a couple of manufacturing standards for rechargeable lithium-ion batteries used in e-bikes. Although it’s not a legal requirement, it may be that one of the standards is actually marked on the battery itself.

The standards are BS EN 50604‑1 and UN38.3, the latter required for lithium-ion battery transport by air, sea or land. Just because these standards are not marked on a battery doesn’t mean it does not comply with them – but it is a reassuring sign if a battery does bear one or both of these marks.

Note that using a replacement battery that does not come from the original manufacturer (whether a dealer is involved or not) may void the warranty of your electric bike or kit. Check with the e-bike or kit company to understand what their policy is regarding the use of aftermarket replacement batteries.

Replacement Batteries from Original Manufacturers

Bosch E-Bike Batteries

Only Bosch manufactured batteries will be used on any new Bosch e-bike – this has always been the case and so it makes advice on interchangeability a little more straightforward than with the likes of Shimano and Brose who have both allowed the use of third party batteries with their mid-drive motor systems.

There have been four basic designs made by Bosch over the years (good online overview here):

  • Rack mounted batteries: PowerPack in 300, 400, and 500 Wh versions which are all interchangeable with each other.
  • Down tube mounted batteries: PowerPack in 300, 400, and 500 Wh versions, current versions of which are all interchangeable with each other.
  • Frame integrated batteries: PowerTubes in 400, 500, and 625Wh versions, with the 400 and 500 units being interchangeable with each other. The 625Wh may be retrofittable but it needs a compatible frame with a big enough space to house it (400 and 500 units are the same physical dimensions but 625 is bigger). 500 and 625 Wh units are used on the Dual Battery system to give a capacity up to 1250Wh.
  • Frame Integrated ‘Smart’ Option batteries: This is a new 750Wh option for 2022 and will be only compatible with 2022 e-bikes that feature the Bosch ‘Smart’ system and will not be compatible with other Bosch e-bikes that are ‘non-Smart’. Similarly, other types of PowerTube batteries (400, 500, and 625Wh versions) will not be compatible with e-bikes featuring Bosch’s ‘Smart’ system.

Some third-party batteries compatible with Bosch systems are available as detailed in the section below.

There are some suppliers of batteries that will fit older models, in some cases dating back to 2011 when the Bosch e-bikes first entered the market, for example, The Holland Bike Shop in Europe sells some batteries compatible with much older Bosch-powered models.

Shimano E-Bike Batteries

Shimano produces its own brand batteries for use on their systems, but you may also find new e-bikes powered by Shimano motor systems with batteries manufactured by their licensed partners Darfon and SMP. These third party batteries are not interchangeable with any Shimano batteries.

Shimano’s current range includes rack-mounted, downtube-mounted and frame-integrated batteries from 418Wh to 630Wh. You can see a brief overview with detailed links to each battery on offer here.

It’s important to note that each battery model has a limited number of specific battery mounts it will work with, so it is important to replace an old battery with one that is compatible with the mount on your e-bike. You can check out detailed compatibility info here and here.

Shimano says that ‘the oldest current battery we have is the BT-E6000 and the corresponding battery mount BM-E6000. These are compatible with all five of our current drive units (DU-EP8/E8000/E7000/E6100/E5000), but not earlier systems. For reference, DU-E8000 is the oldest in that list – it was introduced in 2016.’

Brose E-Bike Batteries

The only battery listed on Brose’s own website is a 630Wh frame-integrated option.

However, Brose systems are widely used by other manufacturers who also spec own-brand or third-party batteries. These include the likes of the widely respected battery manufacturer BMZ and well-known brands like Scott and BULLS.

For example, Specialized’s ‘full power’ range use Brose-based mid drives and a range of their own brand frame-integrated batteries. Although information on interchangeability is scarce, a Specialized FAQ page, in response to the question ‘Can I increase range by using the 604Wh aftermarket battery in any Turbo Vado/Como?’ says yes, all Vado batteries are cross-compatible as long as you are running the latest firmware (by implication so are Como and Turbo full power batteries are cross-compatible too).

The above appears only to address compatibility on current Specialized models and battery availability for older models appears a bit more complex with lots of debate online over the matter.

The fact that the latest Specialized e-bike batteries contain a Bluetooth chip to communicate with the latest Mission Control App certainly suggest both backward compatibility and availability of third party batteries will be very limited. Current e-bike batteries available from Specialized can be found here.

Yamaha E-Bike Batteries

Yamaha has integrated, rack-mounted and frame-mounted options ranging between 400Wh and 600Wh but information on backward compatibility is rather hard to find. Their systems appear on Haibike models and in the US on their own brand models too.

Giant use Yamaha motor systems but apparently have their own brand of battery – the EnergyPak range. The standard EnergyPak comes in rack-mounted and frame-integrated options whilst the Smart Compact variant allows for faster charging.

Finally, there is the Giant EnergyPak Plus, for use with the Smart Compact – a range extender style battery that fits onto the frame and effectively increases the capacity of the main Plus battery.

Giant’s Service web page states that there are EnergyPaks with 300, 360, 400, 500 and 625Wh capacities and also states ‘Giant EnergyPaks are interchangeable’.

Fazua E-Bike Batteries

This lightweight German-made system uses a frame-integrated 250Wh design and there have been two types of battery, Battery 250 and Battery 250X, the latter having the ability to be switched on and off remotely.

The latest Fazua Evation 250X battery is compatible with all Fazua electric bikes from 2019-22.

GRIN and Cytronex E-bike Kit Batteries

Canada’s GRIN is a true expert in producing a wide variety of e-bike kits. Whilst they do several designs of batteries, one of their best options from a replaceability point of view is their own brand LiGo batteries.

LiGo batteries are very unusual in being modular so that you can easily connect together as many as you like to increase or decrease battery capacity at will. They are particularly suitable for lightweight and folding bikes (I use them on a GRIN Brompton kit) and also for those who want to air travel with e-bikes as the individual battery units are only 98Wh and so are generally allowed on passenger aircraft (disconnect them from each other for travel and reconnect them on landing to make a useful e-bike battery).

The design has been around for several years and is backward compatible.

The UK’s Cytronex produces both European and US spec lightweight kits which use a unique own-design of ‘bottle battery’.

Cytronex says all their lithium bottles are compatible forwards and backward from the first version in 2017. They have different firmware for the new Bluetooth variant but both this and the non-Bluetooth version allow you to use the new 2-way – 5 level Boost Button or the previous one-way 3 level button.

In fact, if you have old and new kits on two bikes you can switch the bottle between both and it will recognize the two different button types automatically.

E-bike Manufacturers Own Brand Batteries

There are hundreds of e-bike manufacturers in the more budget space so it’s way beyond the scope of this guide to cover the options for each one; rather we’ll take a look at a couple of the market leaders.

Rad Power Bikes E-Bike Batteries

Rad Power Bikes first started producing e-bikes for the North American market in 2015 and now claims to be the US market leader. Their website lists several replacement batteries and their current lineup of bikes uses one of two battery designs.

There is the External Battery Pack (with the option for the smaller pack specific to the RadMission) which is compatible with all 2018 and newer model ebikes except the RadRover 6 Plus and RadCity 5 Plus, which use the Semi-Integrated Battery Pack.

Rad Power Bikes does offer legacy options for bikes older than that 2018 ‘cutoff’ and although some of these legacy batteries are currently out of stock Rad says they have plans to restock them.

The battery packs are consistent across their main sales areas of Canada, US and Europe.

The Rad Power website has a great filter system so you can track down the compatibility of what batteries are in stock against all current and previous models, right back to the original 2015 RadRover. All e-bike manufacturers’ websites should provide this service!

Pedego E-Bike Batteries

A longstanding US manufacturer with a clear set of battery specs for current models here. However, there doesn’t appear to be any info about legacy batteries or backward compatibility.

Interestingly, and it seems uniquely amongst the mainstream manufacturers, Pedego have recently introduced a serviceable battery (pictured above) – designed to be easily maintained at the local Pedego store. It features a rear light, brake light and indicators to boot.

Batteries for Out-Dated Motor Systems

There are a number of older motor and battery systems that are either not used or little used these days but there are still some suppliers out there who may be able to help out and if you are in this position a bit of internet research might just turn something up. Let’s take a look at a couple of examples.

BionX E-Bike Batteries

BionX operated between 1998 and 2018 and were once one of the leading e-bike system manufacturers in North America, with the likes of Trek and Kalkhoff using their systems.

There are still limited stocks of spare parts available here and there, including batteries, for example on this Ohm webpage.

Heinzmann E-Bike Batteries

German company Heinzmann had a great reputation for quality and produced the now obsolete Classic system and the newer Direct Power system. At various times both were available as kits or fitted to off-the-peg e-bikes.

In the UK Electric Vehicle Solutions are the main stockist of complete Direct Power kits and of spare parts for the Classic system.

What About Non-removable Frame Integrated Batteries?

A relatively small number of e-bike batteries are incorporated into the frame and not designed to be removed by the rider – they must be charged on the bike. Whilst perhaps inconvenient for some, the system has the benefit of a sleeker and simpler design and keeps the battery cells well-protected.

The Ebikemotion X35 system is one example of the most common lightweight systems out there to feature a frame-enclosed battery.

When it comes to replacing these batteries, to be clear, our official advice is that this is a job for the dealer, or expert shops to do only.

DIY in this area can get tricky in a hurry. Looking into service options to replace batteries in an integrated system is something to consider before purchasing the bike.

Third-Party Replacement E-Bike Batteries

For some older batteries – or even some current ones – there may be manufacturers other than the so-called OEMs (original equipment manufacturers) who made the original batteries. These third-party companies are not recognized by the original e-bike manufacturers so if possible it is always best to go back to your dealer or the manufacturer directly to source an original battery.

However, third-party batteries may be a solution where no original batteries appear to be available.

There are a growing number of companies that provide third-party batteries and here we take a look at a couple of the bigger operations.

Please note that on e-bikes that are still in their warranty period, replacing the battery with one from a third-party manufacturer will most likely void the warranty.

FTH Power has a good amount of experience in the electronics business and has diagnostics and assembly capabilities. They look to have good stocks of popular far eastern battery brands such as Reention (used by the likes of Juiced and Surface 604) and Hailong. They also have this handy battery/model finder to see if they have batteries for your particular model of e-bike.

Third-party battery provision (and recelling services) appear to be bigger business in mainland northern Europe than in the U.S. It makes sense, this is where e-bikes have been around much longer and where the average value of e-bikes is higher. The need to keep older bikes going longer is greater. For example, Heskon is a major supplier of replacement batteries to dealers and Fiets Accu Revisie is the part of Heskon that sells direct to customers.

The UK’s Electric Transport Shop network offers battery diagnosis (refundable against a replacement battery or recell if required). The ETS says they also have stocks of Battery Management System chips that can be used on certain packs, usually on older e-bikes.

The ETS also says ‘There are so many shapes of e-bike batteries now that we cannot guarantee that we have cell packs to fit them all and it is usually cheaper to buy a factory-built replacement than to hand-build a replacement pack in the UK so we usually recommend buying a battery from the original supplier if the diagnosis proves that’s what is needed. If their supplier is no longer available to supply a replacement pack in this instance we will help people find a suitable replacement or as a last resort we will offer to wire in an alternative pack which may be in a different position on the bike.’

What Should I Do With My Old E-bike Battery?

If at all possible the ideal solution is to take it back to the dealer you bought it from who will send it on for recycling.

In the US the industry is in the midst of setting up its own recycling scheme. It was organized by People for Bikes and will be directly coordinated under the auspices of Call2Recycle. There will be a network of battery drop-off locations from the nation’s roughly 3,000 independent bike shops. Manufacturers and retailers can sign up here.

The batteries will be sent on to ‘processing partners’, four of which are domestic and two of which are foreign—one in South Korea and one in Belgium.

The consortium brands are funding the recycling service, which will be free to riders; of course, consumers will still have to pay for replacement batteries. There are also plans for a consumer-direct mail-in recycling option in the summer – EBR will keep you posted on its development.

There are already such ready-made recycling networks in mainland Europe and the UK is just beginning to establish such a network.

This guide to replacement electric bike batteries hopefully covered the basics of what is out there for you. It’s certainly just the tip of the iceberg though. If there is anything else that wasn’t covered here, let us know in the Комментарии и мнения владельцев below and we’ll update this guide with the info our readers are looking for!

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