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Hero Electric Flash e2 electric scooter retrofitted with PureLithium battery

Written By: Kamlesh Mallick & Atul Gopal
Introduction
​Learn how to replace the lead acid battery in your Hero Electric Flash electric scooter with a Lithium-Ion battery with this battery replacement guide. The Hero Electric Flash e2 can support Lithium based batteries that operates at a voltage of 48V. 
Tools 
  • Star ScrewDriver to remove original lead acid battery
  • ​20 Amp rated Discharge Connector that goes into the Battery
  • Duct Tape
Choosing the battery pack - PureLithium Battery
Choosing a Lithium battery is most important aspect of any conversion. Ensure that the battery you use is a certified battery to be used in Indian conditions. For this conversion we use a Made In India battery by PureLithium, a startup based in Hyderabad.
The battery can store 1 kWh worth of energy and is the same battery used in the ETRANCE electric scooter also made by PureEV.

Check minimum requirements to use the Pure Lithium 1 kWh Battery
  • You electric scooter must have a 48V system - 48V old battery, 48V rated controller, 48V based motor
  • Your Motor Power Should not Exceed 1 KW Peak Power draw
  • Controller Peak Rating Should not be more than 22A
  • Female Connector to the Battery Input should be IEC 3 Pin and Rated above 20A

The Hero Electric Flash e2 meets all the above conditions. It has a 48V system, the controller is rated at 19 Amps.
The peak power of the motor is around 800W. Thus the PureLithium 1.0 kWh Battery can be used for this conversion.

Do note that the Hero Electric Flash e5 comes with a 35A controller rating. That scooter cannot use this battery. Always check the minimum requirements mentioned above.

If you want to use a battery from another manufacturer, please ensure the battery is certified and also find out the minimum requirements of the battery pack from the battery manufacturer before installing it on the Hero Electric Flash e2 Electric Scooter.

Here are some details of the PureEV battery pack
Picture
PureLithium 1 kWh Lithium battery pack
Step 1
⚡​ Power off the scooter by turning off the MCB

  1. Remove the lead acid battery

  2. Make a note of the red positive and black negative connector wires coming out from the controller.

  3. The IEC 3 Pin Female Connector to the Battery Input should be kept ready
Step 2
  1. ​Connect the connector's positive side to the positive wire from the Hero Electric Flash's controller.

  2. ​Connect the connector's negative side to the negative wire from the Hero Electric Flash's controller.

  3. Use a duct tape on the connectors to ensure the connection is firm.​
Step 3
  1. Connect the connector to the battery pack.

  2. Slide the battery pack in the the case.

  3. Add thermocol or packing material to fill in the spaces. Ensure the battery does not shake around.
Step 4
🛵 Now that all connections are complete, it's time to test!

  1. Turn the key on and check if the LCD panel turns on. The LCD should turn on with the battery status indicator. 

  2. Place the scooter on the main stand and twist the throttle. Check if the motor is spinning.

  3. The speedometer should go upto 30 kmph.

  4. Ensure the battery fits snugly and pack it with thermocol or other soft packing material. This ensures the battery is stable.

  5. To charge the battery, disconnect the connection to the controller and place the charger's connector.
Step 5
Verifying Battery Removal and Placement

  1. To remove the battery to charge. Turn off the MCB. 

  2. Disconnect the discharge connector.

  3. Take out the battery.
Step 6
  1. Go on a ride. Test it on bad roads.

  2. Your Hero Electric Flash e2 Lithium Ion conversion is ready to ride!
Conclusion​
If you have to remove the battery, just ensure the padding keeps the battery firm.
​
We have used the converted Hero Electric Flash e2 with PureLithium's 1.0 kWh Lithium Ion battery and found that the scooter could easily do more than 40 km per charge. 
If you need more range, you will need a larger capacity battery.
If you have done the same conversion, and have done it better, do share your pics or comments and we shall add your suggestions in the guide.
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