Essential guide for the use, maintenance and activation of lithium batteries for electric bicycles (60V 16S ternary lithium)

Lithium batteries, especially the 60V 16S ternary lithium batteries used in e-bikes, are a vital component that significantly impacts the bike's performance and lifespan. Proper care and timely maintenance can extend the life of your e-bike's battery and ensure optimal performance. In this guide, we'll cover essential precautions, maintenance tips, and how to manage a low-power battery.

1. Basic precautions for daily use: Maximize battery life

To get the most out of your electric bike's lithium battery, it's essential to follow specific charging and discharging guidelines. Doing so will help you avoid damaging the battery and extend its lifespan.

Charging tips: Don't let the battery "starve"

Always recharge the battery when the charge drops to 20-30%, as indicated on the dashboard display. This prevents the battery from going into a "starvation" state, which can occur if it's left discharged for too long. If you let your motorcycle completely shut down and leave it unused for more than a week, you risk damaging the battery, which will void the manufacturer's warranty.

Attention: Lithium battery "starvation" occurs due to over-discharge and failure to recharge in a timely manner. This type of damage is caused by human error, not a manufacturing defect, and is excluded from the warranty.

Pro tip: Never leave your bike plugged in overnight to avoid overcharging. After fully charging, let the battery float for 1-2 hours before unplugging it.

Charging specifications: Stay true to the original charger

Only use the original 67.2V dedicated charger for your motorcycle battery. Never mix chargers with different voltages, as this can cause malfunction or damage. Charge in a well-ventilated, dry area and avoid high temperatures, humidity, or flammable materials. If the battery shows signs of swelling or abnormal heating during charging, disconnect it immediately.

Breaking down taboos: Avoid heavy burdens

Avoid prolonged high-speed riding, climbing, or other activities that put a heavy load on the battery. In cold weather (below 0°C), a decrease in driving range is normal. Be careful not to push the battery to the point of complete discharge.

2. Storage and maintenance: Keep the battery in optimal condition

Proper storage plays a vital role in maintaining your electric bike's lithium battery, especially during periods of inactivity.

Short-term storage (up to 1 week)

If you're not going to use the bike for a short period, charge the battery to 50-70% (approximately 52-56V). Store the battery in a cool, dry place, away from direct sunlight or heat sources such as heaters. Never store it in areas with temperatures below -10°C.

Long-term storage (more than 1 week)

For longer storage periods, recharge the battery at least once a month to ensure the voltage remains above 48V. Never leave the battery discharged (especially below 48V) for extended periods, as this could cause permanent damage.

Storage tip: Do not leave the battery in hot, enclosed spaces such as car trunks or balconies. High temperatures accelerate self-discharge and could drastically shorten the battery's lifespan.

3. How to deal with a "hungry" battery

If your battery voltage drops below 48V but remains above 40V, it may have entered a "starvation" state. Here's how to check and revive it.

Battery "starvation" assessment

If there's no response when you plug in the charger, or the charger only shows a green light indicating no charging, the battery may be fine. Additionally, using a multimeter to measure the total voltage will help confirm if it's below 48V (but be careful it doesn't go below 40V, as that can cause almost irreparable damage).

Activation process: Step-by-step guide

For batteries with a voltage below 48V, but not completely damaged (above 40V), follow these steps to try to activate it:

Prepare your tools: You will need the original 67.2V charger, a multimeter (optional), and a specialized lithium battery activator.

Safety first: Before you begin, visually inspect the battery. If you notice any swelling, leaks, or damage, stop immediately and replace the battery.

Activation procedure

Using a specialized lithium battery activator: Connect the activator to the positive and negative terminals of the battery. Set the current to 0.1 to 0.2V (e.g., 3-6A for a 30Ah battery). This pre-charge will raise the voltage above 48V. After this, connect the battery to the original charger for 8-10 hours of normal charging.

Without an activator: You can connect the original charger directly to the battery. If the charger light flashes green or it gets slightly warm, it may be slowly pre-charging. Leave it connected for 2-4 hours to see if it changes to red (charging mode). If there is no response, unplug the charger to avoid damage.

Post-activation inspection

Once the battery is charged, test the motorcycle's riding range. If the range has decreased significantly (less than 50% of its original capacity) or the battery is rapidly losing power, it may be partially damaged. It is advisable to check that the cell voltages are balanced.

4. Activation Precautions: Avoid common errors

When attempting to activate a lithium battery, it is essential to avoid the following:

Never use a charger with a voltage higher than 67.2V. Doing so can cause overvoltage, which may lead to swelling or fire.

Do not attempt to open the battery compartment. This could cause short circuits and dangerous situations.

If the battery voltage drops below 40V or if it emits an odor after activation, discard it immediately. Continued use may pose a safety risk.

Conclusion: Proper battery care equals long-lasting performance

Maintaining your e-bike's lithium battery is essential for ensuring a long lifespan and safe operation. By following these tips on proper charging, discharging, storage, and activation, you can avoid issues like "starvation" and prevent unnecessary damage. Always be proactive with maintenance, and your battery will serve you well for years to come.

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