Tag Archives: lifepo4

Ping Battery Replacement with Clean Republic e-Bike Motor and Controller

[Original Blog post with details of what’s inside a Clean Republic Battery pack is here.]

Received the new Ping 36V 10AH Li-FePO4 Battery from China today – very well-packed for shipment and partially charged.

Upon unboxing, the Ping Battery Management circuit is heat-shrinked to top of battery pack. Red and Black main leads are to the front (6 ga. heavy wires) and run to the Management circuit. The charging connector wires are Blue and Black are terminated in a male XLR connector which mates to the 36VDC Li-On charger (not pictured).  Battery shipped with a complimentary 2.5AH charger.

Removed the switch and plastic mount from the original Clean Republic metal battery case (which cannot fit a different battery because of a tight design), and de-soldered the 4 pin male panel mount DIN connector from its original PC board (which had the Clean Republic battery charge management circuitry on it).  Resoldered the 4-pin DIN chassis mount to the new Ping battery main leads (Red-to-Red, Black-to-Black).  The 4-pin DIN is wired with 2 pins negative and 2 pins positive (refer to the wire color from the female 4-pin DIN mate plug which goes to the Clean Republic Controller box (which connects via the multi-pin connector to the motor and throttle switch). Shrink-wrapped the connections and later zip-tied the battery leads together to stiffen them against tear-away.

Plugged the battery back into the Clean Republic controller via the 4-pin DIN and re-connected the power switch.  Temporarily strapped everything to the bike’s original Topeak beam rack and plugged it in – Presto! works fine and runs about 25% faster.  Have it charging at the moment and will take it on a test run next week once the new case is fitted to the rack.

Battery is about 6 x 6 x 4, so the original Clean Republic nylon case won’t fit. Will be substituting a standard Topeak nylon snap-in zip pack instead to hold the battery.  Power switch mount is temporarily taped to the opposite side just above the Controller box. All of this fits pretty well in a Topeak MTX Trunk Bag DX which slides right back into the MTX rack and locks in tight. (author note: actually, I have an RX rack, and had an RX/EX bag, which didn’t quite close with the battery in it.  So I unbolted the slide mechanism from the EX bag and re-mounted in into the MTX/DX bag and placed the original MTX plate at the bottom for stiffness.  Equals a MTX/DX bag mounted on an RX rack.

New, more powerful battery replaced for US$360 including shipping.

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