What battery sizes are available for converting a diesel transporter? Your guide 2025
Up to 425 km of range after a diesel-to-electric upgrade - without the cost of a new vehicle. Upgrading your van is not only a response to rising diesel prices and the Clean Vehicles Directive, but also a strategic investment in the future of your fleet. Find out which battery sizes are available for your needs and how to optimally utilize the funding deadline on August 31, 2025.
The topic briefly and concisely
For most diesel van conversions, a battery size of 110 kWh (gross) / 96 kWh (net) is available, enabling ranges of up to 425 km.
The BMDV funding covers 80% of the conversion costs and 40% of the charging infrastructure; applications must be submitted by August 31, 2025.
The conversion reduces the Total Cost of Ownership (TCO) by up to 50% lower maintenance and energy costs compared to diesel.
The electrification of commercial vehicle fleets is the biggest challenge of the decade for many companies and municipalities. High diesel costs, impending city tolls, and the strict requirements of the EU's Clean Vehicles Directive create pressure to act. A diesel-to-electric conversion (DTE) offers a pragmatic and economically superior solution: you keep your proven vehicles and expensive specialized equipment while drastically reducing operating costs. This article explains which battery sizes are available for converting your diesel van, how to find the appropriate capacity for your route planning, and how to apply for the state subsidy of 80% on time.
Standardized battery options for maximum flexibility and range
The central question when converting a diesel van is about the appropriate battery size. Heero relies on a standardized, yet highly flexible solution to ensure planning security and economies of scale. For most van models, from panel vans to flatbed trucks, a battery system with 110 kWh gross capacity is used, which corresponds to a usable net capacity of 96 kWh. This sizing allows for ranges of up to 425 km for a converted Sprinter and up to 500 km for an E-Transporter. An exception is the mid-low-floor bus, which receives a larger battery with 137 kWh gross (115 kWh net) due to its specific use profile, achieving up to 300 km. This standardization not only ensures availability but also optimizes the Total Cost of Ownership (TCO), i.e., the total operating costs over the entire service life. The decision for a specific battery size thus depends less on the model and more on the intended use.
Funding pots and deadlines: secure an 80% subsidy until August 2025
The time for electrifying your fleet is pressing, as the current funding conditions are limited in time. The funding guideline for electromobility from the Federal Ministry for Digital and Transport (BMDV) is the decisive instrument for an economical transition. It subsidizes the additional costs of a DTE conversion compared to a diesel counterpart by up to 80%. Applications must be submitted by August 31, 2025. Additionally, the establishment of the necessary charging infrastructure is subsidized by 40%. This funding is crucial to significantly reduce the higher acquisition costs, the main factor in the TCO calculation. The guideline aims to accelerate market ramp-up and achieve the climate goals according to the Clean Vehicles Directive, which has already obligated public clients to procure clean vehicles since 2021. To avoid missing the deadline, immediate planning is essential.
Your checklist for a funded conversion:
Analyze vehicle inventory and driving profiles (km/day, idle times).
Select appropriate conversion solution and battery size.
Request offers for the DTE conversion and charging infrastructure.
Submit funding application on time by August 31, 2025, to the project sponsor.
This structured approach ensures you receive maximum financial support and a smooth transition to e-mobility.
Economic Efficiency in Focus: The TCO Analysis of Diesel vs. Electric
Retrofitting is more than an ecological statement; it is a business decision. The Total Cost of Ownership (TCO) impressively demonstrates this. While the initial costs for a DTE retrofit are higher, they often pay off within four to six years due to drastically lower operating costs. The energy costs per 100 km for an e-transporter are about 5 to 6 euros (at 30 cents/kWh), while a comparable diesel vehicle incurs around 12.25 euros at 1.75 euros/liter. Additionally, there are up to 50% lower maintenance costs because many wear parts of the combustion engine are eliminated. Furthermore, the CO₂ pricing, which could increase diesel and gasoline prices by around 65 cents per liter by 2030, clearly favors electric drive. By electrifying your fleet, you protect yourself from these unpredictable price increases.
Charging infrastructure and charging power: The backbone of your e-fleet
The performance of your e-fleet directly depends on the charging infrastructure. Heero vehicles are designed for demanding commercial use. All van models come standard with fast DC charging with up to 135 kW. This allows the 96 kWh battery to be charged to 80% in around 30 minutes, minimizing downtime and maximizing vehicle availability. The medium low-floor bus even charges at up to 165 kW. Planning the charging infrastructure should always be part of the overall strategy. With the 40% subsidy from the BMDV, the development of depot charging points is significantly facilitated. An intelligent charging plan that utilizes, for example, favorable night-time tariffs further reduces operating costs. This way, the transition becomes a holistic success for your service vehicles in field operations.
Sustainability through Circular Economy: The Second Life of the Battery
The conversion of an existing vehicle is the epitome of the circular economy. Instead of scrapping a functioning vehicle, its lifespan is extended by many years. This also applies to the battery. The high-voltage batteries in HEERO vehicles are designed for a lifespan of eight to ten years in the vehicle. After that, they still retain 70 to 80% of their original capacity. Instead of being recycled, these batteries can begin a "Second Life" as stationary energy storage for photovoltaic systems or for grid stabilization, serving for another ten to twelve years. Only then does recycling take place, where up to 96% of valuable raw materials like lithium and cobalt can be recovered. This approach not only conserves resources but is also a central component of a credible and sustainable corporate strategy.
Your path to funding: In three steps to the grant roadmap
The path to successful fleet electrification begins now. Don't wait until the funding deadlines pass. With our free funding analysis, you will quickly and easily gain clarity on your options. Just answer three central questions about your fleet and driving profiles. Based on this, we create your personal subsidy roadmap and show you how to make the most of the 80% funding. Start your transformation now and make your fleet future-proof.
For a free analysis
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More useful links
Wikipedia describes drive batteries, particularly for electric vehicles.
BALM provides information on the funding program for climate protection and sustainability in transport (KSNI).
Federal Motor Transport Authority (KBA) provides the annual balance of vehicle stock in Germany.
Statista delivers statistics on the truck stock and its development in Germany.
Federal Environment Agency offers an analysis of the environmental balance of motor vehicles.
Federal Ministry for Digital and Transport (BMDV) informs about electromobility with batteries.
TÜV Association provides information on alternative drives and electric vehicles.
German Energy Agency (dena) explains electromobility as an opportunity for the power grids.
Central Association of the German Motor Vehicle Industry offers a dossier on the topic of electromobility.
FAQ
What battery sizes does Heero offer for DTE conversion?
Heero uses a standard battery with 110 kWh gross and 96 kWh net capacity for most van models. For the medium-low-floor bus, a larger variant with 137 kWh gross / 115 kWh net is used to meet specific requirements.
By when do I need to submit the funding application for the 80% subsidy?
The deadline for submitting applications under the current BMDV Electromobility funding guideline is August 31, 2025. Early planning is urgently recommended due to the necessary offer collection and application submission.
What does Diesel-to-Electric (DTE) conversion mean?
DTE is the process where the diesel engine and related components (tank, exhaust system) are removed from an existing commercial vehicle and replaced with a complete electric drive train (electric motor, battery, power electronics). The vehicle chassis and body remain intact.
What is the Total Cost of Ownership (TCO)?
The Total Cost of Ownership is a calculation method that considers all incurred costs over the entire lifetime of a vehicle. This includes purchase, funding, energy, maintenance, insurance, taxes, and residual value.
Do converted vehicles meet the Clean Vehicles Directive (CVD)?
Yes, a van converted to electric is a zero-emission vehicle and thus fully meets the requirements of the Clean Vehicles Directive (CVD) and the German Clean Vehicles Procurement Act (SaubFahrzeugBeschG).
Does the conversion affect the payload of my van?
Heero conversions are designed to largely retain the original payload of the vehicle. Exact data can be found in the technical data sheet of the respective model. This is a significant advantage over some new electric vehicles.
