What battery sizes are available for converting a diesel transporter? Your guide 2025
Up to 425 km range after an upgrade – without the costs of a new vehicle. Retrofitting your van is not only a response to rising diesel prices and the Clean Vehicles Directive, but a strategic investment in the future of your fleet. Find out which battery sizes are suitable for your requirements and what the KsNI funding deadline until 2024 meant for the retrofitting.
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 covered up to 80% of the additional costs of a conversion and 40% of the charging infrastructure; it ran until 2024, and no new calls for funding are planned.
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 greatest challenge of the decade for many companies and municipalities. High diesel costs, the threat of city tolls, and the strict requirements of the EU's Clean Vehicles Directive are creating pressure to act. Converting your vehicles offers a pragmatic and economically superior solution: you retain your proven vehicles and expensive special bodies while drastically reducing operating costs. This article explains which battery sizes are available for converting your diesel transporter, how to find the right capacity for your route planning, and how to evaluate the government funding of up to 80% that ran until 2024.
Standardized battery options for maximum flexibility and range
The central question when converting a diesel transporter is that of the appropriate battery size. HEERO relies on a standardized but highly flexible solution to ensure planning reliability and economies of scale. For most transporter 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 dimensioning enables ranges of up to 425 km for a converted Sprinter and up to 500 km for an e-transporter. An exception is the medium low-floor bus, which, due to its specific application profile, receives a larger battery with 137 kWh gross (115 kWh net) and thus achieves up to 300 km. This standardization not only secures 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 therefore depends less on the model and more on the intended use.
Funding pots and deadlines: There was an 80% subsidy until 2024
The electrification of your fleet requires a clear calculation, as the funding conditions have shifted. The Electromobility Funding Guideline of the Federal Ministry for Digital and Transport (BMDV) was the decisive instrument for an economic transition. It subsidized the additional costs of conversion compared to a diesel counterpart by up to 80%. Applications were possible until 2024; since August 2024, no new funding calls are planned. In addition, the installation of the necessary charging infrastructure was subsidized at 40%. This funding significantly reduced the higher acquisition costs, the main factor in the TCO calculation. The guideline aims to accelerate the market ramp-up and achieve the climate targets in accordance with the Clean Vehicles Directive, which has obliged public contracting authorities to procure clean vehicles since 2021. Careful planning is essential for a reliable decision.
Your checklist for a funded conversion:
Analyze vehicle fleet and driving profiles (km/day, idle times).
Select the suitable conversion solution and battery size.
Obtain a quote for the conversion and charging infrastructure.
Submit funding applications for open programs to the project sponsor.
This structured approach ensures a reliable calculation and a smooth transition to e-mobility.
Economic Efficiency in Focus: The TCO Analysis of Diesel vs. Electric
A conversion is more than an ecological statement; it is a business decision. The Total Cost of Ownership (TCO) proves this impressively. While the initial costs for a conversion are higher, they often amortize within four to six years through drastically lower operating costs. The energy costs per 100 km for an electric van are around 5 to 6 euros (at 30 cents/kWh), while a comparable diesel causes around 12.25 euros at 1.75 euros/liter. In addition, there are up to 50% lower maintenance costs, as many wear parts of the internal combustion engine are eliminated. The CO₂ pricing, which could make diesel and gasoline around 65 cents more expensive per liter by 2030, also speaks clearly in favor of the electric drive. By electrifying your fleet, you protect yourself against these unpredictable price increases.
Charging infrastructure and charging power: The backbone of your e-fleet
The performance of your e-fleet depends directly on the charging infrastructure. HEERO vehicles are designed for demanding commercial use. All transporter models support DC fast charging with up to 135 kW as standard. This allows the 96 kWh battery to be charged to 80% in around 30 minutes, minimizing downtime and maximizing vehicle availability. The mid-low-floor bus even charges with up to 165 kW. Planning the charging infrastructure should always be part of the overall strategy. With the BMDV's 40% funding, the installation of depot charging points was significantly facilitated until 2024. Smart charging planning, which for example uses favorable night electricity tariffs, additionally reduces operating costs. This makes the transition a holistic success for your field service vehicles.
Sustainability through Circular Economy: The Second Life of the Battery
Converting an existing vehicle is the epitome of the circular economy. Instead of scrapping a functioning vehicle, its service life is extended by many years. This also applies to the battery. The high-voltage batteries in HEERO vehicles are designed for a service life of eight to ten years in the vehicle. After that, they still have 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 there for another ten to twelve years. Only then does recycling take place, in which up to 96% of the valuable raw materials such as lithium and cobalt can be recovered. This approach not only conserves resources, but is also a central building block for a credible and sustainable corporate strategy.
Your path to funding: In three steps to the grant roadmap
The path to successful fleet electrification begins with a clear assessment. The KsNI funding scheme ran until 2024. With our free funding analysis, you will quickly and easily gain clarity about your options. Simply answer three key questions about your fleet and your driving profiles. Based on this, we will create your personal subsidy roadmap and evaluate what the 80% funding scheme that was in place until 2024 means for you. Start your transformation and make your fleet future-proof.
To the free analysis
free of charge · non-binding · objective
More useful links
Wikipedia describes traction batteries, particularly for electric vehicles.
BALM provides information on the funding program for climate protection and sustainability in transport (KSNI).
Kraftfahrt-Bundesamt (KBA) provides the annual balance sheet on the vehicle stock in Germany.
Statista provides statistics on the truck stock and its development in Germany.
Umweltbundesamt offers an analysis on the environmental balance of motor vehicles.
Bundesministerium für Digitales und Verkehr (BMDV) provides information on electromobility with batteries.
TÜV-Verband offers information on alternative drives and electric vehicles.
Deutsche Energie-Agentur (dena) explains electromobility as an opportunity for the power grids.
Zentralverband Deutsches Kraftfahrzeuggewerbe offers a dossier on the topic of electromobility.
