Dual battery systems are a fantastic feature for e-bike riders looking to extend their range. The ability to connect two batteries is a major advantage, and systems like Bosch’s dual battery setup are generally well-regarded for their performance. However, our team at usabikers.net recently encountered a serious safety issue while testing a dual battery balancer, highlighting the potential risks associated with these components, especially those from unverified sources.
Earlier this year, during routine testing of a dual-battery balancer module with two 52V batteries, we experienced a frightening incident: the electronic balancer module caught fire. Fortunately, the e-bike battery itself was not compromised, but the battery base sustained significant burn damage. This event served as a stark reminder of the variability in quality control within the market for Bike Balancers and the critical importance of due diligence. A single malfunction can not only ruin equipment but also pose a serious safety hazard. We strongly advise ensuring any bike balancer module you consider using has UL-certification as a baseline safety measure.
Burnt battery balancer module
Following this incident, we’ve adopted a more cautious approach to dual battery setups. For the majority of our custom e-bike builds, particularly those utilizing hub motors or custom mid-drives, we are currently prioritizing single battery configurations to ensure rider safety. We are thankful that this issue was identified during our internal testing and did not affect any of our customers. This experience underscores the importance of rigorous testing and careful component selection when dealing with high-voltage e-bike systems.
Semi-burnt battery base
The key takeaway for e-bike enthusiasts is to exercise extreme caution when considering dual-battery modules, especially with high-voltage batteries such as 52V systems. Unless you have complete confidence in the source of your bike balancer and possess comprehensive engineering specifications for its wiring and electronics, the risks may outweigh the benefits. We encourage riders who have had positive experiences with dual battery modules on hub-motor e-bikes to share their insights and recommendations in the comments below, contributing to a safer and more informed e-bike community.
Our testing area after using the fire-extinguisher
