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EV Bus Solutions & Options

Fitting a bus with an electric or range-extended drivetrain is a relatively straightforward process involving the removal of the engine and gearbox. There’s no need to modify any other existing vehicle structures or systems. Electric conversion involves removing 2.1 tonne of diesel engine and gearbox and replacing with 1.9 tonne of battery packs, electric motors and solid state converters.

MAGTEC’s compact and lightweight generator, traction motor and gearbox can usually be accommodated in the space occupied by the gearbox in a conventional transmission. The power electronic controllers for the motor and generator and the energy storage buffer can be fitted into the bus chassis without any negative impact on load space or weight.

The battery pack is capable of holding a maximum capacity of 266 kwh with individual modules offering 67kwh. Cells are assembled into battery compartments which are designed and manufactured at our Sheffield facility.  Batteries make use of LiFePO4 chemistry and are made from lithium iron phosphate so they can be charged/discharged thousands of times without memory effect.

We will work with your own design team to devise and develop the best approach to installing the new drive system into your buses. Our state-of-the-art facilities in Sheffield are equipped to carry out installation into new vehicles or conversion of existing fleets. For large-scale conversions we work in partnership with a number of specialist vehicle converters.

EV bus solutions at Magtec conversion facility in Sheffield

The Magtec re-power facilities at Bessemer Park, Sheffield

Range extension solutions

There are a number of range-extension options and MAGTEC is at the vanguard of several projects seeking to optimise the performance of such vehicles.

We’re currently working with Innovate UK, Transport for London, Tower Transit, Arcola Energy and Imperial College to design and test a range-extended hydrogen power-pack for a bus on a standard London route.  The zero-emission vehicle will be capable of a 20-hour, 140 mile duty cycle.

We’re also in an active partnership with Reading Buses which is converting an ADL E400H from a five year-old hybrid system to a compressed natural gas (CNG) range extended vehicle.  The bus will have a range of 180 miles over a 20-hour duty cycle and is set to become the world’s first CNG-powered double-decker bus in active service.

Reading zero emissions bus

Enviro 400

How the repowering process works

In the world of electric and range-extended drivetrain solutions one size certainly doesn’t fit all. The process begins with an assessment of the vehicle’s typical duty cycle. The vehicle itself then undergoes a ‘health check’ which encompasses starting, 24V battery, doors, interior lighting, ramps, warning lights, CAN system, buzzers and general condition.

magtec dia

We’ll then work with you to determine the optimal solution for your bus or bus fleet. If appropriate, we’ll also recommend the most appropriate range extension technology (whether hydrogen, diesel or petrol extension) to ensure your repowered buses offer the best possible performance.

The selected drivetrain will be installed at our new Bessemer Park facility and extensive road testing carried out before the vehicle is released for duty.

But the story doesn’t end here. Because we understand that after-sales service and support are critical customer requirements, we provide full support from our UK-based service team. We supply a dedicated telematics and logging system as standard, allowing remote access and detailed operational data. We also offer driver training, 24-hour call-out and a warranty of up to 10 years.

The re-power process

Re-power your bus

If you would like us provide you with a detailed quotation, please share some information on the vehicle type, duty cycle and other factors of operation.

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Vehicle and usage details

Make and model of Bus to be converted
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