Existing Battery Bank
Battery type, nominal voltage, capacity, series/parallel arrangement, age, installation orientation and replacement constraints.
Energy Storage & Electric Mobility
Custom LiFePO4 Battery Systems for Lead-acid Replacement
Custom lead acid replacement lithium battery solutions engineered around the host equipment's voltage window, peak and continuous current, charger compatibility, low-voltage behaviour, enclosure constraints and service expectations.
REPLACEMENT COMPATIBILITY
Start With the Existing Equipment and Charging System
A battery that fits the same space may still be electrically or operationally incompatible. The first review should establish how the original lead-acid bank, charger, controller, cabling and low-voltage protections work together before the replacement configuration is defined.
WHAT TO DEFINE
Inputs That Determine a Safe Replacement Direction
Existing equipment information is the baseline. Nameplate data helps, but measured load and charger behavior provide a stronger basis for engineering decisions.
Equipment Load Profile
Normal current, startup or motor peaks, pulse duration, regenerative behavior, runtime target and low-voltage cutoff.
Charger & Electrical Interface
Charger model, charging curve, maximum voltage and current, connector, cable, fuse, contactor and controller expectations.
Mechanical & Service Conditions
Available envelope, mounting, ventilation, handling, maintenance access, temperature, vibration, moisture and required service life.
ENGINEERING CONSIDERATIONS
Compatibility Extends Beyond Voltage and Capacity
LiFePO4 changes the discharge curve, usable energy window, charging behavior and protection response. Cell selection, BMS limits, enclosure, charger compatibility and equipment controls must therefore be coordinated as one system.
Voltage Window & Runtime
Match the equipment operating range and cutoff behavior while defining usable energy from the real duty cycle rather than lead-acid nameplate capacity alone.
Peak Load & BMS Response
Size cells, conductors and protection logic for startup, acceleration, hydraulic or inverter peaks without nuisance shutdown or excessive voltage drop.
Charging Compatibility
Review the existing charger profile, termination logic, float behavior and temperature assumptions; retain it only when compatibility is demonstrated.
Mechanical Retrofit & Service
Coordinate dimensions, terminals, mounting, weight distribution, enclosure protection, isolation, fuse access and installation instructions for the actual equipment.
RETROFIT-SPECIFIC DEFINITION
Parameters Defined From the Existing Lead-acid System
No fixed reference configuration is published on this page yet. The battery is engineered for the target equipment; voltage, capacity, continuous and peak current, charging, BMS logic, communication, protection rating and mechanical interfaces can be customized. Final specifications are subject to the approved project definition. A lithium replacement is not approved from nominal voltage and amp-hours alone; charger behaviour, equipment cutoffs, peak load and mechanical retrofit must be verified.
Project parameterHow it is defined
System voltage & energyDefined from the equipment voltage window, duty cycle, runtime or autonomy target and reserve. Continuous current | Defined from sustained operating loads and the required thermal margin. Peak current & duration | Defined from startup, acceleration, actuator or fault events with an explicit pulse duration. Charging interface | Defined from charger or power-source voltage, current, connector, control and recharge window. BMS & communication | Protection, sensing, SOC/SOH and CAN, RS485, RS232 or application-specific interfaces as required. Protection & environment | Ingress, vibration, shock, temperature, storage and corrosion requirements are assigned from the real operating environment. Mechanical integration | Enclosure, mounting, connector, cabling, service access and replacement method are developed around the equipment. Customization note | No fixed reference configuration is published on this page yet. The battery is engineered for the target equipment; voltage, capacity, continuous and peak current, charging, BMS logic, communication, protection rating and mechanical interfaces can be customized. Final specifications are subject to the approved project definition.
VALIDATION & RELEASE
Verify the Battery With the Equipment, Charger and Duty Cycle
A replacement sample should confirm the assumptions already defined during engineering. Validation should cover the complete operating loop rather than only an isolated charge-discharge test.
Bench Verification
Confirm capacity, voltage behavior, continuous and peak-load response, protection thresholds, thermal behavior and charger interaction.
Equipment Integration
Check physical fit, polarity, terminal and cable arrangement, startup behavior, controller cutoffs, indicators and any communication.
Duty-cycle Trial
Run representative work and charging cycles to evaluate runtime, voltage sag, temperature rise and repeatability under expected conditions.
Production Release
Freeze the approved electrical and mechanical configuration, acceptance criteria, installation guidance and production test requirements.
FROM EXISTING SYSTEM TO RELEASED PACK
A Controlled Replacement Process Reduces Field Risk
Stellova translates the existing lead-acid system and equipment duty cycle into a battery definition, coordinates the electrical and mechanical design, prepares the sample-validation plan and carries the approved configuration into controlled production.
View the Engineering Process ↗DISCUSS YOUR REPLACEMENT PROJECT
Share the Existing Battery, Charger and Equipment Data
Send photos and labels for the current battery bank and charger, the equipment model, voltage, load or runtime information, available space, connector details, operating environment and target quantity. We will identify the key compatibility questions before recommending a configuration.
Discuss Your Project ↗