Custom Battery Packs
Custom Packs
We are able to make up many custom battery packs using : Alkaline, Ni-Cd, Ni-Mh or Sealed lead acid Batteries
We offer a full design and refurbishment service for your battery needs, using specialist manufacturing facilities and tools such as:
- Parallel Gap Welding Machines : ensure a solid connection between cells
- Hand Solders : we only use lead free solder to comply with RoHS regulations.
- rapid cycle guillotine : for cutting of sleeving and tag material
- Komax automatic wire cut and strip machine
- In house test equipment including calibrated astratec checkmate 2 and vencon tester
- A large range of Capacity and rundown equipment
Other Facilities and tools include: - Flying leads and output connectors - thermal protection - Current Protection - Customized jigs and fixtures to ensure the consistency of all battery assemblies - custom labeling facility.
Pack configurations using "Ni-Cd D High temp 4000mAh" cells as example.
NS - Not standard
| Description | Voltage | Capacity | Tagged ends | Wires | Leads and AMP connector | With back plate and leads | With back plate, leads and AMP connector |
| Single Cell | 1.2v | 4000mAh | 1DH4-0T | 1DH4-0L | 1DH4-0LA | N/A | N/A |
| Style 1 | |||||||
| 2 SBS + 1 cell in grove (pyramid) | 3.6v | 4000mAh | 3DH4-0T1 | 3DH4-0L1 | 3DH4-0LA1 | NS | NS |
| 2 SBS + 2 SBS in grove | 4.8v | 4000mAh | 4DH4-0T1 | 4DH4-0L1 | 4DH4-0LA1 | NS | NS |
| 3 SBS + 2 SBS in grove | 6.0v | 4000mAh | 5DH4-0T1 | 5DH4-0L1 | 5DH4-0LA1 | NS | NS |
| 3 SBS + 3 SBS in grove | 7.2v | 4000mAh | 6DH4-0T1 | 6DH4-0L1 | 6DH4-0LA1 | NS | NS |
| 4 SBS + 3 SBS in grove | 8.4v | 4000mAh | 7DH4-0T1 | 7DH4-0T1 | 7DH4-0LA1 | NS | NS |
| Style 2 | |||||||
| 2x2 cells block | 4.8v | 4000mAh | 4DH4-0T1 | 4DH4-0L1 | 4DH4-0LA1 | NS | NS |
| 3x2 cells block | 7.2v | 4000mAh | 6DH4-0T1 | 6DH4-0L1 | 6DH4-0LA1 | NS | NS |
| 4x2 cells block | 9.6v | 4000mAh | 8DH4-0T1 | 8DH4-0L1 | 8DH4-0LA1 | NS | NS |
| 5x2 cells block | 12.0v | 4000mAh | 10DH4-0T1 | 10DH4-0L1 | 10DH4-0LA1 | NS | NS |
| Style 3 packs | |||||||
| 2 cells side by side | 2.4v | 4000mAh | 2DH4-0T3 | 2DH4-0L3 | 2DH4-0LA3 | 2DH4-0LP3 | 2DH4-0LAP3 |
| 3 cells side by side | 3.6v | 4000mAh | 3DH4-0T3 | 3DH4-0L3 | 3DH4-0LA3 | 3DH4-0LP3 | 3DH4-0LAP3 |
| 4 cells side by side | 4.8v | 4000mAh | 4DH4-0T3 | 4DH4-0L3 | 4DH4-0LA3 | 4DH4-0LP3 | 4DH4-0LAP3 |
| 5 cells side by side | 6.0v | 4000mAh | 5DH4-0T3 | 5DH4-0L3 | 5DH4-0LA3 | 5DH4-0LP3 | 5DH4-0LAP3 |
| 6 cells side by side | 7.2v | 4000mAh | 6DH4-0T3 | 6DH4-0L3 | 6DH4-0LA3 | 6DH4-0LP3 | 6DH4-0LAP3 |
| Style 4 packs | |||||||
| 2 cells inline (stick) | 2.4v | 4000mAh | 2DH4-0T4 | 2DH4-0L4 | 2DH4-0LA4 | Use end caps | Use end caps |
| 3 cells inline (stick) | 3.6v | 4000mAh | 3DH4-0T4 | 3DH4-0L4 | 3DH4-0LA4 | Use end caps | Use end caps |
| 4 cells inline (stick) | 4.8v | 4000mAh | 4DH4-0T4 | 4DH4-0L4 | 4DH4-0LA4 | Use end caps | Use end caps |
| 5 cells inline (stick) | 6.0v | 4000mAh | 5DH4-0T4 | 5DH4-0L4 | 5DH4-0LA4 | Use end caps | Use end caps |
| 6 cells inline (stick) | 7.2v | 4000mAh | 6DH4-0T4 | 6DH4-0L4 | 6DH4-0LA4 | Use end caps | Use end caps |
| 7 cells inline (stick) | 8.4v | 4000mAh | 7DH4-0T4 | 7DH4-0L4 | 7DH4-0LA4 | Use end caps | Use end caps |
| 8 cells inline (stick) | 9.6v | 4000mAh | 8DH4-0T4 | 8DH4-0L4 | 8DH4-0LA4 | Use end caps | Use end caps |
| 9 cells inline (stick) | 10.8v | 4000mAh | 9DH4-0T4 | 9DH4-0L4 | 9DH4-0LA4 | Use end caps | Use end caps |
| 10 cells inline (stick) | 12.0v | 4000mAh | 10DH4-0T4 | 10DH4-0L4 | 10DH4-0LA4 | Use end caps | Use end caps |
| Style 5 packs | |||||||
| 2+1 D cell sticks SBS | 3.6v | 4000mAh | 3DH4-0T5 | 3DH4-0L5 | 3DH4-0LA5 | NS | NS |
| 2+2 D cell sticks SBS | 4.8v | 4000mAh | 4DH4-0T5 | 4DH4-0L5 | 4DH4-0LA5 | NS | NS |
| 3+2 D cell sticks SBS | 6.0v | 4000mAh | 5DH4-0T5 | 5DH4-0L5 | 5DH4-0LA5 | NS | NS |
| 3+3 D cell sticks SBS | 7.2v | 4000mAh | 6DH4-0T5 | 6DH4-0L5 | 6DH4-0LA5 | NS | NS |
| 4+3 D cell sticks SBS | 8.4v | 4000mAh | 7DH4-0T5 | 7DH4-0L5 | 7DH4-0LA5 | NS | NS |
| 4+4 D cell sticks SBS | 9.6v | 4000mAh | 8DH4-0T5 | 8DH4-0L5 | 8DH4-0LA5 | NS | NS |
| 5+4 D cell sticks SBS | 10.8v | 4000mAh | 9DH4-0T5 | 9DH4-0L5 | 9DH4-0LA5 | NS | NS |
| 5+5 D cell sticks SBS | 12.0v | 4000mAh | 10DH4-0T5 | 10DH4-0L5 | 10DH4-0LA5 | NS | NS |
| Style 6 | |||||||
| 4 cell style 2 (x 2 high) 8 cells | 9.6V | 4000mAh | 8DH4-0T6 | 8DH4-0L6 | 8DH4-0LA6 | NS | NS |
| 4 cell style 3 (x 2 high) 12 cells | 14.4V | 4000mAh | 12DH4-0T6 | 12DH4-0L6 | 12DH4-0LA6 | NS | NS |
| Style 7 | |||||||
| 3 cell style 1 (x 2 high) 6 cells | 7.2V | 4000mAh | 6DH4-0T7 | 6DH4-0L7 | 6DH4-0LA7 | NS | NS |
| 3 cell style 1 (x 3 high) 9 cells | 10.8V | 4000mAh | 9DH4-0T7 | 9DH4-0L7 | 9DH4-0LA7 | NS | NS |
| Style 8 | |||||||
| 3 cell SBS + 1 in grove | 4.8V | 4000mAh | 4DH4-0T8 | 4DH4-0L8 | 4DH4-0LA8 | NS | NS |
| 4 cell SBS + 1 in grove | 6.0V | 4000mAh | 5DH4-0T8 | 5DH4-0L8 | 5DH4-0LA8 | NS | NS |
| 5 cell SBS + 1 in grove | 7.2V | 4000mAh | 6DH4-0T8 | 6DH4-0L8 | 6DH4-0LA8 | NS | NS |
| Style 9 packs | |||||||
| 2 + 1 (2 cell inline linked to 1 cell) | 3.6v | 4000mAh | 3DH4-0T9 | 3DH4-0L9 | 3DH4-0LA9 | Use end caps | Use end caps |
| 2+2 (2 cell inline linked to 2 cell inline) | 4.8v | 4000mAh | 4DH4-0T9 | 4DH4-0L9 | 4DH4-0LA9 | Use end caps | Use end caps |
| 3+2 (3 cell inline linked to 2 cell inline) | 6.0v | 4000mAh | 5DH4-0T9 | 5DH4-0L9 | 5DH4-0LA9 | Use end caps | Use end caps |
| 3+3 (3 cell inline linked to 3 cell inline) | 7.2v | 4000mAh | 6DH4-0T9 | 6DH4-0L9 | 6DH4-0LA9 | Use end caps | Use end caps |
| 4+3 (4 cell inline linked to 3 cell inline) | 8.4v | 4000mAh | 7DH4-0T9 | 7DH4-0L9 | 7DH4-0LA9 | Use end caps | Use end caps |
| 4+4 (4 cell inline linked to 4 cell inline) | 9.6v | 4000mAh | 8DH4-0T9 | 8DH4-0L9 | 8DH4-0LA9 | Use end caps | Use end caps |
| 5+4 (5 cell inline linked to 4 cell inline) | 10.8v | 4000mAh | 9DH4-0T9 | 9DH4-0L9 | 9DH4-0LA9 | Use end caps | Use end caps |
| 5+5 (5 cell inline linked to 5 cell inline) | 12.0v | 4000mAh | 10DH4-0T9 | 10DH4-0L9 | 10DH4-0LA9 | Use end caps | Use end caps |
| Style 10 | |||||||
| 7 cell cluster most compact form | 8.4v | 4000mAh | 7DH4-0T10 | 7DH4-0L10 | 7DH4-0LA10 | NS | NS |
| 10 cell cluster most compact form | 12.0v | 4000mAh | 10DH4-0T10 | 10DH4-0L10 | 10DH4-0LA10 | NS | NS |
| Style 11 | |||||||
| 2 SBS + 1 Cell | 3.6v | 4000mAh | 3DH4-0T11 | 3DH4-0L11 | 3DH4-0LA11 | NS | NS |
| 2 SBS + 2 SBS cell pack | 4.8v | 4000mAh | 4DH4-0T11 | 4DH4-0L11 | 4DH4-0LA11 | NS | NS |
| 3 SBS + 2 SBS cell pack | 6.0v | 4000mAh | 5DH4-0T11 | 5DH4-0L11 | 5DH4-0LA11 | NS | NS |
| 3 SBS + 3SBS cell pack | 7.2v | 4000mAh | 6DH4-0T11 | 6DH4-0L11 | 6DH4-0LA11 | NS | NS |
| 4 SBS + 3 SBS cell pack | 8.4v | 4000mAh | 7DH4-0T11 | 7DH4-0L11 | 7DH4-0LA11 | NS | NS |
| 4 SBS + 4 SBS cell pack | 9.6v | 4000mAh | 8DH4-0T11 | 8DH4-0L11 | 8DH4-0LA11 | NS | NS |
| 5 SBS + 4 SBS cell pack | 10.8v | 4000mAh | 9DH4-0T11 | 9DH4-0L11 | 9DH4-0LA11 | NS | NS |
| 5 SBS + 5 SBS cell pack | 12.0v | 4000mAh | 10DH4-0T11 | 10DH4-0L11 | 10DH4-0LA11 | NS | NS |
| Style DC - single cells interlinked with wire "daisy chain" style battery pack, leads out same end | |||||||
| 1+1 | 2.4v | 4000mAh | NA | 2DH4-0DC | 2DH4-0DCA | NA | NA |
| 1+1+1 | 3.6v | 4000mAh | NA | 3DH4-0DC | 3DH4-0DCA | NA | NA |
| 1+1+1+1 | 4.8v | 4000mAh | NA | 4DH4-0DC | 4DH4-0DCA | NA | NA |
| 1+1+1+1+1 | 6.0v | 4000mAh | NA | 5DH4-0DC | 5DH4-0DCA | NA | NA |







