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