Lead-Acid Systems
Review charging profile, usable capacity, voltage behavior and current demand.
LEAD-ACID · AGM · LEGACY LITHIUM CONVERSION
Battery Replacement Guide
battery systems.
Application-led LiFePO4 conversion for existing battery systems. Compatibility is determined from the voltage window, charger, controller, peak current, tray, terminals, mounting and operating temperature—not from nominal voltage or case size alone.
EQUIPMENT / APPLICATION TYPES
Conversion starts with the existing system.
This page is organized by the battery being replaced and the equipment interface, rather than by end-use industry.
AGM / GEL Systems
Confirm float charging, low-voltage cutoff, controller and physical installation.
Legacy Lithium Systems
Match voltage window, BMS behavior, communication and protection.
System-Specific Conversion
Evaluate the complete electrical and mechanical interface before confirmation.
DESIGN PRIORITIES
Requirements that define the battery.
Each industry is reviewed through its own operating and integration constraints.
Voltage window
Nominal, full-charge, cutoff and controller operating limits.
Charger & controller
Charge profile, float behavior, current and equipment control settings.
Load current
Continuous current, acceleration or startup peak, surge duration and regeneration.
Physical fit
Tray, dimensions, terminals, cables, mounting, orientation and temperature.
BATTERY PLATFORM / ARCHITECTURE
A conversion is an interface-matching exercise.
The battery architecture is selected only after the existing electrical and mechanical system has been documented.
Operating window confirmed against equipment and charger
Continuous, peak and regenerative requirements reviewed
Tray, terminals, mounting and cable routing confirmed
Controller, cutoff behavior and communication reviewed
MANLY does not describe a conversion as drop-in or fully compatible until the actual system data has been reviewed.
CONFIGURATION SCOPE
System checks before replacement.
Only the functions required by the equipment are included in the final specification.
- Voltage window
- Charger model and settings
- Controller model and cutoff
- Continuous current
- Peak current and duration
- Regenerative current
- Tray dimensions
- Terminal position
- Mounting and orientation
- Cable and connector
- Operating temperature
- Communication where required
RELATED PRODUCTS / STARTING PLATFORMS
Start from the nearest architecture.
These links are starting points only. Final suitability is confirmed after the project information is reviewed.
CONFIGURATION STARTING POINT12.8V Conversion ReviewFor existing 12V-class battery systems.View 12V platforms CONFIGURATION STARTING POINT25.6V Conversion ReviewFor existing 24V-class battery systems.View 24V platforms CONFIGURATION STARTING POINT36V–72V Motive ReviewFor vehicle and mobile-equipment conversions.View motive platforms
PROJECT INFORMATION REQUIRED
Send the system data before battery selection.
This moves the discussion from a general price request to a configuration that can be checked against the equipment.
- 01Equipment and existing battery model
- 02Existing battery voltage and capacity
- 03Charge voltage, float voltage and current
- 04Controller model and voltage limits
- 05Continuous and peak load
- 06Regenerative-current requirement
- 07Battery tray and maximum dimensions
- 08Terminal, connector and cable details
- 09Operating temperature and quantity
BATTERY REPLACEMENT GUIDE PROJECT