Enersys offers a comprehensive range of aftermarket spare parts for industrial and automotive energy storage systems, focusing on advanced battery components and maintenance solutions. Key offerings include lithium-ion and lead-acid battery modules, battery management systems (BMS), charging interfaces, and cooling system components. These parts support critical applications in electric vehicles, material handling equipment, and renewable energy storage systems. Pro Tip: Always verify BMS firmware compatibility before replacing modules to prevent system communication errors.
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What battery components does Enersys provide for replacements?
Enersys supplies lithium-ion cells, lead-acid plates, and complete battery racks designed for forklifts and EVs. Their modular designs enable partial system repairs without full replacements, reducing downtime.
Enersys’ aftermarket battery packs feature standardized voltage configurations (24V-80V) compatible with most industrial equipment. The lithium NMC cells maintain 4,000+ cycles at 80% DoD when properly maintained. For lead-acid systems, their TPPL (Thin Plate Pure Lead) technology delivers 30% longer lifespan than conventional AGM batteries. A typical 48V 600Ah Li-ion forklift battery weighs 20% less than equivalent lead-acid versions, improving operational efficiency. Pro Tip: Use Enersys’ proprietary electrolyte testing kits quarterly to detect cell imbalance early. For example, their FlexModule series allows swapping individual 12V blocks in 48V systems—like replacing damaged rungs on a ladder while keeping the structure intact.
Are motor control units available as spare parts?
Enersys provides motor controllers rated 50-300A for EV drivetrains and industrial motors. These units integrate CAN bus communication for real-time diagnostics.
Their HVC-300 controller supports 72V-144V systems with peak efficiency of 98%, using silicon carbide MOSFETs for reduced thermal stress. Controllers come pre-loaded with application-specific firmware for forklifts, airport ground vehicles, or solar storage systems. Technicians can reprogram parameters via Enersys’ EnerSuite software, but firmware updates require factory authorization to prevent unauthorized modifications. Why does this matter? A mismatched controller in a 96V warehouse AGV could cause torque fluctuations during heavy lifting operations. Enersys offers plug-and-play replacements with color-coded connectors to prevent installation errors.
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| Model | Voltage Range | Peak Current |
|---|---|---|
| HVC-150 | 48-96V | 150A |
| HVC-300 | 72-144V | 300A |
What charging system components are offered?
Enersys sells smart chargers, contactors, and voltage regulators supporting CC-CV and pulsed charging modes. Their 3-stage chargers prevent sulfation in lead-acid batteries.
The EC-4800 charger delivers 48V/100A output with adaptive temperature compensation (±2mV/°C). For lithium systems, the LiPro series uses active cell balancing during charging, achieving ±1% voltage uniformity across cells. All chargers include GFCI protection and IP54-rated enclosures for damp environments. Consider this: A distribution center using Enersys’ 80V chargers reduced battery swap frequency by 22% through optimized charge curves. Remember to replace thermal fuses every 3 years—overheated charging contacts account for 17% of warranty claims.
Do they offer battery thermal management parts?
Yes, Enersys provides cooling plates, temperature sensors, and glycol-based coolant kits. Their liquid cooling systems maintain cells within 25°C±5°C optimal range.
The CoolFlow Pro system reduces peak battery temperatures by 18°C compared to passive cooling, using aluminum microchannel plates with 0.5mm fin spacing. Replacement sensors feature NTC thermistors with ±0.5°C accuracy and MIL-SPEC connectors. For cold climates, their battery heaters maintain 15°C minimum temperature using self-regulating PTC elements. Pro Tip: Always purge air from coolant lines after plate replacement—trapped bubbles increase thermal resistance by 40%.
| Component | Operating Temp | Compatibility |
|---|---|---|
| CoolFlow Pro | -20°C to +60°C | Li-ion ≥ 30kWh |
| NTC Sensor | -40°C to +125°C | All systems |
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FAQs
Not recommended—Enersys employs unique charge algorithms. Non-certified chargers may trigger BMS fault codes and void cell warranties.
Are Enersys motor controllers cross-compatible?
Only within voltage classes. A 96V controller won’t function in 144V systems despite physical connector matches—verify nameplate ratings first.
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