Custom 24V 100Ah LiFePO4 Drop-in Battery Pack

A 25.6V 100Ah LiFePO4 drop-in replacement built to the footprint of the lead-acid battery it replaces, so the installation itself does not change. It carries 2.56 kWh of usable energy and delivers 100A continuous — a full 1C draw, with headroom for the surge loads motive duty demands.

Charging at 50A brings it to full in roughly 2.5 hours. The operating window is -20~75°C on discharge and 0~55°C on charge. The pack measures 522 x 238 x 217 mm and weighs 19 kg.

Where it sits in the range

Within our 24V range this sits between the 90Ah and 126Ah builds. If your runtime target is tighter than expected once we model the duty cycle, the 126Ah configuration is the usual next step; if weight or envelope is the binding constraint, the 90Ah build is lighter.

What we customise

Case footprint, terminal type and position, capacity and BMS behaviour are specified so the replacement drops into the existing installation unchanged. Communication over CAN or RS485 is available where the system expects it, with Bluetooth for local monitoring.

Common questions

Do we need to change the charger?
Usually yes — a lead-acid charging profile will not charge LiFePO4 correctly. Send the charger model and we confirm.

Can we mix these with existing lead-acid batteries?
No. Mixing chemistries in one bank damages both. Replace the whole bank.

Cells, compliance and lead time

Grade A prismatic LFP cells, generally specified with UL recognition at cell level. Every pack ships with a UN38.3 test summary and MSDS prepared for air, sea and road transport. Assembly and testing take around 7 working days. Cell supply is what sets the overall schedule: when the cells your design needs are in stock, samples ship in 12–15 working days; when they have to be sourced, allow 20–25. Tell us your target date early and we will confirm cell availability before you commit to it. Production runs 30–35 working days. There is no minimum order quantity — this is a custom design business and we quote single units, with pricing improving noticeably from 100 packs upward. LiFePO4 warranty typically runs 3–5 years, set against the discharge duty of the application; high-rate cycling shortens it.