Two ultra-thin battery modules installed in protected bays of a trailer-mounted industrial cable winch

Battery systems for cable handling equipment

96V Lithium Battery Systems for Cable Pulling Machines & Industrial Winches

Ultra-thin, high-current battery modules for cable pullers, industrial winches and mobile utility equipment. Built around a 97V nominal NMC module with engineered single- and dual-pack options.

Review the Verified Module
135mmEnclosure height
200AContinuous per module
IP67Ingress rating
4G IoTConfigurable option

Start with the machine

Built for Space-Constrained, High-Current Equipment

Cable handling equipment combines packaging limits with demanding, intermittent loads. Battery selection therefore starts with the machine—not with a generic voltage label.

01 / PACKAGING

Restricted installation height

A 135mm enclosure can support layouts beneath decks or inside shallow equipment bays, subject to clearance and mounting review.

02 / LOAD

Intermittent high current

200A maximum continuous discharge and 300A for 10 seconds per module create defined inputs for duty-cycle calculations.

03 / ENVIRONMENT

Dust and rain exposure

An IP67 aluminum-alloy enclosure supports evaluation for outdoor work sites; it is not a claim of indefinite immersion.

04 / TEMPERATURE

Cold-weather planning

Charging and discharging ranges define the starting boundary for charger, BMS and operating-strategy review.

05 / DATA

Machine communication

CAN and a configurable 4G IoT option can support integration and maintenance after required BMS data is confirmed.

Compatibility is not automatic. Check motor and controller voltage limits, continuous and peak current, duty cycle, protection, installation space and charging architecture for every machine.
97V nominal Bonnen NMC battery module with low-profile aluminum enclosure and front connection panel

Verified single module

96V-Class / 97V Nominal Ultra-Thin NMC Battery Module

The verified module combines an 11.4kWh energy rating with a low-profile aluminum-alloy enclosure. The specification applies to one module.

118AhRated capacity
11.4kWhNominal energy
CANBMS communication

Swipe horizontally to review the complete specification table.

Equipment voltage class96V class
Nominal voltage97V nominal NMC
Rated capacity118Ah
Nominal energy11.4kWh
Recommended charge current50A
Maximum continuous discharge current200A per module
Peak discharge current300A for 10 seconds per module
CommunicationBMS with CAN communication
Enclosure / ingress ratingAluminum alloy / IP67
Cycle lifeMore than 1,500 cycles at 80% DoD
Charging ambient temperature−10°C to 50°C
Discharging ambient temperature−20°C to 60°C
Parallel connectionSupported; complete-system engineering required
Remote monitoringConfigurable 4G IoT option
Dimensions1060 × 430 × 135mm (L × W × H)

Configuration choice

One Battery Module. Two System Configurations.

Choose the architecture after energy, duty cycle, available space and system-current requirements are known.

Single module

97V nominal / 118Ah / approximately 11.4kWh

Evaluate for compact machines, shorter working cycles and prototype integration after power, runtime and thermal requirements are calculated.

Two matched modules in parallel

97V nominal / 236Ah / approximately 22.8kWh

Evaluate for longer operating targets, separated installation spaces and designed current sharing. Parallel connection does not create a higher-voltage series pack.

Conceptual single and dual-parallel battery architectureOne module or two matched modules connect through engineered power distribution and protection to the motor controller. Single module97V nominal Matched module 2Dual option only Engineered distributionProtection / pre-charge / monitoringProject-specific implementation Motor controllerVoltage range verified
Matched BAT-01 and BAT-02 modules installed in separate protected equipment bays

Mechanical packaging

Only 135mm High—Packaging That Works With the Machine

At 1060 × 430 × 135mm, the enclosure prioritizes a low installed profile for beneath-deck or shallow-bay layouts.

200AMaximum continuous discharge per module
300A / 10sPeak discharge per module
Low-profile battery module mounted beneath an industrial cable pulling machine with a 135mm height annotation
Cable pulling machine operating with a protected low-profile battery installed beneath the reel

Load profile matters

Define the Pulling Duty Before Sizing Energy

Starting events, sustained pulls, pauses, line load and gearing shape both current demand and useful runtime. The module ratings establish engineering inputs; they do not replace a machine duty-cycle calculation.

Share rated and peak motor current, expected pull duration, recovery time and the required daily operating window.

Field conditions

Engineered for Outdoor and Low-Temperature Evaluation

The IP67 aluminum-alloy enclosure supports projects that must account for dust, rain and field handling. Temperature limits remain part of the charging and operating strategy.

IP67Ingress rating; not indefinite immersion
−10°C to 50°CCharging ambient temperature
−20°C to 60°CDischarging ambient temperature

The same charge rate is not assumed across the full temperature range. Review site temperature, storage, condensation and charger/BMS behavior.

Low-profile battery installed inside a protected service bay during cold utility work
Utility equipment manager reviewing illustrative status information on a rugged tablet

Integration and maintenance

CAN Integration and Configurable 4G IoT

CAN communication gives the host machine a path for battery status and control integration. A configurable 4G IoT option can also be evaluated for remote maintenance workflows.

State of charge, temperature, alarms, location and combined pack views must be confirmed against the selected BMS, gateway and platform. SIM availability, network coverage, cloud services and subscription terms are project-specific.

Potential fit categories

Applications to Evaluate

These categories describe relevant operating problems, not completed customer deployments. Verify each motor, controller, duty cycle and installation space.

Cable pulling equipment guiding heavy cable through rollers beside a utility trench
Underground utility

Cable Pulling Machines

Evaluate controller voltage, pulling profile, cable length, setup time and available bay height.

Industrial electric winch pulling steel wire rope in a fabrication and utility yard
Line pull

Industrial Electric Winches

Size energy and current around line pull, gearing, working cycle and cooling intervals.

Utility operator safely tending rope around a compact vertical capstan winch
Compact equipment

Capstan Winches

Review transient load, operator cycle, mechanical layout and charging access.

Twin-drum cable tensioner and puller managing conductor at a remote power project
Controlled tension

Cable Tensioners & Pullers

Coordinate the battery with tension control, drive electronics and separated equipment spaces.

Power-line stringing puller and tensioner operating in a transmission corridor
Remote sites

Power Line Stringing Equipment

Include temperature, operating window, transport requirements and service access in the review.

Trailer-mounted utility winch pulling cable into an underground access chamber
Mobile platform

Trailer-Mounted Utility Equipment

Explore under-deck or side-bay layouts while maintaining protected access and mounting clearance.

Project inputs

Custom Engineering Around Your Machine

Bonnen can evaluate mounting, interfaces, connectors, CAN integration, monitoring, single- or dual-module architecture, and other voltage or capacity targets. Each option remains subject to project engineering.

What We Need to Size Your Battery

  • Motor and controller voltage range
  • Rated and peak power or current
  • Required runtime and duty cycle
  • Battery-compartment dimensions
  • Single or separated installation spaces
  • Minimum ambient temperature
  • Charging setup and available window
  • Communication and monitoring requirements
Incomplete information is fine. Share what you already know, and our engineers can start from there.

Explore Other 96V Battery Platforms

FAQs About 96V Lithium Battery Systems for Cable Pulling Machines & Industrial Winches

This 96V lithium battery system is designed for electrically powered cable pulling machines, industrial winches, capstan winches, cable tensioners and pullers, power line stringing equipment, trailer-mounted utility machines, and other mobile industrial equipment requiring high discharge current. Final compatibility should be confirmed based on the motor voltage, controller input range, continuous and peak current, operating cycle, installation space, and environmental conditions of the machine.

In industrial equipment, 96V is commonly used as a system voltage class rather than an exact battery nominal voltage. Our battery has a nominal voltage of approximately 97V because of the series configuration and nominal voltage of the lithium cells used inside the pack, while it is designed for applications commonly referred to as 96V systems. Before integration, Bonnen Battery will verify the controller operating voltage range and charging voltage to ensure compatibility.

In many cases, yes, but compatibility should be verified before installation because the battery must match the controller’s operating voltage range, continuous current demand, peak current demand, regenerative current if applicable, and communication requirements. If you provide the motor and controller specifications, Bonnen Battery can evaluate whether the existing 96V battery platform is suitable or whether electrical or mechanical customization is required.

The standard battery platform supports up to 200A continuous discharge and can provide higher short-duration current for demanding operating conditions, with the current design supporting up to 300A for approximately 10 seconds per battery module. The actual current configuration can be engineered according to the motor power, controller current limit, pulling load, acceleration requirements, operating duration, and thermal conditions of the equipment.

Yes, the battery system can be engineered as a coordinated two-module parallel configuration when greater capacity, longer operating time, or higher system current capability is required. The two batteries must use compatible BMS control, electrical protection, cabling, connectors, and current-sharing strategies rather than simply connecting two independent batteries together, so Bonnen Battery designs and validates the complete parallel system according to the machine requirements.

The standard 96V battery modules should not be connected in series unless the battery system, BMS, contactors, insulation design, charger, controller, and protection architecture have specifically been engineered for series operation. If your equipment requires a higher voltage such as 144V, 192V, 300V, or another voltage platform, Bonnen Battery can evaluate the application and develop a dedicated battery system rather than using an unsupported field series connection.

Operating time depends on the actual energy consumption of the machine rather than motor rated power alone, because cable pulling and winch applications often operate intermittently with changing load levels. To estimate runtime accurately, we consider motor power, average operating current, peak pulling current, pulling duration, idle time, mechanical load, gearing, duty cycle, terrain, temperature, and available battery capacity, and we can recommend the required single- or dual-battery configuration based on your working cycle.

Yes, the battery has been developed specifically for applications where vertical installation space is limited, with an enclosure height of only approximately 135mm. This ultra-thin configuration makes it suitable for installation under equipment decks, inside low-profile chassis spaces, underneath machinery platforms, or in other restricted compartments where conventional industrial battery packs may be too tall, while the final installation should still provide adequate mounting strength, cable clearance, ventilation considerations, and service access.

The battery enclosure is designed to achieve IP67 protection, making it suitable for outdoor industrial equipment exposed to rain, dust, mud, splashing water, and demanding job-site environments. IP67 protection does not mean the battery should be continuously submerged or installed in an environment where water can remain around connectors or cable interfaces for extended periods, so the installation position, connector sealing, drainage, and mechanical protection should also be considered during machine integration.

Yes, the battery is designed for industrial applications that may operate in low-temperature environments, with the standard system supporting discharge operation down to approximately -20°C depending on the final battery configuration. Charging lithium batteries at low temperatures requires more careful control, so the BMS, charger strategy, optional heating system, charging current, and minimum charging temperature can be configured according to the lowest ambient temperature expected in the customer’s actual operating environment.

Yes, CAN communication can be integrated so that the battery BMS can exchange operating information with the machine controller, display, gateway, or vehicle control system. Depending on the project, communication data may include SOC, battery voltage, current, temperature, alarms, operating status, fault information, and other BMS parameters, while the exact CAN baud rate, message IDs, data mapping, protocol requirements, and integration method should be confirmed during the engineering stage.

An optional 4G IoT monitoring solution can be integrated for remote battery management and fleet monitoring, allowing selected battery information such as SOC, voltage, current, temperature, alarm status, operating history, and potentially location or maintenance-related data to be transmitted to a remote platform. The exact monitoring functions depend on the BMS, 4G gateway, cloud platform, SIM configuration, regional network availability, and customer requirements, so the IoT system can be configured according to the needs of the equipment manufacturer or fleet operator.

The charger must be matched to the battery chemistry, series configuration, maximum charging voltage, BMS limits, charging current, connector type, and communication requirements of the final battery system. Bonnen Battery can supply or recommend a compatible charger as part of the complete battery solution, and the charging current can be selected according to the required charging time, available AC power, cell specifications, battery capacity, operating temperature, and daily working schedule of the machine.

The industrial BMS monitors and protects the battery against conditions such as cell overvoltage, cell undervoltage, overcurrent, short circuit, excessive charging or discharging temperature, and other abnormal operating conditions. Depending on the project configuration, the system can also integrate contactor control, pre-charge management, insulation-related functions, CAN communication, SOC calculation, fault reporting, event recording, heating control, and remote monitoring to support safer and more reliable operation in demanding industrial equipment.

Yes, Bonnen Battery specializes in customized lithium battery systems and can modify the enclosure dimensions, mounting structure, capacity, discharge current, connector arrangement, cable direction, charging interface, CAN communication, display, heating function, 4G monitoring, and other electrical or mechanical features according to the equipment design. Customization is based on the available battery compartment, motor and controller specifications, operating duty cycle, environmental requirements, and expected production quantity rather than simply changing the battery enclosure size.

To recommend the correct battery system, it is helpful to provide the motor voltage and power, controller operating voltage and current limits, continuous and peak current requirements, expected runtime or working cycle, maximum battery compartment dimensions, installation drawings or CAD files if available, charging method, operating temperature range, IP requirements, CAN or other communication requirements, connector preferences, and expected order quantity. If some of this information is not yet available, you can still send us the specifications you already have and our engineering team can help identify the remaining parameters needed for battery selection.

Next engineering step

Get an Engineering Recommendation

Send the machine voltage limits, load profile, operating target and installation space. Bonnen engineers can evaluate the most appropriate single-module or engineered dual-parallel direction.