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2 | www.systems-sunlight.com
SUNLIGHT’s motive power (traction) batteries “motivate your business”,
as they provide reliable energy to your industrial vehicles every day.
SUNLIGHT’s specialized R&D department is continuously working on innova-
tive and cost effective solutions to reduce our customers’ operating costs and
to maximize their operating efficiency.

SUNLIGHT batteries fully comply to the international DIN and BS standards,

covering all types of motive power needs, from light duty single-shift opera-
tion to heavy duty multi-shift operations, and are suitable for all industrial elec-
tric forklift types, such as counterbalanced, narrow isle and hand trucks.
Their optimum design, the exclusive use of high quality raw materials, as well as the incor-
poration of SUNLIGHT’s robust know how in designing and manufacturing advanced tech-
nology batteries (e.g. for submarine and torpedo) guarantees the reliability and efficiency of
every energy solution we provide. Additionally, the state-of-the-art manufacturing process,
provides a premium quality product characterised by its high energy density, superior per-
formance and durability.

Applications
• Forklifts
• Cleaning machines
• Electric tractors
• Lifting platforms
• Electric vehicles

Technical Features
• Lead Acid vented type batteries with liquid electrolyte
• Advanced technology tubular positive plate
• Full product series with dimensions according to international standards
DIN/EN 60254-2 & IEC 254-2
• Capacity for DIN product range: 120-1550Ah and for BS product range: 46-900Ah
• Available both as 2V cells and as complete batteries with various voltages ranging
from 12V to 96V
• Fully insulated terminals

Quality Features & Product Benefits

Capacities exceed Low maintenance
nominal values of requirements
req
requ
international standards High quality raw
materials and
components
High performance,
reliability and long
service life Complete Product
& Services Offering

High energy density

Recyclable
Robust and
durable construction
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 Battery
1. Inter-cell Connector
Fully insulated flexible bolt-on
cable connectors
• Allows fast and easy cell
replacement
• Reduces time & cost
2. Bolt
Plastic-head connector bolt
Touch proof insulated
with voltage measurement point
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4. Exit Cables
Insulated color marked cables
Prevent short circuit and allow
correct and fast installation
4
3
5. Tray
• Made of steel
• Protected with plastic powder
coating (standard configuration)
• Durability
• Corrosion protection
3. Battery Connectors • Available in various sizes and colors
(Plugs & Sockets)
Available in the following types:
• DIN Type connectors
according to DIN 43589
• Flat pole connectors with
color coding
Technical feature
Benefits
 Cell
1. Positive Plate
• Tubular plate design
• Alloy with optimized Sb
(antimony) concentration
• Red Lead in-house production
by Pure Lead 99,99%
• Dry Filling with Red Lead
• Increased gauntlet diameter
• Stable cycling performance
and longer service life
• Lower water consumption, lower
temperature increase, high and
stable final charging voltage,
less corrosion
• 100% of nominal capacity in
the first 3-5 cycles
• Increased capacity
2. Negative Plate
• Pasted lead grid & advanced
Negative Active Mass (NAM)
composition
• Alloy with optimized Sb
(antimony) concentration
• Stable cycling performance
• Lower water consumption
3. Separator
Polyethylene roll separator with
high porosity grade material
envelopes the positive plates
• Electrical resistance improved
by up to 20% over conventional
separators
• High porosity enables superior
battery capacity
• Acid displacement decreased
by 15% resulting in higher
capacity
• High oxidation resistance and
high porosity ensures longer
service life
• Short circuits avoided
4. Gauntlet
Reinforced non-woven polyester
material with high fibers bonding
and smaller pore’ s size
• Better utilization of active
material
• Eliminates active mass
shedding
• Reduces corrosion of spine
• Longer service life
5. Bottom Bar 7. Cell Container
Polypropylene (PP) Lid welding,
Ultrasonic welding
trimming and tightness control
• More secure fitment with Boxes and lids are resistant and
gauntlet thermowelded to prevent
• Growth of positive spine into electrolyte leakage
bottom bar’s cavity is easily
accomodated
• Retains active material on the
spines 8. Vent Plug
Electrolyte basket level marking,
specially designed lid, anti-surge
baffle
• Allows optimum cell gasing
8 • Electrolyte basket level marking
allows visual control of
electrolyte level
• Anti-surge baffle prevents
spillage of electrolyte during
operation of the battery through
8 ventilation openings
Automatic Water Filling Plug
The plug consists of a float and
9 7 a shut-off valve, with white level
10 indicator
• Ensures the optimum electrolyte
level in the battery
• No need of removing plugs and
topping up the cells manually
3 • Reduces excessive labor cost
• Eliminates the risk of direct
contact with battery acid
9. Pole Terminal
Advanced design of pole post
and its sealing to the lid. Rubber
ring with optimized hardness
2 and acid resistance
• Operational safety
• Perfect sealing
• Low maintenance requirements
1 • Better current conductivity
• Positive plate’s expansion is
6 safely absorbed
4 • Prevention of top lid cracks and
5 acid leakages
10. Pole Bridge
Terminal bridge manufactured
with Cast On Strap process
6. Sediment Space
• Consistent and uniform pole
Optimized height to prevent bridge composition
short circuits • Increased robustness
and durability
Longer service life • Perfect connection for
poles-bridge-plate block
as a whole
Technical feature
Benefits
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 Performance Curves
Proven Lifetime
PzS Expected Cycle-Life vs D.O.D.
100%
90%
Depth of Discharge (%Cnom)

80%
70%
60%
50%
40%
30%
20%
10%
0%
1000 1500 2000 2500 3000 3500 4000 4500

Number of cycles

• With DoD 80% and 300 cycles per year the expected service life is 5 years at 30oC
• With DoD 60% and 300 cycles per year the expected service life is 6-7 years at 30oC

Proven Cycling Resistance

Capacity Evolution Through Cycles
110%

105%
Capacity (% to the nominal)

100%

95%

90%

85%

80%

75%

70%
0 200 400 600 800 1000 1200 1400 1600

Number of cycles

• 1500 cycles at 80%DoD according to IEC 60254-1

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Accessories
SUNLIGHT’s complete range of accessories is selected to facilitate your day-to-day busi-
ness. Our complete solutions can protect your batteries and vehicles, secure longer service
life and lower operating costs.

Chargers
SUNLIGHT Premium Battery Chargers (conventional 50Hz and High Fre-
quency Series) are designed to meet the most demanding traction battery
needs and on the same time minimize charging costs.

Aqua Filling System

Automatic Filling System (A.F.S.) allows the user to top up the cells of
the battery from one central point through an integrated piping system,
installed on the battery. The automatic filling plugs ensure the optimum
filling level of the cells, minimizing the required maintenance time for
the battery.

Electrolyte Circulation
System (Airlift System)
Airlift System improves battery performance and extends battery service
life in heavy duty applications. The principle behind it, is that a pump is
used to circulate low-level compressed air into the cells and to create a
homogenous electrolyte mixture throughout them.

Battery Monitoring
Systems
SUNLIGHT’s Battery Monitoring Systems range consists of advanced
technology systems which continuously monitor cycles, voltage, op-
portunity charging, electrolyte level and temperature of the battery. All
these important data can be viewed in graphs via internet. Our Battery
Monitoring Systems range can provide an accurate estimation of the
remaining service life of the battery.

Electrolyte Level Indicator

SUNLIGHT’s Electrolyte Level Indicators are smart electrolyte moni-
tors that alert personnel when a battery needs water. Resistant to the
harshest environments, Blinkies improve battery maintenance and re-
duce operating costs.

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DIN Product Range

Plate Type: 60 Ah Plate Type: 80 Ah Plate Type: 90 Ah

max cell max cell max cell
dimensions mm*** dimensions mm*** dimensions mm***
Nominal h1: 343 Weight in Nominal h1: 408 Weight in Nominal h1: 478 Weight in
Type Type Type
Capacity b: 198 Capacity b: 198 Capacity b: 198
Designation h2: 370 kg** Designation h2: 435 kg** Designation h2: 505 kg**
Ah (C5)* Ah (C5)* Ah (C5)*
l l l

2 PzS 120 120 47 8.5 2 PzS 160 160 47 10.0 2 PzS 180 180 47 11.9
3 PzS 180 180 65 12.0 3 PzS 240 240 65 14.2 3 PzS 270 270 65 17.0
4 PzS 240 240 83 15.4 4 PzS 320 320 83 18.4 4 PzS 360 360 83 22.1
5 PzS 300 300 101 19.0 5 PzS 400 400 101 22.6 5 PzS 450 450 101 27.1
6 PzS 360 360 119 22.5 6 PzS 480 480 119 26.7 6 PzS 540 540 119 32.2
7 PzS 420 420 137 26.0 7 PzS 560 560 137 31.3 7 PzS 630 630 137 37.2
8 PzS 480 480 155 29.5 8 PzS 640 640 155 35.1 8 PzS 720 720 155 42.3
9 PzS 540 540 174 33.0 9 PzS 720 720 174 39.3 9 PzS 810 810 174 47.4
10 PzS 600 600 192 36.5 10 PzS 800 800 192 43.4 10 PzS 900 900 192 52.4

Plate Type: 105 Ah Plate Type: 115 Ah Plate Type: 125 Ah

max cell max cell max cell
dimensions mm*** dimensions mm*** dimensions mm***
Nominal h1: 514 Weight in Nominal h1: 548 Weight in Nominal h1: 568 Weight in
Type Type Type
Capacity b: 198 Capacity b: 198 Capacity b: 198
Designation h2: 541 kg** Designation h2: 575 kg** Designation h2: 595 kg**
Ah (C5)* Ah (C5)* Ah (C5)*
l l l
2 PzS 210 210 47 13.5 2 PzS 230 230 47 14.2 2 PzS 250 250 47 15.0
3 PzS 315 315 65 19.1 3 PzS 345 345 65 20.3 3 PzS 375 375 65 21.2
4 PzS 420 420 83 24.6 4 PzS 460 460 83 26.4 4 PzS 500 500 83 27.4
5 PzS 525 525 101 30.5 5 PzS 575 575 101 32.4 5 PzS 625 625 101 33.9
6 PzS 630 630 119 36.1 6 PzS 690 690 119 39.0 6 PzS 750 750 119 40.3
7 PzS 735 735 137 41.8 7 PzS 805 805 137 44.7 7 PzS 875 875 137 46.5
8 PzS 840 840 155 47.4 8 PzS 920 920 155 50.6 8 PzS 1000 1000 155 53.1
9 PzS 945 945 174 53.1 9 PzS 1035 1035 174 56.6 9 PzS 1125 1125 174 59.4
10 PzS 1050 1050 192 58.4 10 PzS 1150 1150 192 62.7 10 PzS 1250 1250 192 66.0

Plate Type: 140 Ah Plate Type: 155 Ah

max cell max cell
dimensions mm*** dimensions mm***
Nominal h1: 688 Weight in Nominal h1: 713 Weight in
Type Type
Capacity b: 198 Capacity b: 198
Designation h2: 715 kg** Designation h2: 740 kg**
Ah (C5)* Ah (C5)*
l l
2 PzS 280 280 47 17.5 2 PzS 310 310 47 18.9
3 PzS 420 420 65 24.7 3 PzS 465 465 65 26.7
4 PzS 560 560 83 31.8 4 PzS 620 620 83 34.6
5 PzS 700 700 101 39.3 5 PzS 775 775 101 42.6
6 PzS 840 840 119 46.7 6 PzS 930 930 119 50.5
7 PzS 980 980 137 53.9 7 PzS 1085 1085 137 58.5
8 PzS 1120 1120 155 61.3 8 PzS 1240 1240 155 66.4
9 PzS 1260 1260 174 68.6 9 PzS 1395 1395 174 74.4
10 PzS 1400 1400 192 76.0 10 PzS 1550 1550 192 82.4

* According to IEC 60254- Part 1

l

** Filled and charged cell weights ± 5%

*** Cells’ dimensions ±2mm, according to IEC 60254- Part 2

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BS Product Range

Plate Type: 23 Ah**** Plate Type: 32 Ah**** Plate Type: 42 Ah****

max cell max cell max cell
dimensions mm*** dimensions mm*** dimensions mm***
Nominal h1: 203 Weight in Nominal h1: 265 Weight in Nominal h1: 331 Weight in
Type Type Type
Capacity b: 158 Capacity b: 158 Capacity b: 158
Designation h2: 230 kg** Designation h2: 292 kg** Designation h2: 358 kg**
Ah (C5)* Ah (C5)* Ah (C5)*
l l l
2 PzB 46 46 45 4.1 2 PzB 64 64 45 5.4 2 PzB 84 84 45 6.9
3 PzB 96 96 61 7.3 3 PzB 126 126 61 9.4
3 PzB 69 69 61 5.6
4 PzB 128 128 77 9.2 4 PzB 168 168 77 11.9
4 PzB 92 92 77 7.0 5 PzB 160 160 93 11.3 5 PzB 210 210 93 14.5
6 PzB 192 192 109 13.2 6 PzB 252 252 109 17.1
5 PzB 115 115 93 8.5
7 PzB 224 224 125 15.2 7 PzB 294 294 125 19.7
6 PzB 138 138 109 10.0 8 PzB 256 256 141 17.2 8 PzB 336 336 141 22.2

Plate Type: 55 Ah Plate Type: 65 Ah Plate Type: 75 Ah

max cell max cell max cell
dimensions mm*** dimensions mm*** dimensions mm***
Nominal h1: 401 Weight in Nominal h1: 457 Weight in Nominal h1: 514 Weight in
Type Type Type
Capacity b: 158 Capacity b: 158 Capacity b: 158
Designation h2: 428 kg** Designation h2: 484 kg** Designation h2: 541 kg**
Ah (C5)* Ah (C5)* Ah (C5)*
l l l
2 PzB 110 110 45 8.4 2 PzB 130 130 45 9.6 2 PzB 150 150 45 10.9
3 PzB 165 165 61 11.5 3 PzB 195 195 61 13.2 3 PzB 225 225 61 14.9
4 PzB 220 220 77 14.6 4 PzB 260 260 77 16.8 4 PzB 300 300 77 19.0
5 PzB 275 275 93 17.8 5 PzB 325 325 93 20.5 5 PzB 375 375 93 23.1
6 PzB 330 330 109 20.9 6 PzB 390 390 109 24.1 6 PzB 450 450 109 27.3
7 PzB 385 385 125 24.0 7 PzB 455 455 125 27.7 7 PzB 525 525 125 31.4
8 PzB 440 440 141 27.2 8 PzB 520 520 141 31.4 8 PzB 600 600 141 35.6
9 PzB 495 495 157 30.3 9 PzB 585 585 157 35.0 9 PzB 675 675 157 39.5
10 PzB 550 550 173 33.3 10 PzB 650 650 173 38.5 10 PzB 750 750 173 43.7

Plate Type: 85 Ah Plate Type: 100 Ah Plate Type: 105 Ah

max cell max cell max cell
dimensions mm*** dimensions mm*** dimensions mm***
Nominal h1: 570 Weight in Nominal h1: 606 Weight in Nominal h1: 686 Weight in
Type Type Type
Capacity b: 158 Capacity b: 158 Capacity b: 158
Designation h2: 597 kg** Designation h2: 633 kg** Designation h2: 713 kg**
Ah (C5)* Ah (C5)* Ah (C5)*
l l l
2 PzB 170 170 45 12.3 2 PzB 200 200 45 12.9 2 PzB 210 210 45 14.8
3 PzB 255 255 61 17.0 3 PzB 300 300 61 17.7 3 PzB 315 315 61 20.4
4 PzB 340 340 77 21.6 4 PzB 400 400 77 22.6 4 PzB 420 420 77 26.1
5 PzB 425 425 93 26.3
5 PzB 500 500 93 27.5
6 PzB 510 510 109 30.9 5 PzB 525 525 93 31.7
6 PzB 600 600 109 32.4
7 PzB 595 595 125 35.6 6 PzB 630 630 109 37.3
8 PzB 680 680 141 40.4 7 PzB 700 700 125 37.3
7 PzB 735 735 125 43.0
9 PzB 765 765 157 44.8 8 PzB 800 800 141 42.2
10 PzB 850 850 173 49.7 9 PzB 900 900 157 46.8 8 PzB 840 840 141 48.7

* According to IEC 60254- Part 1

** Filled and charged cell weights ± 5%
*** Cells’ dimensions ±2mm, according to IEC 60254- Part 2
**** Available upon request

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 Added Value Services
Installation
Training
Rental/Leasing
Preventive or corrective
maintenance contract
360o Technical Support (24x7)
Spare parts availability
Refurbishment service
Collection & recycling

10 | www.systems-sunlight.com
Why SUNLIGHT?
25 years of experience in battery design,
manufacturing and marketing
• TOP 3 in the global advanced technology battery sector  
• TOP 5 in the European industrial battery sector 
• 98% of battery production is being exported

“One Stop Solution”

• From single components/products to turn-key solutions
• Robust high quality products & services portfolio
• Lifetime value maximization & total cost of ownership approach

Exceptional Customer Service

• Highly experienced engineering team for design & development
• Pre-Sales & After-Sales Service providing global support
• Project Management competence

Extensive Global Know How & Experience

in Motive Power Batteries Business
• Co-operation with TOP Forklift manufacturers worldwide
• A fast growing Global Partners Network
 ET-PP_120605-EN
2 Ermou & Nikis Street, Syntagma Square
105 63 Athens, Attica, Greece
Τ +30 210 6245400
F +30 210 6245409

European Manufacturing Plant

Neo Olvio
672 00 Xanthi, Greece
Τ +30 25410 48100
F +30 25410 95446

Global Service Department

366 Tatoiou Street
136 73 Acharnes, Attica, Greece
Τ +30 210 6245600
F +30 210 6245619

Member of SUNLIGHT Global Partners Network

Data in this document are subject to change without notice and become contractual only after written confirmation.
12 | www.systems-sunlight.com