U.S. Partner: 693kWh High-Voltage ESS Case Study
A cabinet-based 441.6V / 693.312kWh C&I energy storage solution designed for scalable high-voltage battery deployment.
- Project Country: United States
- System Capacity: 693.312kWh
- Nominal Voltage: 441.6V DC
- Configuration: 5 × 42U battery cabinets in parallel
- Battery Architecture: 5 × 1P138S
- Cell Type: 314Ah LiFePO4 cell
Challenge
Commercial and industrial energy storage projects require more than battery capacity. The system must be safe, serviceable, and suitable for high-voltage inverter integration while keeping the cabinet layout clear for installation and maintenance.
For this U.S. project, the requirement was to configure a large-capacity high-voltage ESS with a modular cabinet structure, stable DC voltage platform, reliable BMS/BCU control, and protection functions for long-term C&I operation.
Solution
Avepower provided a 693kWh high-voltage ESS based on five parallel 42U battery cabinets.
Each cabinet contains six 73.6V 314Ah battery packs and one high-voltage box with BCU control. The full system is configured as 5 × 1P138S, with a nominal voltage of 441.6V DC and a working voltage range of 345V-503.7V DC.
The system is designed with CAN communication, BCU monitoring, BMU cell-level sampling and multi-level protection functions to support safe and stable operation in C&I energy storage environments.
Outcome
The final system was delivered as a structured five-cabinet high-voltage ESS platform with a total footprint of approximately 4000 × 1000 × 2055mm.
The system supports CAN communication, cabinet-level high-voltage management, BMU/BCU monitoring, and multi-level protection for voltage, current, temperature, insulation, and battery status.
From Project Requirements to a Custom HV ESS Configuration
System Requirement Review
The project started with a clear capacity and voltage target: a high-voltage battery system around 693kWh, suitable for commercial energy storage and inverter matching.
Avepower reviewed the required energy capacity, cabinet layout, DC voltage range, current requirements, battery pack structure, and communication method before finalizing the high-voltage ESS architecture.
Cabinet-Based Battery System Design
To keep the system modular and easier to deploy, Avepower configured the ESS as five independent high-voltage battery cabinets connected in parallel.
Each cabinet includes:
- 6 × 73.6V 314Ah high-voltage battery packs
- 1 × high-voltage BCU box
- 42U high load-bearing cabinet
- Power cable assemblies
- Communication cable assemblies
- CAN communication architecture
- IP20 cabinet protection
BCU and Protection System
The high-voltage box is equipped with a BCU for system-level monitoring and control. It supports total voltage sampling, current sampling, temperature sampling, insulation detection and SOC estimation.
Protection functions include:
- Cell voltage detection
- Temperature monitoring
- Passive balancing
- CAN isolated communication
- Overcharge protection
- Over-discharge protection
- Over-current protection
- Over-temperature protection
- Low-temperature protection
- Multi-level alarm mechanism
- Battery status and data storage
Engineering the 693.312kWh / 441.6V HV ESS
The system was engineered around a 5 × 1P138S architecture. Each battery pack is built as 1P23S, and six packs are installed in one cabinet to form a single 1P138S battery cluster.
Each cabinet provides 138.6624kWh, and five cabinets connected in parallel provide the final system energy of 693.312kWh.
The nominal DC voltage is 441.6V, with a working voltage range of 345V-503.7V, making the system suitable for high-voltage C&I energy storage applications when matched with the correct inverter, PCS, EMS, and site electrical design.
Specs Table
| Item | Specification |
|---|---|
| Total Energy | 693.312kWh |
| Single Cabinet Energy | 138.6624kWh |
| Nominal DC Voltage | 441.6V |
| Working Voltage Range | 345V-503.7V |
| Nominal Capacity | 1570Ah |
| System Configuration | 5 × 1P138S |
| Cabinet Quantity | 5 × 42U cabinets |
| Cabinet Structure | 6 battery packs + 1 high-voltage BCU box |
| Battery Pack Design | 1P23S |
| Single Pack Energy | 23.1104kWh |
| Single Pack Voltage | 73.6V DC |
| Single Pack Capacity | 314Ah |
| Cell Type | LiFePO4 |
| Cell Model | 71173207 / 314Ah / 3.2V |
| Rated Charge Current | 50A per cabinet / 250A after parallel |
| Max Continuous Charge Current | 100A per cabinet / 500A after parallel |
| Rated Discharge Current | 50A per cabinet / 250A after parallel |
| Max Continuous Discharge Current | 100A per cabinet / 500A after parallel |
| Communication | CAN |
| Protection Level | IP20 |
| Single Cabinet Size | W600 × L1000 × H2055mm |
| Full System Footprint | Approx. 4000 × 1000 × 2055mm |
| Single Battery Pack Weight | Approx. 165kg |
| Full System Weight | Approx. 6000kg |
| Recommended Operating Temperature | 25 ±5°C |
| Humidity | 65% ±20% RH |
| Altitude | ≤3600m |
| Inverter Matching | 2 × 50kW inverters, DC input 160V-1000V |
Delivery Configuration
The delivery configuration includes:
- 5 × 42U high load-bearing cabinets
- 30 × high-voltage battery packs
- 5 × high-voltage BCU boxes
- Power cable assemblies
- Communication cable assemblies
- Combiner box with 250A 4P molded case circuit breaker
- Parallel communication cable design
- Cabinet-level DC connection structure
The deployed system uses intelligent battery monitoring to collect voltage, current, temperature, insulation, and SOC information. With BMU and BCU coordination, the system provides overcharge, over-discharge, over-current, over-temperature, low-temperature, and multi-level alarm protection.
Why Choose Avepower?
Avepower provides project-based high-voltage ESS solutions, not just standard battery cabinets. From capacity planning and voltage platform design to BMS/BCU integration, cabinet layout, communication matching and technical documentation, Avepower helps customers configure energy storage systems around real project requirements.
With LiFePO4 battery technology, modular cabinet design, multi-level protection and OEM/ODM customization support, Avepower is a reliable partner for C&I energy storage, solar-plus-storage, backup power and custom high-voltage battery projects.
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