Project Background
This project is deployed at a medium-sized food manufacturing plant with available rooftop space for PV installation. The factory operates on self-consumption rooftop solar. Excess PV power is generated during sunny hours, while cloud coverage causes sudden PV power drop. The customer wants to maximize solar self-consumption, smooth solar intermittency and achieve peak-valley arbitrage. The client selects our 125kW/241kWh PV-ESS all-in-one cabinet with DC-coupled design, allowing direct DC connection of rooftop PV modules, minimizing power conversion loss and simplifying on-site installation.
Core Customer Pain Points
Intermittent solar output caused by cloud transients leads to power fluctuation and curtailment of surplus rooftop PV energy.
Traditional AC-coupled solutions require separate solar inverters and standalone PCS units, leading to more equipment, heavy cable work and higher civil cost.
During high-tariff peak production hours, solar generation often falls short, forcing expensive grid power purchase.
Limited available space on site; no extra power room to accommodate multiple discrete power cabinets.
System Configuration & Product Selection
125kW/241kWh PV-ESS all-in-one cabinet, DC-coupled topology
The integrated cabinet integrates DC-DC converter, bi-directional PCS, LFP battery pack, BMS, thermal management, aerosol fire suppression and local controller. Rated power 125kW, usable capacity 241kWh. Rooftop PV array connects directly to the DC port of the all-in-one cabinet, without separate solar inverter. Auxiliary equipment: rooftop PV modules, DC combiner box, AC grid connection cabinet, cloud EMS energy management system.
Core Control Strategy
PV power for on-site load first: Solar energy feeds factory loads directly during daytime; surplus DC power charges the battery inside the cabinet.
Solar fluctuation smoothing: The storage system charges/discharges rapidly to offset sudden irradiance changes, stabilize grid voltage and reduce PV curtailment.
Peak shaving & valley arbitrage: During high tariff periods, stored solar energy is discharged to cut grid power import. The system can also charge from grid during low-tariff valley hours for extra arbitrage revenue.
Remote O&M: Cloud EMS monitors PV generation, battery SOC, temperature and power flow 24/7 with automatic fault alerts.
On-site Installation Challenges & Our Solutions
Challenge 1: Long DC cabling for rooftop PV, high losses & complicated wiring for discrete systems Solution: DC-coupled all-in-one cabinet accepts direct PV DC input, removing the need for separate solar inverters. Less equipment reduces cable routes, cuts power loss and shortens commissioning time.
Challenge 2: Limited outdoor space, no dedicated power room Solution: Highly compact all-in-one design. Battery, converter, fire protection and thermal control are fully integrated into one cabinet. Only simple foundation is required. It can be placed at factory corners without new power room construction.
Challenge 3: Short construction window; factory cannot afford long production shutdown Solution: Pre-tested at factory before delivery. On-site work only includes foundation mounting and cable connection. Fast grid connection minimizes disruption to manufacturing.
Challenge 4: PV intermittency induces voltage fluctuation and risks sensitive production equipment Solution: Built-in DC voltage stabilization algorithm plus fast PCS power regulation smooth solar power swings and stabilize grid voltage for factory loads.
Project Outcomes & Benefits
Higher PV self-consumption rate and lower solar curtailment. DC coupling reduces multi-stage AC/DC conversion losses to boost solar revenue.
Discharge stored solar power during peak tariff hours, reducing peak electricity bills and demand charges.
Integrated cabinet greatly cuts civil engineering, cabling and installation work, shortening project lead time.
Cloud EMS enables 24/7 remote monitoring and simple maintenance, lowering on-site inspection workload.
125KW 241kWh Battery Energy Storage System Cabinet
The BESS 125KW 241kWh Lithium Battery Energy Storage Cabinet is a high-power, large-capacity integrated energy storage solution engineered for medium-to-large commercial, industrial, and utility-scale applications. It integrates a 125kW high-performance bidirectional inverter, a 241kWh lithium iron phosphate (LiFePO4) battery bank, and a full-featured intelligent energy management system (EMS) into a modular cabinet design. This system enables efficient renewable energy storage, peak shaving, load shifting, grid frequency regulation, and emergency backup power supply. Ideal for large factories, shopping malls, industrial parks, utility-scale solar/wind farms, and microgrids, it enhances energy independence, reduces high grid demand charges, and supports the stable integration of high-penetration renewable energy into the grid.