Project Background
This hybrid PV-ESS project is built for a building material manufacturing factory with rooftop solar installation. An AC-coupled topology is adopted, where solar inverters and energy storage PCS connect separately to the factory AC busbar. Solar output fluctuates under changing irradiance, and surplus solar power cannot be fully consumed onsite. The customer selects 1 set of 125kW/261kWh liquid-cooled PCS energy storage cabinet to boost PV self-consumption, smooth power fluctuation and achieve peak-valley arbitrage. The cabinet is deployed outdoors to withstand dusty and humid factory conditions.
Core Customer Pain Points
Intermittent rooftop PV generation causes power swings and voltage disturbance; excess solar energy is curtailed.
Mismatch between PV generation and factory load leads to wasted midday solar power.
Heavy dust and high humidity on site clog air-cooled ESS filters quickly, requiring frequent shutdown for cleaning and raising maintenance costs.
The customer wants to retain existing solar inverters and avoid large-scale PV retrofitting; DC-coupled solution would be too invasive.
Frequent start-stop of production lines creates rapid load variation and pushes up grid import cost.
System Configuration & Product Selection
1 × 125kW/261kWh liquid-cooled PCS energy storage cabinet, AC-coupled, working with existing rooftop PV. The cabinet integrates bi-directional PCS, LFP battery pack, liquid thermal management, BMS, aerosol fire suppression and local controller. Rated power:125kW, usable capacity:261kWh, IP55 rating. Auxiliary: existing rooftop PV modules & solar inverters, AC combiner cabinet, cloud EMS platform.
Core Control Strategy
PV power for on-site load first: Solar energy supplies workshop loads preferentially, surplus AC power charges the ESS.
Fluctuation smoothing: Fast charge/discharge offsets irradiance change and production load transients, stabilizes voltage and reduces PV curtailment.
Peak-valley arbitrage: Charge from grid during low tariff valley hours; discharge stored energy during high-price peak periods to cut expensive grid purchase.
Remote intelligent O&M: EMS monitors PV generation, battery SOC and temperature in real time, triggers fault alerts and generates saving reports automatically.
On-site Installation Challenges & Our Solutions
Challenge1: Retrofit on existing PV system; client refuses to remove original solar inverters Solution: AC-coupled architecture is fully compatible with legacy PV. The original solar inverters remain unchanged; the ESS connects independently to the AC bus. No modification to rooftop PV DC wiring, minimizing construction work.
Challenge2: Dusty & humid plant environment, air-cooled units require frequent maintenance Solution: Fully enclosed liquid-cooled IP55 cabinet with no exposed filter mesh. Dust is isolated from battery compartment. Stable liquid temperature control reduces degradation and cuts routine maintenance.
Challenge3: Fast load transients from production line startup cause voltage disturbance Solution: Millisecond PCS power response absorbs or releases power instantly to smooth fluctuations from PV and production loads, stabilizing bus voltage and protecting manufacturing equipment.
Challenge4: Limited outdoor space and tight construction schedule Solution: Pre-tested all-in-one liquid-cooled cabinet. Only simple foundation and cable connection are required on site. Fast commissioning without disrupting material production.
Project Outcomes & Benefits
Retrofit-friendly PV + ESS solution, no replacement of existing solar hardware, higher PV self-consumption and less curtailment.
Liquid cooling adapts to dusty, humid industrial environments, delivers even battery temperature, lower degradation and longer service life with minimal maintenance.
Dual value: PV fluctuation smoothing plus peak-valley arbitrage, reducing comprehensive electricity expenditure.
Liquid Cooling 125KW 261kWh Lithium Battery Energy Storage Cabinet
The IP55 Protected All-in-One Solar Energy Storage Cabinet is a high-performance, integrated energy solution engineered for outdoor commercial, industrial, and utility-scale solar applications. It integrates a 125kW Power Conversion System (PCS), a 261kWh lithium iron phosphate (LiFePO4) battery bank, an advanced liquid cooling system, and a intelligent Battery Management System (BMS) into a single cabinet with IP55 weatherproof protection. Designed to withstand harsh outdoor environments while delivering efficient energy conversion and storage, it supports solar energy absorption, peak shaving, load shifting, grid auxiliary services, and emergency backup power. Ideal for utility-scale solar farms, industrial parks, large commercial complexes, and remote microgrids, it provides a reliable, space-saving, and low-maintenance solution for large-scale renewable energy integration.
