2024 and 2025 are seeing huge growth for LFP based BESS in Australia, LiFePo4 Australia can assist in the supply and procurement of Hithium, EVE, and CATL commercial solutions. We don’t just do residential, off-grid and small business, we can help SME and commercial companies make the right connections and supply anything from a cell, right up to MegaWatt hour container batteries. We have formed partnerships with many of the leading Lithium, LiFePo4 and Sodium battery manufacturing companies globally.
Now lets get to the news!
Lightsource BP, a global leader in renewable energy development, has partnered with Hithium, a prominent energy storage solutions provider, to supply a 640 MWh Battery Energy Storage System (BESS) for the Woolooga Solar Farm in Queensland, Australia.
Project Overview
The Woolooga Solar Farm, located in Queensland’s Lower Wonga region, comprises three sites totaling 214 MWp of generation capacity, sharing a 176 MWac grid export connection. The integration of a 222 MW/640 MWh BESS will enhance the farm’s ability to store and dispatch solar energy, thereby improving grid stability and reliability.
Hithium’s 5 MWh BESS Containers
This project marks the first deployment in Australia of Hithium’s 5 MWh containerized BESS solution. Each 20-foot container houses prismatic 314 Ah lithium iron phosphate (LFP) cells, offering a 25-year warranty. These double-length modules with an IP67 protection rating provide 40% more energy compared to previous generations, optimizing space and performance.
Partnerships and Operations
Hithium is collaborating with INTEC Energy Solutions to deliver full Engineering, Procurement, and Construction (EPC) services, along with 25 years of operation and maintenance for the Woolooga BESS Stage 1 project. This partnership aims to ensure the project’s long-term efficiency and reliability.
In line with sustainability goals, Envirostream Australia, a subsidiary of Livium, has signed an exclusive agreement with Hithium to recycle the lithium-ion batteries supplied for this project. This initiative underscores a commitment to responsible resource management and environmental stewardship.
Significance for Australia’s Renewable Energy Sector
The Woolooga BESS project represents a significant advancement in Australia’s renewable energy landscape. By integrating substantial energy storage capacity with solar generation, it addresses the challenges of renewable energy variability, providing optimized grid management, load regulation, and ensuring continuity and stability of supply.
This collaboration between Lightsource bp and Hithium not only enhances renewable energy integration in Australia but also sets a precedent for future large-scale energy storage projects in the region.
We’re thrilled to announce that the highly anticipated EVE MB56 LF560K 628Ah cells are now available to order! While these cells are not yet shipping, we expect stock to be sourced and available within the coming weeks.
In addition to the EVE MB56, we’ll also be offering the CATL 587Ah cells, a similarly high-capacity option for your energy storage needs.
Why Choose EVE MB56 LF560K?
The EVE MB56 LF560K cells are a standout choice for those looking for high-quality, high-capacity battery cells. Here’s why we’re prioritizing these cells:
Capacity: A massive 628Ah, perfect for large-scale energy storage systems.
A-Grade Quality: Supplied in Automotive Grade to ensure durability and top-tier performance.
Direct from the Manufacturer: We’re sourcing these cells directly from EVE, ensuring authenticity and competitive pricing.
About CATL 587Ah Cells
The CATL 587Ah cells also offer impressive capacity and are an excellent alternative. While they provide slightly less capacity than the EVE MB56, they remain a reliable option for high-demand applications.
Why Pre-Order?
By pre-ordering, you’ll secure your place in line for these cutting-edge cells as soon as they’re available. Both the EVE MB56 LF560K and CATL 587Ah cells represent the latest in energy storage technology, making them ideal for applications ranging from electric vehicles to large-scale battery energy storage systems (BESS).
If you’re ready to take advantage of these advanced cells, don’t wait—pre-order today to stay ahead of the curve!
Quick Facts About LiFePO4 Batteries and Lifepo4 Float Voltage
Nominal Voltage per Cell: 3.2 V (often you’ll see 3.2–3.3 V).
Full Charge Voltage per Cell: 3.65 V.
Typical Float Voltage per Cell: 3.375V (LiFePO4 does not necessarily require a float, but if your charger/controller does have a float stage, these are typical values).
Recommended Charge per Cell: 3.55 V
Maximum Charge per Cell: 3.65 V
Float Voltage per Cell: 3.375 V
Low Voltage Cutoff per Cell: 2.8 V
These settings are our own recommendations, we base these figures on many years of community feedback and consultation with other professionals. We believe these will offer you the best balance of lifespan and usage.
A basic SOC % to voltage chart for quick and easy reference
These numbers are affected by various factors such as who the manufacturer is, what temperature it is, the grade and age of the cell. These are a reference for new LFP cells especially prismatic cells manufactured by companies similar to EVE Energy or CATL.
Use these 12v, 24v and 48v
sections below to check your battery and chargers are set with the most accurate general LFP settings
4S (12.8 V) LiFePO4 Battery
Parameter
Value
Notes
Nominal Voltage
12.8 V (4 × 3.2 V)
Standard “label” voltage for a 4S LFP pack.
Recommended Charge Voltage
14.2 V (4 × 3.55 V)
Preferred charging level to balance performance and longevity.
Maximum Charge Voltage
14.6 V (4 × 3.65 V)
Typically used briefly for topping off; not ideal for continuous charging.
Float Voltage
13.5 V (4 × 3.375 V)
If using a float stage, keep it at or below this voltage.
Low Voltage Cutoff
11.2 V (4 × 2.8 V)
Avoid discharging below 2.8 V per cell to prevent damage.
Resting Voltage (approx.)
~13.2 V
About 3.3 V/cell when neither charging nor under significant load.
12v 300ah battery box 280Ah, 300Ah, 304Ah 314Ah
8S (25.6 V) LiFePO4 Battery
Parameter
Value
Notes
Nominal Voltage
25.6 V (8 × 3.2 V)
Standard “label” voltage for an 8S LFP pack.
Recommended Charge Voltage
28.4 V (8 × 3.55 V)
Preferred charging level to balance performance and longevity.
Maximum Charge Voltage
29.2 V (8 × 3.65 V)
Typically used briefly for topping off; not ideal for continuous charging.
Float Voltage
27.0 V (8 × 3.375 V)
If using a float stage, keep it at or below this voltage.
Low Voltage Cutoff
22.4 V (8 × 2.8 V)
Avoid discharging below 2.8 V per cell to prevent damage.
Resting Voltage (approx.)
~26.4 V
About 3.3 V/cell when neither charging nor under significant load.
8s_25.6V_280ah-314ah-304ah
16S (51.2 V) LiFePO4 Battery
Parameter
Value
Notes
Nominal Voltage
51.2 V (16 × 3.2 V)
Common “label” voltage for a 16S LFP pack.
Recommended Charge Voltage
56.8 V (16 × 3.55 V)
Preferred charging level to balance performance and longevity.
Maximum Charge Voltage
58.4 V (16 × 3.65 V)
Typically used briefly for topping off; not ideal for continuous charging.
Float Voltage
54.0 V (16 × 3.375 V)
If using a float stage, keep it at or below this voltage.
Low Voltage Cutoff
44.8 V (16 × 2.8 V)
Avoid discharging below 2.8 V per cell to prevent damage.
Resting Voltage (approx.)
~52.8 V
Around 3.3 V/cell when neither charging nor under significant load.
Tips for Using These Charts
Use the Recommended Charge Voltage (3.55 V/cell) for routine charging.
Only reach Maximum Charge Voltage (3.65 V/cell) briefly if the BMS or charger calls for a top-off.
Float Voltage (3.375 V/cell) is optional; many LiFePO4 systems don’t float in the same manner as lead-acid.
Low Voltage Cutoff (2.8 V/cell) is the absolute minimum. Staying above it ensures longer battery life.
Check Manufacturer Specs if they differ from these standard guidelines.
State of Charge (SoC) vs. Voltage (Rest & Load)
The next table provides approximate voltages for different States of Charge (SoC) at 25 °C. Each SoC row shows the “Volt per cell” under two conditions:
rest: The battery resting or lightly loaded.
load: The battery under typical discharge load.
SoC (25 °C temp)
Rest Voltage
0.33C Load Voltage
100.00%
3.50
3.40
99.00%
3.45
3.35
90.00%
3.35
3.32
70.00%
3.30
3.30
40.00%
3.30
3.27
30.00%
3.25
3.24
20.00%
3.22
3.21
17.00%
3.20
3.15
14.00%
3.15
3.12
9.00%
3.10
3.00
0.00%
2.60
2.50
Those per-cell values then scale to 12 V (4S), 24 V (8S), and 48 V (16S) packs, again shown as “rest” and “load” columns.
.This Table is a combined table of single cell voltages, and then the common 4S, 8S and 16S configurations
SoC
Cell Rest (V)
Cell Load (V)
4S Rest (V)
4S Load (V)
8S Rest (V)
8S Load (V)
16S Rest (V)
16S Load (V)
100.0%
3.50
3.40
14.00
13.60
28.00
27.20
56.00
54.40
99.0%
3.45
3.35
13.80
13.40
27.60
26.80
55.20
53.60
90.0%
3.35
3.32
13.40
13.28
26.80
26.56
53.60
53.12
70.0%
3.30
3.30
13.20
13.20
26.40
26.40
52.80
52.80
40.0%
3.30
3.27
13.20
13.08
26.40
26.16
52.80
52.32
30.0%
3.25
3.24
13.00
12.96
26.00
25.92
52.00
51.84
20.0%
3.22
3.21
12.88
12.84
25.76
25.68
51.52
51.36
17.0%
3.20
3.15
12.80
12.60
25.60
25.20
51.20
50.40
14.0%
3.15
3.12
12.60
12.48
25.20
24.96
50.40
49.92
9.0%
3.10
3.00
12.40
12.00
24.80
24.00
49.60
48.00
0.0%
2.60
2.50
10.40
10.00
20.80
20.00
41.60
40.00
Note: Actual voltages can vary slightly with temperature, battery condition, and specific manufacturer chemistry.
Storage Guidelines:
Store batteries (longer than 1 month) indoors in a dry, clean environment between 0 °C and 35 °C (32 °F–95 °F). Avoid contact with corrosive substances, fire, or direct heat sources. Charge and discharge the battery every 6 months if in long-term storage.
Recommended storage SoC is 30–50%.
Operating Temperature Ranges: Discharge: –10 °C (min) to +50 °C (max) Charge: +2 °C (min) to +50 °C (max)
Manufacturer Specs: Always refer to the specific datasheet for exact values.
All of these values are guidelines only, the relationship to temperature and current draw, will affect cycle life.
The 2024 standard no longer includes a “stand-alone mode” definition.
Previously, systems that could operate independent of the grid were sometimes lumped under “stand-alone” references. Now, those arrangements are typically categorized as Independent, Alternative, or Substitute supplies, each with specific requirements.
Why It Matters:
Eliminates confusion and overlapping requirements that once existed for hybrid or off-grid-capable systems.
Provides more consistent terminology, ensuring users apply the correct standard(s) for their specific supply arrangement.
2. Clear Demarcation of Standards
AS/NZS 5033:
Covers the PV array up to the input terminals of the inverter.
AS/NZS 4777.1:
Covers the installation requirements for the inverter energy system (IES).
AS/NZS 5139:
Applies to battery systems from the battery through to the inverter input terminals.
Why It Matters:
This distinct separation streamlines updates and reduces the confusion of having overlapping or redundant clauses in different standards.
Each standard has a well-defined scope, making it easier to maintain compliance and manage changes over a system’s lifecycle.
3. Phase Balance Update
What Changed:
A new 30 kVA limit is set for single-phase installations.
The permissible capacity depends on grid supply capacity or available overcurrent protection.
Stricter phase balance requirements apply particularly to commercial and industrial installations to ensure equitable load distribution across phases.
Why It Matters:
Helps prevent grid imbalances and voltage rise issues.
Provides a clear threshold for when multi-phase distribution or load balancing measures are required.
4. Interface Protection Replaces Central Protection
What Changed:
“Central protection” terminology is replaced by “interface protection.”
Systems under 200 kVA generally do not require interface protection (subject to DNSP approval).
For larger systems, DNSPs still have authority to require interface protection or additional protective measures.
Why It Matters:
Aligns Australian/New Zealand terminology with IEC standards and global best practices.
Offers greater flexibility for small to medium-scale IES by removing a layer of complexity and cost.
5. Minimizing Main Switches (Two Inverter Main Switches)
What Changed:
Limits the number of main switches for inverters to two per switchboard that also supplies other loads.
For systems with three or more inverters, an aggregation board must be installed so a single main switch can isolate all inverters.
Why It Matters:
Simplifies the isolation process, improves safety, and reduces confusion during maintenance or emergency shutdowns.
Ensures a more organized switchboard layout and fewer potential error points.
6. New Definitions
6.1 Inverter Power Sharing Devices (IPSD)
What They Are:
Technology that allows multiple users (e.g., apartment dwellers) to share a single PV system or a set of inverters.
IP sharing can also apply in other multi-occupancy or embedded network scenarios.
Key Requirements:
Inverters used with IPSDs must be tested to AS/NZS 4777.2.
Systems over 30 kVA require interface protection.
Must island in under 2 seconds upon loss of grid connection.
Signage and protective measures (like securing current transformers, system schematics) required at the main switchboard.
Why It Matters:
Facilitates new business models and more efficient use of rooftop PV in multi-tenancy buildings.
6.2 Vehicle-to-Grid (V2G) Technology
What Changed:
Mode 3 (AC) and Mode 4 (DC) electric vehicle (EV) chargers can now be used for reverse power flow to the grid (i.e., V2G).
Mode 1 & 2 (plug-in type chargers) do not allow reverse power flow and thus are outside AS/NZS 4777.1 scope.
Why It Matters:
Recognizes the growing importance of bidirectional EV charging in demand management and grid support.
Establishes clear rules for safe and compliant integration of EVs as part of the IES.
6.3 New Supply Type Definitions
Supplementary Supply
Operates in parallel with the normal supply but switches off when grid supply is lost.
Formerly considered “stand-alone,” can be grid-charged but no export allowed.
Substitute Supply
Single point supply during grid failure, max rating 15 A.
Why It Matters:
Provides a clear operational framework for each supply category.
Reduces confusion about when and how each supply type can connect or export.
7. Alignment with IEC Terminology
What Changed:
“Secondary protection” is now termed “interface protection.”
Reflects the ongoing efforts to harmonize Australian/New Zealand standards with international IEC standards.
Why It Matters:
Encourages global consistency and makes local standards easier to interpret for international manufacturers and designers.
8. Interface Protection for Multiple Electrical Installations
What Changed:
In multiple electrical installations (e.g., large embedded networks or precincts), interface protection is not required for systems over 200 kVA (assuming DNSP approval).
Systems under 200 kVA can also be exempt, but it depends on DNSP and local conditions.
Why It Matters:
Offers greater flexibility for large-scale and multi-tenant setups, reducing redundant protection systems.
9. Ganged Devices and Isolator Requirements
What Changed:
Ganged devices used to isolate more than one IES are considered one main switch in multiple IES scenarios.
If one inverter is within 3 meters and visible from the main switchboard, no adjacent AC isolator at the inverter is needed.
Why It Matters:
Reduces hardware duplication and simplifies installations, while still providing adequate safety and a single point of isolation.
10. DC and AC EVSE Supply Modes
What Changed:
Supplementary or Alternative supplies can be provided by both DC and AC EVSE.
EV arrangements that don’t parallel the grid (e.g., “Alternative Supply”) are not subject to AS/NZS 4777.2.
Why It Matters:
Expands the permissible configurations for EV charging solutions, supporting both AC and DC approaches.
Streamlines compliance where EV chargers do not feed power back to the grid.
11. Inverter Power Sharing Device (IPSD) Requirements
What Changed:
Clarifies that IPSDs must use AS/NZS 4777.2-compliant inverters.
For IES over 30 kVA, interface protection is mandatory.
Islanding requirements dictate a disconnect within 2 seconds of grid loss.
Why It Matters:
Ensures multi-user PV setups remain safe and reliable under both normal and abnormal grid conditions.
Mandates adequate labeling and protection to avoid confusion among multiple occupants.
12. Signage and Protection for IPSDs
What Changed:
The standard outlines comprehensive signage requirements for IPSDs, including schematic diagrams, warning labels, and secure current transformers.
Must be installed at the main switchboard or a clearly visible location.
Why It Matters:
Promotes safer operation, quicker identification of system components, and clearer emergency shutdown procedures.
Particularly important for multi-tenant buildings where multiple parties share the same generation resource.
Conclusion
AS/NZS 4777.1:2024 reflects the ongoing evolution of inverter energy systems and their integration with emerging technologies such as vehicle-to-grid and power-sharing devices. By removing ambiguous references (e.g., stand-alone mode), clarifying standards boundaries, and updating terminology to align with international norms, the 2024 standard aims to:
Simplify compliance for designers, installers, and system owners.
Enhance safety and clarity for multi-technology and multi-occupancy scenarios.
Foster innovative solutions (e.g., IPSDs, V2G) that support dynamic and flexible energy management.
Stakeholders involved in specifying, installing, or maintaining grid-connected inverters should carefully review these changes and ensure full compliance with AS/NZS 4777.1:2024, AS/NZS 4777.2, and any local DNSP requirements.
Disclaimer (Australia)
The information provided here is for general guidance and educational purposes only. We are not licensed electricians, accredited solar installers, or qualified to provide definitive technical or legal advice in Australia. While we strive to present accurate and up-to-date information, the standards and regulations governing electrical installations (including AS/NZS 4777.1) may change over time and can vary depending on your state or territory.
Ultimately, it is the responsibility of the licensed installer or qualified professional to ensure compliance with all applicable standards, regulations, and local network requirements. Always consult with a certified electrician, accredited installer, or relevant authority before commencing any installation, modification, or maintenance of grid-connected inverter systems. We disclaim all liability for any direct, indirect, or consequential loss or damage arising from reliance on, or use of, the information provided.
a comprehensive guide specifically for sub-60VDC lithium battery systems that include an inverter or are connected to the grid in Australia. Since these systems operate with AC components, grounding is mandatory under most circumstances to ensure safety and regulatory compliance. Always consult a licensed electrician or qualified engineer for final verification.
Safety Guidelines for Grounding Sub-60VDC Lithium Battery Systems with Inverters or Grid Connections in Australia
1. Introduction
Sub-60VDC lithium battery systems are classified as Extra-Low Voltage (ELV) under AS/NZS 3000:2018. However, once an inverter or grid connection is involved, the system can operate with higher AC voltages that carry an increased risk of electric shock and fault currents. Grounding provides a safe path for these fault currents, protecting both equipment and personnel.
2. Key Considerations
Voltage Classification
Sub-60VDC is considered ELV, but the addition of an inverter or grid interface means AC voltages are present.
Mandatory Grounding
Any system with an inverter or grid tie must be grounded to comply with AS/NZS 3000:2018 and relevant local regulations.
Regulatory Context
Clause 4.4 of AS/NZS 3000:2018 emphasizes that safety at higher voltages relies on proper insulation and protective measures, including grounding.
3. Grounding Requirements
Connection to Earth
A dedicated earth conductor must be provided to ensure that any fault current has a low-resistance path to ground.
The earth connection should be installed in accordance with local regulations, including proper bonding to the main earthing system.
Bonding of Equipment
Metal enclosures, frames, or supports associated with the inverter and battery system must be bonded to the grounding system to eliminate touch voltages.
Ground-Fault Detection
In many cases, ground-fault detection and protection devices are required to ensure that any earth leakage or ground fault is quickly identified and isolated.
4. System Setup
Inverter Integration
AC Side: The inverter’s AC output circuit must be grounded and protected per AS/NZS 3000:2018.
DC Side: While the battery side is considered ELV, the presence of the inverter typically necessitates a grounding arrangement for overall fault protection.
Grid Connection
Compliance with Utility Standards: Each electricity distributor may have additional grounding and metering requirements.
Residual Current Devices (RCDs): Often required on the AC side to protect against fault currents and ensure fast disconnection in the event of a ground fault.
Isolation Transformers (If Applicable)
Some systems include isolation transformers for additional safety. These transformers must also be bonded to the grounding system in accordance with local regulations.
5. Larger Systems & Parallel Configurations
Multiple Batteries or Parallel Strings
When multiple battery packs are paralleled, ensure all enclosures and negative/positive busbars are consistently referenced to ground if required by design.
Use suitably rated protective devices (fuses, circuit breakers) for each battery string.
High-Power or Industrial Systems
Larger installations with higher fault currents may require specialized grounding solutions (e.g., ground rods, earth grids).
Industrial sites may have additional standards or site-specific requirements.
Earth Faults: Grounding ensures a controlled path for fault currents, reducing the risk of fire or electric shock.
Short Circuits: Proper earthing aids in the rapid operation of circuit breakers or fuses, minimizing damage to equipment.
Overvoltage & Surges
Lightning strikes or grid disturbances can introduce high transient voltages.
Surge protection devices (SPDs) work most effectively when a reliable grounding system is in place.
Environmental Factors
Moisture & Corrosion: In humid or corrosive environments, grounding can mitigate risks associated with damaged insulation or rusted enclosures.
Hazardous Locations: Specialized facilities, such as chemical plants, may have stricter grounding requirements to prevent sparking or ignition.
7. Regulatory Requirements
AS/NZS 3000:2018
Governs electrical wiring rules, including grounding and bonding requirements.
Clause 4.4 underlines general safety principles for extra-low voltage systems with higher-risk elements (like inverters).
Local and Utility Regulations
Requirements can vary between states or electricity distributors.
Some areas enforce additional measures, such as mandatory RCDs on dedicated circuits.
Industry-Specific Standards
Sectors like healthcare, mining, or telecommunications may have extra guidelines for grounding to protect sensitive equipment and ensure robust fault management.
8. Practical Recommendations
Use Qualified Professionals
Hire a licensed electrician or engineer knowledgeable about AS/NZS 3000:2018 and local codes.
An expert can properly size conductors, select protective devices, and ensure compliant grounding.
Install Comprehensive Protection
Combine grounding with overcurrent protection (circuit breakers, fuses), RCDs, and surge protection devices.
Verify correct polarity and cable connections to avoid dangerous wiring errors.
Perform Regular Inspections
Periodically check grounding connections, looking for corrosion or loose bonds.
Routine testing (e.g., earth continuity tests) helps maintain a safe and compliant system.
Document Your Setup
Keep detailed records of grounding points, conductor sizes, and protective devices.
Maintain installation diagrams and test certificates for reference, future maintenance, or inspections.
9. Conclusion
When sub-60VDC lithium battery systems involve inverters or a connection to the grid, grounding is mandatory to handle AC voltages safely and comply with AS/NZS 3000:2018. Proper grounding reduces shock risks, aids in fault clearing, and protects both equipment and people. To achieve a safe and legally compliant setup:
Follow local and national regulations for grounding and bonding.
Incorporate protective devices such as circuit breakers, fuses, RCDs, and surge protectors.
Consult qualified professionals for system design, installation, and inspection.
By adhering to these guidelines, you ensure a robust, safe, and compliant energy storage solution in Australia.
Disclaimer: This information is a general overview and does not replace official standards or on-site professional advice. Always consult a licensed electrician or qualified engineer to ensure full compliance with current regulations and safety best practices.
Envirostream Australia Envirostream Australia – Website, a subsidiary of Lithium Australia, is the first onshore lithium and mixed battery recycling company in Australia. Established in 2017, Envirostream employs innovative, environmentally safe processes to recover valuable materials from end-of-life batteries. Their operations include discharging, dismantling, shredding, washing, and screening batteries to recover metals like copper, aluminum, and steel, which are then reused in manufacturing new batteries. Their facility in Melbourne is EPA-licensed and equipped with fire and safety systems to manage the risks associated with battery recycling.
Victron GX products are Victron’s state-of-the-art monitoring solution. The family consists of the different GX products, and their accessories. The GX-device lies at the heart of the system – providing monitoring, and operating as the communication-centre of your installation. All the other system-components – such as inverter/chargers, solar chargers, and batteries – are connected to it. Monitoring can be carried out locally and remotely – via our free-to-use Victron Remote Management portal (VRM). The GX device also provides Remote firmware updates (link) and allows inverter/charger settings to be changed remotely (VRM Portal).
The GX Family consists of these models: Ekrano GX – Our latest GX product with integrated 7 inch touchscreen. Cerbo GX – Most commonly used GX product. Cerbo GX MK2 – Almost identical to the Cerbo GX, this new model has improvements in its VE.Can ports, USB ports and pulse counting. See table below for details, as well as foot note 26. Cerbo-S GX – Lower cost version, same as normal Cerbo GX but without BMS-Can port, Tank- and Temperature monitoring inputs. Color Control GX – Our first released GX product, the CCGX has a display and buttons. Venus GX – The Venus GX has more analog and digital IO, no LCD and is more cost effective than the CCGX. CANvu GX – The CANvu GX is best for harsh environments – when its IP67 rating and touch LCD is a must. Octo GX – The Octo GX is particularly suited to medium size installations which have many MPPT Solar Chargers, as it has 10 VE.Direct ports. (EOL (End of line)) Maxi GX – Compared to the other GX devices, the Maxi GX has most CPU power and most VE.Direct ports: 25. This is the GX device to use for large systems with many VE.Direct MPPT Solar Chargers. (EOL (End of line)) Lastly, there is a GX device built into our MultiPlus-II GX and EasySolar-II GX Inverter/chargers.
Available accessories
GX Touch – Touch screen display accessory for the Cerbo GX and Cerbo GX MK2 GX GSM – A 2G and 3G cellular modem. It connects to GX device via USB, and takes a SIM card GX LTE 4G – A 2G, 3G, and 4G cellular modem. It connects to GX device via USB and takes a SIM card WiFi USB sticks Energy Meters – Measures PV Inverter Output where PV Inverters cannot be read-out directly. Also used as a grid meter in an Energy Storage System (ESS) VE.Can resistive tank sender adapter – Allows a standard resistive tank-level sender to be connected to the GX device. Note that some GX Devices feature resistive tank-level inputs themselves. GX Touch adapter for CCGX cut-out – An adapter that fits in a cut-out made for a CCGX, into which fits a Cerbo GX. For when upgrading a CCGX system to a Cerbo GX. More details available asap. Temperature sensor for Quattro, MultiPlus and GX Device – Temperature sensor accessory for the temperature inputs of the Venus GX, Cerbo GX, Cerbo GX MK2, and Ekrano GX.
The demand for high-efficiency and long-lasting energy storage systems has driven the advancement of lithium-ion battery technologies. Among the dominant formats—cylindrical, prismatic, and pouch cells—prismatic cells have emerged as the superior choice for large-scale energy storage systems (ESS) due to their structural robustness, enhanced energy density, and extended lifespan. This article explores the inherent design advantages of prismatic cells over cylindrical cells, focusing on energy storage capacity, thermal management, safety, and durability.
Introduction
The exponential growth in renewable energy adoption, electric vehicles (EVs), and grid energy storage has elevated the importance of lithium-ion batteries. While cylindrical cells were the industry standard in the early days of lithium-ion technology, prismatic cells are increasingly favored in large-scale energy applications due to their optimized design for energy density and long-term performance.
This article provides an in-depth analysis of the key differences between prismatic and cylindrical cells, emphasizing why prismatic cells are better suited for energy storage applications. The evaluation is framed around critical factors such as energy density, lifespan, safety, thermal stability, and mechanical design.
1. Structural Design and Energy Density
1.1 Cylindrical Cells: The Traditional Design
Cylindrical cells, such as the 18650 or 21700 formats, feature a jellyroll design where electrodes and separators are wound into a cylindrical shape. While this design offers simplicity in manufacturing and scalability for mass production, the shape is not optimized for packing efficiency in space-constrained environments. Dead spaces between cells in a battery pack reduce the volumetric energy density.
1.2 Prismatic Cells: Optimized for Space Utilization
Prismatic cells, on the other hand, feature a flat, rectangular design that allows for optimal space utilization. In battery packs, prismatic cells can be stacked with minimal gaps, resulting in higher volumetric energy density compared to cylindrical cells. This feature is particularly advantageous in energy storage systems and EVs, where space constraints are critical.
1.3 Cylindrical vs. Prismatic Cells for High-Performance Applications
Cylindrical cells are often preferred for high-performance applications due to their superior surface-area-to-volume ratio, which facilitates efficient thermal management and energy output in high-discharge scenarios.
2. Lifespan and Durability
2.1 Cycle Life
The cycle life of a lithium-ion battery refers to the number of charge-discharge cycles it can endure before its capacity falls below 80% of the initial value. Prismatic cells typically offer a longer cycle life due to better thermal management and reduced mechanical stress during operation.
Cylindrical Cells: More prone to internal resistance growth due to uneven heat distribution within the jellyroll design, potentially leading to a shorter cycle life compared to prismatic cells. However, advancements in cell design have mitigated this issue in high-quality cylindrical cells.
Prismatic Cells: With their uniform thermal distribution and robust mechanical design, prismatic cells exhibit lower degradation rates. Premium prismatic cells can achieve cycle lives exceeding 10,000 cycles, making them a popular choice for energy storage systems requiring long operational lifespans.
Analysis:
Cycle life is influenced by factors such as thermal management, mechanical design, and operational conditions. While prismatic cells can offer longer cycle lives due to efficient thermal management, cylindrical cells have also demonstrated substantial cycle life improvements through design enhancements. For instance, a study comparing prismatic and cylindrical lithium-ion batteries found that prismatic cells exhibited better thermal performance at high discharge rates, which can contribute to longer cycle life
Cylindrical Cells: Due to their relatively thinner steel casings, cylindrical cells are more susceptible to deformation under external mechanical stress. This can increase the risk of damage in applications with high physical demands.
Prismatic Cells: Constructed with thicker aluminum casings, prismatic cells provide superior resistance to mechanical stress and physical impacts. This makes them ideal for energy storage systems exposed to environmental stressors, such as vibration or shock.
Analysis:
The mechanical durability of battery cells is crucial in applications subject to physical stress. Prismatic cells, with their robust casing, offer enhanced resistance to deformation. However, cylindrical cells are designed to withstand significant mechanical stress and are widely used in various applications, including electric vehicles, where durability is essential.
The compact, wound design of cylindrical cells offers a high surface-area-to-volume ratio, which allows for efficient heat dissipation. This reduces the likelihood of thermal hotspots and overheating, supporting higher discharge currents in high-performance applications.
Drawback: In scenarios of extreme current demand, improper thermal management can still lead to localized overheating, potentially triggering thermal runaway.
Analysis:
Cylindrical cells benefit from efficient heat dissipation due to their design. However, without proper thermal management, they can develop localized hotspots under high current demands, leading to potential safety risks. Effective thermal management systems are essential to mitigate these risks.
The flat design of prismatic cells provides a relatively large surface area for heat dissipation. However, as the size of the cell increases, it becomes more challenging to effectively remove heat from the cell’s center. This makes prismatic cells better suited for applications involving lower current demands and large-scale packs, rather than high-performance or extreme discharge applications.
Advantage: With efficient thermal management, prismatic cells can achieve longer operational life and reduce the risk of catastrophic failure.
Analysis:
Prismatic cells offer a large surface area for heat dissipation, but their larger size can lead to thermal management challenges, especially in the cell’s core. They are well-suited for applications with moderate current demands. A study on the thermal management of prismatic lithium-ion batteries highlights the importance of effective thermal management systems to prevent thermal runaway and ensure safety
Cylindrical Cells: With their superior surface-area-to-volume ratio, cylindrical cells excel at heat dissipation, making them better suited for high-discharge applications that require consistent thermal performance.
Prismatic Cells: Optimal for applications with lower current demands, where heat dissipation is less critical. These cells are more efficient in large-scale energy storage systems designed for moderate performance.
Analysis:
Both cell types have distinct thermal management characteristics. Cylindrical cells are advantageous in high-discharge scenarios due to efficient heat dissipation, while prismatic cells are preferable in applications with lower current demands. The choice between cylindrical and prismatic cells should consider specific application requirements, including thermal management needs, mechanical durability, and desired cycle life.
4. Safety Features
4.1 Enhanced Safety in Prismatic Cells
Prismatic cells incorporate robust safety mechanisms, such as thicker aluminum casings, ceramic separators, and pressure-relief vents. These features significantly reduce the likelihood of thermal runaway and internal short circuits. For energy storage applications where safety is paramount, these enhancements make prismatic cells a preferred choice.
4.2 Cylindrical Cells: Safety Concerns
Cylindrical cells are less robust in high-stress environments due to their thinner casings and susceptibility to deformation. Their reliance on external battery management systems (BMS) for safety adds complexity and cost to large-scale applications.
5. Applications in Energy Storage Systems
5.1 Large-Scale Energy Storage
The modular nature of prismatic cells makes them ideal for energy storage systems (ESS). Their high energy density, long lifespan, and efficient thermal management enable them to deliver consistent performance over decades.
5.2 Cylindrical Cells: Limited Utility in ESS
While cylindrical cells excel in high-power, small-scale applications like power tools, their limitations in energy density and thermal management make them less suitable for ESS.
Case Study: Renewable Energy Storage
In large renewable energy installations, prismatic cells provide the durability and reliability required for continuous operation, outpacing cylindrical cells in both performance and cost-effectiveness.
6. Economic and Environmental Considerations
6.1 Cost Efficiency
Although prismatic cells have higher upfront manufacturing costs due to their complex design, their longer lifespan and higher energy density result in lower total cost of ownership (TCO) over time. For ESS, this cost advantage is amplified due to reduced maintenance and replacement costs.
6.2 Environmental Benefits
The longer lifespan of prismatic cells reduces the frequency of battery replacements, minimizing the environmental impact associated with battery manufacturing and disposal.
Conclusion
Prismatic cells outperform cylindrical cells in nearly every metric relevant to energy storage and lifespan. Their superior energy density, robust mechanical design, efficient thermal management, and enhanced safety features make them the ideal choice for large-scale energy storage systems and long-term applications. While cylindrical cells retain their relevance in smaller, high-power applications, the evolution of lithium-ion technology increasingly favors prismatic cells for their ability to meet the demands of modern energy systems.
As the world moves towards a greener, more sustainable future, the role of prismatic cells in facilitating the energy transition cannot be overstated. By addressing the challenges of energy density, safety, and longevity, prismatic cells are poised to become the cornerstone of next-generation energy storage solutions.
References
Battery Design. (2023). Prismatic Cells: An Overview.
Electrochimica Acta. (2023). “Cell Teardown and Characterization of an Automotive Prismatic LFP Battery.”
EV Reporter. (2022). “Comparison of Prismatic and Cylindrical Cell Technologies.”
All About Circuits. (2022). “Lithium-Ion Battery Formats and Their Applications.”
What is LP572 and how does it differ in this cell, and others such as the 10000 cycle EVE and 11000 cycle Hithium and 12000 cycle CATL cells What is LP572? LP572 is a commonly used electrolyte formulation in lithium-ion batteries. It typically contains a mixture of organic solvents, lithium salts (like LiPF₆), and additives that enhance ionic conductivity, stability, and cycle life. Its main components and properties include:
Organic Solvents: Typically, a mix of ethylene carbonate (EC), dimethyl carbonate (DMC), diethyl carbonate (DEC), or ethyl methyl carbonate (EMC).
EC is a high-dielectric constant solvent, improving the solubility of LiPF₆. DMC/DEC/EMC act as low-viscosity solvents for better ionic conductivity. Lithium Salt: Lithium hexafluorophosphate (LiPF₆) is the standard salt, which ensures good ionic conductivity and stability under a range of operating conditions.
Additives: These are tailored to improve solid electrolyte interface (SEI) formation, cycle life, and thermal stability.
Electrolyte in the Tesla Prismatic LFP Cell The study highlights that the electrolyte used in the Tesla prismatic LFP cell outperforms the standard LP572 in terms of electrochemical stability and cycle life. While the paper doesn’t specify the exact composition of the electrolyte, some key differentiators likely include:
Advanced Additives: The Tesla cell may use a more advanced mix of additives designed for superior SEI formation and cathode stability. Thermal Stability: The electrolyte is likely engineered to handle the thermal demands of high-energy automotive applications better. Compatibility with LFP Cathodes: The electrolyte may be optimized for the relatively lower operating voltage and specific requirements of LFP chemistry, which differs from higher-voltage nickel-based cathodes. Comparison with Other High-Cycle Life Cells EVE (10,000 Cycle Cells) Chemistry: LFP-based cells with 10,000 cycle capability are designed for energy storage systems. Electrolyte: Likely uses advanced additives to enhance cycle life, with a focus on reducing electrolyte degradation at low C-rates (used in BESS applications). Key Features: Optimized SEI layer stability on the graphite anode. Low gas generation to prevent swelling. High resistance to electrolyte decomposition.
Hithium (11,000 Cycle Cells) Chemistry: LFP cells engineered with chemistry tweaks for an exceptionally long lifespan. Electrolyte Enhancements: Contains additives that minimize microcracking in the cathode and anode over time. Advanced thermal stability additives to support continuous operation in BESS applications. Low moisture content during manufacturing, reducing the rate of electrolyte breakdown. Key Advantage: Longer cycle life due to slower degradation of cathode material.
CATL (12,000 Cycle Cells) Chemistry: LFP cells with enhanced electrode material quality and a highly engineered electrolyte system. Electrolyte Features: Likely proprietary additives for ultra-stable SEI layer formation. High-performance solvents that resist breakdown even under frequent cycling. Additives that specifically reduce lithium plating on the anode during high-rate charging cycles. Cycle Life Edge: CATL achieves extended cycle life through precise control of manufacturing tolerances and electrode surface treatments, in addition to advanced electrolyte formulations. Key Differences Between LP572 and These High-Performance Cells Additive Optimization:
LP572 relies on standard additives that offer reasonable performance for commercial-grade cells. EVE, Hithium, and CATL cells employ advanced and proprietary additives tailored to maximize cycle life. Thermal Stability:
LP572 performs adequately in moderate conditions. High-cycle cells use electrolytes engineered for higher thermal stability, which is crucial for extended use in energy-dense systems. Compatibility with High-Cycle Cathodes:
LP572 may be prone to degradation over many cycles. High-cycle cells use formulations designed to resist breakdown and maintain conductivity even after thousands of cycles. Moisture Content: High-cycle cells are manufactured with stricter controls on electrolyte purity, reducing water contamination that can degrade LiPF₆ and generate HF (hydrofluoric acid), leading to cycle life reduction. Summary LP572 is a versatile, standard electrolyte for general lithium-ion battery use but is not optimized for ultra-long cycle life applications.
High-cycle life cells from EVE, Hithium, and CATL integrate advanced electrolyte formulations with proprietary additives and strict manufacturing controls to achieve cycle lives of 10,000–12,000 cycles. The Tesla prismatic LFP cell likely incorporates an intermediate-level electrolyte with better thermal stability and additive design than LP572 but may not match the performance of the specialized formulations in Hithium or CATL cells. This comparison underscores the importance of electrolyte innovation and material optimization in pushing the limits of cycle life and energy density for different applications. Let me know if you’d like to dive deeper into any specific cell chemistry!
Overview: CATL offers a portfolio of integrated energy storage solutions designed for various scales and applications. Among their product lines, “EnerD” and “EnerC” are two types of turnkey energy storage systems that leverage CATL’s high-performance lithium iron phosphate (LFP) battery technology. Both solutions are engineered to provide safe, reliable, and efficient energy storage for different use cases, from commercial and industrial (C&I) facilities up to utility-scale deployments.
EnerD – Distributed Energy Storage System
Application Scenario: EnerD is typically positioned for medium-scale distributed energy storage projects. It’s commonly deployed in commercial buildings, industrial parks, community microgrids, or distribution networks that require flexible and scalable storage solutions.
Form Factor and Modularity: EnerD systems are often rack-based or cabinet-based solutions. They can be installed indoors or outdoors and are designed to be easily scaled by adding more modules. This modularity allows customization of the system’s capacity and voltage to match specific energy requirements.
CATL’s 5MWh EnerD series liquid-cooled energy storage prefabricated cabin system took the lead in successfully achieving the world’s first mass production delivery.
EnerD series products use CATL’s new generation of energy storage dedicated 314Ah batteries, equipped with CTP liquid cooling 3.0 high-efficiency grouping technology, optimizing the grouping structure and conductive connection structure of the cells, achieving a 20-foot single cabin power increase from 3.354MWh to 5.0MWh.
Compared with the previous generation of products, the new EnerD series liquid-cooled energy storage prefabricated cabins save more than 20% in floor space, reduce construction work by 15%, and reduce commissioning, operation and maintenance costs by 10%.
Key Features:
LFP Battery Technology: CATL’s lithium iron phosphate cells provide long cycle life, strong thermal stability, and enhanced safety.
Battery Management System (BMS): Integrated BMS ensures optimal performance, monitors state of health (SOH) and state of charge (SOC), and provides comprehensive safety controls.
Flexible Integration: EnerD can be integrated with various power conversion systems, on-site renewable generation (like rooftop solar), and energy management systems (EMS) for peak shaving, load shifting, and emergency backup.
Distributed Applications: Ideal for localized energy storage setups where balancing local supply and demand, improving power quality, or increasing renewable self-consumption is paramount.
CATL’s improved, next generation 10,000 cycle 314AH cell is featured in EnerD
EnerC – Containerized Utility-Scale Solution
Application Scenario: EnerC is geared towards larger-scale, often utility-grade energy storage applications. These might include renewable energy integration (wind or solar farms), frequency regulation, capacity reserve, grid stabilization, and large commercial/industrial sites that need significant energy buffering.
Form Factor and Deployment: EnerC systems are typically housed in standardized shipping containers (e.g., 20-foot or 40-foot ISO containers), making them easily transportable, relatively quick to install, and straightforward to scale to multi-megawatt-hour (MWh) levels.
Key Features:
High Energy Density: Uses CATL’s advanced LFP cells arranged in large battery racks, delivering a broad range of capacities. Depending on configuration, these can reach into the hundreds of kWh or multiple MWh per container.
Integrated Thermal Management: The container includes HVAC systems or liquid cooling (depending on configuration) to maintain optimal battery temperatures, ensuring consistent performance and longevity.
Comprehensive Safety Measures: Fire suppression systems, advanced fault detection, and robust enclosure designs ensure safe operation even in harsh environments.
Plug-and-Play Design: Pre-integrated components (batteries, BMS, power conversion devices, EMS, and safety systems) enable rapid deployment and commissioning.
Scalability and Flexibility: Multiple EnerC containers can be combined to form large-scale energy storage plants, supporting grid-level functions like peak shaving, load shifting, and ancillary services.
Comparing EnerD and EnerC:
Scale:
EnerD: More suited for tens to hundreds of kWh or possibly lower MWh ranges in distributed settings.
EnerC: Optimized for hundreds of kWh to multi-MWh-scale projects.
Deployment Model:
EnerD: Often involves indoor/outdoor cabinet or rack installations, potentially scattered across different parts of a facility or distribution grid.
EnerC: Self-contained, modular container units designed for centralized placement, easy transport, and quick utility-scale deployment.
Use Cases:
EnerD: Ideal for commercial buildings, industrial complexes, microgrids, and behind-the-meter use cases where footprint and flexible sizing matter.
EnerC: Focused on front-of-the-meter utility projects, large commercial installations, or renewable generation sites requiring substantial, consolidated energy storage.
In Summary:
EnerD: A flexible, modular distributed energy storage solution well-suited for medium-scale C&I and community applications.
EnerC: A containerized, large-scale, turnkey system designed for utility-level or large commercial energy storage deployments. Both leverage CATL’s proven LFP technology, robust BMS, and integration capabilities, ensuring safe and reliable energy storage solutions tailored to the needs of diverse energy stakeholders.
