In energy storage systems, high-voltage (HV) batteries are defined as those with a rated voltage of 90V-1000V. Higher voltage brings stronger energy storage and power supply capabilities for high-demand scenarios, but also higher safety risks.
Ensuring HV battery safety is a systematic, multi-layered task. Beyond basic measures like HV control box, BMS, and safety equipment, customized energy storage integrated cabinets play a key role. Below is a detailed breakdown of core safety measures.
Proper Battery Cluster Structure & Dedicated High-Voltage Control Box
HV batteries operate in battery clusters (typically 5–11 modules in series) to meet high-power load demands (e.g., commercial & industrial power supplies, utility-scale solar storage). Each cluster is equipped with a dedicated HV control box, which acts as the "command center" for cluster-level safety:
(1) Regulates charging/discharging currents and voltages in real time to avoid abnormal fluctuations.
(2) Integrates overcurrent, overvoltage, and short-circuit protection relays, automatically cutting off the circuit if risks occur (e.g., sudden current surges).
(3) Monitoring each cluster, preventing fault propagation from one cluster to the entire system.
Customized Energy Storage Integrated Cabinets
UE offers tailored cabinets for different capacities:
Small/medium outdoor cabinets (50kWh-225kWh for commercial/industrial use) with intelligent air conditioning for heat dissipation.
20ft/40ft containerized systems (for large utility/microgrid projects) integrating thermal management, fire protection, and structural safety.
These cabinets serve as the "last line of defense" for on-site safety, with key features including:
(1) Air Conditioning & Ventilation
HV batteries generate a lot of heat during charging/discharging; excessive or uneven temperature can accelerate cell aging and trigger thermal runaway. So smart temperature control is crucial to the safety of energy storage systems.
The air conditioning system is responsible for cooling and dehumidifying the internal environment. The ventilation system is responsible for exhausting hot air from the cabinet and replacing it with outside air or internal circulation to prevent excessive internal temperatures.
(2) Rapid Fire Extinguishing System
The fire extinguishing system mainly consists of HFC-227ea fire extinguishing device, a pressure relief device, gas fire extinguishing controller, a smoke detector, etc., which have the functions of automatic pre-emption, automatic monitoring and automatic fire extinguishing.
The device responds quickly and can carry out targeted fire extinguishing within 5s, quickly cooling the battery and blocking the combustion chain reaction, achieving dual physical and chemical fire extinguishing measures.
(3) Solid Cabinet Structure
IP65/IP54 Waterproof & Dustproof Rating: The cabinet body is made of 2mm-thick galvanized steel (with anti-corrosion coating) and features rubber gaskets at door seams, protecting internal batteries from rain, dust, and humidity.
Anti-Impact & Anti-Tipping: Reinforced steel frames and base anchors enable the cabinet to withstand accidental collisions (e.g., on-site construction impacts) and strong winds (up to 12 levels).
Explosion-Relief Design: The cabinet’s top or side panels are equipped with explosion-relief valves—if internal pressure rises sharply due to gas release from thermal runaway, the valves open to release pressure, avoiding cabinet rupture.
(4) Emergency Button
A prominent red ESD button is installed on the cabinet exterior; pressing it cuts off all power inputs/outputs to the cluster within 0.5 seconds, enabling on-site personnel to quickly halt operations in emergencies.
Core Protection Part- BMS
The BMS serves as the "brain" of the entire HV energy storage system. With a triple energy storage BMS structure (battery cell unit - cluster - battery system), we can adopt to better ensure the safety of the energy storage system.
- BMU (Battery Management Unit): Collects single-cell voltage/temperature, calculates battery status, and controls balancing/thermal management.
- BCMS (Battery Cluster Management System): Collects cluster voltage/current, conducts insulation tests, and controls relays/fans.
- BAMS (Battery System Management System): Displays data, monitors in real time, identifies anomalies, and enables remote alarm/diagnosis.
Comprehensive Safety Equipment
To improve safety, the high-voltage energy storage system is also equipped with safety devices that work in conjunction with the battery pack:
- Basic Electrical Protection: battery combiner boxes (with high-voltage fuses) and circuit breakers to isolate faulty modules and block abnormal currents—preventing thermal runaway triggers.
- DC/DC Modules: Regulates direct current to a stable range, ensuring consistent power supply to internal components (e.g., BMS, control boxes) and preventing overload-induced damage.
- Power Conversion System (PCS): Stabilizes power input/output between batteries and the grid, eliminating voltage spikes that could damage cell structures.
- Automatic Transfer Switch (ATS): Switches power sources within 0.1 seconds during grid outages or anomalies, avoiding backflow current or prolonged over-discharging of batteries.
Conclusión
With the rising demand for energy storage across commercial, industrial, and utility-scale applications, business and project operators are no longer focused solely on high energy output—they are increasingly prioritizing the safety, reliability, and sustainability of entire energy systems.
Ensuring the safety of high-voltage (HV) batteries, therefore, is never a single measure; it is a comprehensive commitment woven into every stage of a system’s design, configuration, and day-to-day operation.
For UE, this commitment translates to tailoring solutions to the unique requirements of diverse scenarios. By integrating safety into every phase of your project’s life cycle, we empower you to unlock the full energy potential of HV batteries while proactively mitigating risks.
At UE, our goal is to deliver more than just safe HV battery systems: we provide the stability and confidence needed to keep your energy operations running smoothly, even in demanding conditions—helping you balance performance and protection, now and in the long term.