BESS Product · TC-1P104S Reference
ToneCooling Australia is the Australian BESS cold plate supplier for grid-scale battery energy storage programmes aligned with AS/NZS 5139:2019, AS/NZS 4777.2:2020, and IEC 62619:2017 — operating from the Carlton, Victoria customer engineering office (Suite 69, 139 Cardigan Street, Carlton VIC 3053; ABN 96 653 174 040). The flagship product for Australian buyers is TC-1P104S — a 39.1 kg stamped-brazed aluminium cold plate for 1P104S battery modules in AEMO ISP and Capacity Investment Scheme (CIS) deployments. Construction: AL3003MOD top + AL3003MOD/AL4045 channel + SPCC steel frame, joined by stamped brazing and laser welding. Verified production-line QA: pressure-decay air-tightness 4 Pa measured against 30 Pa specification (per QC/T 468-2010), CFD-simulated total ΔP 21.2 kPa at 10 L/min on 50/50 EGW, cell-top ΔT 6.2 °C across all 104 cells. Material substrates dual-certified RoHS 2.0 + PFAS-free per SGS Shanghai EN 17681-1:2022 — enabling Australian federal and state procurement programmes that include PFAS-free as a tender requirement. The Carlton VIC team coordinates customer engineering support, AS/NZS-aligned compliance documentation, ChAFTA Certificate of Origin, and project handover; cold plate design, engineering, and manufacturing performed at our IATF 16949-aligned partner facility in Huizhou.
Verified production specifications for the ToneCooling TC-1P104S energy-storage cold plate (model CP-00079). Values are validated at the stated working point; final values are confirmed per drawing, heat load, flow rate and pressure-drop limit.
| Application | 1P104S battery module — grid-scale BESS |
|---|---|
| Finished size (L × W × H) | 2180 × 790 × 42 mm |
| Internal volume | 1.95 L |
| Total weight | 39.1–40.3 kg |
| Load-bearing (module area) | < 750 kg |
| Coolant medium | 50% ethylene glycol aqueous (EGW) |
| Flow rate (recommended) | 10 L/min (operating 8–10 L/min) |
| Pressure drop (total) | 24.6 kPa at 10 L/min (< 25 kPa; max allowable 30 kPa) |
| Cell-top ΔT | 6.2 °C across 104 cells at 15 W/cell (CFD) |
| Inlet temperature (recommended) | 20 °C |
| Max working pressure | 0.35 MPa |
| Burst pressure | 4 MPa |
| Air-tightness | 4 Pa measured vs 30 Pa spec (QC/T 468-2010), 100% tested |
| Top & channel plate | AL3003MOD + AL4045 brazing alloy (1.3–1.5 mm) |
| Structural frame | SPCC / Q235 steel |
| Joining process | Stamped brazing (CAB, aluminium) + laser welding (steel) |
| Surface treatment | Insulating powder coating (epoxy, 200±50 µm); frame electrophoretic |
| Flow channel | Parallel, ~12–15 mm width × 3–3.5 mm depth |
| Flatness | ≤ 3 mm overall; ≤ 1.8 mm module area; ≤ 1 mm under load |
| Quick-connect fitting | CQC14 / CQC16 / CQC18 (customer selection) |
| Compatible cell | 0.5C, 280 Ah / 314 Ah (customer selection) |
| Compliance | RoHS 2.0 + PFAS-free (SGS EN 17681-1:2022); AS/NZS 5139/4777-aware; V0 flame-retardant insulation |
Designed, engineered and manufactured at the IATF 16949-aligned ToneCooling facility in Huizhou, Guangdong, China; Australian customer engineering support and AS/NZS compliance documentation from Carlton, Victoria.
Product Snapshot · 4 KPI
Engineering Reference & Standards
Section 1 of 6
| Parameter | Verified value | Test method / source |
|---|---|---|
| Module configuration | 1P104S — 1 parallel × 104 cells in series | Battery module geometry standard |
| Weight (TC variant) | 39.1 kg | Production-line CMM dimensional verification |
| Weight (GX variant) | 40.3 kg | Production-line CMM dimensional verification |
| Air-tightness leak (the production sample) | 4 Pa measured (vs 30 Pa spec) | Pressure-decay test per QC/T 468-2010, production batch |
| Pressure-decay test method | 350 kPa, 120 s inflate / 40 s hold / 60 s test / 20 s depressurise | QC/T 468-2010 |
| Burst pressure | 4 MPa | Lot-sample destructive test |
| Maximum working pressure | 0.35 MPa | Hydraulic specification |
| Total hydraulic ΔP @ 10 L/min | 24.61 kPa (with port losses) | CFD simulation REV-0 |
| Bare cold plate ΔP @ 10 L/min | 21.2 kPa | CFD simulation REV-0, 50/50 EGW, 20 °C inlet |
| Cell-top ΔT (104 cells) | 6.2 °C | CFD, 50/50 EGW @ 20 °C, 10 L/min, 15 W per cell |
| Top plate material | AL3003MOD | RoHS 2.0 certified, CNAS-accredited Wonder Labs (CNAS L5954, ILAC-MRA recognised) |
| Channel material | AL3003MOD + AL4045 brazing alloy | RoHS 2.0 certified |
| Frame material | SPCC / Q235 steel | RoHS 2.0 + PFAS-free per SGS Shanghai EN 17681-1:2022 (PFOS, PFOA, PFOSA, FOSAA all ND) |
| Joining processes | Stamped brazing (CAB) + laser welding | IATF 16949-aligned production line, Huizhou |
| Helium leak rate (production target) | ≤ 1×10⁻⁹ mbar·L/s | High-sensitivity helium mass-spectrometer, every unit |
| Operating temperature range | −40 °C to 150 °C, 20–98 % RH | Per AS/NZS 60068-2-14 thermal cycling |
| Coolant compatibility | 50/50 EGW (default) · 25 % PG · per ASHRAE W32 / W40 | Validation lab tested |
Section 2 of 6
Modified 3003-series aluminium alloy — established BESS cold plate substrate. Higher manganese content for improved corrosion resistance with EGW coolants. RoHS 2.0 compliant per CNAS-accredited Wonder Labs (CNAS L5954, ILAC-MRA recognised).
Aluminium-silicon brazing filler clad on AL3003MOD core; melts in CAB furnace to form the brazed joint between channel and top plate. Established Tier-1 automotive process.
Cold-rolled steel structural frame attached by laser welding. Dual-certified RoHS 2.0 + PFAS-free per SGS Shanghai EN 17681-1:2022 — enabling AU procurement programmes that include PFAS-free as a tender requirement.
Controlled Atmosphere Brazing — same process family used in Tier-1 automotive battery cold plates. Mature, reliable, scalable for Australian BESS programme volumes.
Steel frame attachment via laser welding for high precision and minimal heat-affected zone. Compatible with PFAS-free steel substrate.
CMM-verified dimensional tolerance ±0.1 mm typical on cold plate envelope. Channel dimensions and brazing parameters discussed under NDA during DFM review.
Section 3 of 6
| Substrate | Material | Certification | Issuing body |
|---|---|---|---|
| Top plate | AL3003MOD aluminium alloy | RoHS 2.0 compliant | CNAS-accredited Wonder Labs (CNAS L5954, ILAC-MRA recognised — NATA equivalent) |
| Channel | AL3003MOD + AL4045 brazing alloy | RoHS 2.0 compliant | CNAS-accredited Wonder Labs |
| Frame | SPCC / Q235 steel | RoHS 2.0 + PFAS-free (PFOS, PFOA, PFOSA, FOSAA all ND) | SGS Shanghai per EN 17681-1:2022 |
| Coolant interface | 50/50 EGW compatibility | Validation lab tested | ToneCooling internal QA + customer validation |
Section 4 of 6
The Carlton VIC team coordinates the AS/NZS documentation pack handoff to the licensed Australian electrical installer's compliance review. Items provided per shipment:
| Document | AS/NZS reference | Frequency |
|---|---|---|
| Cold plate thermal performance data | AS/NZS 5139 §6 thermal management context | Per shipment (CFD-verified output) |
| Pressure-decay leak test certificate | QC/T 468-2010 method (referenced) | Per cold plate |
| Hydrostatic pressure test report | 0.35 MPa working / 4 MPa burst | Per lot |
| Helium leak certificate | ≤ 1×10⁻⁹ mbar·L/s sensitivity | Per cold plate |
| Material declarations | RoHS 2.0 + PFAS-free | Per lot |
| Thermal cycling endurance | AS/NZS 60068-2-14 method | Per qualification cycle |
| BMS thermal interface design notes | AS/NZS 5139 §7 monitoring context | Per programme (under NDA) |
| ChAFTA Certificate of Origin | HS 8419 / 8537 | Per shipment |
Section 5 of 6
| Stage | Owner | Documentation |
|---|---|---|
| Prototype | Huizhou manufacturing → AU customer site | Helium leak certificate · CFD output · material declarations |
| Pre-production qualification | Huizhou QMS + Carlton documentation | + FAI per AS9102 (on request) · thermal cycling endurance |
| Production | Huizhou manufacturing | + PPAP Levels 1–5 per programme · lot-traceable QC certificates |
Section 6 of 6
All quotes in Australian Dollars; line pricing typically GST-exclusive (10% GST applied at invoice).
Supplied per shipment, issued by authorised China-side body. Reduces AU import duty on HS 8419 / 8537 from ~ 5% to 0%.
PPAP Levels 1–5 supported with documented PFMEA, FAI per AS9102, material certificates per lot, and lot-traceable QMS evidence.
Frequently Asked
Production-line the production sample sample (production batch): pressure-decay air-tightness 4 Pa measured against 30 Pa specification per QC/T 468-2010 method. CFD simulation REV-0: bare cold plate ΔP 21.2 kPa at 10 L/min; total hydraulic ΔP 24.61 kPa with port losses; cell-top ΔT 6.2 °C across all 104 prismatic cells under 15 W per cell heat load. Lot-sample destructive testing: burst pressure 4 MPa, working pressure 0.35 MPa.
AL3003MOD top + AL3003MOD/AL4045 channel + SPCC steel frame. Joining: stamped brazing (CAB — controlled atmosphere brazing) for the aluminium body, plus laser welding for the steel frame. CAB is the same family of joining used in Tier-1 automotive battery cold plates.
AICIS regulation and federal procurement for energy infrastructure increasingly require PFAS-free declarations. Our TC-1P104S steel frame is dual-certified PFAS-free per SGS Shanghai EN 17681-1:2022 (PFOS, PFOA, PFOSA, FOSAA all ND) — enabling AU tender requirements to specify the TC-1P104S without compliance gaps.
Yes. AS/NZS 5139:2019 design-aware: thermal runaway containment context, cell-to-cell ΔT envelope (≤ 6 °C measured), single-cell thermal isolation, BMS thermal monitoring integration. AS/NZS 5139 installation compliance is the licensed AU electrical installer's responsibility.
Prototype and production lead times, MOQ, and annual capacity are agreed at quotation per programme. PPAP Levels 1–5 supported.
ToneCooling supplies the cold plate plus the documentation pack (thermal performance, pressure tests, helium leak, material decl., AS/NZS 60068-2-14 thermal cycling, BMS interface notes, ChAFTA). The licensed Australian electrical installer is responsible for AS/NZS 5139 installation compliance at the deployment site.
Yes — all quotes are issued in AUD with line pricing typically GST-exclusive (10 % GST applied at invoice). Commercial terms (payment schedule, incoterms) are agreed by separate written commercial agreement during the quotation process.
Yes — per shipment, issued by authorised China-side body. Reduces AU import duty on HS 8419 / 8537 from ~ 5 % to 0 %. Customs documentation pack also includes commercial invoice, packing list, helium leak certificate, and material certificates.
Continue Exploring
Cold plates for AU grid-scale battery energy storage; AEMO ISP / CIS-aligned.
View solution → RESOURCE14-section engineering reference — cell ΔT envelope, channel topology, AS/NZS 5139 context.
Read the guide → RESOURCE24+ standards mapped including AS/NZS 5139, 4777, 60068-2-14, 60529, ChAFTA.
View reference → CAPABILITYDocumentation handoff to AU electrical installer for AS/NZS 5139 BESS programmes.
View capability →Send a complete RFQ — module configuration, target ΔP and flow rate, AS/NZS 5139 context, BMS interface, programme volume, lead time — and receive a Carlton-coordinated response within 24 working hours, with technical review by the Huizhou design and engineering team. You receive a thermal sensitivity table, process recommendation (CAB / FSW), CFD output, material declarations, and draft quote in AUD.
Request a Quote Email info@tonecooling.com.au
