BESS Liquid Cooling · AU Industry Application
ToneCooling Australia supplies liquid cooling cold plates for Australian grid-scale battery energy storage projects aligned to the AEMO 2024 Integrated System Plan and the Capacity Investment Scheme. Reference product TC-1P104S — 39.1 kg stamped-brazed aluminium cold plate for 1P104S battery modules — has real production-line test data: 4 Pa air-tightness leak (vs 30 Pa specification), 21.2 kPa CFD ΔP at 10 L/min, 6.2 °C cell-top ΔT across 104 cells. Material substrates dual-certified RoHS 2.0 + PFAS-free per SGS Shanghai. AS/NZS 5139 design-aware, AS/NZS 4777 inverter-context aware. Cold plates designed, engineered & manufactured in Huizhou; AU compliance documentation from Carlton VIC.
Engineering Reference & Standards
Section 1 of 6
Cell-to-cell ΔT is the primary thermal constraint for lithium-ion calendar life. Cells running > 5 °C above their pack-mean degrade ~ 2× faster than cells at the pack mean; over a 10-year BESS asset life this translates to early single-cell failure, BMS-triggered string isolation, and lost availability. Liquid cooling — distributed across all cells in the module via a stamped-channel cold plate — delivers the cell-pack thermal uniformity that air cooling cannot achieve at high discharge rates.
Section 2 of 6
| Parameter | Verified value | Test method / source |
|---|---|---|
| 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 (production-line sample) | 4 Pa measured (vs 30 Pa spec) | Pressure-decay test per QC/T 468-2010, production batch |
| 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, 50/50 EGW, 20 °C inlet |
| Bare cold plate ΔP @ 10 L/min | 21.2 kPa | CFD simulation REV-0 |
| Cell-top ΔT (104 cells) | 6.2 °C | CFD, 50/50 EGW, 20 °C inlet, 15 W per cell |
| Top plate material | AL3003MOD | RoHS 2.0 certified, CNAS-accredited Wonder Labs |
| Channel material | AL3003MOD + AL4045 brazing | RoHS 2.0 certified |
| Frame material | SPCC / Q235 steel | RoHS 2.0 + PFAS-free SGS Shanghai EN 17681-1:2022 |
| Joining processes | Stamped brazing (CAB) + laser welding | IATF 16949-aligned production line |
| Helium leak rate (production target) | ≤ 1×10⁻⁹ mbar·L/s | High-sensitivity helium mass-spectrometer |
| Operating temperature range | −40 °C to 150 °C, 20–98 % RH | Per AS/NZS 60068-2-14 thermal cycling |
Section 3 of 6
| Standard | Scope | ToneCooling alignment |
|---|---|---|
| AS/NZS 5139:2019 | Battery system installation safety, including thermal management context | Cold plate design-aware: cell-to-cell ΔT ≤ 6 °C envelope, single-cell isolation, BMS integration support |
| AS/NZS 4777.2:2020 | Grid-connected inverter (PCS) installation — relevant for grid-forming BESS | Cold plate context-aware: PCS/inverter cooling support across grid-forming and grid-following modes |
| AS/NZS 60068-2-14:2014 | Environmental testing: change of temperature endurance | Validation: −40 °C to 150 °C thermal cycling reports per shipment |
| AS/NZS 60529:2004 | Degrees of protection by enclosures (IP code) | Validation: IP65 / IP66 evidence on request for outdoor BESS deployments |
| IEC 62619:2022 | Secondary cells and batteries — safety requirements (referenced via AS/NZS) | Material substrates RoHS 2.0 compliant; thermal envelope aligned |
| UL 1973:2022 | Stationary batteries (relevant for AU integrators with US-aligned UL programmes) | Cold plate compatible with UL 1973 BESS programmes via documentation handoff |
Section 4 of 6
Australian Industrial Chemicals Introduction Scheme is the federal scheme under which PFAS substances are reviewed. National Chemicals Working Group recommendations are progressively translating into procurement specifications.
Steel frame substrate tested per EN 17681-1:2022 by SGS Shanghai (international third-party laboratory). PFOS, PFOA, PFOSA, FOSAA — all four targeted PFAS species — returned ND (not detected) results.
For AU energy infrastructure tenders that include PFAS-free as a sub-component requirement, the TC-1P104S material declarations integrate directly into your tender response without compliance-gap remediation.
Section 5 of 6
Integrated System Plan projects BESS as dominant new firming capacity through 2050. Liquid-cooled BESS extends asset calendar life to meet ISP lifetime assumptions.
CIS Round 2 results show 6 GW BESS capacity awarded; programme momentum continues. Cold plate documentation supports the CIS contract reporting cycle.
74% of AU's BESS pipeline now uses grid-forming inverters per AEMO Q1 2026 — generating higher inverter cooling demands than legacy grid-following systems.
Daily cycling on AEMO despatch profiles requires liquid cooling to maintain cell-pack uniformity and extend calendar life beyond 10 years.
Section 6 of 6
| Stage | Owner | Output |
|---|---|---|
| 1. RFQ intake & acknowledgement | Carlton VIC customer engineering support team | Receipt confirmation; completeness check on TDP / ΔP / qualification scope |
| 2. Engineering response | Carlton-coordinated; Huizhou design and engineering team technical review | Thermal sensitivity table, process recommendation, draft AUD quote |
| 3. NDA execution | Carlton VIC team | Mutual NDA signed; design-IP exchange enabled |
| 4. DFM review session | Carlton + Huizhou joint Zoom session | CFD output, channel-topology proposal, manifold-port alignment, hydraulic budget review |
| 5. Prototype & production delivery | Huizhou manufacturing → AU customer site | Lot-traceable QC certificates per shipment |
Frequently Asked
Australian grid-scale BESS sites cycle daily on AEMO ISP / CIS-aligned despatch profiles, with cell-level heat generation that scales with charge/discharge rate. Air-cooled BESS is limited to ~ 0.5C continuous discharge before cell-to-cell ΔT exceeds the 5–8 °C envelope that maintains lithium-ion calendar life. Liquid-cooled BESS extends continuous discharge capability to 1C–2C, enables higher cell-pack density, and tightens cell-to-cell ΔT to ≤ 6 °C — measured on our TC-1P104S production cold plate at 50/50 EGW, 10 L/min, 15 W per cell.
TC-1P104S is ToneCooling's flagship BESS cold plate — a 39.1 kg stamped-brazed aluminium cold plate for 1P104S battery modules used in grid-scale energy storage. 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 against 30 Pa specification (per QC/T 468-2010 method), 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 under 15 W per cell heat load. Material substrates dual-certified RoHS 2.0 + PFAS-free per SGS Shanghai EN 17681-1:2022.
Yes. AS/NZS 5139:2019 governs Australian battery system installation including thermal management. The TC-1P104S is design-aware to AS/NZS 5139 — our DFM engineering review covers thermal runaway containment context, cell-to-cell ΔT envelope alignment, single-cell thermal isolation, and BMS thermal monitoring integration. ToneCooling supplies cold plates; AS/NZS 5139 installation compliance is the responsibility of the licensed Australian electrical installer.
Australia is moving toward harmonised PFAS regulation under AICIS following the National Chemicals Working Group review. Federal procurement for major energy infrastructure increasingly requires PFAS-free declarations for BESS sub-components. 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 procurement programmes that include PFAS-free as a tender requirement to specify the TC-1P104S without compliance gaps.
AEMO's 2024 ISP projects BESS as the dominant new firming capacity to 2050; CIS auctioned 6 GW of BESS capacity to support grid-forming inverter deployment (74 % of AU's BESS pipeline now uses grid-forming inverters per AEMO Q1 2026). These despatch profiles cycle BESS daily on charge/discharge windows with second-resolution power swings; liquid cooling is necessary to maintain cell-pack thermal stability under high cycling frequency and to extend calendar life beyond 10 years to meet ISP-aligned BESS lifetime assumptions.
Engagement cycle: Carlton-coordinated engineering response on receipt of complete RFQ; NDA execution; joint Carlton + Huizhou DFM review session; tooled prototype manufacturing and shipping. MOQ, prototype and production lead times, and annual capacity are agreed at quotation per programme.
Continue Exploring
Liquid cold plate vs immersion cooling for Australian grid-scale BESS.
PRODUCT39.1 kg AL3003MOD stamped-brazed cold plate; real test data 4 Pa leak, 21.2 kPa ΔP, 6.2 °C cell-top ΔT.
View product → RESOURCE14-section engineering reference — cell ΔT envelope, channel topology, AS/NZS 5139 thermal context.
Read the guide → RESOURCE24+ AS/NZS / IEC / ISO / EN standards mapped to BESS cold plate programmes.
View reference → CAPABILITYAS/NZS 5139 design-aware documentation handoff to AU electrical installers.
View capability →A complete RFQ — cell-pack configuration, target ΔP and flow rate, AS/NZS 5139 context, BMS interface, lead time — receives 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, and draft quote in AUD.
Request a Quote Email info@tonecooling.com.au
