BESS Cabling: Solutions for Power and Data Transmission

Battery Energy Storage Systems (BESS) are becoming increasingly important as renewable energy generation grows and the energy system evolves. They enable electricity to be stored when generation is high and used later when needed. Energy storage systems can be used, for example, to store electricity generated by solar and wind power, manage peak loads, balance the power grid and ensure a reliable power supply for industrial applications.

However, a BESS is much more than just a battery. Its operation requires power and data transmission between battery modules, inverters, control and monitoring systems and the power grid. Cabling and connection technology therefore play an essential role in the overall system.

Cablex offers solutions from several manufacturers for BESS cabling and electrical connections. We also help select suitable products and solutions based on the technical requirements of the application.

For DC cabling in BESS applications, HELU offers solutions including SOLARFLEX®-X H1Z2Z2-K, which is suitable for solar power systems. The cable is resistant to UV radiation and weathering, suitable for outdoor use and direct burial, and has a rated voltage of 1,500 V DC. NSGAFÖU 1.8/3 kV can also be used for DC cabling. It is highly flexible and suitable, for example, for installations in switchgear and distribution boards. However, the cable is not suitable for outdoor installation, which should be considered when selecting the cable.

For fixed power supply installations, HELU offers HELUPOWER® 1100-RZ1-K LS0H GREEN. The cable is particularly suitable for applications where a high level of safety is required. It is halogen-free and has a CPR classification of Cca.

For connection to the power grid, the portfolio also includes 6/10 kV, 12/20 kV and 18/30 kV medium-voltage cables, such as N2XSY, N2XS2Y, N2XS(F)2Y and N2XS(FL)2Y. Options are available for different installation conditions, including longitudinally and laterally waterproof cables.

In addition to power transmission, data transmission is required between the different parts of a BESS. HELU offers Ethernet, RS485 and CAN Bus cables as well as fibre optic solutions for these applications. Cables are also available for control, HVAC and variable frequency drive applications.

Studer Cables offers aluminium cables for DC power transmission in BESS applications. SOLARpower® Alu-ATA XS is suitable for connections between large battery energy storage systems and inverters, as well as for direct burial. The cable features an aluminium wire and sheath, which protects the cable against moisture and provides mechanical protection. The aluminium sheath can also be used as a grounding wire and for EMC shielding. The cable is halogen-free and UV-resistant.

SOLARpower® Outdoor Alu XS is suitable for DC power transmission in BESS applications, particularly for outdoor use and protected, fixed installations in the ground.

In addition to the system current, factors such as the installation method, ambient temperature and cable arrangement affect the selection of the correct cable cross-section. These factors must be taken into account when determining the permissible current-carrying capacity of the cable.

Current-carrying capacity tables and technical sizing information are available for both HELU and Studer Cables products to support cable selection. Where required, the cable solution can be sized and customised according to the electrical requirements and installation conditions of the project.

A complete cabling solution also includes cable fixing, connections and cable entries. Icotek MSMC cable clamps can also be used to secure rigid power cables. The modular clamps can be installed side by side or stacked, allowing the fixing system to be adapted to different cabling methods.

Cablex also offers Klauke cable lugs and crimping tools for copper and aluminium wires. When designing a connection, the compatibility of the wire, cable lug, crimping profile and tool must be taken into account.

For routing cables into enclosures and cabinets, Cablex offers icotek cable entry solutions. The range includes solutions for both cables with and without connectors to meet different sealing and strain relief requirements.