Technical Specification for 100kW Non-Isolated Air-Cooled Bidirectional DC-DC Converter for Large-Scale Energy Storage Power Stations

1. Basic Product Information

• Product Name: 100kW Non-Isolated Air-Cooled Bidirectional DC-DC Converter
• Topology: Non-isolated bidirectional synchronous Buck-Boost topology (adapted to high-power, high-efficiency and wide-voltage working conditions, no isolation transformer, reducing power loss and product volume)
• Control Mode: Digital DSP closed-loop control, supporting smooth bidirectional switching among constant voltage, constant current and constant power modes
• Cooling Mode: Intelligent variable-frequency forced air cooling (temperature-controlled speed regulation, low noise, high reliability, suitable for closed container installation environment)
• Installation Method: Standard rack-mounted or container built-in, supporting parallel cluster control deployment and hot-swappable compatible design

2. Core Electrical Performance Parameters

2.1 Rated Power and Voltage Range

• Rated Power: 100kW (full bidirectional power output, consistent rated power in charging and discharging modes, no power derating)
• Peak Power: 110kW, continuous operation time ≤ 30s, adapted to short-term frequency regulation and peak shaving demands of power stations
• Battery Side Voltage (Input/Output): 250V~1000V wide-range adaptive, fully covering the voltage range from full charge to depletion of lithium iron phosphate battery clusters, no operating dead zone
• Bus Side Voltage (Input/Output): 1000V~1500V rated voltage stabilization, default stable 1500V DC bus, compatible with mainstream high-voltage bus systems for large-scale energy storage
• Rated Current: Battery side rated current ≤ 400A, bus side rated current ≤ 70A; peak current matches peak power, with short-term overload capacity

2.2 Efficiency Indicators (Core Hard Requirements)

• Peak Conversion Efficiency: ≥98.5% (under rated voltage and rated load conditions)
• Full-Load Efficiency: ≥98.0% (full-load operation in full voltage range)
• 50% Load Efficiency: ≥98.2% (maintaining high efficiency under light load conditions, reducing energy storage cycle loss)
• Standby Loss: ≤50W, low-power standby, suitable for idle working conditions of power stations
• Round-Trip Efficiency: ≥96% (complete charging and discharging cycle, improving overall revenue of energy storage power stations)

2.3 Control and Dynamic Performance

• Voltage Stabilization Accuracy: ≤±0.5%, stable output voltage on the bus side without large fluctuations, ensuring efficient operation of the rear-end PCS
• Dynamic Response Time: ≤20ms, quickly responding to EMS/PCS power dispatching instructions, adapted to fast AGC/AVC regulation demands of the power grid
• Switching Speed: Uninterrupted and impact-free smooth switching between charging and discharging, no current overshoot
• Current Sharing Performance: When multiple clusters operate in parallel, the current imbalance between modules ≤±3%, avoiding single module overload and prolonging system service life

3. Core Functional Requirements

• Bidirectional Controllable Energy: Supports bidirectional controllable operation for battery cluster charging (grid/photovoltaic bus → battery) and discharging (battery → DC bus), power adjustable range 0~100% rated power
• Independent Cluster Control: Each unit corresponds to a single battery cluster, each cluster can be started, stopped, dispatched and maintained independently without mutual interference, thoroughly solving the problem of poor consistency among battery clusters
• Wide Voltage Adaptation: Stabilizes the output rated bus voltage within the full fluctuation range of battery side voltage, ensuring that PCS always operates at the optimal efficiency interval
• Fault Isolation Protection: Single unit fault is automatically locked, only the corresponding battery cluster is isolated without affecting the normal operation of other clusters, improving the overall availability rate of the power station
• Intelligent Temperature-Controlled Speed Regulation: Automatically adjusts fan speed according to the temperature of internal power devices, low speed and noise reduction at low temperature, high speed and heat dissipation at high temperature, prolonging fan service life
• Black Start Support: Supports power station black start mode, cooperating with battery clusters to complete system startup without mains power
• Backflow Prevention Protection: Built-in backflow prevention circuit, avoiding current backflow from the bus side to the battery cluster, ensuring battery safety

4. Protection Function Configuration

• Electrical Protection: Overvoltage, undervoltage, overcurrent, overload and short-circuit protection on battery side and bus side, short-circuit self-recovery is configurable
• Temperature Protection: Overtemperature protection for power devices and ambient over-temperature, automatic power derating in case of abnormal temperature control, overtemperature locking
• Safety Protection: High voltage interlock (HVIL), insulation monitoring (insulation resistance abnormality alarm), emergency stop interface, reverse connection protection
• Fault Handling: Fault self-diagnosis, real-time alarm, fault locking, fault code storage and upload, supporting historical fault query

5. Environmental and Mechanical Parameters

• Operating Temperature: -20℃~+55℃, rated power operation in full temperature range without derating
• Storage Temperature: -40℃~+70℃, adapted to extreme storage and transportation environments
• Operating Humidity: 5%~95%RH, no condensation, no icing
• Protection Grade: IP54 (front side), suitable for internal container installation, dustproof and splash-proof, meeting environmental requirements of outdoor energy storage power stations
• Altitude: ≤3000m, standard derating shall be implemented when altitude exceeds 1000m
• Noise: ≤65dB (under full load operation, 1m away from the unit), meeting noise reduction requirements of containerized energy storage
• Electromagnetic Compatibility: Complies with relevant GB/T 17626 standards, strong anti-interference ability, no electromagnetic pollution, adapted to multi-equipment coexistence scenarios of power stations

6. Communication and Monitoring Functions

• Communication Interfaces: Standard configuration of CAN 2.0B and Modbus RTU, optional Modbus TCP, adapted to mainstream communication protocols for large-scale energy storage power stations
• Docking Equipment: Supports direct docking with Battery Management System (BMS), Power Conversion System (PCS), Energy Management System (EMS), and power station environment monitoring system
• Data Upload: Real-time upload of core parameters such as voltage, current, power, temperature, operation mode, fault status and cumulative power
• Remote Control and Management: Supports remote start/stop, remote power setting, remote parameter calibration, remote firmware upgrade, reducing on-site operation and maintenance workload

7. Other Technical Requirements

• Electrolytic capacitor-free design, improving product reliability and reducing later maintenance frequency
• Supports vertical and horizontal installation, adapted to flexible layout inside containers
• Equipped with operation status indicator light, enabling quick local check of equipment working conditions for convenient on-site operation and maintenance troubleshooting