— A P P L I C AT I O N N O T E POWER AND CONTROL SOLUTIONS FOR THERMAL MANAGEMENT SYSTEMS Battery Energy Storage Systems (BESS) (UL) What is a thermal management system? A thermal management system (TMS) allows for safe and efficient battery performance through temperature regulation. The system controls the operating temperature of a battery by dissipating heat when the battery is too hot or supplying heat when the battery becomes too cold. This functionality is critical as high temperatures can reduce battery life and cause safety hazards, such as fires, while low temperatures can decrease battery capacity and charging/ discharging capabilities. Thermal management systems function through active, passive, or hybrid heat transfer solutions that preserve the battery to mitigate costs and optimize energy storage. Why is power and control important for your thermal management system? Continuous operation of the thermal management system is critical to ensuring a safe operating temperature for the battery energy storage system. ABB’s control and power protection products help to reduce downtime and support continuity of service in any condition. Continuous operation Keep your thermal management system up and running in any condition thanks to reliable connections, reliable power, and a reliable partner. Compact and easy to install Save space in the control panel with our AF contactors and reduced-width electronic compact starters. Save time during the installation phase using our readymade starter connection kits to make compact and safe connections. Safety and protection Reduce the chance of a fire in your system and loss of valuable assets by using circuit breakers, monitoring relays, or safety components. Energy-efficiency Increase the energy efficiency of your TMS panel by incorporating AF contactor technology. This technology reduces contactor coil consumption, minimizes heat dissipation, lowers temperature rise, and enables higher installation density within the panel. Main benefits Enhance the performance of your thermal management system with our control and power protection solutions. A complete product offering from a reliable supplierfor safely starting and protecting thermal management systems in battery energy storage systems. 2P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) Battery energy storage systems (BESS) BESS overview The battery energy storage system (BESS) market is forecasted to become a megatrend in upcoming years as there is a shifting focus towards decarbonization, decentralization, and digitalization. Fueled by federal incentives such as the Inflation Reduction Act (IRA) and lower overall costs, BESS are becoming more imperative for reliable, clean energy. These systems source and store energy for various applications such as peak shaving, transmission and distribution congestion relief, and energy arbitrage. As more dependence is placed on BESS, it is critical to optimize battery performance and durability through thermal stability. -40 °C Charge failure 15 °C 35 °C 90 ∼ 120 °C Thermal runaway High-performance Intensified side reaction Battery performance Increased resistance Optimal temperature 3 Thermal management systems (TMS) Temperature is one of the key factors that affect battery performance. The ambient temperature and heat generated during the battery's operation collectively impact the overall temperature of the battery energy storage system (BESS). Effective thermal management is essential to ensure the safe and efficient operation of the BESS. Safety One of the primary safety considerations for battery energy storage systems is the prevention of fires and explosions. Uncontrolled heat generation within the battery cells can trigger a chain reaction known as thermal runaway. This occurrence begins when the heat produced within a battery exceeds its capacity to dissipate heat. Subsequently, a repetitive chemical reaction ensues. This reaction is fueled by the escalating temperature, ultimately leading to the potential occurrence of a fire or an explosion. Performance and efficiency Batteries utilize chemical reactions to convert stored chemical energy into electrical energy. The efficiency of these reactions is dependent on temperature. Exposure to both extremely high and low temperatures can significantly impact battery performance. Higher temperatures accelerate the chemical reactions within a battery, leading to increased electrical energy production. On the other hand, lower temperatures slow down these reactions, leading to a decrease in electrical energy production. In colder temperatures, the internal resistance of the battery rises, impeding the flow of current and consequently reducing the amount of energy that the battery can release. Lifespan While higher temperatures enhance battery capacity and performance, there is a trade-off. Exposure to extreme heat accelerates the degradation of the battery’s components, leading to a reduced lifespan. Temperature uniformity among the battery packs and modules is also imperative to prolong the life of the battery. An uneven temperature distribution leads to a reduction in cycle life and performance. Proper thermal management is essential to maximize the longevity of the battery, ensuring a balance between improved performance and sustained durability. This includes controlling and maintaining the temperature of the batteries and associated electrical components within a specified range. For lithium-ion batteries, the primary battery type used in BESS, optimal performance is achieved within the temperature range of 15 °C to 35 °C (1). Proper thermal management not only helps to prevent safety hazards but also prolongs the lifespan of the batteries and enhances overall performance. Battery performance over temperature range Fig. 1: Optimal tempera- ture range for lithium-ion batteries (1) Air Filter Heat Exchanger Intake Air Outlet Battery Cells Battery Cells Fan Pump Pump Cooling Liquid 4P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) Thermal management systems are categorized as active, passive, or hybrid. Active systems employ external devices such as fans, pumps, or compressors to control or disperse heat from the batteries. Alternatively, passive thermal management does not require additional energy input for heat dissipation. Instead, it relies on natural methods such as radiation and conduction for heat transfer. Hybrid systems integrate aspects of both active and passive methods to maintain an optimal temperature. Examples of active thermal management include forced air and liquid cooling, while phase change materials (PCMs) and heat pipes are examples of passive techniques. Active air and liquid cooling are the primary thermal management methods utilized in BESS (2). Phase change materials and heat pipe cooling are still in the R&D stages for BESS. Forced air cooling uses fans or blowers to generate airflow, facilitating the dissipation of heat from the BESS enclosure and battery’s components. Its main advantages are its simple design, low cost, and ease of maintenance. However, its primary disadvantage is that it transfers heat less efficiently in comparison to alternative cooling methods due to its low heat capacity and small thermal conductivity (3). Liquid cooling uses a liquid coolant such as water or ethylene glycol to absorb heat and consequently lower the temperature of the batteries. Pumps or other mechanical devices move the liquid coolant through tubes or channels that are in contact with the battery’s cells. The heat is then removed from the coolant via equipment such as a heat exchanger or radiator. Liquid cooling boosts better efficiency, enhanced heat transfer, and uniform temperature distribution. Complexity and cost are its key disadvantages. Cooling load, environmental conditions, cost constraints, and scalability requirements are factors to consider when choosing the optimal system. Air cooling Liquid cooling Basic schematic of an air-cooling system Basic schematic of a liquid cooling system 5 Core mechanical components Compressors An integral part of air-cooling systems, the compressor plays a vital role in circulating liquid refrigerant. Its function involves compressing the refrigerant, enabling it to extract heat from the air. Fans Employed in both air and liquid cooling setups, fans contribute to air circulation within the battery energy storage system. This enhances the heat exchange process, promoting more effective thermal management. Pumps A critical component in liquid cooling systems, pumps are responsible for circulating the coolant throughout the system. Their role is to ensure a continuous flow of coolant across components that require cooling, facilitating efficient temperature regulation. Different types of air and liquid-based thermal management systems are available. Each system comes with its own set of advantages, and the choice is typically based on meeting the specific requirements of the energy storage system. Key components in these systems require a motor for operation including compressors, fans, and pumps. VFD starter M KM1 FM1 Q1 F2 1 2 4 6 2 4 6 2 4 6 2 4 6 X Y Z M 3~ 3 5 1 3 5 1 3 5 1 3 5 1 3 5 KM2 KM3 KM3 Q1 L1 L2 L3 1 2 4 6 2 U V W M 3~ 4 6 3 5 1 3 5 1 3 5 KM1 Q1 L1 L2 L3 F2 Direct-on-line starter Star-Delta starter Softstarter starter1 2 3 6P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) Recommended starters For compressor, fan, and pump control ABB’s scalable motor starting solutions provide complete flexibility in choosing the right starter for full-speed motor control. The three most common starter types are Direct-on-line (DOL), Star-Delta (Wye-Delta), and Softstarter. Each starter type has its own unique advantages such as: 1. DOL is the simplest and most common motor starter type, it offers the fewest number of components and has a low cost. 2. Star-Delta (Wye-Delta) is a slightly more complex starter type but starts the motor with less shock (torque) to the system and has a lower starting current. 3. A softstarter is a more advanced starting solution and gives a controlled start with a programmable ramp up or ramp down of the motor. 7 Design requirements For compressors, fans, and pumps Primary requirements • Short-circuit protection • Overload protection (with the adjustable current setting) • Voltage level monitoring • Phase loss & phase sequence – for correct management of motor operation • Ground fault protection Optional requirements • Thermistor protection relay for monitoring winding temperature • Digital connectivity (control, energy measurements, etc.) • Locked rotor protection – in the case of a jammed motor • Safety relays (if required, based on design) • Temperature monitoring relay (if required, based on design) Starter panel design parameters • Motor rated voltage • Motor rated current • Maximum operating current • Number of switching cycles (ON/OFF) • Starting torque depending on motor load • Acceleration time (starting time) • Control voltage • Ambient temperature • Altitude • Enclosure type • Starter type • Operations – auto/manual & local/remote • Digital connectivity (control/monitor) Continous operation Safety and protection Advanced Enhanced Essential Integrated and future ready Easy to Install 8P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) Power and control solutions Discover our power and control solutions designed for thermal management systems. These solutions help to maintain optimal temperatures for BESS, ensuring efficient and reliable performance. This table provides an overview of the possible functions in our different solution offerings for thermal management systems in BESS. Solution level Basic protection functions Monitoring of additional protection functions Digital connectivity and cloud monitoring Essential Enhanced Advanced Essential Solution Get the essentials right with fast and reliable installations The Essential Solution helps to ensure that combinations of core power devices function in a coordinated way, thereby enabling continuous operation and ease of installation. In addition, the Essential Solution typically covers the requirements of stand-alone machinery like fans, pumps, compressors, etc. Enhanced Solution Get going with our robust protection offering featuring enhanced safety, control and monitoring functions The Enhanced Solution provides enhanced control, safety and monitoring functions for applications in the discrete automation field. The Enhanced Solution for thermal management systems in battery energy storage systems includes additional protection functions such as temperature monitoring, voltage monitoring relay, safety relays, and more. We can address any other requirements to suit end- user requests. Advanced Solution Get ahead with smart data and predictive applications to keep your thermal management system running The Advanced Solution for thermal management systems includes integrated and future-ready motor protection, flexible motor control, fault diagnostics, maintenance schedules, and supports all major communication protocols. MCCB Tmax XT B mini contactor MMS MS… Push-In spring AF...K Push-In spring MS...K Control transformer Fuse holder Fan Pump Or Or Compressor Enclosed safety switch¹ Fan Pump Or Or EOT enclosed rotary switch¹ Switch OFF push button Switch ON push button Hand/Auto control Emergency stop ON Status OFF Status Interface relay MCB RCD MMS MS… Compressor AF contactor Fan Pump Or Or Compressor EOT enclosed rotary switch¹ Ambient temperature sensor 3 phase system, 480V AC, 60Hz Power circuit Control circuit 9 ABB’s Essential Solution The table below provides an overview of the difference between the combination of products offered in the Essential Solution for thermal management systems in battery energy storage systems. Product combination Key Differentiator B mini contactor For efficiency and space savings Contactor + MMS (Screw version) For standard offerings Contactor + MMS (Push-In Spring) For reliable connections, faster/easier wiring, and vibration protection MMS – manual motor starter Note: The type of enclosed switch used depends on the application and environment. 1 The enclosed safety switch will be close to the motor in case it needs maintenance to isolate the power supply and help to ensure safety for a person working close to the motor. Inca Emergency Stop Smile 11RA Reset AFS contactor Optional AF contactor Sentry safety relay AFS contactor MMS MS… OS fusible disconnect switch AF contactor PSE softstarter Fan Pump Or Or Compressor Enclosed safety switch¹ Fan Pump Or Or Compressor Enclosed safety switch¹ Fan Pump Or Or Compressor EOT enclosed rotary switch¹ Overload relay TF/EF AF contactor MCCB Tmax XT Ekip Dip I ON Status OFF Status Interface relay Thermistor relay PTC sensor Switch OFF push button Switch ON push button Hand/Auto control Emergency stop MCB Control transformer Fuse holder Fuse holder Voltage monitoring relay Ambient temperature sensor Temperature monitoring relay MCCB Tmax XT 3 phase system, 480V AC, 60Hz Fan Pump Or Or Compressor Enclosed safety switch¹ MMS MS… PSR softstarter RCD Power circuit Control circuit Safety contactor control and feedback 10P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) ABB’s Enhanced Solution The table below provides an overview of the difference between the combination of products offered in the Enhanced Solution for thermal management systems in battery energy storage systems. Product combination Key Differentiator AF contactor + TF/EF overload relay For efficiency and space savings PSR + MMS (Softstarter) For smooth start and stop OS switch + PSE (Softstarter) For smooth start and stop MMS MS… + AFS contactor For machine safety offerings MMS – manual motor starter Note: The type of enclosed switch used depends on the application and environment. 1 The enclosed safety switch will be close to the motor in case it needs maintenance to isolate the power supply and help to ensure safety for a person working close to the motor. PSTX softstarter AF contactor Motor Controller UMC100.3 Temperature monitoring relay MMS MO… Optional AF contactor Tmax XT Ekip Dip I AF contactor Tmax XT Ekip M Touch LRIU MCCB Tmax XT Control transformer Fuse holder Switch OFF push button Switch ON push button Hand/Auto control Emergency stop MCB 3 phase system, 480V AC, 60Hz Fan Pump Or Or Compressor Enclosed safety switch¹ Enclosed safety switch¹ Enclosed safety switch¹ Fan Pump Or Or ON Status OFF Status Interface relay Compressor Fan Pump Or Or Compressor Ambient temperature sensor RCD Power circuit Control circuit 11 MMS – manual motor starter MCCB – molded case circuit breaker Note: The type of enclosed switch used depends on the application and environment. 1 The enclosed safety switch will be close to the motor in case it needs maintenance to isolate the power supply and help to ensure safety for a person working close to the motor. ABB’s Advanced Solution The table below provides an overview of the difference between the combination of products offered in the Advanced Solution for thermal management systems in battery energy storage systems. Product combination Key Differentiator MMS MO… + UMC100 + AF contactor For efficiency and space savings Tmax XT MCCB + PSTX (Softstarter) For smooth start and stops Tmax XT MCCB + AF contactor For efficiency and space savings Enclosed PSTX-ND softstarter Enclosed PSTX-XD softstarter 3 phase system, 480V AC, 60Hz… Power circuit Enclosed safety switch¹ Enclosed safety switch¹ Fan Fan Pump Pump Or Or Compressor Or Or Compressor MCCB Tmax XT 12P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) ABB’s Advanced Solution The table below provides an overview of the difference between the combination of products offered in the Advanced Solution for thermal management systems in battery energy storage systems. Product combination Key Differentiator Enclosed PSTX-ND (Softstarter) For normal duty Enclosed PSTX-XD (Softstarter) For normal and extreme duty MMS – manual motor starter Note: The type of enclosed switch used depends on the application and environment. 1 The enclosed safety switch will be close to the motor in case it needs maintenance to isolate the power supply and help to ensure safety for a person working close to the motor. Enclosed PSTX-ND softstarter Enclosed PSTX-XD softstarter 3 phase system, 480V AC, 60Hz… Power circuit Enclosed safety switch¹ Enclosed safety switch¹ Fan Fan Pump Pump Or Or Compressor Or Or Compressor MCCB Tmax XT Switch PLC/DCS controller Fan Fan Fan Pump Pump Pump Or Or Compressor Or Or Compressor Or Or Compressor Motor starters Power circuit Communication circuit 13 Digital offering Our digital offering for Advanced motor starting solutions will help you digitally connect your thermal management system and monitor it with 100% data availability. Digitalization allows flexible remote control of the thermal management system 100% availability of motor measurement data as an aid to predictive maintenance Power circuit Control circuit Communication circuit Optional AF contactor ON Status OFF Status Tmax XT Ekip Dip I MCCB Tmax XT TMF/TMA Control transformer Fuse holder Switch OFF push button Switch ON push button Hand/Auto control Emergency stop MCB PSTX softstarter Enclosed safety switch Fan Pump Or Or Compressor Controller or any other PLC/DCS Interface relay 3 phase system, 480V AC, 60Hz RCD 14P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) — 1st scenario: Digital offering with softstarter for motor control and monitoring. Supporting communication protocols Fieldbus networks • Modbus RTU • Profibus DP • DeviceNet™ Ethernet networks • Modbus TCP • Profinet • Ethernet/IP™ • IEC 61850 Features • Flexible motor control (remote or local)¹ • Advanced protection functions • Status and fault diagnosis • Monitoring of all electrical parameters - Voltage (V) - Current (A) - Power factor (Cos phi) - Active power (kW) - Reactive power (KVAR) - Apparent power (kVArh) - Main frequency (Hz) - Total harmonics distortion (THD) - Consumed Energy in kWh - Motor temperature Note: 1 Motor (pump, fan, compressor) control is coming from the BESS controller. Motor Controller UMC100.3 Power circuit Control circuit Communication circuit MTQ-22 Communication module MMS MO132/165 ON Status OFF Status MCCB Tmax XT TMF/TMA Control transformer Fuse holder Switch OFF push button Switch ON push button Hand/Auto control Emergency stop MCB 3 phase system, 480V AC, 60Hz Interface relay AF contactors Enclosed safety switch Fan Pump Or Or Compressor RCD Controller or any other PLC/DCS 15 — 2nd scenario: Digital offering with UMC100.3 for motor control and monitoring with cloud connectivity. Supporting communication protocols Fieldbus networks • Modbus RTU • Profibus DP • DeviceNet™ Ethernet networks • Modbus TCP • Profinet • Ethernet/IP™ • IEC 61850 Features • Flexible motor control (remote or local)¹ • Advanced protection functions • Status and fault diagnosis • Monitoring of all electrical parameters - Voltage (V) - Current (A) - Power factor (Cos phi) - Active power (kW) - Reactive power (KVAR) - Total harmonics distortion (THD) - Active energy (kWh) - Temperature Note: 1 Motor (pump, fan, compressor) control is coming from the BESS controller. Ekip Cartridge Ekip Supply Ekip CI Ekip Com Ekip 2K signaling Interface to the contactor Tmax XT Ekip M Touch LRIU MCCB Tmax XT TMF/TMA Control transformer Fuse holder Switch OFF push button Switch ON push button Hand/Auto control Emergency stop MCB ON Status OFF Status AF contactors Enclosed safety switch Fan Pump Or Or Compressor RCD Controller or any other PLC/DCS Power circuit Control circuit Communication circuit 16P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) — 3rd scenario: Digital offering with Tmax XT MCCB for motor control and monitoring with cloud connectivity. Features • Flexible motor control (remote or local)¹ • Advanced protection functions • Status and fault diagnosis • Monitoring of all electrical parameters - Voltage (V) - Current (A) - Power factor (Cos phi) - Active power (kW) - Apparent power (kVA) - Reactive power (KVAR) - Total harmonics distortion (THD) - Active energy (kWh) - Reactive energy (kVARh) - Temperature (with Ekip 3T) Supporting communication protocols Fieldbus networks • Modbus RTU • Profibus DP • DeviceNet™ Ethernet networks • Modbus TCP • Profinet • Ethernet/IP™ • IEC 61850 Note: 1 Motor (pump, fan, compressor) control is coming from the BESS controller. 17 Push-In Spring motor starting solution Measuring and monitoring relays Interface relays & optocouplers Universal motor controller UMC100.3Control power and machine tool transformers Manual motor startersContactors Softstarters W E B PA G E C ATA L O G L I N K Product offering W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K 18P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) Power supplies SACE® Tmax® XT molded case circuit breakers Jokab Safety Products Miniature circuit breakers OS fusible disconnect switches Enclosed safety switches Enclosed rotary switches 22 mm pilot devices W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K 19 Enclosed softstarters Fuse holders W E B PA G E C ATA L O G L I N K W E B PA G E C ATA L O G L I N K 20P O W E R A N D C O N T R O L S O L U T I O N S F O R T H E R M A L M A N A G E M E N T S Y S T E M S B AT T E R Y E N E R G Y S TO R A G E S Y S T E M S ( B E S S ) ( U L ) References (1) Q. L. Yue, C. X. He, M. C. Wu, and T. S. Zhao, “Advances in thermal management systems for next-generation power batteries,” *International Journal of Heat and Mass Transfer*, vol. 181, p. 121902, 2021. (2) A. G. Olabi et al., “Battery thermal management systems: Recent progress and challenges,” *International Journal of Thermofluids*, vol. 15, p. 100197, 2022. (3) M. Shahjalal et al., “A review of thermal management for Li- ion batteries: Prospects, challenges, and issues,” *Journal of Energy Storage*, vol. 39, art. no. 102518, 2021. 21 9AKK108469A4316 Rev. B — U.S. HQ Office: ABB 305 Gregson Drive Cary, NC 27511 United States Phone: (800) 435-7365 electrification.us.abb.com © Copyright 2026 ABB. All rights reserved. Specifications subject to change without notice. Additional information We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. 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