Designing High-Energy Rack-Mount LiFePO₄ Battery Packs for 21” Enclosures (57.6V / 314Ah+)

As energy storage systems evolve, space, power density, and compatibility have become decisive design factors. This article explores how engineers can design high-voltage (57.6V), high-capacity (314Ah+) LiFePO₄ rack batteries that fit within a compact 21” (533mm-wide) enclosure—ideal for telecom, UPS, and modular ESS applications.

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1. Key Design Constraints

• Envelope: 533mm (W) × 700mm (D), with all connectors positioned on the front width face.
• Voltage: 57.6V nominal (18S LiFePO₄ configuration).
• Capacity: ≥314Ah usable energy for 1C discharge capability.
• Cooling: Optional liquid-cooling loop recommended for sustained high loads.
• BMS: Multi-parallel communication, CAN protocol, aggregated SOC balancing.
• Mechanical: Compatible with standard rack-mount brackets or sliding rails.

To compare with standard formats, visit our 51.2V 100Ah rack battery module, which shares similar mechanical standards.

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2. Optimizing the Cell Configuration

High-energy rack modules rely on large-format prismatic or pouch-type LiFePO₄ cells to minimize internal resistance and improve energy density. Using an 18S3P layout (e.g., 54 cells of 105Ah each) yields approximately 315Ah at 57.6V nominal voltage. Engineers should aim for a 60%–65% active cell volume utilization to leave room for cooling components and busbars.

At PKNERGY, all modules are built using Grade-A certified LiFePO₄ cells with precise voltage matching and thermal consistency to ensure long-term reliability.

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3. Thermal Management Strategy

For continuous 1C operation (~314A), efficient cooling is crucial. Two primary methods are adopted:

• Cold plates with liquid manifolds: Efficiently distribute coolant across each cell bank.
• Conductive pads: Facilitate heat transfer to the cooling channels.
• Temperature sensors: Monitor each module for dynamic flow control.

Projects operating in high-temperature environments can also integrate liquid-cooled rack batteries for optimized thermal stability.

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4. BMS Architecture and Communication

A robust Battery Management System (BMS) is key to reliable performance:

• Each pack is equipped with an individual smart BMS.
• All packs communicate via CAN bus for aggregated control.
• System-level BMS provides combined SOC data, fault reporting, and balancing control.
• Fully compatible with Victron VE.Can / Venus OS through mapped CAN protocols.

Through intelligent SOC averaging, PKNERGY’s multi-pack systems maintain synchronization across all racks, reducing imbalance and extending overall lifespan.

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5. Mechanical & Structural Design

• Horizontal stacking structure for easy scalability.
• All front-facing ports: power, CAN, and coolant interfaces.
• Compatible with both L-brackets and slide-rail mounting systems.
• Safety compliance: UN38.3, CE, and optional UL1973 certifications.

PKNERGY’s rack battery series are designed to simplify both assembly and maintenance—no rear access required.

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6. Vendor Benchmarks & Market Landscape

Several manufacturers are advancing the rack-based ESS field, including:

• Hitek Energy: 51.2V 314Ah rack system
• Kevolt Solar: Modular ESS designs with BMS integration
• Sunpro ESS: CAN-enabled enclosed units for telecom sites

However, PKNERGY differentiates itself with custom engineering support, liquid-cooling options, and localized partner programs for project deployment. Explore collaboration opportunities via our Contact Page.

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7. Conclusion

A 57.6V 314Ah LiFePO₄ rack module that supports 1C continuous output, liquid cooling, and Victron BMS compatibility is not only feasible—it’s already being deployed in commercial and telecom sectors worldwide. By optimizing mechanical layout, thermal pathways, and digital communication, engineers can achieve compact, scalable, and service-friendly energy storage cabinets.

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Author & Sales Contact

Cassie
Email: sale4@pknergy.com
WhatsApp/Tel: +86 13974604556