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Japan Single‑Family Home – Ultra‑Thin Wall‑Mounted Energy Storage System

Structure & Form Customization
Client Background

A Japanese residential equipment integrator serving the “single‑family home” renovation market in the Tokyo metropolitan area. Japanese homes are generally compact, with limited exterior wall space, requiring the energy storage device to be no thicker than 180 mm.

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Technical Solution
  • 16‑series LiFePO4 cells (3.2 V each), capacity 7.68kWh, voltage 51.2 V, 1P16S configuration.
  • Overall unit thickness compressed to 120 mm (1100 × 120 × 700 mm), weight 63 kg.
  • IP21 protection rating for indoor wall‑mount installation.
  • Built‑in BMS supporting parallel expansion of up to 9 battery packs.
  • Communication interfaces: CAN / RS485 dual protocol.
  • Dual PV inputs (Max 12 kW), suitable for households with PV arrays on multiple sides.
  • Grid‑tied / off‑grid transition: built‑in high‑speed bypass relay enables UPS‑grade seamless switching (< 10 ms) – crucial for typhoon‑ and earthquake‑prone areas to keep lighting, refrigerators, and medical devices online.
Technical Challenges & Solutions

The ultra‑thin design placed extreme demands on heat dissipation and cell arrangement. Through a custom sheet metal enclosure with an internal honeycomb support structure, we maintained a minimum 5 mm air convection gap between cells within the limited thickness.

The BMS mainboard and power components were placed in separate compartments to avoid electromagnetic interference.

BMS voltage sampling deviation was controlled within ±20 mV, and temperature monitoring included 4 cell temperature sensors + 1 ambient temperature sensor + 1 MOSFET temperature sensor, with deviation within ±2 °C.

Feature 1

The 10‑year design life requirement (≥4,000 cycles at 80% DoD) – perfectly aligned with the typical renovation cycle of Japanese single‑family homes – therefore imposed extremely stringent demands on cell ageing consistency and long‑term balancing efficiency across parallel‑connected packs. Through a dedicated innovative adaptive equalisation algorithm that activates only during the constant‑voltage (CV) phase at the end of charging, we limited overall cell‑voltage divergence to within ±30 mV over the entire cycle life, effectively preventing premature capacity degradation of any single cell.

Feature 2

The humid coastal climate and occasional indoor condensation in the Tokyo‑Kanagawa area posed risks of insulation degradation and overcurrent faults. Beyond the existing ±20 mV voltage sampling and 6‑point temperature monitoring (4 cell + 1 ambient + 1 MOSFET, deviation ±2 °C), we integrated a real‑time insulation‑resistance monitoring circuit and a two‑stage overcurrent protection (warning + relay trip) – all embedded into the BMS without increasing the 120 mm profile. These measures ensure safe and reliable operation even during the rainy season or in condensing environments.

Honeycomb Structure

Ensure air convection and heat dissipation

Separated Compartment Design

Avoid electromagnetic interference

  • 4 x Cell Temperature Sensors
  • 1 x Ambient Temperature Sensor
  • 1 x MOSFET Temperature Sensor
Multi-point Temperature Monitoring

Deviation within ±2 °C

Japan‑Market Adapted Design

Beyond the ultra‑thin 120 mm profile, this solution addresses two critical requirements for Japanese single‑family homes:

  • Seismic mounting – The rear bracket is engineered as an integrated heavy‑duty hanger that fixes directly to load‑bearing wall studs. It passes equivalent seismic calculations per Japan’s Building Standards Act, preventing displacement or fall during tremors.
  • Fire regulation compliance – The intrinsically safe LiFePO4 chemistry, combined with IP21 rating, eliminates the need for complex fire‑compartmentalisation works indoors (significantly reducing permitting effort compared to NMC‑based alternatives).
7.68kWh Ultra-Thin Wall-Mounted Solar Battery Install
Delivery Results

First batch delivered in 35 days. The product passed Japan’s PSE certification and has been installed in more than 800 households across Tokyo and Kanagawa Prefecture.

35 Days

First batch delivered

PSE

Japan PSE certified

800+

Households Installed

Economic Benefits (PV + Storage Synergy)

With dual PV inputs (up to 12 kW), the system capitalises on TEPCO’s time‑of‑use tariff (peak evening rates 17:00–22:00). Through daily “solar‑charging by day, discharging at peak hours” arbitrage, a typical 4‑person household can save ¥150,000 – ¥200,000 per year on electricity bills. The static payback period shortens to 5–6 years (even less after applying Japanese government storage subsidies).

Integrator Testimonial

“We had long struggled with the narrow side‑walls of Japanese detached houses – many potential customers gave up on storage because of space. TURSAN’s 120 mm ultra‑thin product completely resolved our selection headache. More importantly, the fanless silent design and seismic bracket have earned outstanding end‑user satisfaction. ”

– Project Manager, Tokyo‑based residential equipment integrator

Have a requirement? We'll make it work.

Whether you need a specific capacity, a thinner profile, a custom BMS protocol, or a product that passes PSE, VCCI, CE, or UL – we design and manufacture it for you. Straight to your solution..

From prototyping to OEM/ODM bulk production, we deliver ready‑to‑sell energy storage systems tailored to your market.

Tell us your spec. We’ll respond with a feasibility assessment within 12 hours.

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