Flexible Battery Energy Storage Control Supporting Sustainable BESS Development in Central Europe

ComAp collaborated with IBG Česko s.r.o., a Central European technology company providing comprehensive energy solutions, to support the development of a flexible and reliable battery energy storage system (BESS) tailored to a rapidly evolving market. The project focused on creating a European-developed BESS solution capable of accommodating both second-life battery modules from electric vehicles and new batteries, while ensuring high levels of safety, reliability, and long-term sustainability. By integrating ComAp control and monitoring technologies, featuring ComAp's InteliNeo 530 BESS controller, IBG accelerated development and reduced system complexity without compromising performance.

IBG has been active in the energy market for more than thirty years, delivering a wide range of projects in the Czech Republic, Slovakia and Hungary. These include photovoltaic power plants, battery energy storage systems ranging from hundreds of kWh to large-scale installations in the tens to hundreds of MWh, backup power systems (UPS and diesel generators), EV charging infrastructure, as well as traction battery systems and batteries for material handling equipment. As the company expanded its portfolio to include advanced battery storage systems, it required a control platform capable of handling different battery sizes, capacities, chemistries, and cell ages, while remaining adaptable to changing market conditions.

During the early stages of development, IBG encountered limitations with conventional PLC-based systems. However, by introducing ComAp's InteliNeo 530 BESS controller and leveraging its predefined functionalities, including regulators, protections, power configurations, AC synchronisation, and detailed data logging, development time was significantly reduced and the risk of errors minimised. This allowed the team to focus on system optimisation rather than building control logic from scratch.

The first developed model of the BESS has a nominal power of 210 kW and consists of multiple battery strings. To ensure safe and reliable operation, the system utilises the advanced MultiBMS functionality, which enables coordinated control of DC switchgear and the safe interconnection of individual battery strings. This approach significantly reduces inrush current during DC bus energising, improving system safety and protecting battery components during start-up and operational transitions.

IBG selected Danfoss, a well-known European brand, as the power conversion partner, integrating their Vacon PCS model seamlessly into the BESS system’s architecture. Through the InteliNeo 530 BESS controller, IBG achieved unified communication with all critical system components, including the power conversion system, individual battery string management units, and integrated air conditioning. This coordinated control ensures stable operation, efficient energy conversion, and reliable thermal management, contributing to long-term system performance and battery longevity.

The solution integrates the InteliNeo 530 BESS controller with supporting CAN I/O, alongside WebSupervisor for remote monitoring and control, enabling real-time visibility of system performance, alarms, and operational data. Additional tools such as WinScope 1000 for real-time data visualisation and deep analysis, and InteliConfig for configuration and parameterisation, further simplify commissioning, operation, and maintenance.

As a result of their collaboration with ComAp, IBG has established a scalable, modular, and repeatable BESS platform. The standardised control architecture, combined with predefined functions and proven integration of key components, enables IBG to easily scale production, shorten delivery times, and reduce overall system costs. The simplicity and reliability of the solution make it straightforward to replicate across multiple projects, supporting IBG’s long-term strategy of efficient manufacturing and rapid deployment of high-quality European battery energy storage systems across diverse market segments.