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PTC coolant heater 6KW
    Publish time 2018-07-02 17:24    

New Energy Vehicle Coolant PTC heater Assembly


Function


The coolant PTC heater assembly can provide heat for new energy vehicle battery and meet the criteria for safe defrost and defogging.


At the same time, it provides heat for other parts of the vehicle that need temperature regulation.


Features                               


•       Electric heating of antifreeze, heating through the heating core


•       Installed in a water-cooled circulation system


•       Soft warm and temperature control


•       PWM adjustment drive IGBT to adjust the power


•       Short-term heat storage


•       Vehicle cycle, support battery thermal management


•       Environmental protection


Electrical performance


Basic parameters


          Description                     

               Conditions

Min

Typ

Max

Units

          Power

           a) Test voltage: Control voltage: DC24V; Load voltage: 600VDC

           b) Ambient temperature: 25°C ± 2°C; Inlet temperature: 0°C; Flow rate: 10L/min

           c) Air pressure: 70kPa~106ka

6000

W

          Weight

          No coolant, no connection

 

2.5

kg

         Coolant volume

 

145

mL


 


Temperature


Description

Conditions

Min

Typ

Max

Units

     Storage temperature  

-40

 

125

     Working temperature 

 

-30

 

105

Maximum coolant temperature

Input pressure 200kPa

-40

 

100


Low voltage: (Low voltage can be 12V)


         Description                      

             Conditions    

           Min         

           Typ

            Max

             Units

         Control voltage

       

               18   

            24  

             32

               V         

         Grand

 


 

               V

         Supply Current        

        Steady Current        

90

120

160

              mA

         Starting current

 

 

 

1

              A


High Voltage: (High Voltage can be from 100-650V)


           Description               

              Conditions

            Min

           Typ

            Max   

           Units

          Supply voltage

         Turn on heating

              550

            600

            750    

            V

          Supply current

         Nominal conditions

             A

         Surge current

         Nominal conditions

  

1.3 times of rated voltage

             A

         Standby current

         Nominal conditions

 

1.6

mA


High pressure:


              Name        

              High Pressure Safety

               Remarks

           High-pressure mark         

           Adhesion warning mark

        Material wear-resistant, resistant to vehicle typical chemicals

           Contact protection  

        1. Meets the requirements for Class II components 2. Meets IPXXD after assembly

 

           High voltage short circuit protection      

                    existence

 

            High voltage overload protection 

                   existence

 

           High and low voltage electrical isolation

              Coupling isolation

           High and low voltage power supplies use magnetic isolation, optical isolation for control signals

       Insulation resistance  

          ≥50 MΩ 

            satisfies more than 500Ω/V

           Voltage resistance

        No dielectric breakdown or      arcing at AC800V for 1 minute

           Performance requirements for PTC wafers

           Insulation pressure

 AC2500V, 50~60Hz, leakage current <10mA, 60s, no dielectric breakdown or arc phenomenon

Performance requirements for insulation protection

          IP protection         class                    

I     P67


Others:


Description

Conditions

Min

Typ

Max

Units

Humidity

 

5

 

95

%

ESD resistance strength

 

-8KV

 

+8KV

 

         Pressure loss

Coolant temperature=0flow rate=10L/min

 

10

 

kPa

Working pressure

 

 

0.25

 

MPa

Peak pressure 0.5 Mpa during work

 

 

0.5

 

Mpa

Coolant filling allowable negative pressure

 

 

 

0.4

kPa


 


Control method::


 CAN communication           


1 PWM Soft start


PWM uses 30 seconds from 0 to 100%  . This feature is used to protect high-inrush currents and sudden changes on the high-voltage bus. Each step is soft-started and there is ripple current in the soft-start process, and the inrush current is small (<1.3 times of the rated current).


2 Limiting function


2.1 Temperature limiting


2.1.1 When the outlet temperature reaches 80°C, the power will be gradually reduced to maintain a relatively constant water temperature at the outlet.


2.1.2 When any IGBT temperature reaches 85°C, it will gradually reduce the power or shut down . When it is lower than 80°C, it will resume working so that the IGBT temperature does not exceed the limit value.


3. Power limiting


3.1 Soft start power limiting


Each channel power is limited to 1425W during soft start


3.2 Overcurrent protection


In the heating operation, if the road lasts for more than 2 times  of the rated current for 5s, it is considered overloaded and the road will be shut down and restarted.


4 Protective function


4.1  High voltage overvoltage and undervoltage protection


The operating voltage range can be set according to the customer's requirements. Heaters that are not in the range will not start and will be turned off. Resetting to the range will restart the soft start to the current set value.


4.2  IGBT Drive voltage over-voltage protection


The heater will be completely turned off when the IGBT driving voltage is not in the range of  the set working range , and the soft start will be resumed to the current setting value after recovery.


4.3  Low voltage reverse connection protection


The heater will not work if low voltage are reverse connecting .


4.4 Outlet temperature protection


When the outlet water temperature exceeds 105°C for 3 seconds, all heating will turn off immediately .


4.5  Short circuit protection


Any road of PTC short circuit, the road will  immediately close, then repeate testing 5 times, if still short circuit, the road will no longer turn on heating before re-power.


Warning: high pressure does not have the ability to prevent reverse connection, high pressure reverse connection will lead to direct heating can not controlled, high voltage reverse connection may lead to PTC damage and  failure to precharge and fail to start and can cause burnout of the precharge resistor  of the  whole vehicle!