~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        0     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  IP67  
Others:
Description  Conditions  Min  Typ  Max  Units
Humidity     5     95  %
ESD resistance strength     -8KV     +8KV   
Pressure loss  Coolant temperature=0℃，flow 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!