NEWBASE BTMS Water-Cooled Unit Product Lineup: Complete Guide for Electric Commercial Vehicle Applications
2026-05-22
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NEWBASE BTMS Water-Cooled Unit Product Lineup: Complete Guide for Electric Commercial Vehicle Applications
Choosing the right Battery Thermal Management System (BTMS) for your electric commercial vehicle isn't just about cooling capacity — it's about matching the system's capabilities to your vehicle's battery size, charging requirements, operating environment, and space constraints.
NEWBASE (Zhengzhou NEWBASE Automotive Electronics Co., Ltd.) offers a comprehensive range of water-cooled BTMS units designed specifically for commercial EV applications. Here's a detailed guide to help you find the perfect match.
BTMS Model NBSLJZ-03-01 — Entry-Level Compact Solution
Cooling Capacity: 3.5 kW | Weight: 35 kg ± 1 kg | Dimensions: 530(L) * 446(W) * 365(H) mm
Electrical Specifications:
High Voltage: DC 400V – DC 750V
Low Voltage: DC 24V (18V–32V)
Low-Voltage Power: 450W
Built-in Water Pump: >20 L/min @ 110 kPa
Key Features:
Configurable PTC liquid heater (6–14 kW)
Standby, cooling, heating, and self-circulating operating modes
CAN2.0 communication protocol
Self-diagnostic fault detection
Real-time power information upload
EMC Level III compliance
IPX7 protection rating
Refrigerant: R134a
Secondary refrigerant: 50% V/V ethylene glycol aqueous solution
Ideal For: Electric light-duty trucks, small VANs, and urban delivery vehicles with smaller battery packs (up to ~100 kWh).
BTMS Model NBSLJZ-05-01 — Mid-Range All-Rounder
Cooling Capacity: 5 kW | Heating Capacity: 6–14 kW (optional) | Weight: 40 kg ± 1 kg | Dimensions: 635(L) * 530(W) * 380(H) mm
Electrical Specifications:
High Voltage: Rated 320V DC (220–450 VDC)
Low Voltage: DC 24V (18V–32V)
Low-Voltage Power: 600W
Built-in Water Pump: 11m head & 1,800 L/h flow rate
Key Features:
All NBSLJZ-03-01 features, plus enhanced cooling capacity
30% smaller installation footprint compared to competitors
Mounting: 569 mm * 369 mm, Φ12 holes * 4
Inlet/outlet water pipe: Φ25
Custom connector configurations available
Ideal For: Electric light trucks and logistics vehicles with battery packs of 100–200 kWh. The compact design is perfect for vehicles with limited underbody space.
BTMS Model NBSLJZ-08-01 — Heavy-Duty Workhorse
Cooling Capacity: 8 kW | Weight: 50 kg ± 2 kg | Dimensions: 820(L) * 575(W) * 285(H) mm
Electrical Specifications:
High Voltage: DC 400V – DC 750V
Low-Voltage Power: 600W
Built-in Water Pump: 20m head & 2,000 L/h flow rate
Key Features:
Four-in-one / three-in-one integrated electronic control
Network control capability
Dual-loop redundancy for fail-safe operation
4C fast-charging support
Mounting: 495 mm * 320 mm, Φ12 holes * 6
Inlet/outlet water pipe: Φ25 (reserved overflow pipe Φ8)
Refrigerant options: R134a or R407C
Ideal For: Electric heavy trucks, port tractors, and construction machinery with battery packs of 200–400 kWh. This is NEWBASE's most popular model, validated through over 1,500 4C fast-charging cycles with battery capacity retention above 95%.
BTMS Model NBSLJZ-10-01 — High-Capacity Solution
Cooling Capacity: 10 kW | Heating Capacity: 24 kW (optional) | Weight: 68 kg ± 2 kg | Dimensions: 960(L) * 603(W) * 291(H) mm
Electrical Specifications:
High Voltage: 640V DC (400–750 VDC)
Built-in Water Pump: 17.5m head & 2,880 L/h flow rate
Key Features:
Extended cooling capacity for larger battery packs
Four-in-one / three-in-one integrated electronic control
Enhanced heating option (24 kW PTC) for extreme cold climates
Network control and full CAN2.0 communication
Same comprehensive diagnostic and monitoring features as the full range
Ideal For: Large electric buses, heavy-duty mining trucks, and specialized vehicles requiring higher thermal management capacity.
BTMS Model NBSLJZ-13-01 — Maximum Performance
Cooling Capacity: 12 kW | Heating Capacity: 24–30 kW (optional) | EER: 2.0 | Weight: 110 kg ± 4 kg | Dimensions: 1,370(L) * 1,030(W) * 285(H) mm
Electrical Specifications:
High Voltage: DC 400V – DC 750V
Low Voltage: DC 18V – DC 32V
Key Features:
Maximum cooling capacity in the lineup
5C ultra-fast charging compatible
Intelligent pre-cooling and pre-heating
Highest heating capacity option (30 kW) for extreme cold
Mounting: Φ12 holes * 8
Full integration with NEWBASE's MPC and digital twin platform
Ideal For: Battery-swap heavy trucks, mining dump trucks, and other high-intensity applications where maximum thermal management performance is non-negotiable.
Quick Selection Guide
Application
Battery Size
Recommended Model
Urban delivery van
≤100 kWh
NBSLJZ-03-01
Light truck / logistics
100–200 kWh
NBSLJZ-05-01
Heavy truck / port tractor
200–400 kWh
NBSLJZ-08-01
Large bus / mining truck
300–500 kWh
NBSLJZ-10-01
Battery-swap truck / dumper
400+ kWh
NBSLJZ-13-01
Special / custom
Any
Custom solution
Common Features Across All Models
Every NEWBASE BTMS water-cooled unit includes:
IPX7 protection rating (dust-tight, 1m water immersion for 72 hours)
CAN2.0 communication protocol
Self-diagnostic fault detection
Real-time power information upload
EMC Level III compliance
Configurable PTC liquid heater
Standby, cooling, heating, and self-circulating operating modes
50% ethylene glycol aqueous solution as secondary refrigerant
Custom connector configurations available
Request a Quote
Ready to specify the right BTMS for your electric commercial vehicle? Contact NEWBASE's technical team for detailed specifications, prototype samples, and customized solutions.
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AI-Powered Battery Health: NEWBASE's Digital Twin Platform Transforms Fleet Thermal Management
2026-05-22
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Imagine knowing that a thermal management component will fail — 15 to 30 days before it actually does. Imagine watching your entire fleet's battery temperature distribution in real-time on a 3D visualization dashboard. Imagine your thermal management system improving itself over time through over-the-air updates tailored to each vehicle's unique operating conditions.
This is not a vision of the future. It's what NEWBASE's BTMS (Battery Thermal Management System) water-cooled units deliver today through the integration of digital twin technology and AI-powered fault prediction.
Real-Time Digital Twin: A Virtual Mirror of Every Vehicle
At the core of NEWBASE's intelligent platform is a cloud-based digital twin — a virtual replica of each vehicle's physical battery thermal management system. This digital twin operates with less than 100 milliseconds of latency, meaning the virtual model and the physical system are essentially synchronized in real time.
What the digital twin provides:
3D visualization of temperature field distribution — see exactly how heat is distributed across every cell in the battery pack, not just at a few sensor points
Coolant flow rate and pressure drop monitoring — track the health of the entire liquid cooling circuit in real time
Historical data backtracking — replay any past operating scenario to diagnose fault root causes, understand performance patterns, and optimize future thermal strategies
For fleet managers overseeing dozens or hundreds of electric trucks, this level of visibility transforms thermal management from a reactive maintenance burden into a proactive operational advantage.
AI Fault Prediction and Health Management (PHM)
NEWBASE has embedded deep learning-based anomaly detection algorithms directly into its BTMS platform. These algorithms continuously analyze sensor data streams — temperature, pressure, flow rate, voltage, current — to identify subtle patterns that precede equipment failures.
Key PHM capabilities:
15–30 day advance fault warning — The system identifies degradation trends long before they manifest as visible symptoms, giving maintenance teams ample time to schedule repairs during planned downtime rather than suffering unexpected breakdowns.
Real-time SOH (State of Health) estimation — The platform continuously estimates the health status of the entire thermal management system, not just the battery. Compressor wear, pump efficiency degradation, coolant contamination — all are tracked and reported.
RUL (Remaining Useful Life) prediction — By predicting how long each component will last, fleet operators can optimize their spare parts inventory and maintenance schedules, reducing both stock-outs and over-inventory.
≥95% fault diagnosis accuracy with less than 1% false alarm rate — High accuracy combined with low false positive rates means maintenance teams can trust the system's alerts and act on them immediately.
OTA Remote Optimization: Your System Gets Smarter Every Day
Perhaps the most powerful feature is OTA (Over-The-Air) capability for thermal management control strategies. As NEWBASE collects anonymized operating data from thousands of vehicles in the field, its engineering team identifies optimization opportunities and pushes updated control strategies to all connected units — remotely, without any vehicle downtime.
"One vehicle, one profile" personalized adaptation: Each BTMS unit's control parameters are continuously optimized based on that specific vehicle's operating data. A truck running daily port-to-warehouse routes in Shanghai will develop a different thermal profile than one doing long-haul highway runs across the Tibetan plateau. The OTA system recognizes these differences and adapts accordingly.
Case Study: Port Autonomous Container Trucks
At a major automated port terminal, 7x24 hour autonomous container trucks equipped with NEWBASE BTMS units achieved a thermal management system reliability rate of 99.95%. The digital twin platform enabled remote centralized monitoring that reduced maintenance staffing requirements by 50% — a transformational improvement for port operations where every minute of downtime costs significant revenue.
Why Fleet Operators Should Care
The commercial vehicle industry is shifting from selling trucks to selling uptime. Every unexpected breakdown costs money — in delayed deliveries, penalty fees, driver idle time, and replacement vehicle rentals. AI-powered predictive maintenance transforms this equation by converting surprise breakdowns into planned maintenance events.
With NEWBASE's digital twin and AI platform, fleet thermal management becomes predictable, optimizable, visible, and actionable.
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From -40°C to +85°C: How NEWBASE BTMS Water-Cooled Units Protect EV Batteries in Extreme Climates
2026-05-22
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From -40°C to +85°C: How NEWBASE BTMS Water-Cooled Units Protect EV Batteries in Extreme Climates
China's vast territory presents a unique challenge for electric commercial vehicles: a fleet operating in Mohe, Heilongjiang province may face -40°C winters, while the same vehicle model running in Turpan, Xinjiang must withstand 85°C surface temperatures in summer. No single thermal management approach has historically covered this range effectively — until now.
NEWBASE's next-generation BTMS (Battery Thermal Management System) water-cooled units have achieved full-coverage adaptation across an unprecedented -40°C to +85°C operating temperature range, enabling electric commercial vehicles to operate reliably anywhere on the map.
The Cold Challenge: -40°C Winter Operation
In extreme cold, lithium-ion batteries suffer from reduced capacity, slower charging rates, and the risk of lithium plating during charging — a condition that can permanently damage cells and create safety hazards. Traditional thermal management systems struggle to warm batteries quickly enough in sub-zero conditions, leading to reduced fleet availability and extended downtime.
NEWBASE's BTMS addresses this with:
Intelligent Pre-Heating Algorithm + PTC Auxiliary Heating
The system can warm a battery pack from -30°C to 5°C in just 15 minutes, using an intelligent pre-heating algorithm that coordinates PTC liquid heaters (6–14 kW configurable) with the vehicle's charging cycle. This means the battery is at an optimal temperature before fast charging begins.
35% Lower Pre-Heating Energy Consumption
Compared to conventional heating approaches, NEWBASE's intelligent algorithm reduces pre-heating energy consumption by 35%. For fleet operators in cold regions, this directly translates to preserved driving range and lower operational costs during winter months.
Real-World Validation: Northeast China Logistics Fleet
A fleet of 50 light trucks equipped with BTMS-500 units operating in Northeast China saw winter attendance rates jump from 82% (with legacy thermal systems) to 98% — even in ambient temperatures as low as -25°C. Each vehicle saved over RMB 8,000 in annual maintenance costs.
The Heat Challenge: 85°C High-Temperature Operation
At the other extreme, high ambient temperatures combined with fast charging create a perfect thermal storm. Battery packs can exceed safe operating temperatures within minutes, triggering thermal protection that limits charging speed and can lead to permanent cell degradation.
NEWBASE's high-temperature solutions include:
High-Efficiency Nano-Composite Liquid Cooling Plates
The cooling plates use nano-composite materials that increase heat transfer coefficients by 40% compared to conventional designs. This enhanced thermal conductivity is critical during 4C fast-charging sessions, where heat generation peaks.
Dual-Loop Redundant Design
If one cooling loop fails, the system automatically switches to the backup loop without interrupting operation. This redundancy is essential for fleet applications where unplanned downtime costs thousands of dollars per day.
Continuous 4C Fast-Charging Support
Even under continuous 4C fast-charging cycles, the BTMS keeps battery pack maximum temperatures below 45°C — well within the safe operating window for lithium-ion cells.
Extreme Condition Certifications
NEWBASE's BTMS water-cooled units have been rigorously tested and certified:
GB38031-2025 thermal diffusion protection standard — meeting the latest Chinese national standard for electric vehicle battery safety
IP67 protection rating — fully dust-tight and capable of withstanding 1-meter water immersion for 72 hours
1,000+ hours salt spray testing — proving suitability for coastal and high-humidity operations
Why Climate Resilience Matters for Fleet Buyers
For fleet operators considering electric commercial vehicles, climate resilience is often the deciding factor. A thermal management system that fails in extreme cold or heat means lost revenue, stranded cargo, and damaged batteries — costs that far exceed any initial savings on a cheaper system.
NEWBASE's BTMS water-cooled units eliminate this concern. Whether your fleet operates in the frozen north of Heilongjiang or the scorching deserts of Xinjiang, the system adapts automatically — ensuring consistent performance, maximum uptime, and protected battery investment year after year.
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How Model Predictive Control (MPC) Is Revolutionizing Battery Thermal Management in Electric Commercial Vehicles
2026-05-22
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How Model Predictive Control (MPC) Is Revolutionizing Battery Thermal Management in Electric Commercial Vehicles
Traditional PID temperature control in electric vehicles works like "driving by looking in the rearview mirror" — it reacts to temperature changes after they've already occurred. For passenger cars, this approach is often sufficient. But for commercial electric vehicles carrying 200–400 kWh battery packs and demanding 4C fast charging, reactive cooling simply cannot keep up.
This is where Model Predictive Control (MPC) changes everything.
What Is Model Predictive Control?
Model Predictive Control is an advanced control strategy that uses a mathematical model of the system to predict its future behavior and optimize control actions accordingly. In academic research, MPC has been shown to significantly reduce energy consumption in battery thermal management systems while maintaining tighter temperature control compared to conventional methods.
NEWBASE has become the first company to successfully deploy MPC algorithms in the commercial vehicle BTMS (Battery Thermal Management System) sector — moving thermal management from reactive adjustment to proactive prediction.
How NEWBASE's MPC Works
The MPC-based BTMS water-cooled unit operates through a three-step intelligent cycle:
1. Predictive Digital Twin Modeling
A battery thermal-electrical coupled digital twin model is established in real-time, predicting the battery temperature trajectory for the next 30–60 seconds. This model continuously updates based on actual sensor feedback, ensuring prediction accuracy even as battery conditions evolve over its lifecycle.
2. Multi-Dimensional Input Integration
The system doesn't just look at current battery temperature. It factors in road conditions, charging power profiles, ambient temperature forecasts, and even anticipated driving patterns. By combining these inputs, the MPC algorithm plans the optimal cooling strategy before heat becomes a problem.
3. Rolling Optimization with Feedback Correction
Within each control cycle, the system performs rolling optimization — constantly comparing predicted outcomes with actual measurements and adjusting its model in real time. This "predict-execute-correct" closed-loop ensures that the cooling system is always one step ahead of thermal events.
Real-World Performance Data
The results of implementing MPC in NEWBASE's BTMS water-cooled units are measurable and significant:
Cell temperature variance controlled within ±2°C during 4C fast-charging scenarios — compared to the industry standard of ±3–5°C. Tighter temperature uniformity directly translates to longer battery lifespan and more consistent performance.
System energy consumption reduced by 25–30% compared to traditional PID-controlled systems. For fleet operators running dozens of electric trucks, this represents substantial operational cost savings over the vehicle's lifetime.
Response latency shortened from seconds to milliseconds. In thermal management, every millisecond matters — especially during fast charging when battery temperatures can rise rapidly.
Why This Matters for 4C and 5C Fast Charging
As the commercial EV market transitions to 4C and 5C ultra-fast charging standards, the thermal load on battery packs increases dramatically. A 4C charge delivers four times the battery's capacity in current — generating far more heat than conventional charging. Without intelligent thermal management, this heat can degrade battery cells, reduce charging efficiency, and even trigger thermal runaway events.
MPC-based thermal management is uniquely suited to address this challenge because it can anticipate the thermal load before charging begins and pre-cool the battery pack to the optimal starting temperature. During the charge, it dynamically adjusts cooling intensity based on real-time temperature predictions — preventing both overheating and over-cooling.
The Broader Context
Research published in MDPI's journal World Electric Vehicle Journal (2025) confirms that MPC strategies for BTMS can optimize energy consumption while maintaining battery temperatures within safe operating windows. Multiple academic studies from institutions including the Beijing Institute of Technology have validated that MPC-based thermal management outperforms conventional rule-based and PID approaches in both energy efficiency and temperature control precision.
NEWBASE's achievement lies in translating these academic advances into a production-ready, commercially viable system for heavy-duty applications — where reliability, durability, and cost-effectiveness are non-negotiable.
The Bottom Line
MPC is not just a control algorithm upgrade — it's the foundation of truly intelligent battery thermal management. As commercial electric vehicles become more powerful and charge faster, the ability to predict, plan, and prevent thermal issues before they arise will separate industry leaders from the rest.
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NEWBASE Launches Next-Generation Intelligent BTMS Water-Cooled Units for Commercial EV Battery Thermal Management
2026-05-22
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NEWBASE Launches Next-Generation Intelligent BTMS Water-Cooled Units for Commercial EV Battery Thermal Management
As 4C and 5C ultra-fast charging become the standard for new energy commercial vehicles — turning the promise of "10-minute charge, 400 km range" into everyday reality — battery thermal management systems are facing unprecedented challenges. Heat dissipation demands are growing exponentially, temperature control precision must shift from degree-level to sub-degree accuracy, and system response times need to leap from seconds to milliseconds.
Zhengzhou, China — NEWBASE (Zhengzhou NEWBASE Automotive Electronics Co., Ltd.), the only domestic company with full-stack self-developed underlying control technology for new energy thermal management systems, has officially released its next-generation intelligent BTMS (Battery Thermal Management System) water-cooled unit lineup. This is not a simple product iteration — it represents a paradigm shift from passive cooling to proactive intelligent control in commercial vehicle thermal management.
Three Manufacturing Bases, Full-Chain Capability
NEWBASE operates three R&D and production bases across Zhengzhou, Jiaozuo, and Huangshan, covering a total area of 40,000 square meters. The company has built a complete industrial chain for new energy thermal management systems — from research and development through manufacturing to after-sales service.
The dedicated BTMS production line adopts a flexible manufacturing model, supporting multi-variety, small-batch customized production. With an annual capacity of 100,000 units, NEWBASE serves the full spectrum of commercial vehicle applications including heavy trucks, light trucks, and construction machinery.
As a Ministry of Industry and Information Technology (MIIT) nationally recognized "Specialized, Refined, Differential, and Innovative" (Little Giant) enterprise, NEWBASE stands as the only company in China owning the complete proprietary control technology chain for new energy vehicle thermal management.
A Complete Product Portfolio for Every Application
The new BTMS lineup covers every commercial vehicle scenario:
Model
Cooling Capacity
Target Application
Key Feature
BTMS-500
5 kW
Electric light trucks, VAN logistics
Compact design, 30% smaller footprint
BTMS-800
8 kW
Electric heavy trucks, port tractors
4C fast-charging support, dual-loop redundancy
BTMS-1200
12 kW
Battery-swap heavy trucks, mining dumpers
5C ultra-fast charging ready, intelligent pre-cooling
Custom Series
Tailored
Special vehicles, construction machinery
Modular architecture, flexible adaptation
The flagship BTMS-800 model delivers 8 kW of rated cooling capacity for battery packs ranging from 200 to 400 kWh, operates at DC 540V/800V, carries an IP67 protection rating, and weighs just 85 kg — all while communicating via CAN/J1939 protocols.
What This Means for the Industry
For OEMs, NEWBASE provides a complete chain of services from thermal management strategy development to calibration and validation, shortening new vehicle development cycles and reducing per-vehicle thermal management costs by 15–20% through integrated design.
For fleet operators, the benefits translate directly into operational efficiency: 50% shorter charging times in 4C fast-charging scenarios, a 30% increase in daily operating mileage, and AI-driven fault prediction that reduces unexpected downtime by 90%.
The global battery thermal management system market is projected to reach USD 13.2 billion by 2035, growing at a CAGR of 12.7%. NEWBASE is positioning itself at the forefront of this growth, particularly in the commercial vehicle segment which is expected to grow fastest due to the rapid electrification of buses, heavy-duty trucks, and delivery fleets.
Get in Touch
NEWBASE's next-generation BTMS water-cooled units are now open for prototype applications. OEMs and fleet operators are welcome to contact the technical team for consultation and collaboration.
Locations: Zhengzhou | Jiaozuo | Huangshan, China
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