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20kW 600V Liquid-Cooled High-Voltage PTC Heater for Electric Vehicle Battery Thermal Management
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20kW 600V Liquid-Cooled High-Voltage PTC Heater for Electric Vehicle Battery Thermal Management
  • name
  • name
  • name

20kW 600V Liquid-Cooled High-Voltage PTC Heater for Electric Vehicle Battery Thermal Management

Detail Information
Product Description
Detail Information
Highlight:

20kW PTC Heater

,

600V PTC Heater

,

Liquid-Cooled PTC Heater

Product Description
20kW High-Voltage Water-Heating PTC Heater
The 20kW Water-Heating PTC Heater (600V) is a high-power, safety-critical component within the Knock-Down (KD) assembly of advanced Battery Thermal Management Systems (BTMS) for electric buses, commercial vehicles, and large-format energy storage platforms. Designed to operate on 600V DC high-voltage traction systems, this liquid-cooled Positive Temperature Coefficient (PTC) heater delivers rapid, controllable, and fail-safe heating for battery coolant circuits—ensuring optimal battery temperature during cold starts, fast charging in sub-zero conditions, and cabin preconditioning.
As part of NEWBASE's integrated thermal portfolio, the 20kW PTC heater combines inherent self-regulating safety, automotive-grade robustness, and intelligent control compatibility to meet the stringent reliability and functional safety requirements of modern zero-emission fleets operating in extreme climates.
Key Features & Technical Advantages
High-Power, Liquid-Cooled Heating for Battery Warm-Up
With a nominal output of 20 kW at 600V DC, this PTC heater is engineered to warm glycol-water coolant flowing through the battery cold plate or secondary loop, enabling:
  • Fast battery warm-up from -20°C to 15°C in under 30 minutes
  • Support for ultra-fast DC charging in winter by maintaining cells within optimal temperature windows (15-35°C)
  • Integration with heat pump systems as a supplemental heat source during low-ambient defrost or heating demand spikes
According to research by the National Renewable Energy Laboratory (NREL), active battery heating using PTC elements can improve winter driving range by up to 45% compared to passive or resistive-only strategies—making high-power PTCs essential for year-round EV operability.
Inherent Safety via Self-Regulating PTC Ceramic
Unlike conventional resistive heaters, the core heating element uses doped barium titanate (BaTiO₃) PTC ceramic chips that exhibit a sharp increase in electrical resistance above a critical Curie temperature (typically 180-220°C). This self-limiting behavior prevents overheating even under dry-run, flow-failure, or control fault scenarios—eliminating the need for redundant thermal fuses in many designs.
This intrinsic safety aligns with ISO 26262 ASIL C requirements for thermal components in high-voltage systems and satisfies UN ECE R100 Rev.3 safety mandates for electric vehicle heating devices.
600V High-Voltage System Compatibility
The heater is fully rated for 600V DC nominal systems (with surge tolerance up to 800-1,000V), featuring:
  • Reinforced insulation between live parts and coolant channels
  • Creepage/clearance distances compliant with IEC 60664-1 for HV automotive applications
  • Dielectric strength ≥ 3.5 kV AC
  • Leakage current < 0.5 mA at operating voltage
All high-voltage interfaces use automotive-grade HV connectors (e.g., TE HVA 280, Amphenol LT series) with secondary locking and IP67 sealing.
Optimized for KD (Knock-Down) Assembly
Supplied as a pre-tested KD module, the PTC heater includes:
  • Integrated aluminum or stainless steel liquid manifold with standardized ports (SAE J1453 or ISO 12100)
  • Pre-routed high-voltage harness with strain relief
  • Mounting brackets compatible with common bus HVAC or BTMS frames
  • Barcode/RFID for traceability in global manufacturing networks
This design enables efficient final assembly at regional production sites while ensuring consistent performance and compliance.
Intelligent Control & Diagnostics
The unit supports:
  • PWM or LIN/CAN-based power modulation (0-100% duty cycle)
  • Real-time temperature feedback via built-in NTC or PT sensors
  • Open-circuit and short-circuit detection
  • Thermal runaway prevention logic via BMS coordination
Communication protocols comply with SAE J1939 and ISO 11898, allowing seamless integration into vehicle thermal management controllers.
Technical Specifications
Parameter Specification
Rated Power 20 kW @ 600 VDC
Operating Voltage Range 450 - 750 VDC
Heating Element Type PTC Ceramic (BaTiO₃-based)
Max Coolant Temperature 95°C (continuous); 110°C (peak)
Coolant Compatibility Ethylene/propylene glycol mixtures (up to 60%)
Flow Rate Range 8 - 25 L/min
Pressure Rating 300 kPa (max working); 600 kPa (burst)
Ingress Protection IP67 (electrical); IP6K9K (coolant interface)
Control Interface PWM, LIN, or CAN 2.0B
Built-in Sensors 1-2 x NTC or PT1000 for coolant monitoring
Certifications CE, E-Mark, ISO 16949, UL 2580, IEC 60529
Life Cycle ≥ 10,000 hours @ 85°C ambient
Weight 4.5 - 6.5 kg (depending on housing material)
Applications in Battery Thermal Management
The 20kW water-heating PTC is deployed in:
  • Electric city buses with 24kW heat pump HVAC systems requiring supplemental heating below -5°C
  • Cold-climate commercial EVs needing rapid battery preconditioning before fast charging
  • Battery swap stations where packs must be thermally stabilized between swaps
  • Hybrid thermal architectures combining heat pumps + PTC for redundancy and performance
When integrated with NEWBASE's electronic water pump, high-voltage PT sensors, and 10kW compressor, the PTC heater completes a full-spectrum thermal solution capable of both cooling and heating—critical for all-season battery longevity and performance.
Industry Context & Compliance
As emphasized by the International Energy Agency (IEA) and European Battery Alliance, effective thermal management is non-negotiable for achieving >2,000 battery cycles in heavy-duty applications. The shift toward high-voltage (>400V) platforms in commercial EVs has driven demand for 600V-class PTC heaters that balance power density, safety, and serviceability.
NEWBASE's 20kW PTC heater meets this demand with a design validated per SAE J2929, ISO 19453, and LV123 standards—ensuring compatibility with global OEM specifications.
For KD kit customization—including port orientation, connector type, control protocol, or material selection (aluminum vs. stainless steel)—NEWBASE offers engineering co-development, thermal simulation support, and full documentation packages aligned with automotive APQP and PPAP requirements.
Tags: 

heater blend door actuator,  

hvac blend door actuator,  

automotive aircon parts

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products
PRODUCTS DETAILS
Products

Electric Bus Air Conditioner

Parking Air Conditioner

Transportation Refrigeration Units

BTMS System

Refrigerated Tricycle

DC DC Converter

HVAC Control Module

Automotive PDU

Bus Air Purifier

Bus Defroster

Vehicle AC Accessories

Refrigerated Storage Container

Mini Refrigerated Van

Autonomous Delivery Vehicle

Automotive Shock Absorbers
20kW 600V Liquid-Cooled High-Voltage PTC Heater for Electric Vehicle Battery Thermal Management
  • name
  • name
  • name
20kW 600V Liquid-Cooled High-Voltage PTC Heater for Electric Vehicle Battery Thermal Management
Detail Information
Product Description
Detail Information
Highlight

20kW PTC Heater

,

600V PTC Heater

,

Liquid-Cooled PTC Heater

Product Description
20kW High-Voltage Water-Heating PTC Heater
The 20kW Water-Heating PTC Heater (600V) is a high-power, safety-critical component within the Knock-Down (KD) assembly of advanced Battery Thermal Management Systems (BTMS) for electric buses, commercial vehicles, and large-format energy storage platforms. Designed to operate on 600V DC high-voltage traction systems, this liquid-cooled Positive Temperature Coefficient (PTC) heater delivers rapid, controllable, and fail-safe heating for battery coolant circuits—ensuring optimal battery temperature during cold starts, fast charging in sub-zero conditions, and cabin preconditioning.
As part of NEWBASE's integrated thermal portfolio, the 20kW PTC heater combines inherent self-regulating safety, automotive-grade robustness, and intelligent control compatibility to meet the stringent reliability and functional safety requirements of modern zero-emission fleets operating in extreme climates.
Key Features & Technical Advantages
High-Power, Liquid-Cooled Heating for Battery Warm-Up
With a nominal output of 20 kW at 600V DC, this PTC heater is engineered to warm glycol-water coolant flowing through the battery cold plate or secondary loop, enabling:
  • Fast battery warm-up from -20°C to 15°C in under 30 minutes
  • Support for ultra-fast DC charging in winter by maintaining cells within optimal temperature windows (15-35°C)
  • Integration with heat pump systems as a supplemental heat source during low-ambient defrost or heating demand spikes
According to research by the National Renewable Energy Laboratory (NREL), active battery heating using PTC elements can improve winter driving range by up to 45% compared to passive or resistive-only strategies—making high-power PTCs essential for year-round EV operability.
Inherent Safety via Self-Regulating PTC Ceramic
Unlike conventional resistive heaters, the core heating element uses doped barium titanate (BaTiO₃) PTC ceramic chips that exhibit a sharp increase in electrical resistance above a critical Curie temperature (typically 180-220°C). This self-limiting behavior prevents overheating even under dry-run, flow-failure, or control fault scenarios—eliminating the need for redundant thermal fuses in many designs.
This intrinsic safety aligns with ISO 26262 ASIL C requirements for thermal components in high-voltage systems and satisfies UN ECE R100 Rev.3 safety mandates for electric vehicle heating devices.
600V High-Voltage System Compatibility
The heater is fully rated for 600V DC nominal systems (with surge tolerance up to 800-1,000V), featuring:
  • Reinforced insulation between live parts and coolant channels
  • Creepage/clearance distances compliant with IEC 60664-1 for HV automotive applications
  • Dielectric strength ≥ 3.5 kV AC
  • Leakage current < 0.5 mA at operating voltage
All high-voltage interfaces use automotive-grade HV connectors (e.g., TE HVA 280, Amphenol LT series) with secondary locking and IP67 sealing.
Optimized for KD (Knock-Down) Assembly
Supplied as a pre-tested KD module, the PTC heater includes:
  • Integrated aluminum or stainless steel liquid manifold with standardized ports (SAE J1453 or ISO 12100)
  • Pre-routed high-voltage harness with strain relief
  • Mounting brackets compatible with common bus HVAC or BTMS frames
  • Barcode/RFID for traceability in global manufacturing networks
This design enables efficient final assembly at regional production sites while ensuring consistent performance and compliance.
Intelligent Control & Diagnostics
The unit supports:
  • PWM or LIN/CAN-based power modulation (0-100% duty cycle)
  • Real-time temperature feedback via built-in NTC or PT sensors
  • Open-circuit and short-circuit detection
  • Thermal runaway prevention logic via BMS coordination
Communication protocols comply with SAE J1939 and ISO 11898, allowing seamless integration into vehicle thermal management controllers.
Technical Specifications
Parameter Specification
Rated Power 20 kW @ 600 VDC
Operating Voltage Range 450 - 750 VDC
Heating Element Type PTC Ceramic (BaTiO₃-based)
Max Coolant Temperature 95°C (continuous); 110°C (peak)
Coolant Compatibility Ethylene/propylene glycol mixtures (up to 60%)
Flow Rate Range 8 - 25 L/min
Pressure Rating 300 kPa (max working); 600 kPa (burst)
Ingress Protection IP67 (electrical); IP6K9K (coolant interface)
Control Interface PWM, LIN, or CAN 2.0B
Built-in Sensors 1-2 x NTC or PT1000 for coolant monitoring
Certifications CE, E-Mark, ISO 16949, UL 2580, IEC 60529
Life Cycle ≥ 10,000 hours @ 85°C ambient
Weight 4.5 - 6.5 kg (depending on housing material)
Applications in Battery Thermal Management
The 20kW water-heating PTC is deployed in:
  • Electric city buses with 24kW heat pump HVAC systems requiring supplemental heating below -5°C
  • Cold-climate commercial EVs needing rapid battery preconditioning before fast charging
  • Battery swap stations where packs must be thermally stabilized between swaps
  • Hybrid thermal architectures combining heat pumps + PTC for redundancy and performance
When integrated with NEWBASE's electronic water pump, high-voltage PT sensors, and 10kW compressor, the PTC heater completes a full-spectrum thermal solution capable of both cooling and heating—critical for all-season battery longevity and performance.
Industry Context & Compliance
As emphasized by the International Energy Agency (IEA) and European Battery Alliance, effective thermal management is non-negotiable for achieving >2,000 battery cycles in heavy-duty applications. The shift toward high-voltage (>400V) platforms in commercial EVs has driven demand for 600V-class PTC heaters that balance power density, safety, and serviceability.
NEWBASE's 20kW PTC heater meets this demand with a design validated per SAE J2929, ISO 19453, and LV123 standards—ensuring compatibility with global OEM specifications.
For KD kit customization—including port orientation, connector type, control protocol, or material selection (aluminum vs. stainless steel)—NEWBASE offers engineering co-development, thermal simulation support, and full documentation packages aligned with automotive APQP and PPAP requirements.
Tags: 

heater blend door actuator,

hvac blend door actuator,

automotive aircon parts

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