3KW PTC Cabin Heater High Voltage (0001)(1S1)
Terms and Conditions
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A 3 kW high voltage PTC cabin heater, sealed to IP68, with a bimetallic overheat cutout built in. It runs directly off the traction pack and replaces the heater matrix that used to be fed by engine coolant.
A conversion loses its cabin heat the day the engine comes out. A PTC element solves that without a coolant loop, a pump or a header tank: it is an electric heater that sits where the matrix was and blows hot air through the original ducting and fan.
PTC means it regulates itself. The element's resistance rises as it warms, so it draws a lot of current cold and tapers off as it reaches temperature. That is the safety property that makes these suitable for a cabin: it cannot run away, because getting hotter makes it draw less. It is also why a 50 A contactor is recommended for what settles down to under 10 A of running current. Size the contactor and the fusing for the cold inrush, not the steady state.
Check it fits before you commit. This replaces the stock matrix but does not bolt into its place, so custom mounting is needed. The full dimensions are in the table below, and the core is 167 by 145 mm with the mounting tabs taking it out to 232 mm. Measure your matrix housing first.
Key specifications
| Manufacturer part | HSEA 3KW PTC 460V |
|---|---|
| Type | High voltage PTC cabin heater element |
| Rated power | 3 kW within the normal voltage range |
| Normal operating voltage | 348 V to 540 V DC |
| Extended operating range | 96 V to 540 V DC, with reduced output below 348 V |
| Polarity | None. The high voltage input can be connected either way |
| Contactor | 50 A recommended, sized for the cold inrush |
| Overheat protection | Bimetallic normally closed thermostat on the low voltage signal wires |
| Cut out temperature | 150 °C, plus or minus 5 °C |
| Reset temperature | 105 °C, plus or minus 15 °C |
| Protection rating | IP68 |
| Weight | 1.55 kg |
| Documentation | Dimensioned drawing and a STEP model in the Documents tab |
Dimensions and wiring
| Overall width | 232 mm, across the mounting tabs |
|---|---|
| Mounting hole centres | 214 mm, plus or minus 1.5 mm |
| Core width | 167 mm, plus or minus 1.5 mm |
| Overall height | 156 mm, plus or minus 1 mm |
| Core height | 145 mm, plus or minus 0.2 mm |
| Depth | 35 mm, plus or minus 1 mm |
| Mounting holes | 4 x 6 mm diameter |
| High voltage leads | 2 x orange 2.5 mm², 1250 mm long |
| Thermostat lead | 0.75 mm² red PTFE, 1250 mm long, in a 6 mm self extinguishing sleeve |
Features
- Self regulating element that draws less as it heats, so it cannot thermally run away in a cabin
- Bimetallic cutout wired out on its own low voltage pair, so the vehicle can see an overheat rather than just losing heat
- No polarity on the high voltage input, which removes a wiring mistake
- Sealed to IP68, so it survives the damp behind a bulkhead
- Works down to 96 V, at reduced output, so it still gives some heat on a lower voltage pack
- 1250 mm leads, long enough to reach a junction box without extending high voltage cable
Compatibility
For packs running between 348 V and 540 V, where it gives its full 3 kW. It will operate down to 96 V but the output falls away, so on a lower voltage pack treat it as a supplementary heater rather than the main one.
Switch it with a contactor rated for the inrush, not the running current. A contactor is the recommendation, and the same run wants a fuse sized to match.
It replaces a stock heater matrix but will not drop into its mounting. Compare the dimensions above against the matrix housing before ordering, and plan a bracket.
In the box
- 1 x PTC heater element with its high voltage and thermostat leads fitted
Mounting brackets, the contactor and the fuse are not included.
Downloads
The dimensioned drawing in the Documents tab gives every figure in the table above plus the mounting tab geometry. A STEP model is published alongside it, so the heater can be placed in a CAD model of the bulkhead before a bracket is made.
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