classicretrofit Posted January 15, 2024 Posted January 15, 2024 Solid State 3 Stage 1100W PTC Brick Heater 220 – 400V DC Introduction The Classic Retrofit PTC Brick is a compact and versatile modular heating element used in the conversion of vehicles to electric power. Main features • Compact and modular • 220 – 400V DC operation • 3 stage, internally switched (does not need external contactor for switching) • Control by 12V signals • LV fully isolated from HV • 1100W, 3 stages • Electrically isolated fins and holder. Parts List • PTC Element, holder with integrated electronics • HV cables ( orange +, brown -) • LV control cable with 4 way connector Installation For most small to medium sizes cars, 2 PTC bricks mounted side by side will give ample heat (2200W). The bricks can be placed where convenient in the vehicle. This can either be in the vent duct work or inside the original heater unit. If the vehicle has a conventional water heater matrix, this can be removed and a metal carrier plate fabricated as a direct replacement. The bricks are then mounted to the carrier plate using the four fixing holes. Note that two PTC bricks can be mounted side by side by running the HV leads and control cables through the adjacent unit as below: Dimensions: The PTC Brick is 100mm x 150mm x 27mm. Mounting bolts. M5 hex head, centres on a 90 x 105mm rectangle The element aperture is 90 x 93mm. The PTC holder can be removed and used as a template for marking out. Mark out the fixing holes, main element opening and also the six cooling holes. The cooling holes MUST receive air flow from the heater fan to cool the electronics. Electrical Connections High Voltage Connections Each unit comes with 600V rated HV cables in orange(+) and brown(-). The end with the LV connector is the 400V negative (-). Solder the brown wire to the terminal labelled 0V. The other end is the 400V positive (-). Solder the orange wire to the terminal labelled HV. The orange and brown cables can be wired into the HV feed from the battery pack (220 – 400V). Without any control signals there will be no current draw from the PTC Brick. Low voltage Connections The board uses a Molex Microfit connector p/n 43645-0400. A fly lead is provided with the connector pre attached. The Pin allocation Control and enable lines are 12V active high. The enable line has to be held at 12V for the elements to function. We recommend powering the enable after the pre-charge has been completed. The enable can also be part of the HVIL circuit if required. Nominal consumption is 3A at 400V A key Note Do not signal Heater single/double input before heater enable input. likewise do not remove heater enable while single or double are still active. Applying Single / double heat inputs without enable. Or removing Enable with Heater inputs on will damage the PCBs' Specifications:
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