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Press
Release




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BERU launches the next generation of PTC
auxiliary heaters


BERU

has
undertaken

a
critical
step in the development of
a new
generation of electric PTC auxiliary heaters. This innovative concept
offers automakers greater benefits: The new syst
ems are smaller,
lighter and more flexible in application, as well as offer more safety
and reliability during oper
at
ion
.



(Ludwigsburg,
07

may 2008)

Today’s
fu
el
-
efficient engines
have
increased efficiency and therefore
di
ssipate less heat to the cooling

system.

As a consequence, at low outside temperatures these
engines take a long time to provide the desired amount of heat in the
passenger compartment. PTC auxi
liary

heaters from BERU make up
f
or this shortfall

by providing supplementary heating
.

The PTC

heater

i
nstalled in the air duct behind the coolant heat exchanger, heats the
air, wh
ich
in turn heats up the
passenger compartment and clears the
windscreen in seconds.


BERU PTC auxiliary heaters: compact, flexible, and cost
-
efficient


With the latest
generation of electric PTC auxiliary heaters, the
Ludwigsburg specialist for Ignition Technology, Di
esel Cold
-
Start
Technology, Electronics and Sensors has made a further decisive
step in the development of its products.

The innovative concept offers
autom
akers with compelling benefits during development and
manufacturing. The new models have considerably fewer components
and retain the well
-
established ru
gged heating rod concept.

It was
possible to achieve this design through use of extruded aluminium
prof
iles that are optimised from a thermal
st
andpoint.

This d
esign


BERU

279

Date

07
.05.2008

Referenc
e

5.880




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achievement has lowered the number of components in the heater
from an average of 150 down to fewer than 25 per system.



Further benefits of the new PTC auxi
liary heater models:




They are ab
out one
-
third lighter than their pred
ecessors with

fins
.




They are smaller than their predecessors. The new design
principle, for instance, permits construction of compact, three
-
stage heaters with a profile width of about only
70 mill
imetres.




They can b
e manufactured with any number of heating stages.
This means that single
-
stage mini
-
heaters for decentralised
heating can be produced just as readily as powerful, four or
five stage heaters with electronic co
ntrol.



They offer twice the thermal safety, an a
dditional benefit when
it comes to the service life of the product: In all high
-
output
models, the switching elements and PC board are thermally
isolated from each other by a bus bar; in addition, an excess
temperature cut
-
out is incorporated into the PTC’
s electronics.



The tooling costs are lower than that for earlier models with
fins. Moreover, the shorter manufactu
r
ing time for tooling ha
s

made p
ossible for BERU to considerably
reduced
the
de
velopment time needed for customer

specific applications.



BER
U PTC auxiliary heaters: the right solution


From the compact m
echanical model to the electronically controlled
comfort system:

BERU offers flexible product solutions for both, the
climate control system man
uf
acturers as well as its customers in the
in
ter
national automotive industry
.








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Cu
rrently, BERU has five PTC product lines in its range:





Plain Line:

Single or multi
-
stage auxiliary heaters for classic
standard applic
at
ions.

The controls employ relays mounted
e
xt
ernally in a control box in the vehic
le.



M
-
Relay Line:
Compact, multi
-
stage auxiliary heaters with
i
ntegrated mechanical relays.

The benefit of this system is that
the integration

of the auxiliary heater into the electrical system
of a vehicle requires no additional development effort.

Furthe
rmore, the secondary costs associated with wiring,
relays, applications and i
nstallation are reduced.




E
-
Relay Line:

Especially compact PTC auxiliary heater with
integrated, wear
-
free Smart
-
Power switches i
nstead of
mechanical relays.

There is no mechanica
l switching noise,
longer service life and optimal safety due to built
-
in
temperature monitoring.



Basic Line:

Easy
-
to
-
install, microprocessor
-
controlled PTC
auxiliary heater as a plug & play solution r
equiring noticeably
less wiring in the vehicle.

In thi
s compact design, the heater
rods are supplied individually via PWM
-
controlled power
transistors instead of stepwise or incremental control. It
utilises a closed
-
loop control concept
, the heat output is
continually adjusted to satisfy actual requirements.

Internal
diagnostics mon
itor, among other items, the temperature,
voltage and current of the power transistors.



Comfort Line:

The high
-
tech PTC solution from BERU with
maximum functionality, performance and convenience.
Microprocessor
-
based, with variable

co
ntrol of heat output.

Output power adjustment, functioning and diagnosis are based
on one of the common bus systems such as CAN or LIN. The
intelligent control behaviour of the BERU Comfort Line
min
im
ises power fluctuations in the on
-
bo
ard electrical sy
stem.

Battery voltage, current levels, power tra
nsistors and heater
rods are monitored to initiate appropriate countermeasures in





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the event of a sudden voltage drop, short circuit or similar fault
condition.



BERU currently supplies PTC auxiliary heate
rs to

automotive
manufacturers such as Audi, Ford, Hyundai, Ja
guar, Kia, Mazda,
Nissan, Seat, Skoda, Volvo and VW.

The electronics of the PTC
systems are manufactured on fully automated production lines at
BERU Electronics in Bretten. The heating elements
are manufactured
at the joint venture
BERU Eichenauer GmbH in Ka
ndel.



BERU subjects the PTC auxiliary heater components and sy
stems to
extensive testing

to ensure that the PTC auxiliary heater functions
reliably for many years under rigorous everyday use
. BERU also
conducts all qualification tests


in its own test laboratory


from
development to production
-
ready status. The facilities in Bretten,
Ludwigsburg and Kandel have a var
i
ety of special testing equipment
to
accomplish
perfor
mance tests, includin
g clim
ate chambers and
airflo
w measurement set
-
ups as

well as EMC laboratory, to ensure
in
formative results with real
-
world relevance.

Upon request, BERU
can also carry out tests related directly to user appl
ications.

This
eliminates the need for our cu
sto
mer
s

to inst
all and maintain their
o
wn
testin
g and measurement equipment,
albeit
the time and effort
associated with testing.



279
_1:
Smaller, lighter, and more flexible: The latest generation of
electric PTC auxiliary hea
ters fr
om BERU offers climate con
trol
system manufacturers and automakers the optimum solution for every
application.

Currently, BERU has five product lines in its range: From
relay
-
based heaters for classic standard appl
icatio
ns to the high
-
tech
Comfor
t Line for maximum functionality, pe
rformance and
convenience as well as comfort.












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With a world market share of over 40% for glow plugs and electronically
controlled instant
-
start systems for diese
l

engines, BERU AG is one of the
world’s leading su
pplier
s

of Diesel Cold
-
Start Technology. It is also one of
Europe´s four leading suppliers in the field of ignition technology for gasoline
engines. And BERU is rapidly expanding in the electr
o
nics sector with a
focus on complete electronic systems for the

automotive industry. This long
-
established company, founded in 1912, also produces sensors and ignition
systems for the oil
-

and gas
-

burner sector. BERU´s customers include
nearly all of the world’s car and engine manufacturers. BERU AG is
represented at

23 locations on three continents, and the company´s
headquarters are in Ludwigsburg, Germany.

Further information available from:

BERU AG


Hans
-
Peter V
a
ter,

Director


Head Office Marketing Communications, Product Press

Mörikestr.
155, D
-
71636 Ludwig
s
burg, Tel.: +49 (0)7141
-
132
-
233,

Fax:
-
385, E
-
Mail:
produktpresse@beru.de



Or visit us on the Internet:
www.beru.com
. There you'll find more
illustr
a
tions in the BERU image database at
www.beru.com/bildarchiv



Reprinting free of charge, courtesy copy requested.