Thermal Management Breakthrough Powers World’s First Battery Powered Crawler Crane

A major milestone in the electrification of heavy construction equipment has been reached with the deployment of an advanced battery thermal management system on the world’s first fully battery powered crawler crane. Central to this project is DC Airco’s DC6001 liquid to liquid reversible heat pump, delivering precise, energy efficient heating and cooling for high voltage battery systems operating under extreme duty cycles.

Facing the Thermal Challenge of Heavy Electric Machinery
Battery powered crawler cranes place unprecedented demands on energy storage systems. High peak loads, long operating hours, and harsh ambient conditions can cause significant thermal stress, directly impacting battery performance, lifespan, and safety.

To address these challenges, the project team implemented DC Airco’s DC6001 Battery Thermal Management System (BTMS)—a compact yet powerful reversible heat pump specifically designed for mobile, off highway, and high voltage battery applications.

Parallel Configuration Boosts Output to 12 kW
For this application, multiple DC6001 units are connected in parallel, allowing the total thermal capacity to be scaled from 0.5 kW up to 12 kW, for both cooling and heating. This modular approach ensures that thermal performance precisely matches operating conditions, minimizing unnecessary energy consumption during low load operation while ensuring sufficient capacity during peak demand. Key benefits of the parallel setup include:

• Scalable thermal output without system redesign
• High redundancy and operational reliability
• Improved energy efficiency across varying load profiles
• Optimized battery temperature control in all working conditions

High Voltage Compatibility for Large Battery Systems
The DC6001 is available in two high voltage variants, making it ideally suited for different battery architectures used in electrified heavy equipment:

• 350 Vdc model: operating range from 210 to 480 Vdc
• 630 Vdc model: operating range from 400 to 850 Vdc This wide voltage compatibility allows seamless integration into modern high energy battery packs commonly used in crawler cranes, mining equipment, agricultural machinery, and other off highway electric vehicles.

Reversible Heat Pump Maximizes Energy Utilization
Unlike conventional cooling systems, the DC6001 operates as a reversible liquid to liquid heat pump, providing both heating and cooling from a single compact unit. During intense crane operation, excess battery heat is efficiently removed and can be repurposed for warming other systems. In cold environments, the unit reverses operation to quickly bring battery temperatures into the optimal range for charging and discharge.

By intelligently reusing energy rather than dissipating it, the system significantly improves overall machine efficiency while extending battery life.

Compact Design, Industrial Grade Performance
Despite its high thermal output, the DC6001 features a compact footprint and robust design, tailored for mobile industrial applications. Key specifications include:

• Capacity controlled operation up to 8.5 kW per unit
• Power consumption up to 3.4 kW
• CAN based control (CAN 2.0A/B, J1939, CANopen)
• Small dimensions (344 × 346 × 251 mm) and low weight (21.5 kg)
• Use of R134a non flammable refrigerant, approved for mobile EU applications These characteristics make the system easy to integrate into space constrained crawler crane platforms without compromising performance or reliability.

Enabling Longer Battery Life and Higher Uptime
Maintaining batteries within their optimal temperature window directly reduces degradation and enhances safety. By stabilizing temperatures during charging, idle periods, and peak operation, the DC6001 BTMS helps maximize battery lifespan, reduce maintenance needs, and ensure consistent crane availability on demanding job sites. Setting a New Standard for Electric Heavy Equipment The successful deployment of DC Airco’s DC6001 thermal management system demonstrates that zero emission operation is achievable even in the most demanding heavy duty applications. With its scalable output, reversible heat pump technology, and dual high voltage compatibility, the DC6001 provides a future proof solution for next generation electric crawler cranes and other off highway machinery.