Thermal Management Enables the World’s Largest Battery Electric Excavator
The electrification of heavy earth moving machinery reached a significant milestone with the successful implementation of an advanced battery thermal management system on the world’s largest battery electric excavator. Central to this pioneering project is DC Airco’s DC 5030 Liquid Air Battery Thermal Management System, a compact and energy efficient chiller specifically designed for high demand mobile battery applications.
Meeting the Thermal Challenges of Heavy Electric Excavators
Battery electric excavators operate under extreme working conditions, including high continuous power loads, rapid duty cycle changes, and elevated ambient temperatures. These factors generate considerable thermal stress on battery systems, which can negatively impact performance, safety, and lifespan if not properly managed.
To ensure reliable operation, the project team selected the DC 5030, a dedicated battery cooling solution that maintains batteries within their optimal temperature range. By minimizing temperature fluctuations and thermal stress, the system plays a direct role in extending battery life and maintaining consistent machine performance.
Compact Liquid Air Cooling Without Secondary Circuits
The DC 5030 uses a liquid to air cooling concept, integrating the condenser and fan into a single compact unit. Unlike traditional cooling architectures, the system does not require a secondary liquid circuit to dissipate or extract heat from the battery system.
This integrated design delivers key advantages for large mobile machinery, including:
- Reduced system complexity
- Fewer components and connections
- Lower installation effort
- Improved reliability in demanding environments By eliminating unnecessary components, the DC 5030 offers a robust and efficient solution ideally suited for heavy electric excavators.
High Voltage Compatibility for Large Battery Systems
To support modern high energy battery architectures, the DC 5030 is available in two high voltage variants:
- 360 Vdc model, operating from 240 to 420 Vdc
- 540 Vdc model, operating from 400 to 790 Vdc This wide voltage range ensures compatibility with large scale battery packs used in next generation electric earth moving equipment.
Capacity Controlled Cooling for Maximum Efficiency
The DC 5030 provides capacity controlled cooling between approximately 0.5 kW and 4.5 kW, dynamically adjusting output to match real time thermal demand. This ensures efficient energy use during partial load operation while maintaining sufficient cooling capacity during peak excavation activity.
The result is optimized energy consumption, reduced thermal stress on batteries, and improved overall system efficiency—critical factors for large battery electric machines.
Designed for Heavy Duty Mobile Applications
Despite its high cooling capacity, the DC 5030 maintains a compact footprint and lightweight design, enabling easy integration into large excavator platforms. Key system features include:
- Integrated condenser and fan
- CAN based control, remote on/off, or self controlled operation
- Use of R134a non flammable refrigerant, approved for mobile battery applications in the EU
- Robust construction for off highway use These characteristics make the DC 5030 well suited for the harsh operating environments typical of large construction and mining equipment.
Supporting the Future of Zero Emission Earth Moving Equipment
The successful deployment of DC Airco’s DC 5030 on the world’s largest battery electric excavator demonstrates that fully electric solutions are practical and effective even for the heaviest mobile machinery.
By delivering reliable, efficient, and compact battery thermal management without secondary cooling circuits, the DC 5030 contributes to longer battery life, improved operational uptime, and accelerated adoption of zero emission excavation technology.