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SCR Tank Heaters

Series-ready PTC heaters for AdBlue/DEF tanks — VW80000 certified, self-regulating, lightweight. Optional ice detection for energy-efficient heating.

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SCR Tank Heaters

Challenge

EURO 6 legislation mandates SCR (Selective Catalytic Reduction) systems to reduce NOx emissions by up to 90%. The AdBlue/DEF fluid (urea solution) freezes at −11°C, requiring reliable tank heating. Conventional internal heaters cause melting cavities and mechanical deformation inside the tank, complicate retrofitting, and need active temperature control with sensors and electronics. These shortcomings increase system cost, reduce reliability, and make field maintenance difficult.

Our Solution

ATT's carbon-based PTC heaters mount externally on the tank surface with thermal insulation — no tank penetration, no melting cavity issues, easy retrofitting. The PTC effect provides inherent temperature self-regulation: the heater reaches its design temperature (45°C, 62°C or 85°C) without requiring temperature sensors or control electronics. An optional integrated ice sensor detects the frozen state of the AdBlue fluid and enables on-demand heating — significantly reducing energy consumption by heating only when actually needed.

How It Works

1

Tank & Thermal Analysis

We analyse your tank geometry, mounting surfaces and ambient temperature requirements to determine optimal heater size, placement and PTC temperature rating (45°C, 62°C or 85°C).

2

Heater Design & Specification

Custom PTC heater layout designed with optimized power density (up to 12 kW/m²). External mounting concept with thermal insulation ensures efficient heat transfer into the tank wall.

3

Qualification (VW80000)

Complete automotive qualification per VW80000 standard and customer-specific requirements. RoHS, REACH and IMDS compliance verified. Optional ice sensor integration tested and validated.

4

Series Delivery

Series production with full traceability. Lightweight design (118 g for 330 × 150 mm) minimizes vehicle weight impact. Supplied ready for external mounting with insulation kit.

Application Areas

Passenger Car AdBlue Tanks

External PTC heaters prevent AdBlue freezing in passenger vehicles without tank modification. VW80000-certified design ensures OEM-level quality and reliability.

Commercial Vehicle DEF Tanks

Heavy-duty trucks and buses with large DEF tanks benefit from scalable external heating. Multiple heater elements can be combined for larger tank surfaces.

Off-Highway & Agricultural

Construction machinery, agricultural vehicles and mining equipment operating in extreme cold. External mounting enables easy retrofit across diverse tank geometries without modifications.

Retrofit Applications

The external mounting concept makes ATT SCR heaters ideal for aftermarket and retrofit installations — no tank disassembly or internal access required.

Technical Data

Heating Element Carbon-based PTC
Max Temperatures 45°C / 62°C / 85°C
Power Density Up to 12 kW/m²
Mounting External (no tank penetration)
Weight (330 × 150 mm) 118 g
Certification VW80000
Compliance RoHS, REACH, IMDS
Ice Sensor Optional (on-demand heating)

Key Advantages

  • Series-proven: tested and approved per VW80000 norm
  • External placement eliminates tank melting cavities and deformation
  • PTC self-regulation: no temperature sensors or control unit required
  • Selectable max temperature: 45°C, 62°C or 85°C per customer spec
  • Optional ice sensor for on-demand heating — energy-efficient operation
  • Lightweight: 118 g for 330 × 150 mm element
  • Ready for series: IMDS listed, RoHS and REACH compliant
  • Easy retrofit capability due to external mounting concept
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Frequently Asked Questions

Why is external mounting better than internal tank heaters?
Internal heaters create melting cavities in the frozen AdBlue, causing mechanical deformation of the tank. They also require tank penetration, complicating assembly and sealing. ATT's external PTC heaters avoid all these issues — the heater transfers heat through the tank wall from outside, with thermal insulation to direct heat inward. This also makes retrofitting straightforward.
How does the PTC self-regulation work without a controller?
The carbon-based PTC material increases its electrical resistance as temperature rises. At the design temperature (45°C, 62°C or 85°C), resistance becomes so high that power output drops to near zero. The heater physically cannot exceed this temperature — no temperature sensors, control circuits or safety cutoffs are needed. This simplifies the system and improves reliability.
What is the purpose of the optional ice sensor?
The ice sensor detects when the AdBlue fluid is actually frozen, enabling on-demand heating — the heater only operates when needed. Without the ice sensor, the heater runs whenever powered, which wastes energy when the fluid is already liquid. The ice sensor significantly reduces energy consumption, especially in moderate winter conditions.
Which automotive standards does the ATT SCR heater meet?
ATT SCR tank heaters are tested and approved per VW80000, the Volkswagen Group standard for electrical and electronic components. Additionally, all materials are RoHS and REACH compliant, and the product is listed in the International Material Data System (IMDS) for full automotive supply chain traceability.
Can the heater be adapted to different tank sizes and shapes?
Yes. While the reference design is 330 × 150 mm at 118 g, both dimensions and power density are customizable. For larger tanks, multiple heater elements can be combined. The external mounting concept adapts to flat, cylindrical and irregular tank geometries.
At what temperature does AdBlue freeze and what PTC rating is recommended?
AdBlue (32.5% urea solution) freezes at −11°C. The recommended PTC temperature rating depends on the application: 45°C for gentle thawing with minimal energy consumption, 62°C for faster de-icing, and 85°C for extreme cold or rapid thaw requirements. We recommend the lowest effective rating for optimal energy efficiency.

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