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Gigavac FaultBreak FBC600 series — breakthrough EV protection contactor combining fuse and contactor in one device
B2B · PRODUCT SERIES · SENSATA | GIGAVAC
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Sensata | Gigavac · PRODUCT SERIES

FaultBreak™ Series — Breakthrough EV Protection Contactor Combining Fuse and Contactor in One Device

Sensata's 2026 launch · Passive fuse + contactor in one · 16 kA @ 1 kV market-leading fault clearing · Resettable · ISO-26262 compliant · −50% components

Sensata FaultBreak™, launched in March 2026, is a breakthrough next-generation EV protection contactor — the first industrial solution to combine fuse and contactor functions in a single device. Market-leading fault clearing is verified by repeated interruption tests at 16 kA @ 1 kV, protecting the vehicle and its occupants even under full battery short-circuit. The passive fuse function needs no external detection electronics and directly supports ISO-26262 functional-safety compliance.
Its principle is elegant: the magnetic field generated by the fault current is routed into the magnetic actuator, opening ultra-fast only under fault, while magnetic blowout + dielectric gas safely extinguish the arc. Unlike single-shot pyrofuses, the device is resettable after nuisance trips — boosting vehicle uptime and cutting warranty cost and service time. Versus a traditional fuse + contactor architecture it reduces component count by more than 50%, eliminating pyrofuses, extra busbars and LV harnesses to simplify the EV power architecture and lower weight and thermal losses. Hermetic sealing delivers low, stable contact resistance with no extra cooling; dual configuration provides system-level redundancy for higher reliability targets. Sensata showcased FaultBreak as the headline launch at ACT Expo, Las Vegas, 4-7 May 2026.
Next-Generation EVsHigh-Voltage EV ArchitecturesEV Battery Pack Main ProtectionPower Electronics ProtectionEV OEM Supply ChainISO-26262 Certified SystemsPremium & Luxury EVsHeavy-Duty Commercial EVs
REFERENCE SPECIMENFAULTBREAK · 01
Gigavac FaultBreak FBC600 series — breakthrough EV protection contactor combining fuse and contactor in one device
PASSIVE FUSEEV PROTECTION CONTACTORSENSATA
FaultBreak Series series family image; this model's body and terminations may differ.
Models
1
Products
24
01Market-Leading Fault Clearing (Repeated)
16 kA @ 1 kV
02Fuse + Contactor in One Device
2-in-1
03Component Count Reduction
−50%
04Functional Safety Compliant
ISO-26262
01

FaultBreak Series Fault interrupt Contactor Models

Sorted by current rating (150A → 1000A)

1 MODELS24 PRODUCTS
CONFIGURATORMODEL↑ currentContinuous CurrentVoltageContact FormCoil VoltageShort-Circuit WithstandMECHANICAL LIFEPDF
FBC600
600A1000Vdc1 Form A (SPST-NO)12 / 24 Vdc PWM16 kA @ 1000Vdc · <2 ms1,000,000 cyclesDatasheet (PDF) — FBC600
MODEL CONFIGURATOR · FAULTBREAK
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TECHNICAL DIFFERENTIATORS

Why FaultBreak Series?

Market-Leading Fault Clearing

  • 16 kA @ 1 kV repeated interruption — verified by rigorous testing

    Protects the vehicle even in the most dangerous full-battery short-circuit scenarios.

  • Arc suppression via magnetic actuator + magnetic blowout + dielectric gas

    Faster opening than traditional fuses — millisecond-class response.

Fuse + Contactor in One Device

  • Sensata's 2026 first-of-its-kind hybrid protection device

    First-ever industry combination of contactor and fuse — the cornerstone of next-gen EV architecture.

  • Eliminates pyrofuse, busbars and low-voltage harnesses

    Radically simplifies EV power architecture and reduces production and service cost.

Compact, Lightweight System Architecture

  • Reduces component count by more than 50%

    Lower total system weight, volume, assembly time and thermal losses.

  • Hermetic sealing — low, stable contact resistance with no extra cooling

    Thermal management simplifies and BMS integration becomes easier.

ISO-26262 Functional Safety Compliance

  • Passive fuse function inherently supports functional-safety compliance

    Directly supports EV OEM homologation and certification processes.

  • Dual configuration provides system-level redundancy

    For premium and luxury EV platforms targeting the highest reliability.

Resettable Passive Fuse

  • Unlike single-shot pyrofuses — resettable after nuisance faults

    Maximises vehicle uptime and minimises warranty cost.

  • Passive operation — no external detection electronics required

    Shortens service time; no part swap on nuisance trips.

DATASHEET · GUIDE · APPLICATION NOTE

FaultBreak Series — Technical Resources

Datasheets

  • FBC600 FaultBreak™ EV High-Voltage DC Contactor Datasheet — fuse+contactor combined, 16 kA @ 1 kVSOON

Launch & Event Materials

  • Sensata Technologies FaultBreak™ Official Launch (4 March 2026, Swindon UK)SOON
  • FaultBreak at ACT Expo 2026 (4-7 May, Las Vegas, booth 2017) exhibition materialsSOON
  • Webinar: New Strategies for High Voltage Fault Management in Next-Gen EVs (11 March 2026)SOON

Selection Guides

  • GIGAVAC Contactors & Fuses Selection Guide (2026)SOON
  • Sensata EL Contactor Portfolio Brochure (2025)SOON

FREQUENTLY ASKED QUESTIONS

About the FaultBreak series

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