Question 1

What is FaultBreak™ and why is it considered a breakthrough?

Accepted Answer

Sensata FaultBreak™, launched in March 2026, is the first industrial EV protection contactor that combines fuse and contactor functions in a single device. Traditional EV architectures use a separate pyrofuse and main contactor on the high-voltage battery line — costly and complex. FaultBreak merges both into one hermetic device, cutting component count by more than 50% and eliminating pyrofuses, extra busbars and low-voltage harnesses. The result: a radically simpler EV power architecture with lower production, assembly and service cost — and improved vehicle safety.

Question 2

How does FaultBreak work? What is a magnetic actuator?

Accepted Answer

FaultBreak's operating principle is an elegant engineering solution:

• Normal: behaves as a standard contactor — switches the EV high-voltage line on command.
• Fault: under short-circuit or overcurrent, the magnetic field generated by the fault current is routed directly into the magnetic actuator. The actuator triggers ultra fast — far faster than traditional fuses.
• Arc suppression: the arc is safely extinguished by magnetic blowout combined with a dielectric gas environment.
• Resettable: the magnetic actuator design lets the device be reset after nuisance faults — a critical advantage over single-shot pyrofuses.

Passive operation means no external detection electronics are required; the system fails safe automatically.

Question 3

What is FaultBreak's fault-clearing capacity? What does "16 kA @ 1 kV" mean?

Accepted Answer

FaultBreak's market-leading fault-clearing capacity is 16 kA at 1 kV. What this means:

• 16 kA: 16,000 A instantaneous fault current — the highest level that can flow on a fully shorted EV battery
• 1 kV: 1000 V switching — the upper limit of modern 800 V and 1000 V EV architectures
• Verified by repeated tests: rigorous lab tests have cleared this fault level multiple times

This performance protects the vehicle and its occupants even under the most dangerous full-battery short-circuit conditions, giving FaultBreak a competitive edge over other protection devices — Sensata's "market-leading fault clearing" positioning.

Question 4

What does "resettable" mean? How is it different from a pyrofuse?

Accepted Answer

EV power systems traditionally use a pyrofuse — a single-shot pyrotechnic device that permanently breaks the circuit. Drawbacks:

• Single use: replacement is mandatory once triggered
• Service cost: even nuisance faults require pyrofuse replacement
• Uptime: replacement requires a workshop visit
• Warranty cost: high warranty exposure for OEMs

FaultBreak's magnetic-actuator design is different:

• Resettable: the device can be reused after a nuisance fault is cleared
• Minimum downtime: no part swap needed for nuisance trips
• Maximum uptime: the vehicle returns to service quickly
• Lower warranty cost: OEM warranty processes simplify

Per Sensata, this is a strategic reason EV OEMs choose FaultBreak.

Question 5

What is ISO-26262 and why does FaultBreak matter for it?

Accepted Answer

ISO-26262 is the international functional-safety standard for automotive E/E systems. To homologate a modern EV, OEMs must show that safety-critical components meet its requirements. FaultBreak's ISO-26262-relevant traits:

• Passive fuse function: the device fails safe automatically — independent of external sensing electronics
• Consistent fast response: the magnetic-actuator mechanism is predictable and repeatable across fault conditions
• Independence from control electronics: the fuse function works even if the control unit fails
• Dual configuration: two FaultBreaks can be used in series/parallel for system-level redundancy targeting higher ASIL levels

These traits substantially simplify OEM homologation.

Question 6

How does FaultBreak really cut component count by more than 50%?

Accepted Answer

A traditional EV HV protection architecture comprises:

• Main contactor (×1)
• Pyrofuse (×1)
• 2–3 busbar connections between them
• Low-voltage control harness for the pyrofuse trigger
• Pyrofuse trigger control unit
• Extra terminals and mechanical supports

With FaultBreak: a single device combines contactor + fuse. The result: fewer parts to manage, lower assembly time and cost, fewer failure points → higher reliability, less weight → range gain, lower thermal losses → energy efficiency, simpler service. Substantial total-system cost savings.

Question 7

What is dual configuration and when is it preferred?

Accepted Answer

Dual configuration uses two FaultBreaks in series or parallel to provide system-level redundancy. Preferred for:

• Premium / luxury EVs — high reliability expectations
• Commercial fleets — heavy-duty, high uptime
• Autonomous-driving vehicles — fail-operational behaviour required
• ASIL-D systems — the highest ISO-26262 safety level
• Heavy-duty electric trucks and buses — high-power protection

If one FaultBreak fails, the second continues protection so the vehicle can stop safely or keep driving. Even with two devices the architecture still uses fewer components than the traditional fuse + contactor approach.

Question 8

Which EV applications is FaultBreak designed for?

Accepted Answer

FaultBreak targets modern, next-generation EV platforms. Typical applications:

• Main EV power-system protection between battery pack and inverter
• Pack-level battery short-circuit and overcurrent protection
• Power-electronics input protection (inverter, DC-DC, OBC)
• 800 V+ next-gen high-voltage architectures
• Heavy-duty electric trucks, buses and off-highway equipment
• Premium / luxury EVs with the highest reliability targets
• ISO-26262 ASIL-C/D certified systems

Sensata positions FaultBreak as the standard protection solution for next-generation EV platforms launching from 2025–2030 onward.

Question 9

When was FaultBreak launched? What is the availability in Türkiye?

Accepted Answer

FaultBreak was officially announced by Sensata Technologies on 4 March 2026 (Swindon, UK press release). Launch timeline:

• March 2026: official global launch
• 11 March 2026: Sensata webinar "High Voltage Fault Management for Next-Gen EVs"
• 4-7 May 2026: ACT Expo 2026, Las Vegas, booth 2017 — flagship exhibition
• 2026-2027: EV OEM integrations and volume production plans

As the GIGAVAC FaultBreak distributor in Türkiye, IMB Electric handles stock, quotation and technical support. Although FaultBreak is positioned in a premium price segment, its component reduction and ISO-26262 advantages make its lifecycle cost extremely competitive for EV OEM projects.

Question 10

When should I pick FaultBreak versus other GIGAVAC families?

Accepted Answer

Selection depends on protection requirement and architecture level:

• FaultBreak: combined EV main protection + switching, ISO-26262 compliance, dual-configuration redundancy
• GTM: V2G high-power switching for ESS and DC fast-charging — requires a separate fuse
• HX: 1500 Vdc utility-scale solar and EV bus/truck
• GX: 800 Vdc EV main contactor with broad model range
• MX: heavy-duty industrial and military
• GV: economical, high-performance with many variants
• P series: compact precharge and solar

FaultBreak is the right choice for modern EV platforms designed from 2026 onward that want fuse+contactor integration; it is expected to become an industry standard for new EV programs.

Question 11

Is FaultBreak hermetic? How is its environmental withstand?

Accepted Answer

Yes — FaultBreak is hermetically sealed. The hermetic build provides:

• Low, stable contact resistance unaffected by environment
• Low thermal losses; no extra cooling required
• Operation in outdoors / humid / aggressive atmospheres
• Vibration and mechanical-stress withstand for EV engine bay and chassis mounting
• Wide operating temperature range for modern EV power electronics

In Sensata's words: "compact footprint with hermetic sealing that delivers low and stable contact resistance."

Question 12

What are the OEM advantages of FaultBreak?

Accepted Answer

Strategic OEM advantages of FaultBreak:

1. Architecture simplification: 50%+ fewer components; no pyrofuse + busbar + harness; faster design.
2. Production & assembly: fewer parts to manage, shorter assembly time, fewer SKUs.
3. Quality & reliability: fewer failure points, direct ISO-26262 support, hermetic long-life sealing.
4. Service & warranty: resettable design avoids part swaps on nuisance trips; lower warranty cost; maximum customer uptime.
5. Cost: lower total system cost and simpler BOM.

Sensata therefore positions FaultBreak as a strategic component for EV OEM projects from 2026 onward.

Question 13

At which events has Sensata introduced FaultBreak?

Accepted Answer

Main introduction events for FaultBreak:

• 4 March 2026 — official launch press release from Sensata Technologies (NYSE: ST), Swindon, UK
• 11 March 2026 — Sensata webinar "New Strategies for High Voltage Fault Management in Next-Gen EVs"
• 4-7 May 2026 — ACT Expo 2026, Las Vegas, booth 2017 — Sensata's flagship event for electrified transport solutions, with FaultBreak as the headline launch

Since then, Sensata has begun OEM integration discussions worldwide and FaultBreak is expected in volume-production projects in the 2026-2027 timeframe. IMB Electric provides integration support and sampling for EV OEMs and suppliers in Türkiye.

Question 14

How can I purchase and evaluate FaultBreak?

Accepted Answer

As the authorised GIGAVAC FaultBreak distributor in Türkiye, IMB Electric offers EV OEM and supplier customers:

1. Sampling & evaluation — Sensata global stock-based sampling and test/validation support.
2. Technical support — engineering consultation, EV power-architecture integration planning, ISO-26262 assessment, test protocols.
3. Volume production — project-based pricing, supply chain planning, direct Sensata coordination.
4. Training & enablement — technical webinars, datasheets and application notes.

Contact us for details, quotation and technical support — we tailor a project plan for your EV OEM and tier-1 programs.

About the FaultBreak Series series

01What is FaultBreak™ and why is it considered a breakthrough?

02How does FaultBreak work? What is a magnetic actuator?

03What is FaultBreak's fault-clearing capacity? What does "16 kA @ 1 kV" mean?

04What does "resettable" mean? How is it different from a pyrofuse?

05What is ISO-26262 and why does FaultBreak matter for it?

06How does FaultBreak really cut component count by more than 50%?

07What is dual configuration and when is it preferred?

08Which EV applications is FaultBreak designed for?

09When was FaultBreak launched? What is the availability in Türkiye?

10When should I pick FaultBreak versus other GIGAVAC families?

11Is FaultBreak hermetic? How is its environmental withstand?

12What are the OEM advantages of FaultBreak?

13At which events has Sensata introduced FaultBreak?

14How can I purchase and evaluate FaultBreak?