What is PyroFuse and how does it work?

PyroFuse is a pyrotechnic-based high voltage DC circuit breaker that irreversibly disconnects in under 1 millisecond on an external trigger. During a short-circuit or crash the BMS / protection relay sends a pyro-trigger signal; a small pyrotechnic charge severs the main conductor and the arc is rapidly extinguished. Unlike passive fuses, the opening decision is made by the system (BMS / vehicle controller), so scenarios such as crash detection can be folded into the protection decision.

What are the specifications of the STPS500 model?

STPS500: 500 A continuous, 1000 V rating, 20 kA breaking at 500 V or 16 kA at 1000 V, <1 ms interrupt. Its bidirectional design breaks identically in both current directions, providing direction-independent protection on battery charge/discharge lines. It is single-shot — replacement is mandatory after activation.

Does PyroFuse replace GigaFuse or FaultBreak?

No — the three represent different protection layers and are often used together. GigaFuse is a passive / semi-passive electromechanical DC fuse providing continuous protection coordination. FaultBreak is the new-gen hybrid that combines fuse + contactor and is resettable after nuisance trips. PyroFuse is the maximum safety barrier used for crash and large short-circuit scenarios — the fastest opening tier, but single-shot. In premium EV architectures the three layers are complementary.

Is single-shot operation a disadvantage?

Single-shot is not a drawback but an intentional design choice: once triggered, the device opens mechanically and irreversibly with no chance of re-conduction. This guarantees the highest safety margin in crash / fire scenarios. Nuisance-trip tolerance is intentionally low, so PyroFuse is typically positioned alongside a resettable layer (FaultBreak or GigaFuse) and triggered only on real crash / short-circuit conditions.

Which sectors use PyroFuse?

EV battery pack protection, EV crash HV disconnect, DC fast charging stations, aerospace and defense power, railway emergency disconnect, maritime / off-grid HV systems and military / defense DC power are the principal use cases. Common thread: high DC voltage, sub-millisecond interrupt requirement and absolute disconnect guarantee.

How are samples and technical support provided?

IMB Electric is the authorised Sensata PyroFuse distributor in Türkiye. Sampling, engineering consultation, BMS / pyro-trigger integration planning, ISO-26262 assessment and volume production are coordinated directly with Sensata Technologies. Share the application profile with your RFQ to start.

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PyroFuse Series — Pyrotechnic HV DC Circuit Breaker<1 ms

Q: Does PyroFuse replace GigaFuse or FaultBreak?

No — the three represent different protection layers and are often used together. GigaFuse is a passive / semi-passive electromechanical DC fuse providing continuous protection coordination. FaultBreak is the new-gen hybrid that combines fuse + contactor and is resettable after nuisance trips. PyroFuse is the maximum safety barrier used for crash and large short-circuit scenarios — the fastest opening tier, but single-shot. In premium EV architectures the three layers are complementary.

Q: Is single-shot operation a disadvantage?

Single-shot is not a drawback but an intentional design choice: once triggered, the device opens mechanically and irreversibly with no chance of re-conduction. This guarantees the highest safety margin in crash / fire scenarios. Nuisance-trip tolerance is intentionally low, so PyroFuse is typically positioned alongside a resettable layer (FaultBreak or GigaFuse) and triggered only on real crash / short-circuit conditions.

Q: Which sectors use PyroFuse?

EV battery pack protection, EV crash HV disconnect, DC fast charging stations, aerospace and defense power, railway emergency disconnect, maritime / off-grid HV systems and military / defense DC power are the principal use cases. Common thread: high DC voltage, sub-millisecond interrupt requirement and absolute disconnect guarantee.

Q: How are samples and technical support provided?

IMB Electric is the authorised Sensata PyroFuse distributor in Türkiye. Sampling, engineering consultation, BMS / pyro-trigger integration planning, ISO-26262 assessment and volume production are coordinated directly with Sensata Technologies. Share the application profile with your RFQ to start.

STPS500 · 500 A continuous · 1000 V · 16-20 kA breaking · <1 ms interrupt · External trigger · Bidirectional · Single-shot, irreversible

Sensata PyroFuse is a pyrotechnic-based high voltage DC circuit breaker that irreversibly disconnects the circuit in under 1 millisecond on an external trigger signal. During a short-circuit or crash a small pyrotechnic charge severs the main conductor; the arc is rapidly extinguished and the battery / driver remain safe.

The available STPS500 model carries 500 A continuous with 20 kA breaking at 500 V or 16 kA at 1000 V; its bidirectional design breaks identically in both current directions. It is actuated by the EV BMS / pyro-trigger circuit and needs no external sensing electronics.

It is single-shot — replacement is mandatory after activation. This makes it the choice as a maximum safety barrier in EV and ESS systems where nuisance-trip tolerance is low and crash / short-circuit protection is critical. For a resettable alternative see the FaultBreak family.

EV Battery Pack ProtectionEV Crash HV DisconnectDC Fast Charging StationsAerospace & Defense PowerIndustrial High-Power DC BusRailway Emergency DisconnectMaritime / Off-grid HV SystemsMilitary / Defense DC Power

SERIES CERTIFICATIONS09APPROVALS

UL1604
IP67
IP69K
SAE J1171
ISO8846
RoHS
cRUus
CE
EPIC®

Certifications vary by model — see the corresponding model datasheet for details.

01Continuous Current: 500 A
02Voltage Rating: 1000 V
03Breaking Capacity: 20 kA @ 500 V · 16 kA @ 1000 V
04Interrupt Time: <1 ms

PyroFuse Series Pyrotechnic Contactor Models

Sorted by current rating (150A → 1000A)

1 MODELS1 PRODUCTS

CONFIGURATOR	MODEL↑ current	Function	Continuous Current (A)	Rated Voltage (V)	Interrupt Time (ms)	Mounting	Example PN	Coding Pattern
	STPS500	Aktif (Pirotek)	500	1000	<1	—	STPS500	STPS500 + [Tetikleme] + [Mount]
CONFIGURATOR · STPS500MODEL-SPECIFIC

MODEL CONFIGURATOR · PYROFUSEREF · IMB · CFG · 001 VARIANTS

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TECHNICAL DIFFERENTIATORS

Why PyroFuse Series?

05 · CATEGORIES

High Breaking Capacity

20 kA @ 500 V · 16 kA @ 1000 V
Protects vehicle and system even in full-battery short-circuit scenarios.
Bidirectional — direction-independent protection
Identical performance in both current directions on battery charge/discharge lines.

Sub-Millisecond Irreversible Interrupt

<1 ms interrupt time
Fastest opening across all DC protection tiers; for crash and large short-circuit scenarios.
Mechanical irreversibility
Re-conduction is impossible after activation; absolute disconnect guarantee.

Maximum Safety Barrier

Final tier in premium EV protection architectures
Positioned alongside resettable layers (GigaFuse / FaultBreak); engaged only on real fault / crash conditions.
Aerospace / defense-class safety
Compact body, wide temperature range and design intent for heavy-duty service environments.

System-Controlled Opening

BMS / vehicle-controller triggered
Crash detection, thermal-runaway and other supervisory decisions can be folded into the trigger.
Standard pyro-trigger circuit
Simple, low-power trigger interface compatible with mainstream EV BMS ecosystems.

Service and Lifecycle

Single-shot — replacement after trigger
One-time service cost in exchange for absolute safety guarantee; nuisance-trip risk is absorbed by the resettable tier.
Resettable alternative: FaultBreak
Where resettable protection is desired, the FaultBreak family is positioned instead.

DATASHEET · GUIDE · APPLICATION NOTE

PyroFuse Series — Technical Resources

05 · FILES

Datasheets

STPS500 PyroFuse Datasheet — 500 A · 1000 V · 16-20 kA breaking · <1 ms interruptSOON

Selection Guides

GIGAVAC Contactors & Fuses Selection Guide (2026)SOON
EV High Voltage Protection Architectures — Passive Fuse + Pyrotechnic TierSOON

Application Notes

PyroFuse Pyro-Trigger Circuit and BMS IntegrationSOON
PyroFuse vs FaultBreak — Which Tier in Which Scenario?SOON

FREQUENTLY ASKED QUESTIONS

About the PyroFuse series

06/06

RELATED INSIGHTS · PYROFUSEREF · IMB · PUB · 02 ENTRIES

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RELATED INSIGHTS

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02 ENTRIES

// end of index · 02 / 02

PyroFuse Series — Pyrotechnic HV DC Circuit Breaker<1 ms

Haven't picked a model from the table? Configure from scratch

Why PyroFuse Series?

High Breaking Capacity

Sub-Millisecond Irreversible Interrupt

Maximum Safety Barrier

System-Controlled Opening

Service and Lifecycle

PyroFuse Series — Technical Resources

Datasheets

Selection Guides

Application Notes

About the PyroFuse series

Go deeper

GIGAVAC Akıllı Kontaktör Serileri ve GigaFuse

Elektrikli Araçlarda Termal Kaçak Nedenli Yangınlar

PyroFuse Series — Pyrotechnic HV DC Circuit Breaker<1 ms

Haven't picked a model from the table? Configure from scratch

Why PyroFuse Series?

High Breaking Capacity

Sub-Millisecond Irreversible Interrupt

Maximum Safety Barrier

System-Controlled Opening

Service and Lifecycle

PyroFuse Series — Technical Resources

Datasheets

Selection Guides

Application Notes

About the PyroFuse series

01What is PyroFuse and how does it work?

02What are the specifications of the STPS500 model?

03Does PyroFuse replace GigaFuse or FaultBreak?

04Is single-shot operation a disadvantage?

05Which sectors use PyroFuse?

06How are samples and technical support provided?

Go deeper

GIGAVAC Akıllı Kontaktör Serileri ve GigaFuse

Elektrikli Araçlarda Termal Kaçak Nedenli Yangınlar