FaultBreakTM Automotive High Voltage DC Contactor  – Copy – Copy

Contactors and Industrial Fuses
Sensata’s FaultBreak FBC600 series contactor is engineered for advanced protection and reliability in electric vehicles across automotive, truck and bus applications. Designed to address the limitations of traditional fuse and contactor systems, FaultBreak combines resettable fault interruption with a hermetically sealed structure for superior durability and performance. Its passive auto-trigger mechanism ensures rapid disconnection during short-circuit events without external electronics, while the optimized design simplifies system architecture and reduces cost, weight, and complexity. Built to meet the demands of next-generation EV platforms, FaultBreak delivers unmatched safety, reliability, and system-level efficiency.

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Specifications

Item Specifications
Contact Arrangement  1 Form A (normally open)
Contact Resistance (Initial) ≤0.14mΩ (@600A)
Rated Load Current 600A (@200mm2 busbar)
Rated Switching Voltage 850 VDC
Rated Switching Power 510 kW
Max. Switching Voltage 1000 VDC
Max. Switching Power 600 kW
Max. Breaking Current 2000A 850VDC (1op)
Short Circuit 1000V/20000A (Series Interrupt)
Current Endurance 600A, Cont.
800A, 40min
1000A, 10min
1500A, 85s
2000A, 30s
Electrical Endurance Capacitive Load Switch on:10×10⁴ times (20VDC, 160A)
Resistive Load Switching:10×10⁴ times (20A, 850V)
Switch off: 1500 times (250A, 850V)
Switch off: 1 time (2000A, 850)
Switch off: 5 time (1400A, 850V)
Rated Voltage Max. Allowable Voltage Max. operate voltage Min. release voltage Power DUTY
12VDC 16VDC 9V 1V 45W/3W PWM
24VDC 32VDC 20V 2V 45W/3W PWM
Item Specifications
Insulating Property Dielectric Strength 3000VAC 1min, between open contacts​
3000VAC 1min, between coil and contact​
Insulation Resistance 1000MΩ at 1000VDC, between open contacts ​
1000MΩ at 1000VDC, between coil and contact​
Time Parameters Operate Time ≤30ms​
Release Time ≤10ms​
Mechanical Performance Shock Resistance (Functional) For ON : Min. 245 m/s2 (half-sine shock pulse : 6ms)​
For OFF : Min. 343 m/s2 (half-sine shock pulse : 6ms)​
Vibration 10Hz to 500Hz, 49m/s2
Mechanical Endurance 1×105 times , on-off ratio :0.5s:0.5s​
Environment Parameters Operating Temperature -40℃~85℃​
Operating Humidity 20% RH ~85%RH​
Storage Temperature -40℃~85℃​
Storage Humidity ​ 20% RH ~85%RH​
Weight Approx. <600g

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Features

  • Optimized for higher over-current breaking capability compared to conventional contactors
  • Integrated auto-trigger for passive HV load disconnection during fault and short-circuit events
  • Resettable after nuisance triggers to prevent driver stranding
  • Hermetic sealing for low and stable contact resistance; IP67 compliant
  • Potential to eliminate pyrofuse, busbar, LV harness, and associated hardware, reducing size, weight, and thermal losses

Benefits

  • Market-leading fault-clearing performance
  • Improved safety case with redundancy options
  • Simplified system design and reduced component count
  • Lower warranty risk through fewer erroneous trips
  • Cost and weight savings for OEMs

Downloads

sensata-fbc-600-series-contactor-datasheet

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