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High-voltage power distribution and protection

Breaktor circuit protection

As vehicle electrification becomes more prevalent, the demand for increased power levels and charging rates also grows. With these changes and advancements in technology come new vehicle safety implications and challenges.

Electric vehicle (EV) systems must safely and reliably protect people and components during all load situations including short circuits, overloads and collision events, as well as quick charging and normal driving scenarios. Eaton’s all-new Breaktor® circuit protection is the complete solution.

Intelligently safe
Self- and external triggering device can sense current spikes to interrupt the circuit
Reliable
Switching and protection function in one unit, with consistent reaction time and no fatigue
Ease of service
Resettability means no device replacements required

Core features

  • Breaktor® improves vehicle safety and protects components from any level of overcurrent condition.
  • Less than 4-milisecond actuation for short circuit faults up to 900 volts and 25,000 amps
  • Resettable like a circuit breaker, which enables reactivation of the device following a functionality check rather than a time-consuming vehicle service appointment
  • Current limiting in the event of a short circuit, independent of the current direction
  • Enables up to 350kW DC fast charging when used to protect and switch the DC fast-charge circuit
  • Available in multiple configurations including multi-pole configurations
  • Additional optional features such as mirror contact, adjustable overcurrent trigger levels, and options for external triggering

    Breaktor infographic
    Breaktor EV circuit protection cutaway
    • Permanent magnet system: Helps control location of arcing
    • Splitter plates: Split the arcing into smaller, lower voltage arcs to help with extinguishing
    • Current sensor: Senses unsafe overcurrent conditions and communicates to on-board PCBA
    • Driver electronics: Powers Breaktor actuation and deenergizes coil during overcurrent event
    • Driver coil: Actuates Breaktor with low voltage current
    Specifications

    General Specifications

    Max. operating voltage 500V / 480V or 900V / 850V d.c. max. 2000m ASL / max. 4500m ASL
    Contact configuration 1 NO or 2 NO  
    Rated current (continuous load, thermal) 350A based on generic load profile, bidirectional
    Max. switch on current Approx. 1,7kA(+/-20%) current sensor threshold, adjustable
    Max. overload switch off current 25kA  
    Overload switch off time

    up to 4kA < 7ms

    4 – 10kA < 6ms

    10 – 25kA < 4ms

    includes sensing, triggering, and arcing time; load and time constant depending
    *Breaktor 500 and 900 generic technical data, specifications estimation, final value may differ. Other models and configurations available. Consult Eaton for more details.
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