Redefining the boundaries of
electric vehicle design
Electric and hybrid vehicle design demands circuit protection that
does more than just protect sensitive equipment. It requires a circuit
protection partner that can keep up with the demands of a disruptive
technology.
Eaton introduces Bussmann series electric vehicle overcurrent
protective solutions that help extend vehicle range and acceleration
performance.
Go further. Faster.
Accelerated performance and reliability
Bussmann® series Electric Vehicle (EV) fuses are
redefining the boundaries of EV design by going beyond superior
circuit protection and incorporating innovative technologies that
promote a vehicle with higher performance and longer range.
Eaton’s portfolio of Bussmann series EV fuses is specifically
designed to protect sensitive electric and hybrid automotive
equipment, including high voltage, high capacity batteries, power
conversion equipment, contactors, cabling and other auxiliary
circuits.
Our fusible solutions are available in four case sizes. Power fuses
(20, 25 and 30 mm diameter) protect high power battery charging
and management systems up to 500 Vdc in ratings from 50 to
400 amps. Compact 10x38 mm fuses protect auxiliary electrical
systems up to 500 Vdc in ratings that span 5 to 50 amps.
From low voltage hybrid to heavy duty commercial, our complete
portfolio of EV fuses provides the protection and innovation
tomorrow’s electric vehicles demand.
To learn more, visit Eaton.com/bussmannseries/EV.
Up to 10X faster short-circuit
interruption
Smaller footprint
In addition to protecting cables and connectors, our EV
fuses protect sensitive electronic components to enhance
electrical system safety and reduce potential warranty
costs.
Our compact and lightweight fuse design requires up
to 48% less space and weighs up to 50% less when
compared with traditional high speed fuses used for
electric vehicles. This leads to smaller assemblies and
improved energy efficiency - so your vehicle goes further,
faster.
Wider range of overload protection
Greater voltage rating
With protection as low as 135% of rated current,
Bussmann series EV power fuses protect a wider range
of overcurrent conditions while avoiding nuisance
operations associated with cycling fatigue.
Higher interrupting rating
With a 20 kA interrupting rating, our fuses support your
goal of a longer vehicle range by protecting higher
capacity and more efficient batteries that have higher
fault currents.
Our fuses feature an 11% higher voltage rating than
JASO-D622 specification, so there is no need to redesign
or revalidate circuit protection as battery systems
develop and are optimized for higher voltages.
Protection you can predict
For reliability, you need confidence that your circuit protection
partner implements processes and develops products that are
predictable and consistent. With adherence to automotive
manufacturing standards and use of industry-exclusive
simulations, we truly provide protection you can predict.
Automotive manufacturing excellence
Bussmann series EV fuses are designed to the principles of the Automotive Industry Action Group (AIAG), Advanced Product
Quality Planning (APQP) and Design for Six Sigma (DFSS) processes. Our new product development system ensures delivery
of reliable products through robust quality planning and design tools, including:
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Industry-exclusive simulations
With electric and hybrid vehicle applications, electrical systems are often pushed to their limits. High current driving profiles,
aggressive levels of shock and vibration, and elevated temperatures are conditions that circuit protective devices must handle
within a compact and lightweight design footprint. All of these factors can affect electrical system reliability.
Eaton has introduced an industry-exclusive process to ensure fuse performance under these uncompromising conditions.
Using finite element simulation, your specific application conditions can be accounted for, including:
Potential failure mode and effects analysis (pFMEA)
Design for manufacturability (DFM)
Measurement system analysis (MSA)
Product serialization and lot traceability
Poke Yoke (error proofing)
Statistical process control (SPC)
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Together, our processes, tools and standards promote a streamlined, but rigorous, qualification process to reduce time-tomarket and ensure safe and reliable circuit protection solutions for you and your customers.
Complex acceleration and deceleration profiles
Ambient temperature extremes
Shock and vibration considerations
Thermal management requirements
Performance effects from conductors, connection interface and overall fuse mounting
Your unique application condition inputs produce a tailored simulation that verifies proper fuse size selection and examines
performance under a wide range of driving behaviors, all to help project the life of the fuse in your application.
With Eaton, you get confidence that the Bussmann series EV fuse you select will stand the test of time.
Serialization included on
every fuse manufactured
Weight comparison
Size comparison
100 A
100 A
1.55 in3
49.2 g
97 g
Amp rating
2.55 in3
2.75 in
200 A
82.4 g
200 A
3
3.80 in3
300 A
163 g
141 g
300 A
3.97 in3
284.8 g
7.67 in3
Bussmann series EV fuses
Typical industrial fuses
EV fuse case size (diameter)
Available current ratings (amps)
5
25
50
100
150
200
250
300
350
400
10
20
25
30
EV10-50-T
Electric
vehicle
Fuse amp rating
(5 - 400 amp)
Terminal configuration
(T, B, 1P)
*10x38 mm only; others available on
customer request
Fuse diameter
(10, 20, 25, 30 mm)
Certifications | Qualifications
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Designed to JASO D622 and ISO 8820-8 specifications
Manufactured under a TS16949 quality system for compliance with
automotive requirements
CE certified
RoHS compliant
REACH declaration available
Technical expertise at your fingertips
Complete portfolio of EV circuit protection
Bussmann series circuit protection solutions are backed
with more than 100 years of technical expertise and
innovation. When you partner with Eaton, you gain
industry-best tools and resources to help you with your
application needs.
Additionally, our application engineers are available
Monday through Friday, 7:00 a.m. — 5:00 p.m. Central Time
via toll-free phone (855-BUSSMANN) or email (FuseTech@
Eaton.com) to provide thorough answers to your technical
questions or concerns.
Our library of product data sheets is unparalleled in the
industry. Here, you’ll find time-current curves showing
melting and clearing times, coordination curves, I2t
correction factors for variation in fault current and applied
voltage, melting time correction, dimensional drawings,
specifications and certifications.
What’s more, we have a talented and dedicated group of
design and manufacturing experts who can quickly modify
existing products to develop custom solutions to fit your
needs. Whatever the need, we are ready to solve your
circuit protection challenges.
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As the automotive world is becoming more
and more electrified, power requirements
continue to change, and with them, the
demands of circuit protective devices.
Eaton is continually developing designs to
meet these ever-changing requirements.
For EV circuit protection requirements
above 500 volts, Eaton has the expertise
to design and tailor specific solutions
to meet your needs. We offer high
performance fuses rated to over 1000
Vdc and 1000 amps to cover virtually
any electrical requirements within an
electric or hybrid vehicle. These fuses
can be designed to meet your unique
requirements, including shock and
vibration, mounting requirements, high
temperature performance, or other
parameters your application may require.
CURRENT IN AMPERES
1000
1.4
1.0
10
7.5
Average
6.0
5-10 kA
Clearing I2t correction factor
1
Time in seconds
Melting time correction factor
Time in seconds
0.1
1.1
1.0
Maximum
0.9
0.1
0.8
Minimum
0.7
Maximum clearing time
-40.0
-20.0
0.0
20.0
40.0
60.0
80.0
100.0
120.0
Ambient temperature (°C)
0.001
10 X
100 X
Multiple of rated current (amps)
Power fuse time-current
curves
10
0.5
0.4
EV20-125
0.3
1
EV30-400
0.2
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.1
0.5
100
0.01
200
300
400
500
0.0
30%
0.10
Voltage (Vdc)
Melting time correction
factors
Minimum melting time
1X
5.5
20 kA
0.6
0.0
0.6
0.01
0.7
TIME IN SECONDS
Maximum clearing time
6.5
0.8
1.2
1
7.0
100
0.9
1.3
Power loss correction factor
10
Minimum melting time
0.01
0.5 1
0.001
1X
10 X
Multiple of rated Current (amps)
100 X
Auxiliary fuse timecurrent curves
Go to Eaton.com/bussmannseries
for technical data sheets and other resources.
40%
50%
60%
70%
80%
90%
100%
Load as percent of rated current
I t correction factors
2
10
100
1K
10K
EV Coordination.tcc Ref. Voltage: 500V Current in Amps x 1
Coordination curves
Power loss
correction factors
Contact our experts today to learn how
we can tailor our products to meet your
specific application needs.
1000 V
500 V
400 A
500 V EV fuse portfolio
1000 A
Custom Bussmann series EV fuse range
Mississauga, Canada
St. Louis, United States
Burton-on-the-Wolds, United Kingdom
Dublin, Ireland
São Paulo, Brazil
Juarez, Mexico
Morges, Switzerland
Mexico City, Mexico
Cleveland, United States
Pondicherry, India
Shanghai, China
Xi’an, China
Gyor, Hungary
Dongguan, China
Global reach with local responsiveness
Eaton is a true global company, with half of our sales generated outside the United States and a growing
percentage in emerging economies.
From headquarters in Dublin, Ireland, to key locations in North and South America, Asia and Europe,
Eaton’s reach spans the globe. We serve customers in more than 175 countries, so our team is ready to
respond to your needs, anywhere in the world. We have experts on the ground to help you customize
solutions, based on the different regional needs and demands of your customers.
What’s more, Eaton products are manufactured around the world, with numerous global distribution
centers and multiple high power testing facilities. Our global manufacturing capabilities enable us to
move quickly to meet urgent needs or increases in demand.
Whatever your EV circuit protection requirements, we have local Eaton service and support teams ready
to provide the swift response you need to maximize your productivity and uptime.
Legacy of automotive and
fusible technologies
Over 100 years ago, Joseph Eaton teamed up with
Viggo Torbensen to begin manufacturing vehicle axles.
Since that first partnership, Eaton has introduced
innovative vehicle technologies and reached significant
milestones such as:
It’s also been more than 100 years since the Bussmann
brothers first started producing fuses from the
basement of their home. And in that time span,
Bussmann series products have become synonymous
with technological innovation, with milestones such as:
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Partnering with the U.S. military to ship trucks with
our axles to Japan to fight in the first World War in
1918.
Producing axles for Ford passenger cars and trucks,
including the Model T in 1926.
Manufacturing components for two early versions
of automatic transmissions: Cadillac’s Hydra-Matic
Drive and Chrysler’s Fluid Drive in 1940.
Developing the first car air conditioner affordable
enough for the average consumer in 1952.
Developing hydraulic-driven hydrostatic
transmissions in 1965.
Developing one of the first passenger car air bag
systems in 1967.
Partnering with NASA to develop a prototype
propulsion system for electric vehicles in 1980.
Creating an innovative transaxle for electric power
alternating current vehicles in 1982.
Unveiling our first electric car prototype in 1989.
Announcing the first hydraulic hybrid delivery truck
and diesel-electric city bus for the Chinese market
in 2006.
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Producing fuse wire, auto, plug and one-time fuses
for horseless carriages in 1916.
Producing fuses for war plants, tanks, ships, planes,
and radars in 1941.
Developing first mechanical indicating one-time
midget fuses for American naval ships in 1943.
Entering the space age with fuses protecting the
Mercury Program (1961) Gemini Program (1965)
and Apollo Program (1967).
Introducing emergency flashers for automotive
fuses in 1974.
Partnering with NASA in 1975 to provide protection
for all shuttle missions through 2011.
Travelling across the surface of Mars in the NASA
rover robot, Sojourner, in 1997.
Acquired power electronics and battery
management design and manufacturing expertise
in 2007
Expanded investment in power electronics
technology and markets in 2011
And now that Bussmann series products are part of Eaton’s portfolio, the industry’s top innovators of automotive
and fuse technology have united to provide safe, reliable and efficient solutions.
Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com
For Eaton’s Bussmann series
product information,
call 1-855-287-7626 or visit:
Eaton.com/bussmannseries
Bussmann Division
114 Old State Road
Ellisville, MO 63021
United States
Eaton.com/bussmannseries
Eaton.com/bussmannseries/EV
© 2016 Eaton
All Rights Reserved
Printed in USA
Publication No. 10569
August 2016
Eaton and Bussmann are valuable
trademarks of Eaton in the US and other
countries. You are not permitted to use
the Eaton trademarks without prior
written consent of Eaton.
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