Battery Overload Protection Trip Pyroswitch Pyrofuse Explained

Background

Security concerns are always kept at the forefront by all the vehicle manufacturers and as such different sensors, fuses and switches are deployed in passenger cars as well as in commercial vehicles to provide maximum security of the car and its driver with their brands. DEKRA (Deutscher-Kraftfahrzeug-Überwachungs-Verein), a European vehicle inspection company, conducted an investigation on what the extreme deformation of the vehicle body actually causes after an accident occurs. Upon analysis of the facts, it was established that almost 90% of road accidents cause subsequent fire at speeds above 80km/h and the extreme deformation causes an earth fault on the thickest electrical conductor, the cable between the battery and the starter/generator.

In many wire harnesses, the starter/generator cable remain unprotected and in an event of a crash, these unprotected or damaged cables can lead to short-circuit like hazardous results for the passengers and / or rescuers. In such cases of short-circuits, sparks, or arcs can cause direct ignition, or smoldering fires can also occur as a result of the enormous heat development, but apart from these hot components in the engine compartment, the battery is the real culprit where its stored electrical energy contributes to become the primary source of ignition in the car.

Development of PyroSwitch Pyrofuse

To further enhance the advancement in automotive manufacturing line and to prevent these short circuits which can lead to thermal event and burn, disconnection systems and pyrotechnical safety battery terminals are approved as standards of the automotive industry.

A pyrofuse, also known as pyrotechnic fuse, pyroswitch or a pyrotechnic switch and usually denoted by (PSS- Pyrotehcnic safety switches) is one of the fast acting protective switches with a low cost technology which keep you safe during an event of crash, accident or fault and makes your trip a protected one.

What is Pyrofuse/Pyroswitch?

Basically, it is a high voltage positive battery terminal fuse which explodes and disconnects the electrical connection irreversibly to avoid short circuit or fire when a car gets into accident or crash. The positive terminal coming out of battery is disconnected the same second, car is crashed.

What does a Pyroswitch do?

Triggered by airbag control unit or battery management system, it performs its function in milliseconds by disconnecting the power source from the circuit board. It safely, reliably, quickly and effectively disconnects the circuit before a short circuit can occur in the circuit as a result of vehicle deformation and shuts down the power circulation. In other words, we can say that it is a battery disconnection switch which prevents short circuits, caused by collisions.

It is used in many other EV vehicles and hybrid vehicles and is used to separate the starter-generator-cable from the electrical battery.

How does it work?

Million times proven Airbag initiators are used in pyrotechnic-driven PSS disconnection systems. The complete initiation circuit, including the line and initiator are continuously monitored by the controller for functionality. After the initiation pulse, disconnection takes place without any other external aid.

Triggering through airbag ECU or Battery management system BMS, Pyrotechnic accelerates the separation piston. The bus bar is severed in maximum 0.1 milliseconds while this separation of electrical connections is done within 0.20 milliseconds. The plastic piston isolates the bus bar ends and an electric arcing effect is prevented, thereby saving further damage to the electrical components.

Battery overload protection

Automotive battery management system is much more demanding than any other types of battery management and requires continual monitoring for charging and discharging conditions. Isolating the battery in cases of emergency is the main function of BMS. Overload protection of battery is possible with a pyrofuse that would not only prevent the overheating of the battery, but this disconnection also helps to prevent battery draining as power is needed for other important functions.

BMW cables have writing Auto Cable Masevaux.

Cars fitted with autoliv pyroswitch:

Mercedes Benz B class W246 B250e 2015 2016 2017
Mercedes-Benz C class W204 S204 C204
Mercedes-Benz E class W212 S212 A207 C207
Mercedes Benz ML W164 GLE W166 GL X164 GLS X166 SUV
Tesla Model S P85+ Model S 90 2012 2013 2014 2015 2016
Audi A1 S1 82 2019 2020
Audi A6 S6 RS6 4K Allroad Avant Saloo Sedan Esate
2019 2020 2021
Audi A7 S7 RS7 Sportback 4K 2019 2020 2021
Audi A8 S8 D4 4H
Audi A8 A8L S8 D5 4N 2017 2018 2019 2020 2021
55 60 TFSI 5.0 6.0 TDI
Audi Q8 SQ8 RS Q8 2018 2019 2020
VW Tiguan 5N Allspace 2018 2019 2020
VW Tiguan AD1 2016 2017 2018 2019 2020
Audi A3 S3 8P 8P RS3 A4 S4 B8 8K A6 C6 4F
Audi Q7 4L 2007 - 2009
Audi Q7 4L Facelift 2010 2011 2012 20132 2014 2015
Audi A1 8X 2011 - 2019
Audi A6 S6 RS6 C7 2011 - 2014
Audi Q3 8U
Audi Q5 SQ5 8R 2011 2012 2013 2014 2015 2016
VW Touareg 7P 2011 2012 2013 2014 2015 2017 2018
VW Touareg 7P 2011 2012 2013 2014 2015 2017 2018
Volvo XC60 XC90 MK2 S90
Volvo V90 MK2 2016 2017 2018 2019 2020
Volvo XC40 T4 2017 2018 2019 2020 2021
Volvo V60 T5 2019 2020 2021
Volvo V60 Cross Country T5 2019 2020 2021
Porsche Cayenne Panamera
Maserati Levante
Maserati Quattroporte M156 MK6 VI 2013 2014 2015 2016 2017 2018 2019
Aston Martin DB11 V8 V12 AMR Volante 2016 2017 2018 2019 2020
SKODA SUPERB
VW TOUAREG 2006-2010
VW PHEATON
AUDI A4/S4 2008-2015 B8
A4 ALLROAD QUATTRO 2013-2015
A5/S5 2008-2015 A6/S6 2005-2015
C6 C7 A6 ALLROAD QUATTRO 2013-2015
A8/S8 2004-2015 D3 D4 Q5 2009-2015
TT 2007-2014 RS4 2013-2015
RS5 2010-2015 RS6 2013-2015
RS7 2014-2015
SEAT Ibiza
Tesla Model 3 2017 2018 2019 2020 2021
Mercedes-Benz A class W177 A180 A200 A220
Mercedes Benz B class W246 B250e 2015 2016 2017 2018
Mercedes-Benz C class W204 S204 C204 Facelift C180 C200 C220 C250 C300
Mercedes-Benz E class W212 S212 A207 C207
Mercedes Benz ML W164 GLE W166
Mercedes-Benz GLS X166 SUV GL450 GL550 2013 2014 2015 2016
Mercedes Benz GLK X204 2008 - 2015
GLK280 GLK300 GLK350 4Matic
GLK200 GLK220 GLK250 GLK320 GLK350 CDI BlueEfficiency
Mercedes Benz V class Vito Viano W447 Bus 2.2CDI BlueTEC 2014 20215 2016 2017 2018
Tesla Model S P85+ Model S 90 2012 2013 2014 2015 2016
Tesla Model X 60D 70D 75D 90D 100D SUV 2015 2016 2017 2018 2019 2020
BMW 1 series E82 E88 2007 - 2013
1 series F20 F21
114i 116i 118i 120i 125i 135i 140i M-Sport
114d 116d 120d 125d
3 series F30 F31 F34 GT
316i 318i 320i 328i 330i 335i 340i 330e M3
316d 318d 320d 325d 330d 335d
3 series G20 G21 2018 2019 2020 2021
318i 320i 330i 330e M340i M3
316d 318d 320d 330d M340d
3 series F80 M3
4 series F32 2012 - 2017
4 series F32 LCI Facelift 2016 - 2019
4 series F82 M4
4 series F33 2013 - 2017
4 series F83 M4
4 series F36 Gran Coupe 2013 - 2019
418i 420i 428i 430i 435i 440i M4
418d 420d 425d 430d 435d
5 series F10 F11 F07 GT 2010 - 2017
6 series E63 E64 F06 F12 F13 2011 - 2017 G32 GT
630i 630d 645Ci 650i M6
7 series F01 F02 2008 - 2015
i3 Pre-Facelift and i3 LCI Facelift
BMW 5 series G30 Saloon Sedan
BMW 5 series G31 Estate 2016 2017 2018 2019 2020
520i 530i 530e 545e iPerformance 540i M550i xDrive M5
518d 520d 525d 530d 540d xDrive M550d xDrive
7 series G11 G12
730i 730Li 740i 740Li 740e 740Le 745e 745Le
750i 750Li M760Li
725d 725Ld 730d 730Ld 740d 740Ld 7450d 750Ld
8 series G14 Coupe G15 Convertible Cabriolet
8 series G16 Gran Coupe
X5 E70
X5 F15 F85 X5M SUV
xDrive30d xDrive40e Hybrid
X6 E71 F16 F86
X3 F25 X4 F26 E84 X1
F36 F80 M3 F82 F83 F22 F23 F87 220i 228i
Rolls Royce Phantom RR11 2016 - 2019
Rolls Royce Phantom EWB RR12 2016 - 2019
Rolls Royce Cullinan RR31 2017 - 2019

Below you'll find OEM part numbers for pyrofuses, which we have collected and which could be bought at our online shop.

VAG Audi VW Skoda Seat part numbers:

4F0915519
4F0915457
4G0915519
7L0915457
4N0 915 519
4N0915519

Tyco part numbers:

1-1414367-0 114143670
5-1416000-6 514160006

Autoliv NCS-France part numbers:

0080-P1-10.0017
0080-P1-100017
0080P1100017
Actuator PSS-1
ActuatorPSS-1
PSS-1 0080-P1-10.017
PSS2 PSS-2 Actuator
0080/0080.P1.10.0017
00800080P1100017

Delphi Deutschland GmbH detales kodai

PSS2
BAM-PT-1206
BAMPT1206

Tesla part numbers:

1004635-00-A 100463500A
1004635-00-A 100463500A
1077177-00-A
1077177-00-B
1111313-00-E
1095154-00-C 109515400C
1064689-00-I
1064689-00-l
106468900I

Mercedes-Benz part numbers:

N000000006967
MBN10309-PF4-PTE200/400V
N000000004510
32V/200PTE200-MBN10309
N000000004516
32V/200PTE150-MBN10309
N000000006984
N000000008776 MBN10309-PF5

BMW battery cable (plus pole) part numbers:

61126821904 61129322056
61126989780 61129217017
61129225099 61129217033
61129253111 61129322056
61129259425 61126834543
61129217004 61129217036
61139203570-04 61129217031
61126988974 9217036-02
9184191-01 7792130
9259425-02 6929324
618537-101 9350065-03
9391187-01 618540
61129391187 61128704706
6988972 6988974-01
10304410 9217004-01
9350064 65508757
618540-101 9391187-02
6112704746 61126938495
6989779 6989780-03
9127768 6989782-02
9217030 9217031-01
9259424 9253111-03 6989780-02
9217033-02 9217032
9217033-01 9217036-01
9232586 9217034 9217035-01
9232587-02 6944536
9321004 2557087-01
2557087-01 61129321005
6834543-02 6835243
9259425-03 9217018-01
65275149 65169877 618537-103
9115449 9115438
61128796155 61128796959
9322056-03 9322055 9367471
61129127780 9127780
9127036-01 6989784 9127780-01
8704706-01 8704745
61129359665 8801729 2557834
2557835-02 8801729-01 619919-107
65428083 65346373
61128795489 61128796048
61128795485 8795485-08 61128796044
61128796040 8796042-01

BMW B+ junction point, rear fuse box:

6802944-02
61146802944
61149339832
933983205

Mercedes-Benz fuse box oem part numbers:

A4475404326
A4475405931

Mercedes-Benz clamp oem part numbers

N000000006427

Volvo OEM part numbers

31682255

BMW cars have pyroswitch integrated into battery cable (plus pole) terminal, so there is no need to buy new cable to fix, you can just replace faulty autoliv pyrofuse and it will work again.

Mercedes-Benz W447 Viano and Vito has fuse box with oem part number A4475404326 , in which you could find crash pyrofuse.

If you visit dealer shop, they won't sell you separate fuse, they will quote you for whole fuse box, which is not needed to fix not starting engine.

If you have Mercedes W447 Vito or Viano, get in touch with us for new pyroswitch at franction of cost compared to dealer prices.

Diagnostic Trouble codes (DTC) for faulty pyrofuse:

9CFF low resistance in the pyrofuse squib ignition circuit

Pyrofuse will fix the following malfunctions:

DTC Code for Battery Terminal
DTC Code for Safety Battery Terminal
Battery Terminal Code
Pyro Fuse for Battery Terminal

Mercedes-Benz DTC diagnostic trouble codes:

B273513 The squib for the on-board electrical network wire Pyrofuse is faulty. An open circuit exists
B27352B The squib for the on-board electrical network wire Pyrofuse is faulty. The electrical wires have a short circuit to one another
B00792B The squib for the emergency tensioning retractor (ETR/GUS) for belt end fitting (driver) is faulty. The electrical wires have a short circuit to one another
B1C3200 Control Unit Supplemental Restraint system (SRS) has detected a crash

Why pyrofuse is necessary?

For automotive application, the pyrofuse have many advantages. Bosch and Autoliv are the leading manufacturers of pyrofuse pyroswitch in the automotive industry and you can trust the experience and high-quality requirements of the vehicle industry and use the PSS Pyroswitch by Autoliv and Bosch.

Respond to DC transportation requirements
Excellent time to clear the high and fault current
Very low conduction loses.
Low average market price

Lifesaving in only a few milliseconds is possible with a pyrofuse explosion.