The Emergency Plug® does not detect thermal runaway and does not directly measure the battery temperature. The plug reads via the vehicle communication system when the car itself detects an excessively high battery temperature and issues a warning.

The red flashing light is activated when the vehicle itself indicates that the battery temperature is too high. The exact temperature at which this occurs varies per car brand and model, as each manufacturer applies its own limit values due to the diversity of batteries, each of which has its own limit value.

When the red light flashes, it means that the vehicle is reporting an excessively high battery temperature. Normally, the car cools the battery pack. Depending on the situation, take preventive measures in case the car can no longer handle this cooling due to physical damage to the car and/or battery pack.

This depends on the type and hardware version of your current plug. Serial numbers starting with 2211xxxx and higher are suitable for the upgrade. If in doubt, please contact your supplier or Total Safety Solutions to check whether your Emergency Plug® can be upgraded with new software or whether replacement is necessary.

This means that the vehicle is no longer issuing a warning and that the battery temperature is back within safe limits according to the vehicle. Blue light indicates normal operation with no active warnings.

A red flashing signal indicates that the vehicle has detected an excessively high battery temperature; in the event of an accident, it is therefore important to be extra alert to smoke, odours or heat.

No. The Emergency Plug® does not switch off the high voltage and main power, i.e. it does not ‘isolate’ the EV. This means all the electric options, such as windows, seats and lights of the EV can still be used. 

Not always. The R100 regulations oblige an EV manufacturer to ensure that the EV will not drive away under its own propulsion. Each EV manufacturer is free to find a suitable solution to prevent this from happening.

Not always. The R100 regulations oblige an EV manufacturer to ensure that the EV will not drive away under its own propulsion. Each EV manufacturer is free to find a suitable solution to prevent this from happening.

An interlock (HVIL) is a safety feature of EVs that protects individuals during the assembly, repair, maintenance and operation of an EV as well as in the event of an accident. This includes when the airbags have been deployed, or if the first responder loop has been cut. 

However, even when the HVIL should have been deployed, it cannot always be relied upon it. The reasons for this are: 

• There is no external indication that the interlock is properly activated.
• It is a mechanical system that is prone to failures and may even become welded together during an accident.
• There are several situations when it might not be deployed, for example if the EV is not severely damaged or the airbags have not been deployed due to mechanical failure.

The Proximity Pilot (PP) pin on Plug Type 2 tells the EV the type of cable that is connected to the socket – different cable thicknesses can cope with different amounts of electrical current. On Type 1 it can be used to indicate that the plugs will be removed shortly. 

The Control Pilot (CP) pin provides bi-directional communications between the EV and the charging system. This checks the maximum amount of current that the EV is able to take at any one time.

The Plug recognises and communicates the desired PP and CP signal to activate the EV’s safety protocol. This is different for each EV. 

“If a battery can be externally charged by the user, vehicle movement by its own propulsion system shall be impossible as long as the connector of the external electric power supply is physically connected to the vehicle inlet”

The Automotive industry has developed several types of safety solutions in response to the R100 regulations. The Emergency Plug® is capable of activating each safety protocol, ensuring the safety of first responders. Some EVs may activate their safety protocol when a standard charging plug is inserted. However, the user has no continuous visual confirmation of this. Moreover, this type of activation is mainly used in older EV types and is becoming less common.

There are two types of plugs. Download the datasheet of the Emergency Plug® which was developed according to European guidelines here.

There are two types of plugs. Download the datasheet of the Emergency Plug® developed for the USA here.